Deutz F3M 1011F, BF3M, F4M, BF4M Service Manual

Form No.

Deutz Engines

F3M 1011F

BF3M 1011F

F4M 1011F

BF4M 1011F

Used In:

SL4635, SL4835,

SL5635, SL6635

Skid-Steer Loaders

917115

Rev. B

11/05

Engine Service Parts Manual

Introduction

This manual covers F3M 1011F and BF3M 1011F engines used in SL4635 and SL4835 skid-steer loaders and F4M 1011F and BF4M 1011F engines used in SL5635 and SL6635 skid-steer loaders. When ordering service parts, specify the correct part number, full description, quantity required, and the engine model number and serial number (located on a plate on the valve mechanical cover).

Items shown that do not have a part number are shown for reference purposes only and are not available for purchase separately.

Use only genuine original equipment manufacturer service parts. All service parts should be obtained from or ordered through your Gehl® dealer.

Gehl® Company reserves the right to make changes or improvements in the design or construction of any part of the unit without incurring the obligation to install such changes on any previously delivered units.

Table of Contents

Introduction.............................i

REAR END COVER .....................1

DIPSTICK & DIPSTICK GUIDE ............2

CRANKCASEBREATHER................3

CAP..................................4

ENGINEBLOCK........................5

OILPAN ..............................6

CRANKSHAFTACCESSORIES............7

CRANKSHAFT.........................8

POWER TAKE-OFF .....................9

COVERPLATE........................10

FLYWHEEL...........................11

CONNECTING ROD ....................12

PISTON..............................13

FILLER CAP ..........................14

CYLINDER HEAD FASTENINGS ..........15

CYLINDERHEAD......................16

VALVEMECHANICALCOVER............17

CAMSHAFTDRIVE ....................18

CAMSHAFT ..........................19

PROTECTION HOOD & FASTENINGS .....20

ROCKERARMBRACKET...............21

VALVEDRIVE.........................22

LUBRICATIONOILPUMP ...............23

OIL FILTER & FASTENINGS .............24

LUBRICATIONOILLINE.................25

OILSUCTIONLINE ....................26

OILRETURNLINE.....................27

HEATER CONNECTION.................28

RADIATOR CONNECTION...............29

SCREWPLUG ........................30

FUELINJECTORPUMP.................31

FUELINJECTOR ......................32

FUELSUPPLYPUMP...................35

FUELLINE ...........................36

FUELFILTER .........................37

HIGH PRESSURE PIPE .................38

OVERFLOWLINE......................39

SUCTION PIPE FLANGE ................40

SUCTION PIPE........................41

INTAKEMANIFOLD....................42

TURBOCHARGER.....................43

CHARGE AIR PIPE.....................44

CHARGE AIR ELBOW ..................45

TRANSFER PIPE ......................46

AIR FILTER FITMENT ..................47

GLOWPLUG .........................48

BUFFER SPRING ......................49

TORQUE CAPSULE ....................50

FRONTCOVER/GOVERNOR ............51

CONTROL ROD .......................53

NARROW V-BELT......................54

FANSUPPORT........................55

ADAPTER HOUSING ...................56

AIR COMPRESSOR ....................57

STARTER ............................58

ALTERNATOR.........................59

ALTERNATOR BRACKET................60

ALTERNATOR FASTENINGS.............61

COOLING AIR BAFFLE .................62

OILPRESSURESWITCH................63

TEMPERATURE TRANSMITTER..........64

EXHAUSTMANIFOLD..................65

CONNECTING PIPE....................67

CONTROL UNIT .......................68

SHUTDOWN DEVICE...................69

GASKET SET .........................70

INDEX...............................71

REAR END COVER 1011F DEUTZ ENGINE

Ref Part No. No. Description Quantity

1 133390 COVER/REAR END 1 2 133204 BOLT/HEX 8X 30MM CLASS 8.8 8 3 133387 SEAL/ROTATION SHAFT LIP 1 4 133100 COMPOUND/PACKING 250 ML 1

