Deutz B FM 1008 F Service Manual

Workshop Manual B/FM 1008/F

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Workshop Manual F2M 1008

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F3M 1008 F4M 1008 BF4M 1008

F2M 1008 F F3M 1008 F F4M 1008 F

0297 9985 en

In view of continuous design improvements or changes, the technical spe- cifications and the illustrations shown in this Workshop Manual are subject to alteration. Reprinting and reproduction, in part or in whole, are subject to our written approval.

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F O R E W O R D

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eliable engine operation is dependent on properly executed repairs as well as adjustment work.

This Workshop Manual describes the appropriate operations for any repair and adjustment work on the engine and engine components. It is presumed that this work will be carried out by qualified personnel.

The Manual has been laid out to ensure quick comprehension of the contents, i. e illustrations have been placed adjacent to the brief text passages to clearly show the working operations.

Aspects of operation and maintenance are dealt with in the respective Operation Manual.

For spare parts orders the respective spare parts catalogue should be referred to.

This Workshop Manual is not subject to engineering change service and is valid until next issue.

Therefore please refer to the information in our Technical Circulars when carrying out repairs.

General information:

- Please read carefully and observe the instructions given in this Workshop Manual to avoid accidents and ensure that your engine always functions properly and reliably.

- Make sure that this Workshop Manual is readily available for all those carrying out repairs or adjustments and that the contents are well understood.

- Non-compliance with these repair instructions may result in malfunction and engine damage as well as personal injuries for which the manufacturer shall not accept any liability.

- The accident prevention regulations and all other generally recognized regulations on safety and occupational medicine are to be observed.

- A prerequisite for successful repair is that all required equipment, hand and special tools are available and in perfect working order.

- Optimal operation economy, reliability and durability of the engine can only be ensured when genuine parts of DEUTZ AG are used.

- Engine components such as springs, clamps, snap rings, etc. may cause injury if not handled with care.

- Engine repairs must be carried out in accordance with intended use as defined by the equipment manufacturer. For conversions, only parts approved by DEUTZ AG for a specific purpose should be used.

INDEX

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This manual contains pertinent information regarding the repair of DEUTZ water-cooled, indirect injection Diesel engines type

INDEX PAGE

B/FM 1008/F

TROUBLESHOOTING CHART - B/FM 1008/F SERIES ____________________________________ SAFETY AND W

ARNING DECALS - SAFETY INSTRUCTIONS _____________________________

I GENERAL ___________________________________________________________________

POWER RATINGS FOR B/FM 1008/F GENSET SPEC DIESEL ENGINES ______________________ 13 B/FM 1008 SERIES - TECHNICAL SPECIFICATIONS AND CAPACITIES F2/3/4M 1008, BF4M 1008 __________________________________________________ 14 FLUID CAPACITIES (STANDARD) F2/3/4M 1008, BF4M 1008 ________________________________ 14 FM 1008 F SERIES - TECHNICAL SPECIFICATIONS AND CAPACITIES F2/3/4M 1008 F __________ 16 FLUID CAPACITIES (STANDARD) F2/3/4M 1008 F__________________________________________ 16 POWER, TORQUE AND SPECIFIC FUEL CONSUMPTION CURVES F2/3M 1008_______________ 18 POWER, TORQUE AND SPECIFIC FUEL CONSUMPTION CURVES B/F4M 1008 ______________ 19 POWER, TORQUE AND SPECIFIC FUEL CONSUMPTION CURVES F2/3/4M 1008 F ___________ 20 GENERAL ENGINEERING DRAWINGS - F2/3M 1008 _______________________________________ 21 GENERAL ENGINEERING DRAWINGS - B/F4M 1008_______________________________________ 22 GENERAL ENGINEERING DRAWINGS - F2/3/4M 1008 F ___________________________________ 23 B/FM 1008/F SERIES MAINTENANCE SCHEDULE _________________________________________ 24 RECOMMENDED OIL___________________________________________________________________ 25 DIESEL FUEL SPECIFICATIONS _________________________________________________________ 26 ANTI-FREEZE / COOLANT SPECIFICATIONS / DETAILS - B/FM 1008/F SERIES _______________ 27 DRIVING TORQUES FOR STANDARD SCREWS ___________________________________________ 28 SEALANT AND THREAD LOCK LOCATIONS/DETAILS ______________________________________ 28 CRITICAL TORQUE SPECIFICATIONS ____________________________________________________ 29 SPECIAL TOOLS _______________________________________________________________________ 30

