Deutz BFM1013 Diesel Engine Usage and Maintenance Requirements

 The BFM1013 diesel engine uses a unit pump fuel system. For diesel engines using a unit pump fuel supply system, the maintenance and upkeep of the unit pump are completely different from those of traditional diesel engine injection systems, with many special requirements, which brings many troubles to users and maintenance personnel. Due to the special nature of the BFM1013 diesel engine's injection system, most of its usage and maintenance work revolves around the fuel system. If maintenance is not done properly, problems often occur in the fuel system, leading to the diesel engine's inability to operate normally. Therefore, mastering the key points of this diesel engine's maintenance is very important.

 

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  (1) Method for Bleeding Air from the Low-Pressure Fuel Circuit 

  The BFM1013 diesel engine's fuel system uses a unit pump fuel supply system, which has certain special requirements for purging air from the fuel system. Because unit fuel injection pumps require high fuel pre-pressure, there are two systems: 0.3MPa and 0.5MPa (only one system is typically used for a specific diesel engine). Normally, the pressure is no lower than 0.2MPa (0.3MPa system) and 0.45MPa (0.5MPa system). Therefore, in a 0.5MPa system, the spring force of the return bolt is much greater than in an inline pump, making purging with a regular hand pump very difficult. Improper operation can make it difficult to remove air. Incomplete purging may cause difficulty starting the diesel engine or prevent it from starting altogether, and may also cause cavitation in the unit pump and pump chamber.

  ①BFM1013 Diesel Engine Fuel System Purging Methods If the diesel engine cannot start due to air in the fuel system, the following three purging methods are recommended.

 a. Before purging, loosen the high-pressure fuel line clamping nut on the injector and use a hand pump to pressurize and bleed the fuel until all high-pressure fuel lines flow with fuel free of air bubbles. Then tighten the high-pressure fuel lines to complete the purging process.

 b. Before purging, loosen the high-pressure fuel line nut on the unit pump and use a hand pump (Figure 1-19) to pressurize and bleed the fuel until all high-pressure fuel line outlets flow with fuel free of air bubbles. Then tighten the high-pressure fuel line nut to complete the purging process.

 

 Figure 1-19 Hand pump for BFM1013 diesel engine

 

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Regardless of the purging method, it is essential to completely remove air from the fuel system. Otherwise, starting the diesel engine will be very difficult.

② Purging Methods for Other Unit Pump Diesel Engine Fuel Systems Some diesel engine unit pump fuel systems have a purging device installed on the fuel filter (as shown by the arrow in Figure 1-20). The purging requirements are as follows: 

 

 

 

     Figure 1-21 Draining Water from the Oil-Water Separator Water Collector

 a. Loosen the bleed screw plug on top of the fuel filter and use the hand pump on the coarse filter to purge until the fuel filter is full of fuel and the fuel flowing from the bleed screw plug no longer contains air bubbles. Then tighten the bleed screw plug.

 b. Loosen the bleed screw plug on top of the unit pump chamber. Use a hand pump to bleed the system until the pump chamber is full of fuel and no more air bubbles emerge. Then tighten the bleed screw plug.

 

 c. Loosen the connectors between the high-pressure fuel lines and the injectors of each cylinder. Use a hand pump to purge the air from the high-pressure fuel lines until fuel flows out. Then tighten the connectors.

  d. After bleeding, wipe off any fuel that has flowed onto the diesel engine and chassis before starting the diesel engine.

 

 e. Do not use the starter motor to pull the diesel engine to bleed the system.

 f. During bleeding, avoid splashing fuel onto the exhaust pipe, starter motor, and wiring harness (especially connectors). If fuel is accidentally splashed onto these surfaces, wipe them off immediately.

 g. Ensure the fuel is clean and free from contamination during the bleeding process.

 

  (2) Precautions for Using the Unit Pump Fuel Supply System

 

 ① Due to the high injection pressure of the unit pump, the fuel quality requirements are relatively strict. Therefore, the diesel engine fuel system should use at least a two-stage filtration system (coarse filter and fine filter). If possible, a dedicated oil-water separator filtration system can be added.

 ② The fuel should be clean light diesel oil that meets national standards and has undergone at least 2-3 days of sedimentation and filtration.

