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Overhauling of a DEUTZ BF4M1013EC engine


 
My latest assignment is the overhauling of an unfortunate, poorly managed DEUTZ, 04 cylinder, water cooled engine coupled to a new COMPAIR C115-12 portable air compressor. This engine was in its infancy and had not yet completed initial 1000 hours of operation when a group of some pseudo specialist mechanics knocked it with all their comprehension of fuel injection systems rendering it unusable for the rest of the life of this fine-looking portable air compressor by damaging its timing gears and associated cam shaft.

The durability of air cooled DEUTZ engines has always fascinated me. Gone are the days of my student being in University of Engineering & Technology (Lahore) when I was under the false consciousness that air cooled engines cannot be operated in the hot, rather harsher climate of Pakistan. Things have changed for me completely after spending four years in the field of earth moving and construction equipment and a bit after reading "Roland Sparling" who leads his life in line with his sayings which are as under.

"Items that are not there, cannot fail!"

"If it ain't broke, don't fix it!"

"There is no such thing as a water-cooled engine, just those that use water as a

Heat-transfer medium, so if you can cut out the Middle-Man, why not?"

"After making the move to Air-Cooled Power, why go backwards?"

"A Porsche with a radiator is not a REAL Porsche."

Anyhow, if it had been the livelihood of some private contractor, lives would have been complicated at least for the pseudo specialist mechanics. But for a company like ours, we are least bothered about the future utilization of this machine. Most probably we are going to declare it scrap.

Besides, I have indented spares in order to raise a tender enquiry for complete engine overhauling of this machine to make it easier for the higher management to decide whether to scrap it or repair it on the basis of prices received from various bidders.

Details are as under;


Engine TypeBF4M1013EC, Vertical Inline, 4-Stroke diesel with Turbo charging and Direct Injection, Water Cooled.
Number of Cylinders4
Bore108 mm / 4.2 inch
Stroke130 mm / 5.1 inch
Displacement4.764 liters / 290 cu inch
Compression Ratio17.5
Max. Rated Speed2300 rpm
Mean Piston Speed9.97 m/s / 32.71 ft/sec
Charge Air CoolerYes
Direction of RotationCounter-Clockwise
Valve Clearance with Cold EngineInlet 0.3 mm / Outlet 0.5 mm
Injector Opening Pressure250 / 275 bar
Firing order of Engine1-3-4-2
Oil Temperature in Oil Pan125 degree Celsius
Oil Capacity (first fill up) without filter13 liters
Oil Capacity (first fill up) with filter14 liters


DESCRIPTION
CATALOGUE REFERENCE NO.
DEUTZ PART NO.
QUANTITY REQUIRED FOR 01 ENGINE
UNIT
CYLINDER LINER
01/30
04282014
04
NOS.
CYLINDER LINER WATER SEALS (O-SEAL included in above)
01/31
01181178
04
SET
MAIN BEARING 0.025" (84.75mm)
05/2
02931882
05
PAIR
BIG END BEARING 0.025" (67.75mm)
05/4
02931474
04
PAIR
THRUST WASHER 0.025" (67.75mm) (4 PCS)
05/3
02931881
01
SET
CONNECTING ROD (BIG END) BUSH
06/2
04200024
04
NOS.
PISTON, GUDGEON PIN, PISTON RINGS, RETAINER SPRINGS (FOR 01 CYL.) (PISTON)
07/1
04501353
04
SET
VALVE INLET
08/17
04283380
04
NOS.
VALVE EXHAUST
08/15
0428331
04
NOS.
VALVE SEAT INLET (INSERT)
08/16
04252442
04
NOS.
VALVE SEAT EXHAUST (INSERT)
08/14
04252443
04
NOS.
VALVE GUIDE
08/7
02112959
08
NOS.
FUEL INJECTOR NOZZLE (NOZZLE ELEMENT)
19/9
02112959
04
NOS.
TURBOCHARGER
43/1
04259311
01
NO.
OVERHAULING KIT (GASKET SET)
90/3
02931736
01
NO.
FUEL INJECTOR PUMP
17/1
02112860
04
NOS.
FRONT COVER
01/122
04289740
01
NO.
GASKET FRONT COVER
01/121
04283700
01
NO.
SEAL CRANK SHAFT FRONT (ROT. SHAFT LIP SEAL)
01/123
04253373
01
NO.
GASKET OIL PAN
02/1
04204458
01
NO.
SEAL CRANK SHAFT REAR (ROT. SHAFT LIP SEAL)
09/4
04253333
01
NO.
GASKET CYLINDER HEAD (WITH 01 NOTCH 1.55 mm)
08/22
04201562
01
NO.
GASKET CYLINDER HEAD (WITH 01 NOTCH 1.60 mm)
-
04201563
-
-
GASKET CYLINDER HEAD (WITH 01 NOTCH 1.70 mm)
-
04201564
-
-
GASKET VALVE COVER
08/2
04205895
01
NO.
WATER PUMP (COOLANT PUMP)
39/209
02937441
01
NO.
GASKET EXHAUST MANIFOLD
41/82
04283299
04
NOS.
CONTROLLER
27/1
02959528
01
NO.
CRANKSHAFT
04299259
01
NO.
CAMSHAFT
04299275
01
NO.
TOOTHED GEAR
04256808
01
NO.
GEAR (IDLER)
01
NO.


MODEL DESIGNATION

BF 4 M 1013 ECP

B = Turbo charging

F = High speed four-stroke engine

4 = Number of cylinders

M = Liquid cooled

1013 = Engine family designation

E = External cooling system

C = Charge air cooler

P = Upgraded

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