II DISASSEMBLY- REASSEMBLY________________________________________________

Air filter support - (intake manifold) ______________________________________________________ Air restriction switch ___________________________________________________________________ 31 Alternator / cooling fan drive belt ________________________________________________________ 32 Camshaft journal / support bore specifications____________________________________________ 43 Camshaft journal / support measurement ________________________________________________ 43 Camshaft lobe measurement procedure__________________________________________________ 43 Camshaft lobe specifications ___________________________________________________________ 44 Camshaft removal / replacement ________________________________________________________ 43 Camshaft timing pulley ________________________________________________________________ 35 Connecting bearing / rod cap installation _________________________________________________ 52 Connecting rod / connecting rod bearings specifications ____________________________________ 50 Connecting rod alignment ______________________________________________________________ 51 Connecting rod-piston assembly balance ________________________________________________ 51 Cooling fan ___________________________________________________________________________ 32 Cooling fan support ___________________________________________________________________ 33 Crankcase vacuum regulator valve (B/FM 1008/F) _________________________________________ 40 Crankshaft end play ___________________________________________________________________ 55 Crankshaft journal inspection / measurement _____________________________________________ 56 Crankshaft journal specifications ________________________________________________________ 57 Crankshaft lubrication drillings-typical ___________________________________________________ 56 Crankshaft pulley _____________________________________________________________________ 33 Crankshaft seals - front and rear ________________________________________________________ 56

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INDEX

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PAGE

Crankshaft timing pulley _______________________________________________________________ 35 Cylinder class Cylinder head installation_______________________________________________________________ 53 Cylinder head removal _________________________________________________________________ 44 Cylinder head tightening procedure- F4M 1008/F, BF4M 1008 ______________________________ 53 Cylinder head tightening procedure- F2/3M 1008/F________________________________________ 53 Cylinder inspection / dimensional specifications __________________________________________ 49 Cylinder surface finish _________________________________________________________________ 49 Dry type air filter- standard engine mounted ______________________________________________ 31 Exhaust manifold______________________________________________________________________ 32 Flywheel / ring gear____________________________________________________________________ 33 Front / rear main bearing caps / bearings_________________________________________________ 54 Fuel rail ______________________________________________________________________________ 41 Fuel tank - (optional accessory) _________________________________________________________ 33 General piston notes __________________________________________________________________ 48 Governor fork _________________________________________________________________________ 38 Governor springs______________________________________________________________________ 38 Head gasket selection/ installation ______________________________________________________ 52 Hydraulic drive components- no. 3 pto___________________________________________________ 57 Hydraulic pump pto- (no. 3 pto) _________________________________________________________ 57 Idler pulley ___________________________________________________________________________ 35 Injection pump control rod _____________________________________________________________ 41 Limiting speed governor _______________________________________________________________ 39 Main and connecting rod bearings ______________________________________________________ 57 Main bearing caps / bearings- center ____________________________________________________ 54 Main bearing clearance ________________________________________________________________ 54 No. 2 pto (crankshaft pulley) with “ringfeder”- F4M 1008/F, BF4M 1008 ______________________ 34 Oil bath air filter _______________________________________________________________________ 31 Oil pan removal / installation ____________________________________________________________ 47 Oil pump assembly ____________________________________________________________________ 39 Oil pump assembly to the engine________________________________________________________ 39 Oil pump inspection ___________________________________________________________________ 39 Piston / connecting rod disassembly and piston inspection _________________________________ 48 Piston / connecting rod installation ______________________________________________________ 51 Piston balance ________________________________________________________________________ 48 Piston class, weight imbalance and genuine Deutz markings _______________________________ 48 Piston cooling jets- BF4M 1008 _________________________________________________________ 54 Piston protrusion ______________________________________________________________________ 52 Piston removal ________________________________________________________________________ 48 Piston ring assembly location ___________________________________________________________ 50 Piston ring end gap____________________________________________________________________ 50 Piston ring to piston land clearance _____________________________________________________ 50 Piston wrist pin installation / retaining snap ring ___________________________________________ 51 Precision speed governor -(gensets) _____________________________________________________ 38 Pre-combustion chamber installation ____________________________________________________ 47 Pre-combustion chamber removal_______________________________________________________ 47 Pre-combustion chamber ring nut _______________________________________________________ 47 Pre-combustion chamber-overview ______________________________________________________ 46 Rocker arm assembly__________________________________________________________________ 42 Speed governor _______________________________________________________________________ 38 Speed governor reassembly ____________________________________________________________ 39 Thrust bearings _______________________________________________________________________ 55 Thrust surface specifications-crankshaft end _____________________________________________ 55 play corrections _______________________________________________________________________ 55 Timing belt / timing pulley arrangement __________________________________________________ 34 Timing belt cover______________________________________________________________________ 34 Timing belt installation- timing procedure ________________________________________________ 36 Timing belt removal ___________________________________________________________________ 35 Timing belt tension procedure __________________________________________________________ 36 Timing belt tensioning procedure- setup _________________________________________________ 36 Timing pulley - reference marks _________________________________________________________ 36 Undersized bearings- rod and main _____________________________________________________ 57 Unit injector check valve _______________________________________________________________ 41 Unit injector removal / installation _______________________________________________________ 42 Valve / rocker cover ___________________________________________________________________ 40