 

 ③ Replace the diesel fuel filter and clean the diesel fuel tank regularly.

 

  ④ Regularly drain water from the diesel fuel coarse filter equipped with an oil-water separator, as shown in Figure 1-21.

 

 ⑤ Ensure a clean work environment during disassembly and maintenance, and ensure the clean installation of the unit pump.

  ⑥ The unit pump high-pressure fuel line is a single-use component and generally cannot be reused after disassembly.

 ⑦ It is strictly forbidden to disassemble the high-pressure fuel line while the diesel engine is running. Because the pressure inside the high-pressure fuel line is as high as 180.0 MPa, and there is a pressure holding delay, the high-pressure fuel line should only be disassembled 1 minute after the engine has stopped. ⑧ When a diesel engine experiences problems such as difficulty starting, insufficient power, or easy stalling, the low-pressure fuel circuit system of the unit pump fuel system should be checked first.

    

How to remove and replace the JCB Backhoe Loader cab panel

 Removal and Replacement

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Front/Steering Console Removal Park the machine on firm level ground,apply the
parking brake. Lower the loader arms and excavator to
the ground, switch OFF the engine and remove the
starter key.

2 Disconnect the battery.

3 Working in the cab, remove the steering wheel as  shown.

4
Remove the fixings A (4 off at positions shown and take off the steering column pedestal cover.

5 Remove the column switches B.

6 Remove the instrument panel C.

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7 Remove the fixings D (4 off) securing the front console
panel at positions shown and then carefully lift up the
front console clear of the steering column assembly.

Replacement   Replacement is the reverse of the removal sequence.
Take care when removing/replacing the console panel to
ensure that harnesses do not become snagged and that no
other connections have been disturbed.

Afterre-fitting,operate thefront/steeringconsolecontrols
and check they all function correctly.

 

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How to check the bearing clearance of a Caterpillar 320D2 Excavator engine

Note: When the engine is mounted on the chassis, a plastic gauge may not be necessary.

 

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  Caution: Keep all parts clean and free of contaminants. 

Contaminants can cause rapid wear and shorten component life.

 

Note: Cat does not recommend checking actual bearing clearance, especially on small engines. This is because inaccurate results may occur, and bearings or shaft diameters may be damaged. Each Cat engine bearing undergoes a special wall thickness quality check.

 

Note: Measurements must be within specifications and the correct bearing must be used. If the crankshaft journals and bores of the cylinder block and connecting rods were measured during disassembly, no further inspection is required. However, if the technician still wishes to measure the bearing clearance, it can be done using tool (A). If the clearance is less than 0.10 mm (0.004 in), tool (A) will be less accurate for small diameter journal measurements.

  Caution: Wires, feeler gauges, or cylinder gauges may damage the bearing surfaces.

 The technician must use tool (A) very carefully and correctly. The following points must be remembered:

 

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 • Ensure the back of the bearing and bore is clean and dry.

• Ensure the bearing retainer is correctly positioned within its retainer groove. 

• The crankshaft contact points with tool (A) must be free of oil. 

  

  1. Place tool (A) on top of the bearing in the cover. Note: Tool (A) must not extend beyond the bearing edge. 

 2. Install the bearing cover using the correct torque specifications. Do not use an impact wrench. Be careful not to knock the bearing out while installing the cover. Note: Do not rotate the crankshaft while installing tool (A). 

 3. Carefully remove the cover, but do not remove tool (A). Measure the width of tool (A) while it is on the bearing cover or crankshaft journal. Refer to Figure 1.

 

 

 

 4. Remove all tools (A) before installing the bearing cover.

 Note: Readings obtained with tool (A) may sometimes be unclear. For example, not all parts of tool (A) are the same width. Measuring the main width ensures the parts meet the technical specifications. For correct clearances, refer to the technical specification manual, "Connecting Rod Bearing Journals," and the technical specification manual, "Main Bearing Journals."

