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

4.4 (33)
Deutz F3M 1011F, BF3M, F4M, BF4M Service Manual

Deutz Engines

F3M 1011F

BF3M 1011F

F4M 1011F

BF4M 1011F

Used In:

SL4635, SL4835,

SL5635, SL6635

Skid-Steer Loaders

Engine Service Parts Manual

Form No.

917115

Rev. B

11/05

®

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.

i

Table of Contents

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . i REAR END COVER . . . . . . . . . . . . . . . . . . . . . 1 DIPSTICK & DIPSTICK GUIDE . . . . . . . . . . . . 2 CRANKCASE BREATHER . . . . . . . . . . . . . . . . 3 CAP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ENGINE BLOCK . . . . . . . . . . . . . . . . . . . . . . . . 5 OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 CRANKSHAFT ACCESSORIES . . . . . . . . . . . . 7 CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . 8 POWER TAKE-OFF . . . . . . . . . . . . . . . . . . . . . 9 COVER PLATE . . . . . . . . . . . . . . . . . . . . . . . . 10 FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 CONNECTING ROD . . . . . . . . . . . . . . . . . . . . 12 PISTON. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 FILLER CAP . . . . . . . . . . . . . . . . . . . . . . . . . . 14 CYLINDER HEAD FASTENINGS . . . . . . . . . . 15 CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . 16 VALVE MECHANICAL COVER . . . . . . . . . . . . 17 CAMSHAFT DRIVE . . . . . . . . . . . . . . . . . . . . 18 CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 19 PROTECTION HOOD & FASTENINGS . . . . . 20 ROCKER ARM BRACKET . . . . . . . . . . . . . . . 21 VALVE DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . 22 LUBRICATION OIL PUMP . . . . . . . . . . . . . . . 23 OIL FILTER & FASTENINGS . . . . . . . . . . . . . 24 LUBRICATION OIL LINE. . . . . . . . . . . . . . . . . 25 OIL SUCTION LINE . . . . . . . . . . . . . . . . . . . . 26 OIL RETURN LINE . . . . . . . . . . . . . . . . . . . . . 27 HEATER CONNECTION. . . . . . . . . . . . . . . . . 28 RADIATOR CONNECTION. . . . . . . . . . . . . . . 29 SCREW PLUG . . . . . . . . . . . . . . . . . . . . . . . . 30 FUEL INJECTOR PUMP. . . . . . . . . . . . . . . . . 31 FUEL INJECTOR . . . . . . . . . . . . . . . . . . . . . . 32 FUEL SUPPLY PUMP . . . . . . . . . . . . . . . . . . . 35

FUEL LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . 37 HIGH PRESSURE PIPE . . . . . . . . . . . . . . . . . 38 OVERFLOW LINE. . . . . . . . . . . . . . . . . . . . . . 39 SUCTION PIPE FLANGE . . . . . . . . . . . . . . . . 40 SUCTION PIPE. . . . . . . . . . . . . . . . . . . . . . . . 41 INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . 42 TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . 43 CHARGE AIR PIPE. . . . . . . . . . . . . . . . . . . . . 44 CHARGE AIR ELBOW . . . . . . . . . . . . . . . . . . 45 TRANSFER PIPE . . . . . . . . . . . . . . . . . . . . . . 46 AIR FILTER FITMENT . . . . . . . . . . . . . . . . . . 47 GLOW PLUG . . . . . . . . . . . . . . . . . . . . . . . . . 48 BUFFER SPRING . . . . . . . . . . . . . . . . . . . . . . 49 TORQUE CAPSULE . . . . . . . . . . . . . . . . . . . . 50 FRONT COVER/GOVERNOR . . . . . . . . . . . . 51 CONTROL ROD . . . . . . . . . . . . . . . . . . . . . . . 53 NARROW V-BELT. . . . . . . . . . . . . . . . . . . . . . 54 FAN SUPPORT. . . . . . . . . . . . . . . . . . . . . . . . 55 ADAPTER HOUSING . . . . . . . . . . . . . . . . . . . 56 AIR COMPRESSOR . . . . . . . . . . . . . . . . . . . . 57 STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 ALTERNATOR. . . . . . . . . . . . . . . . . . . . . . . . . 59 ALTERNATOR BRACKET. . . . . . . . . . . . . . . . 60 ALTERNATOR FASTENINGS. . . . . . . . . . . . . 61 COOLING AIR BAFFLE . . . . . . . . . . . . . . . . . 62 OIL PRESSURE SWITCH. . . . . . . . . . . . . . . . 63 TEMPERATURE TRANSMITTER. . . . . . . . . . 64 EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . 65 CONNECTING PIPE. . . . . . . . . . . . . . . . . . . . 67 CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . 68 SHUTDOWN DEVICE. . . . . . . . . . . . . . . . . . . 69 GASKET SET . . . . . . . . . . . . . . . . . . . . . . . . . 70 INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

ii

REAR END COVER

1011F DEUTZ ENGINE

 

 

3

1

2

4

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

 

 

6

2

 

5

8

1

 

7

3

4

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

 

 

2

1

4

5

3

6

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

 

 

1

2

2

3

2

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

 

 

 

 

 

10

14

 

 

 

 

 

 

 

 

 

 

 

 

 

11

 

23

 

 

 

 

21

8

 

 

 

 

 

 

 

 

 

 

 

25

 

 

7

 

 

1

 

 

 

 

 

19

 

 

 

 

 

 

 

 

 

 

 

 

18

 

 

 

 

 

 

 

 

 

 

 

6

 

 

 

24

9

 

 

 

 

 

 

12

 

 

 

 

 

 

 

 

 

 

 

17

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5

 

 

 

22

 

 

7

 

 

 

 

 

 

 

 

16

 

 

 

4

 

2

 

 

 

 

 

 

 

 

 

 

13

20

 

3

 

 

 

 

 

15

 

 

 

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

 

 

8

1

3

 

2

 

4

7

 

5

 

 

4

 

6

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

 

 

2

3

1

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

 

 

1

5

3

4

2

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 10 X 1 X 15MM

1

1

PRINTED IN USA

8

917115/BP1105

POWER TAKE-OFF

1011F DEUTZ ENGINE

 

 

1

2

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

 

 

3

1

2

 

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

 

 

1

3

2

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

 

 

4

2

1

3

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

 

 

4

A

A 1

B 5

B

C 6

C

 

 

 

 

 

 

2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Ref

Part

 

 

3

 

 

 

 

 

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

 

 

2

3

1

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

 

 

1

3

4

2

5

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

 

 

9

8

7

1

6

2

3

10

 

5 4

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

 

 

 

4

3

5

 

 

6

1

2

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

 

 

6

5

5

6

8

3

 

 

1

7

 

2

 

 

 

4

 

 

 

 

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

 

 

2

3

1

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

 

 

3

2

 

 

 

 

4

 

 

 

 

1

 

 

5

 

 

 

 

 

 

 

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

 

 

5

4

2

5

 

4

1

3

2

6

2

1

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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