________________________________________________________________________ 49

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INDEX

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Valve / rocker cover gasket _____________________________________________________________ 40 Valve

adjustment ______________________________________________________________________ 41 Valve guide installation guidelines and post installation valve/valve guide specifications________ 45 Valve guides / valve guide bore _________________________________________________________ 45 Valve recess and seat sealing width _____________________________________________________ 46 Valve removal_________________________________________________________________________ 44 Valve seats ___________________________________________________________________________ 46 Valve specifications ___________________________________________________________________ 45 Valve springs _________________________________________________________________________ 45 Valve stem seal installation _____________________________________________________________ 44 Valve timing angles ____________________________________________________________________ 37 Valve timing confirmation_______________________________________________________________ 37

PAGE

III TURBOCHARGER ___________________________________________________________

Turbochar Turbocharger components _____________________________________________________________ 58 Turbocharger pressure testing __________________________________________________________ 58 Turbocharger waste gate adjustement-bench method _____________________________________ 59

ger identification _____________________________________________________________ 58

IV LUBRICATION SYSTEM ______________________________________________________

Lubrication system ____________________________________________________________________ 60 Oil pick-up screen and oil drain back tube________________________________________________ 61 Oil pump specification _________________________________________________________________ 61 Oil filter ______________________________________________________________________________ 62 Oil pressure testing ____________________________________________________________________ 62

V COOLING SYSTEM __________________________________________________________

B/FM 1008/F cooling system schematic _________________________________________________ 63 Cooling system pressure check/radiator cap inspection _____________________________________ 64 Coolant pump details __________________________________________________________________ 64 Thermostat ___________________________________________________________________________ 64

VI FUEL SYSTEM_______________________________________________________________

Barrel and plunger detail- (typical) curr unit injectors (example- 6590-285) ______________________________________________________ 69 Barrel and plunger detail- early unit injectors (typical) ______________________________________ 69 Early unit injectors_____________________________________________________________________ 71 Engine timing reference marks __________________________________________________________ 72 Equalization tool installation, plumbing ___________________________________________________ 73 Fuel filter assembly ____________________________________________________________________ 65 Fuel rate adjustment details ____________________________________________________________ 73 Fuel system schematic ________________________________________________________________ 65 Fuel system special tools ______________________________________________________________ 67 Fuel transfer pump ____________________________________________________________________ 65 Fuel transfer pump push rod protrusion __________________________________________________ 65 Injector ______________________________________________________________________________ 65 Injector nozzle protrusion ______________________________________________________________ 70 Late/ intermediate unit injectors _________________________________________________________ 71 Static injection test instrumentation- early unit injectors _____________________________________ 71 Static timing adjustment _______________________________________________________________ 72 Tdc determination and static injection timing checking ______________________________________ 71 Unit injector __________________________________________________________________________ 68 Unit injector components ______________________________________________________________ 68 Unit injector delivery equalization- preparation ____________________________________________ 73 Unit injector delivery equalization- preparation (cont.) ______________________________________ 73 Unit injector fire ring ___________________________________________________________________ 70 Unit injector plunger reassembly ________________________________________________________ 68

ent ________________________________________________ 69

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INDEX

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PAGE

Unit injector popping pressure testing and adjustment intermediate unit injectors) ______________________________________________________________ 70 Unit injector popping pressure testing and adjustment- high pressure procedure (early unit injectors- all ref. No’s other than 272, 272-, 272-1, 235-3) __________________________________ 70 Unit injector reassembly (cont.) _________________________________________________________ 69 Unit injector ring nut removal / replacement ______________________________________________ 68 Unit injector test stand specifications ____________________________________________________ 69

- low pressure procedure (current /

VII ELECTRICAL SYSTEM _______________________________________________________

12V electrical schematic-marelli 14V-33A ________________________________________________ 77 12V electrical schematic - 20/30 A flywheel alternator _____________________________________ 79 12V electrical schematic-iskra 14V-33A __________________________________________________ 75 Battery sizing _________________________________________________________________________ 77 Battery sizing _________________________________________________________________________ 79 Bosch 12V/1.1 kW starter motor (DW 12V) _______________________________________________ 82 BOSCH 12V/1.6 kW starter motor (DW 12V) ______________________________________________ 82 Electrical system service precautions / warning ___________________________________________ 74 Engine side wiring harness for the Deutz supplied control panel _____________________________ 81 Flywheel alternator - 12V _______________________________________________________________ 77 Glow plug ____________________________________________________________________________ 83 Glow plug controller / relay with coolant temp. Sensor _____________________________________ 83 Iskra 14V/33A performance curve _______________________________________________________ 75 Iskra alternator - 14V/33A ______________________________________________________________ 75 Deutz supplied control panel ___________________________________________________________ 80 Marelli AA 125 R, 14V/45A performance curve ____________________________________________ 76 Marelli alternator (AA 125 R) - 14V-45A___________________________________________________ 76 Oil pressure (low) switch, coolant temperature (high) switch ________________________________ 83 Performance curve - 20A flywheel alternator ______________________________________________ 78 Performance curve - 30A flywheel alternator ______________________________________________ 78 Performance curve - BOSCH 12V/1.1 kW (DW 12V) starter _________________________________ 82 Performance curve - BOSCH 12V/1.6 kW (DW 12V) starter _________________________________ 82 Temperature sensor (thermistor)_________________________________________________________ 83 Voltage regulator connection details (flywheel alternator only) _______________________________ 79