917115/BP1105

1 PRINTED IN USA

1011F DEUTZ ENGINE DIPSTICK & DIPSTICK GUIDE

Ref Part Quantity No. No. Description F3M/BF3M F4M/BF4M

1 133555 TUBE/GUIDE 1 -

187192 TUBE/GUIDE - 1 2 133556 CLAMP/PIPE 1 1 3 187233 BOLT/TORX HEAD 1 1 4 133134 RING/SEALING 1 1

5 187267 NUT/HEX 1 1 6 187227 BOLT/HEX 1 1 7 133561 BRACKET 1 1 8 135503 DIPSTICK 1 -

133562 DIPSTICK - 1

PRINTED IN USA

2 917115/BP1105

CRANKCASE BREATHER 1011F DEUTZ ENGINE

Ref Part Quantity No. No. Description BF4M

1 133552 PIPE/BREATHER 1 2 133202 CLIP/HOSE 1 3 133212 CLIP/HOSE 1 4 133553 GASKET 1 5 133482 CAP 1

6 187221 BOLT/HEX 2

917115/BP1105

3 PRINTED IN USA

1011F DEUTZ ENGINE CAP

Turbo Engines Only

Ref Part Quantity No. No. Description F3M/F4M BF3M

1 135520 CAP 1 -

133518 PLUG - 1 2 133202 CLIP/HOSE 1 2 3 133481 HOSE 50MM - 1

PRINTED IN USA

4 917115/BP1105

ENGINE BLOCK 1011F DEUTZ ENGINE

Ref Part Quantity No. No. Description F3M F4M BF3M BF4M

1 135518 BLOCK/ENGINE (INCLUDES ITEMS 2-18) 1 - - -

133436 BLOCK/ENGINE (INCLUDES ITEMS 2-18) - 1 - 133519 BLOCK/ENGINE (INCLUDES ITEMS 2-18) - - 1 133437 BLOCK/ENGINE (INCLUDES ITEMS 2-18) - - - 1

2 133405 BUSHING/WRAPPED BEARING 2 2 2 2

3 133404 BUSHING/WRAPPED BEARING 2 3 2 3 4 133316 SLEEVE/GUIDE 2 2 2 2 5 133430 PLUG/SCREW 1 1 1 1 6 133536 PLUG/SCREW 12 X 1.5MM 1 1 - 1

133520 PLUG/SCREW - - 2 -

7 133537 PLUG/SCREW 2 2 - 2 8 133538 PLUG/SCREW 14 X 1.5MM 1 1 1 1

9 133539 PLUG/SCREW 10 X 1MM 1 1 1 1 10 133540 PLUG/SCREW 20 X 1.5MM 1 1 1 1 11 133408 TUBE 1 1 1 1

12 133541 PLUG/SCREW 1 1 1 1 13 133166 COVER 1 1 1 1 14 133240 STUD 6 8 6 8 15 133542 PLUG/SCREW 18 X 1.5MM 1 2 2 2 16 133323 BOLT/HEX 8 10 8 10

17 133350 BUSHING 8 10 8 10 18 133473 THERMOSTAT (INCLUDES ITEM 19) 1 1 1 1 19 133411 SPRING/COMPRESSION 1 1 1 1 20 133417 NOZZLE/PISTON COOLING 6 6 6 6 21 187508 COVER 1 1 - 1

133249 COVER - - 1 22 133476 PIN - 1 - 1 23 133543 LINER/CYLINDER AR AR - AR 24 187243 O-SEAL 1 1 1 1 25 133107 SAFETY/LOCK AGENT 50 ML AR AR AR AR

917115/BP1105

5 PRINTED IN USA

1011F DEUTZ ENGINE OIL PAN

Ref Part Quantity

No. No. Description F3M/BF3M F4M/BF4M

1 187145 PAN/OIL 1 -

187100 PAN/OIL - 1 2 187276 PLUG/SCREW 1 1 3 133138 RING/SEALING 1 1 4 133137 RING/SEALING 3 2

5 133149 PLUG/SCREW 2 1 6 187271 PLUG/SCREW 1 1 7 187234 BOLT/TORX HEAD 22 26 8 133104 COMPOUND/PACKING AR AR

PRINTED IN USA

6 917115/BP1105

CRANKSHAFT ACCESSORIES 1011F DEUTZ ENGINE

Ref Part No. No. Description Quantity

1 133325 BOLT/HEX 1 2 133370 PULLEY/SYNCHRONOUS BELT 1 3 133381 FLANGE/OUTPUT 1

917115/BP1105

7 PRINTED IN USA

1011F DEUTZ ENGINE CRANKSHAFT

Ref Part Quantity No. No. Description F3M/BF3M F4M/BF4M

1 133522 CRANKSHAFT (INCLUDES ITEMS 2-4) 1 -

133486 CRANKSHAFT (INCLUDES ITEMS 2-4) - 1 2 133487 BEARING/MAIN STANDARD 70MM 4 4 2A 133488 BEARING/MAIN 1ST UNDERSIZE 69.75MM 4 4 2B 133489 BEARING/MAIN 2ND UNDERSIZE 69.50MM 4 4

