Deutz BF4M 1012 E Generator Set

⚠ Risk of injury if auxiliary tool not used

Tools: Turning gear 100 320, Turning gear 100 330, Feeler gauge

1. Turn engine until valves of cylinder No. 1 overlap.
2. Turn engine further by one complete revolution (360°).
3. Adjust valve clearance at respective cylinder with feeler gauge (inlet 0.3 mm, exhaust 0.5 mm).
4. Tighten locknut with 20 ± 2 Nm and recheck with feeler gauge.
5. Position gasket and fit cylinder head cover; tighten bolts to 9 ± 1 Nm.

Tools: Measuring device 100 780 / 100 860 / 100 840

1. Read off EP code for cylinder from nameplate column 'EP'.
2. Take corrected injection pump installation dimension (EK) from table according to EP code.
3. Take code for injection pump length (A) from new injection pump.
4. Take standard dimension (L0) from table 1.
5. Determine theoretical shim thickness Ts = EK - (L0 + A/100).
6. Select shim thickness Ss according to table 2.

Tools: Compression tester 8005, Torx tool kit 8189, Connector 100 110

1. Injectors have been removed, valve clearance checked.
2. Insert connector with new special seal.
3. Fit clamping pad and tighten bolt.
4. Connect compression tester and turn engine with starter.
5. Compare readings of all cylinders; if deviation exceeds 15%, dismantle affected cylinder unit.

⚠ Beware of injection nozzle fuel jet; fuel penetrates deeply into skin and may cause blood poisoning.

Tools: Nozzle tester 8008, Long socket SW15 8012, Assembly tool 110 110

1. Connect injector to nozzle tester.
2. Slowly press down lever; the pressure at which gauge pointer stops or drops is opening pressure.
3. Unscrew cap nut and remove all parts to adjust pressure.
4. Select appropriate shim - thicker shim gives higher opening pressure.
5. Tighten cap nut 40 - 50 Nm and recheck on nozzle tester.

⚠ Drain and catch remaining oil and coolant and dispose of in accordance with anti-pollution regulations.

Tools: Torx tool kit 8189, Engine assembly stand 6067/6066, Extractor for injector 110 030, Filter cartridges 170 050

1. Mount angled clamping plate and clamp engine in swivelling assembly stand.
2. Drain and catch oil and coolant.
3. Remove alternator, loosen fuel pump, remove V-belt.
4. Remove coolant pipe, breather pipe, intake hose.
5. Remove turbocharger, starter, governor, filters.
6. Remove cylinder head cover, injection lines, injectors.
7. Remove cylinder head, injection pumps, oil pan, pistons.
8. Take out crankshaft, balancing shafts, camshaft, tappets and oil spray nozzles.

Tools: Internal dial gauge

1. Insert bearing shells in main bearing caps.
2. Place half thrust rings on thrust bearing cap, gauge and record width (dimension b).
3. Determine end float = dimension a - dimension b.
4. Mark crankshaft and camshaft and introduce crankshaft with marks in line.
5. Mount bearing caps per numbering; cap No. 1 at flywheel end.
6. Tighten main bearing bolts: initial 30 Nm (1012) / 50 Nm (1013), 60°, 60°.