VIII TESTING-OPERATIONAL-ADJUSTEMENTS ____________________________________

Governor / unit injector rack adjustment High (maximum) speed adjustment ______________________________________________________ 84 Idle speed adjustment _________________________________________________________________ 84 Injection pump control rod stroke limit adjustment_________________________________________ 85 Power, torque device and speed adjustments-dynamometer method ________________________ 85 Torque device adjustment (without dynamometer) _________________________________________ 84 Torque device details __________________________________________________________________ 84

_________________________________________________ 85

IX STORAGE ___________________________________________________________________

Storage ______________________________________________________________________________ 86 Storage - 1 to 6 months ________________________________________________________________ 86 Storage - in excess of 6 months ________________________________________________________ 86 Preparing the engine for use after storage ________________________________________________ 86

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NOTE

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SYMPTOM

TROUBLESHOOTING CHART- B/FM 1008/F SERIES

Engine knocks

Engine will not crank

Engine does not start

Engine starts, but stops

Poor acceleration

White smoke

Unsteady RPM

Black smoke

Blue smoke

Low oil pressure

Oil level rising

Excessive oil consumption

Wet exhaust

Overheating

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POSSIBLE CAUSE

TROUBLESHOOTING CHART-B/FM 1008/F SERIES

Low fuel level Fuel supply/ return lines clogged Clogged fuel tank vent Fuel pump faulty Fuel entrained with air Unit injector(s) faulty/ worn Unit injector settings incorrect Injection pump rack sticking Oil level too high Improper oil viscosity Oil diluted by fuel Oil pressure relief valve faulty Oil pick-up tube clogged Oil pump air entrained at pick-up tube Glow plugs faulty Glow plug controller faulty Glow plug relay inoperable Starter defective Battery voltage too low Battery / battery cable connections corroded Key switch defective Air filter clogged Excessive idle / light load operation Incomplete engine run-in Engine overloaded Excessive parasitic load Valve lash insufficient / excessive Injection timing out of spec- advanced Injection timing out of spec- retarded Governor linkage adjustment incorrect Governor spring fatigued or defective Idle rpm too low Piston rings worn or stuck Piston worn or damaged Cylinders worn or damaged Valves / valve guides worn Valves sticking Bearings (main / rod) worn Governor / governor linkage malfunction Cylinder head gasket damaged Thermostat stuck or malfunctioning Engine seized Radiator clogged (external or internal) Coolant pump faulty Turbocharger faulty

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SAFETY AND WARNING DECALS - SAFETY INSTRUCTIONS

Failure to comply with the instructions could result in damage to persons and property

Failure to comply with the instructions could lead to technical damage to the machine and/or system

DANGER

SAFETY AND WARNING DECALS

CAUTION

SAFETY INSTRUCTIONS

●

Deutz Engines are built to supply their performances in a safe and long-lasting way. To obtain these results, it is essential for users to comply with the servicing instructions given in the relative manual along with the safety recommendations listed below.

●

The engine has been made according to a machine manufacturer's specifications and all actions required to meet the essential safety and health safeguarding requisites have been taken, as prescribed by the current laws in merit. All uses of the engine beyond those specifically established cannot therefore be considered as conforming to the use defined by Deutz which thus declines all liability for any accidents deriving from such operations.

●

The following indications are dedicated to the user of the machine in order to reduce or eliminate risks concerning engine operation in particular, along with the relative routine maintenance work.

●

The user must read these instructions carefully and become familiar with the operations described. Failure to do this could lead to serious danger for his personal safety and health and that of any persons who may be in the vicinity of the machine.

●

The engine may only be used or assembled on a machine by technicians who are adequately trained about its operation and the deriving dangers. This condition is also essential when it comes to routine and, above all, extraordinary maintenance operations which, in the latter case, must only be carried out by persons specifically trained by Deutz and who work in compliance with the existing documentation.

●

Variations to the functional parameters of the engine, adjustments to the fuel flow rate and rotation speed, removal of seals, demounting and refitting of parts not described in the operation and maintenance manual by unauthorized personnel shall relieve Deutz from all and every liability for deriving accidents or for failure to comply with the laws in merit.