3 133338 WASHER/THRUST STANDARD 2.4MM 1 1 3A 133339 WASHER/THRUST 1ST OVERSIZE 2.6MM 1 1 4 135531 BEARING/BIG END STANDARD 55MM 3 -

133490 BEARING/BIG END STANDARD 55MM - 4 4A 135532 BEARING/BIG END 1ST UNDERSIZE 54.75MM 3 -

187520 BEARING/BIG END 1ST UNDERSIZE 54.75MM - 3 4B 135533 BEARING/BIG END 2ND UNDERSIZE 54.50MM 3 -

187521 BEARING/BIG END 2ND UNDERSIZE 54.50MM - 3 5 133515 INSERT/THREADED 10X1X15MM 1 1

PRINTED IN USA

8 917115/BP1105

POWER TAKE-OFF 1011F DEUTZ ENGINE

Ref Part Quantity No. No. Description F3M F4M BF3M BF4M

1 133508 PULLEY/V-GROOVED 1 - - -

133521 PULLEY/V-GROOVED - 1 1 1

2 187240 BOLT/HEX 4 4 4 4

917115/BP1105

9 PRINTED IN USA

1011F DEUTZ ENGINE COVER PLATE

Ref Part No. No. Description Quantity

1 187126 PLATE/COVER 1 2 187127 BOLT/HEX 6 X 10MM CLASS 8.8 3 3 187128 WASHER/PLAIN 3

PRINTED IN USA

10 917115/BP1105

FLYWHEEL 1011F DEUTZ ENGINE

Ref Part No. No. Description Quantity

1 138861a FLYWHEEL (INCLUDES ITEM 2) 1

133446b FLYWHEEL (INCLUDES ITEM 2) 1

2 138860a RIM/GEAR 1

133445b RIM/GEAR 1

3 133335 BOLT/SCREW 8

a) Used in engines with serial number 618098 and later. b) Used in engines with serial number 618097 and earlier.

917115/BP1105

11 PRINTED IN USA

1011F DEUTZ ENGINE CONNECTING ROD

Ref Part Quantity No. No. Description F3M/F4M BF3M/BF4M

1 133442 ROD/CONNECTING (INCLUDES ITEMS 2-4) 1 -

133586 ROD/CONNECTING (INCLUDES ITEMS 2-4) - 1 2 133441 BOLT/BIG END 2 2 3 133318 NUT 2 2 4 133319 BUSHING/BIG END 29.06-29.10MM 1 -

133357 BUSHING/BIG END 33.07-33.11MM - 1 4A 133320 BUSHING/BIG END OVERSIZE 29.31-29.35MM 1 -

133358 BUSHING/BIG END OVERSIZE 33.32-33.36MM - 1

PRINTED IN USA

12 917115/BP1105

PISTON 1011F DEUTZ ENGINE

Ref Part Quantity No. No. Description F3M/F4M BF3M/BF4M

1 135539 PISTON “A” 1 -

187525 PISTON “A” - 1

2 133317 PIN/PISTON 1 -

133369 PIN/PISTON - 1

3 133157 RING/SNAP 2 -

133159 RING/SNAP - 2

4 133455 RINGS/SET OF PISTON 1 -

133503 RINGS/SET OF PISTON - 1 5 135540 PISTON “B” 1 6 135541 PISTON “C” 1 -

917115/BP1105

13 PRINTED IN USA

1011F DEUTZ ENGINE FILLER CAP

Ref Part

No. No. Description Quantity

1 133444 CAP/FILLER 1 2 187132 PLUG/SCREW 1 3 187133 RING/SEALING 1

PRINTED IN USA

14 917115/BP1105

CYLINDER HEAD FASTENINGS 1011F DEUTZ ENGINE

Ref Part Quantity No. No. Description F3M F4M BF3M BF4M

1 135535 BOLT/CYLINDER HEAD 8 10 8 10 2 133427 PIN/SPIRAL 2 2 2 2 3 135544 GASKET/CYLINDER HEAD 1.48MM 1 - 1 -

133574 GASKET/CYLINDER HEAD 1.48MM - 1 - 1 4 135543 GASKET/CYLINDER HEAD 1.55MM 1 - 1 -

133575 GASKET/CYLINDER HEAD 1.55MM - 1 - 1 5 135542 GASKET/CYLINDER HEAD 1.60MM 1 - 1 -

133576 GASKET/CYLINDER HEAD 1.60MM - 1 - 1

917115/BP1105

15 PRINTED IN USA

1011F DEUTZ ENGINE CYLINDER HEAD

Ref Part Quantity

No. No. Description F3M F4M BF3M BF4M

1 187529 HEAD/CYLINDER (INCLUDES ITEMS 2, 3, 4-9) 1 - - -

187530 HEAD/CYLINDER (INCLUDES ITEMS 2, 3 ,4-9) - 1 - 187531 HEAD/CYLINDER (INCLUDES ITEMS 2, 3, 4-9) - - 1 187547 HEAD/CYLINDER (INCLUDES ITEMS 2, 3, 4-9) - - - 1