●

On starting, make sure that the engine is as horizontal as possible, unless the machine specifications differ. In the case of manual start-ups, make sure that the relative actions can take place without the risk of hitting walls or dangerous objects, also considering the movements made by the operator. Pull-starting with a free cord (thus excluding self-winding starting only), is not permitted even in an emergency.

●

Make sure that the machine is stable to prevent the risk of overturning.

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SAFETY AND WARNING DECALS - SAFETY INSTRUCTIONS

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●

Become familiar with how to adjust the rotation speed and stop the engine.

●

Never start the engine in a closed place or where there is insufficient ventilation. Combustion creates carbon monoxide, an odourless and highly poisonous gas. Lengthy stays in places where the engine freely exhausts this gas can lead to unconsciousness and death.

●

The engine must not operate in places containing inflammable materials, in explosive atmospheres, where there is dust that can easily catch fire unles specific, adequate and clearly indicated precautions have been taken and have been certified for the machine.

●

To prevent fire hazards, always keep the machine at least one meter from buildings or from other machinery.

●

Children and animals must be kept at a due distance from operating machines in order to prevent hazards deriving from their operation.

●

Fuel is inflammable. The tank must only be filled when the engine is off. Thoroughly dry any spilt fuel and move the fuel container away along with any rags soaked in fuel or oil. Make sure that no soundproofing panels made of porous material are soaked in fuel or oil. Make sure that the ground or floor on which the machine is standing has not soaked up any fuel or oil.

●

Fully tighten the tank plug each time after refuelling. Do not fill the tank right to the top but leave an adequate space for the fuel to expand.

●

Fuel vapour is highly toxic. Only refuel outdoors or in a well ventilated place.

●

Do not smoke or use naked flames when refuelling.

●

The engine must be started in compliance with the specific instructions in the operation manual of the engine and/or machine itself. Do not use auxiliary starting aids that were not installed on the original machine (e.g. Startpilot’).

●

Before starting, remove any tools that were used to service the engine and/or machine. Make sure that all guards have been refitted.

●

During operation, the surface of the engine can become dangerously hot. Avoid touching the exhaust system in particular.

●

Before proceeding with any operation on the engine, stop it and allow it to cool. Never carry out any operation whilst the engine is running.

●

The coolant fluid circuit is under pressure. Never carry out any inspections until the engine has cooled and even in this case, only open the radiator plug or expansion chamber with the utmost caution, wearing protective garments and goggles. If there is an electric fan, do not approach the engine whilst it is still hot as the fan could also start operating when the engine is at a standstill. Only clean the coolant system when the engine is at a standstill.

●

When cleaning the oil-cooled air filter, make sure that the old oil is disposed of in the correct way in order to safeguard the environment. The spongy filtering material in oil-cooled air filters must not be soaked in oil. The reservoir of the separator pre-filter must not be filled with oil.

●

The oil must be drained whilst the engine is hot (oil T ~ 80°C). Particular care is required to prevent burns. Do not allow the oil to come into contact with the skin.

●

Make sure that the drained oil, the oil filter and the oil it contains are disposed of in the correct way in order to safeguard the environment.

●

Pay attention to the temperature of the oil filter when the filter itself is replaced.

●

Only check, top up and change the coolant fluid when the engine is off and cold. Take care to prevent fluids containing nitrites from being mixed with others that do not contain these substances since "Nitrosamine", dangerous for the health, can form. The coolant fluid is polluting and must therefore be disposed of in the correct way to safeguard the environment.

●

During operations that involve access to moving parts of the engine and/or removal of rotating guards, disconnect and insulate the positive wire of the battery to prevent accidental short-circuits and to stop the starter motor from being energized.

●

Only check belt tension when the engine is off.

●

Only use the eyebolts installed by Deutz to move the engine. These lifting points are not suitable for the entire machine; in this case, the eyebolts installed by the manufacturer should be used.

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All pertinent information needed for engine identification and spare parts ordering can be accessed from the engine data plate. Additionally, the maximum engine speed, “K” number and approval codes are included on the engine data plate. The location of the data plate, as shown below, is identical for all DEUTZ B/FM 1008/F industrial engines. Please supply the engine data plate information to your Authorized DEUTZ Distributor or Dealer when ordering replacement parts or when making technical inquiries.

I GENERAL

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GENERAL I

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POWER RATINGS FOR B/FM 1008/F GENSET SPEC

DIESEL ENGINES

CONTINUOUS (NA) RATING- kW

ENGINE 1500 1800 3000 3600 MODEL r/min r/min r/min r/min

F2M 1008

F3M 1008

F4M 1008

BF4M 1008

F2M 1008 F

F3M 1008 F

F4M 1008 F

NOTE:

THE ABOVE RATINGS ARE FLYWHEEL OUTPUT, NOT ELECTRICAL GENSET OUTPUT

4.5 5.4 9.0 9.9

6.7 8.1 14.0 14.9

9.0 10.8 18.9 19.9

11.7 14.0 24.8 25.8

5.0 5.9 9.9 10.6

7.7 9.0 14.9 16.3

9.9 11.7 19.8 22.8

INTERMITTENT (NB) RATING- kW

ENGINE 1500 1800 3000 3600 MODEL r/min r/min r/min r/min

F2M 1008

5.0 6.0 10.0 11.0

F3M 1008

F4M 1008

BF4M 1008

F2M 1008 F

F3M 1008 F

F4M 1008 F

NOTE:

THE ABOVE RATINGS ARE FL

7.5 9.0 15.5 16.5

10.0 12.0 21.0 22.0

13.0 15.5 27.5 28.5

5.5 6.5 11.0 11.7

8.5 10.0 16.5 18

11.0 13.0 22.0 25

YWHEEL OUTPUT, NOT ELECTRICAL GENSET OUTPUT

POWER RATING STANDARDS

- ISO 3046/1-IFN - Maximum intermittent rating with no overload capacity; operation with constant speed and variable load.

ISO 3046/1-ICXN- Continuous rating with 10% intermittent overload allowed; operation with constant speed and constant load.

Standard Rating Conditions Standard Production Power Tolerance Standard/ General Derations

: 25°C, 100kPa Total Barometric Pressure, 30% Relative Humidity.

= +/- 5%

: 2% per 5°C increase in temperature over 25°C; 1% per 100m over mean sea level

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I GENERAL

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B/FM 1008 SERIES- TECHNICAL SPECIFICATIONS AND CAPACITIES

TECHNICAL SPECIFICATIONS F2M 1008

No. of Cylinders 2 3 4 4 Firing Order 1-2 1-3-2 1-3-4-2 1-3-4-2 Cylinder Bore (mm) 72 72 72 72 Cylinder Stroke (mm) 75 75 75 75 Displacement (cc) 611 916 1222 1222 Aspiration Type Natural Natural Natural Turbo Compression Ratio 22.8:1 22.8:1 22.8:1 22.8:1 RPM- maximum 3600 3600 3600 3600 Power- (N)- ISO 1585- KW(CV)-@3600 r/min 11.8(16.0) 17.2(23.4) 24.4(33.2) 31.0(42.0) Power- (Nb)- ISO 3046-1 IFN- KW(CV)-@3600 r/min 10.3(14.0) 15.6(21.2) 22.0(30.0) 28.5(38.7) Power- (Na)- ISO 3046-1 ICXN- KW(CV)-@3600 r/min 9.2(12.5) 13.7(18.6) 19.9(27.0) 25.8(35.0) Torque(MAX)/rpm @Nb output, (Nm) 34.5/2200 53.5/2000 75.1/2200 98/2400 Maximum Torque Available @ N0. 3 PTO (Nm) 37/1800 37/1800 37/1800 37/1800 Fuel Consumption (Nb)@3600 rpm- (g/KWh) 282 300 290 305 Oil Consumption (Na)- (Kg/hr) 0.007 0.012 0.017 0.019 Dry Weight- (Kg) 65 85 96 101 Inclination (max)- (30 seconds) 35 Inclination (max)- (60 seconds) 30 Inclination (continuous)- APPLICATION DEPENDENT **** **** **** **** Axial Load (max) on Crankshaft (both directions)- (Kg) 300 300 300 300 Radial (side) Load - APPLICATION DEPENDENT **** **** **** ****

F3M 1008 F4M 1008 BF4M 1008

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**** - CONTACT DEUTZ APPLICATION ENGINEERING DEPARTMENT FOR DETAILS

FLUID CAPACITIES (STANDARD)

TECHNICAL SPECIFICATIONS F2M 1008 F3M 1008 F4M 1008 BF4M 1008

Oil Capacity (including oil filter)- (liters) 1.6 2.4 3.2 4.3 Oil Capacity (less oil filter)- (liters) 1.5 2.3 3.0 4.1 Coolant Capacity (including std. radiator)- (liters) 4.0 4.9 6.0 7.5 Coolant Capacity (engine only)- (liters) 0.9 1.3 1.8 2.0 Fuel Tank-standard (OPTIONAL)- (liters) 4.3 10.0 15.0 15.0

NOTE:

The above cooling system capacities (including radiator) assume that the radiator fitted to your Deutz B/FM 1008 series diesel engine is the standard Deutz radiator. Different OEM machines may or may not be fitted with a standard Deutz radiator. Always refer to your equipment documentation for capacity details.