2 133403 INSERT/VALVE SEAT EXHAUST 3 4 3 -

187147 INSERT/VALVE SEAT EXHAUST - - - 4 2A 133327 INSERT/VALVE SEAT EXHAUST 1ST OVERSIZE 37.27MM 3 4 3 4 3 187528 INSERT/VALVE SEAT INTAKE 3 4 3 -

187149 INSERT/VALVE SEAT INTAKE - - - 4 3A 133356 INSERT/VALVE SEAT INTAKE 1ST OVERSIZE 42.87MM 3 4 - -

187169 INSERT/VALVE SEAT INTAKE 1ST OVERSIZE 42.87MM - - 3 4 4 187130 VALVE/INLET 3 4 - -

187125 VALVE/INLET - - 3 4 5 187146 VALVE/EXHAUST 3 4 3 4 6 133352 SEAL/VALVE STEM 6 8 6 8

7 133456 SPRING/COMPRESSION 6 8 6 8 8 187148 CAP/SPRING 6 8 6 8 9 133322 COLLET/VALVE 12 16 12 16

10 133106 SAFETY/LOCK AGENT 250ML AR AR AR AR 11 187170 GUIDE/VALVE (NOT SHOWN) 6 8 6 8

PRINTED IN USA

16 917115/BP1105

VALVE MECHANICAL COVER 1011F DEUTZ ENGINE

Ref Part Quantity No. No. Description F3M/BF3M F4M/BF4M

1 135529 COVER/CYLINDER HEAD HARD 1 -

133565 COVER/CYLINDER HEAD HARD - 1

2 135528 GASKET 1 -

133566 GASKET - 1

3 187264 BOLT/HEX 8 10

4 133163 BOLT/HEX - 1 5 133426 VALVE/BREATHER - 1 6 133250 O-SEAL - 1

917115/BP1105

17 PRINTED IN USA

1011F DEUTZ ENGINE CAMSHAFT DRIVE

Ref Part No. No. Description Quantity

1 133378 PULLEY/SYNCHRONOUS BELT 1 2 133242 BOLT/HEX 14 X 1.5 X 110MM CLASS 12.9 1 3 187509 BOLT/HEX 11 4 133324 WASHER/PLAIN 1 5 133144 PLUG/SCREW 2

6 133132 RING/SEALING 2 7 135506 KIT/REPAIR 1 8 133103 COMPOUND/PACKING AR

PRINTED IN USA

18 917115/BP1105

CAMSHAFT 1011F DEUTZ ENGINE

Ref Part Quantity No. No. Description F3M F4M BF3M BF4M

1 187523 CAMSHAFT 1 - - -

187548 CAMSHAFT - 1 - 133526 CAMSHAFT - - 1 133568 CAMSHAFT - - - 1

2 187209 BOLT/HEX 1 1 1 1

3 133367 WASHER/THRUST 1 1 1 1

917115/BP1105

19 PRINTED IN USA

1011F DEUTZ ENGINE PROTECTION HOOD & FASTENINGS

Ref Part No. No. Description Quantity

1 135545 HOOD/PROTECTION (INCLUDES ITEM 4) 1 2 133467 HOOD/PROTECTION 1 3 135534 PLUG 1 4 133216 PLUG 1 5 133145 BOLT/HEX 6 X 70MM CLASS 8.8 4

PRINTED IN USA

20 917115/BP1105

ROCKER ARM BRACKET 1011F DEUTZ ENGINE

Ref Part No. No. Description Quantity

1 133113 CIRCLIP 2 2 133332 ARM/ROCKER 2 3 133333 SCREW/ADJUSTING 2 4 133334 NUT/HEX 2 5 187237 BOLT/TORX HEAD 2

6 133375 BRACKET/ROCKER ARM (INCLUDES ITEMS 1-4) 1

917115/BP1105

21 PRINTED IN USA

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