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F2M 1008

F3M 1008

F4M 1008

BF4M 1008

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GENERAL I

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I GENERAL

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FM 1008 F SERIES- TECHNICAL SPECIFICATIONS AND CAPACITIES

TECHNICAL SPECIFICATIONS F2M 1008 F

No. of Cylinders 2 3 4 Firing Order 1-2 1-3-2 1-3-4-2 Cylinder Bore (mm) 75 75 75 Cylinder Stroke (mm) 77.6 77.6 77.6 Displacement (cc) 686 1028 1372 Aspiration Type Natural Natural Natural Compression Ratio 22.8:1 22.8:1 22.8:1 RPM- maximum 3600 3600 3600 Power- (N)- ISO 1585- KW(CV)-@3600 r/min 13(17.7) 20(27.2) 27.2(36.7) Power- (Nb)- ISO 3046-1 IFN- KW(CV)-@3600 r/min 11.7(16) 18(24.5) 25(34) Power- (Na)- ISO 3046-1 ICXN- KW(CV)-@3600 r/min 10.6(14.4) 16.3(22.2) 22.8(31) Torque(MAX)/rpm @Nb output, (Nm) 40/2200 59/2200 82.5/2200 Maximum Torque Available @ N0. 3 PTO (Nm) 37/1800 37/1800 37/1800 Fuel Consumption (Nb)@3600 rpm- (g/KWh) 320 300 325 Oil Consumption (Na)- (Kg/hr) 0.009 0.013 0.019 Dry Weight- (Kg) 66 87 98 Inclination (max)- (30 seconds) 35 Inclination (max)- (60 seconds) 30 Inclination (continuous)- APPLICATION DEPENDENT **** **** **** Axial Load (max) on Crankshaft (both directions)- (Kg) 300 300 300 Radial (side) Load - APPLICATION DEPENDENT **** **** ****

F3M 1008 F F4M 1008 F

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**** - CONTACT DEUTZ APPLICATION ENGINEERING DEPARTMENT FOR DETAILS

FLUID CAPACITIES (STANDARD)

TECHNICAL SPECIFICATIONS F2M 1008 F3M 1008 F4M 1008

Oil Capacity (including oil filter)- (liters) 1.6 2.4 3.2 Oil Capacity (less oil filter)- (liters) 1.5 2.3 3.0 Coolant Capacity (including std. radiator)- (liters) 2.3 4.9 6.0 Coolant Capacity (engine only)- (liters) 0.9 1.3 1.7 Fuel Tank-standard (OPTIONAL)- (liters) 4.3 4.3 10.0

NOTE:

The above cooling system capacities (including radiator) assume that the radiator fitted to your Deutz FM 1008 F series diesel engine is the standard Deutz radiator. Different OEM machines may or may not be fitted with a standard Deutz radiator. Always refer to your equipment documentation for capacity details.

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GENERAL I

F2M 1008 F

F3M 1008 F

F4M 1008 F

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I GENERAL

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POWER, TORQUE AND SPECIFIC FUEL CONSUMPTION CURVES

F2M 1008 F3M 1008

F2/3M

1008

- 80/1269/CEE- ISO 1585, Gross automotive rating- intermittent operation with variable speed and variable load.

- ISO 3046/1-IFN - Maximum intermittent rating with no overload capacity; operation with constant speed and variable load. ISO 3046/1-ICXN- Continuous rating with 10% intermittent overload allowed; operation with constant speed and constant load.

M(X)

- Torque at N,NB and NA ratings respectively.

- Specific fuel consumption at NB rating.

Standard Rating Conditions: Standard Production Power Tolerance Standard/ General Derations:

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25°C, 100kPa Total Barometric Pressure, 30% Relative Humidity.

= +/- 5%

2% per 5°C increase in temperature over 25°C; 1% per 100m over mean sea level

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GENERAL I

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POWER, TORQUE AND SPECIFIC FUEL CONSUMPTION CURVES

F4M 1008, BF4M 1008

F4M 1008 BF4M 1008

- 80/1269/CEE- ISO 1585, Gr

M(X)

- Torque at N,NB and NA ratings respectively.

- Specific fuel consumption at NB rating.

Standard Rating Conditions: Standard Production Power Tolerance Standard/ General Derations:

oss automotive rating- intermittent operation with variable speed and variable load.

25°C, 100kPa Total Barometric Pressure, 30% Relative Humidity.

= +/- 5%

2% per 5°C increase in temperature over 25°C; 1% per 100m over mean sea level

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I GENERAL

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POWER, TORQUE AND SPECIFIC FUEL CONSUMPTION CURVES

F2M 1008 F F3M 1008 F

F2/3/4M

1008 F

F4M 1008 F

- 80/1269/CEE- ISO 1585, Gross automotive rating- intermittent operation with variable speed and variable load.

M(X)

- Torque at N,NB and NA ratings respectively.

- Specific fuel consumption at NB rating.

Standard Rating Conditions: Standard Production Power Tolerance Standard/ General Derations:

25°C, 100kPa Total Barometric Pressure, 30% Relative Humidity.

= +/- 5%

2% per 5°C increase in temperature over 25°C; 1% per 100m over mean sea level

2001 / 0297 9985

20©

GENERAL ENGINEERING DRAWINGS- F2/3M 1008

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F2M 1008

GENERAL I

F3M

1008

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I GENERAL

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GENERAL ENGINEERING DRAWINGS- F4M 1008, BF4M 1008

F4M 1008

BF4M

1008

2001 / 0297 9985

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GENERAL ENGINEERING DRAWINGS- F2/3/4M 1008 F

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GENERAL I

F2M 1008

F3M 1008 F

F4M 1008 F

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I GENERAL

(D) Add fluid(s) as required (•) After inspection, adjust, r

epair or replace as required (●) Clean as often as required (*) Replace air filter after air filter restriction switch indication or one(1) year. DEUTZ does not

recommend the removal of air filter elements for purposes of inspection.

(**) Service oil bath filter element (upper and lower) as required. Replace reservoir oil as required.

NOTE:

In dusty conditions, service the oil bath air filter every four(4) hours.

(***) Replace coolant every 1000 hours or 2 years

NOTES:

1. USE ONLY GENUINE DEUTZ REPLACEMENT PARTS.

2. USE ONLY DEUTZ APPROVED FLUIDS.

MAINTENANCE OPERATION

OIL LEVEL CHECK (D)

•

COOLANT LEVEL CHECK (D)

•

FAN/ ALTERNATOR BELT INSPECTION (•)

• AIR FILTER ELEMENT CHECK (DRY TYPE) (*) AIR FILTER CHECK (OIL BATH TYPE) (**)

• RADIATOR CORE INSPECTION

(●)

• FLUID LEAK INSPECTION- GENERAL (•)

• SAFETY GUARD INSPECTION (•)

• OIL REPLACEMENT- INITIAL ONLY-(see RECOMMENDED OIL TYPE)

•

OIL FILTER REPLACEMENT - INITIAL ONLY

•

OIL REPLACEMENT- (see RECOMMENDED OIL TYPE)

•

OIL FILTER REPLACEMENT

•

FUEL FILTER REPLACEMENT

•

COOLANT HOSE INSPECTION

•

FAN/ ALTERNATOR BELT TENSION ADJUSTMENT

•

VALVE ADJUSTMENT

•

FAN/ ALTERNATOR BELT REPLACEMENT

•

FUEL INJECTION SYSTEM ADJUSTMENT

•

CLEAN FUEL TANK (

●

)

•

COOLANT REPLACEMENT (***)

•

REPLACE TIMING

BELT

•

MAINTENANCE INTERVAL

hours

DAILY

see note

hours

125

hours

250

hours

500

hours

1000

hours

2500

hours

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Failure and/or system

to carry out the operations described in the table may lead to technical damage to the machine

B/FM 1008/F SERIES MAINTENANCE SCHEDULE

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GENERAL I

0 5 10 15 20 25 30°C-5-10-15-20-25-30

SAE 0W-30 SAE 0W-40 SAE 5W-30 SAE 5W-40

SAE 10W-30 SAE 10W-40

SAE 15W-30

SAE 20W-50

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The engine could be damaged if allowed to operate with insufficient oil. It is also dangerous to add too much oil as its combustion could sharply increase the rotation speed. Use a suitable oil in order to protect the engine. The lubrication oil influences the performances and life of the engine in an incredible way. Use of an inferior quality oil or failure to regularly change the oil will increase the risk of piston seizure, may make the compression rings jam and will lead to rapid wear on the cylinder liner, the bearings and all other moving parts. Engine life will also be notably reduced. Oil viscosity must suit the ambient temperature in which the engine operates.

Old oil can cause skin cancer if repeatedly left in contact with the skin and for long periods of time. If contact with the oil is inevitable, you are advised to thoroughly wash your hands with soap and water as soon as possible. Appropriate protective gloves etc should be wore during this operation. Old oil is highly polluting and must be disposed of in the correct way. Do not litter.

RECOMMENDED OIL

SINT 2000 5W40 specification API SJ/CF ACEA A3-96

AGIP B3-96 MIL-L-46152 D/E. ESSO ULTRA 10W40 specification API SJ/CF ACEA A3-96 MIL-L-46152 D/E. In countries where AGIP and ESSO products are not available, use API SJ/CF oil for gasoline-fuelled engines or oil that complies with military specification MIL-L-46152 D/E.

OIL SUPPLY (liters) F2M 1008/F Standard oil sump filter included 1.6 filter excluded 1.5

OIL SUPPLY (liters) F3M 1008/F Standard oil sump filter included 2.4 filter excluded 2.3

OIL SUPPLY (liters) F4M 1008/F Standard oil sump filter included 3.2 filter excluded 3.0

OIL SUPPLY (liters) BF4M 1008 Standard oil sump filter included 4.3 filter excluded 4.1

GRADE

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