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How to disassemble 320D2 excavator sprocket

SMCS-4164-010 

S/N - DFM1-UP 

S/N - DNP1-UP 

S/N - EAL1-UP 

 S/N - EKT1-UP 

 S/N - ESG1-UP 

 S/N - FKK1-UP 

S/N - GBA1-UP 

 S/N-HDM1-UP 

 S/N - JFM1-UP 

 S/N - KHR1-UP 

S/N - LMA1-UP 

S/N - NBT1-UP 

S/N-TGJ1-UP 

S/N - TMF1-UP 

S/N-WDJ1-UP 

S/N - XAN1-UP 

S/N - XBB1-UP 

S/N - XCC1-UP 

S/N - YEA1-UP 

S/N - ZBD1-UP 

S/N - ZCS1-UP

1. As shown in the diagram, position the machine on the appropriate stack under the first support roller. Ensure the kingpin is above the sprocket centerline. 

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2. Separate the track. See Disassembly and Assembly, "Track - Separation". 

 

 

 3. Remove the bolts (1) securing the sprocket (2) to the final drive. 

 

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                             4. As shown in the diagram, attach tool (A) and appropriate lifting equipment to the sprocket (2). 

 

 

                   5. Remove the sprocket (2). The sprocket (2) weighs approximately 40 kg (90 lb).

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   (1) Removal of the main bearing cap, lower bearing shell, and thrust bearing 

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① Rotate the engine on the test bench so that the oil pan mounting flange faces upward. The markings on the main bearing cap must match the numbers on the cylinder block oil pan flange, see Figure 2-134. During installation, the numbers on the main bearing cap and oil pan flange should match, and the locating tongue of the main bearing cap must be aligned with the locating tongue. 

 

② Use the ST-1178 main bearing cap puller to remove the main bearing cap, see Figure 2-135. The No. 4 main bearing cap is connected to the cylinder block by a locating pin, and the No. 4 main bearing shell is fitted with a thrust bearing. During disassembly, it is strictly forbidden to shake the main bearing cap; only the puller can be used to pull the main bearing cap vertically upward.

 

 

 

 

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 ③ Remove the lower bearing shell from the main bearing cover and mark the journal number at the time of disassembly on the surface of the locating tongue, as shown in Figure 2-136. 

 

 ④ Remove the lower thrust bearing from the No. 4 main bearing cover and mark it with the letters "L" and "front" or "rear", as shown in Figure 2-137.

 

 

 

 

 

 Remove the upper thrust bearing from spindle journal No. 4 and mark it with the letters "U" and either "front" or "rear", as shown in the figure.  2-138。

 

 

(2) Crankshaft and Upper Bearing Removal

 ① Place nylon slings on connecting rod journals No. 3 and No. 4, and use a crane to remove the crankshaft, as shown in Figure 2-139. 

 

 ② Remove the upper bearing and mark the journal number at the time of removal on the surface of the bearing locating tongue, as shown in Figure 2-140.

 

 

 

 

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How to disassemble the pistons and connecting rods of a Cummins M11 series engine

 (1) Installing the Engine Turning Tool: Install the engine turning tool onto the flywheel end of the crankshaft using two bolts, see Figure 2-123. 

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 (2) Removing the Piston Cooling Nozzles: Before disassembling the piston and connecting rod assembly, the piston cooling nozzles must be removed to avoid damaging them. Use the turning tool to continuously rotate the crankshaft to remove all nozzles. Remove each retaining screw and nozzle, see Figure 2-124. 

(3) Removing the Piston and Connecting Rod: ① Rotate the crankshaft to expose the carbon deposits above the piston inside the cylinder liner. Remove the carbon deposits using a fine-fiber abrasive pad (such as Scotch-Brite 7448, part number 3823258 or equivalent) and solvent, see Figure 2-125.

 

 

  Figure 2-122 Removing the Gear Chamber Housing

 

 ② Use a crankshaft turning tool to rotate the crankshaft and fix the connecting rod at the bottom dead center (BDC) position so that the connecting rod bolts can be removed and loosened, as shown in Figure 2-126.

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 ③ Use a hammer to tap the connecting rod bolt head to loosen the connecting rod cap from the annular locating pin. Remove the connecting rod bolt and connecting rod cap, see Figure 2-127. 

 

 ④ Mark the cylinder number and the letter "L" on the surface of the lower bearing locating tongue, see Figure 2-128. However, it is strictly forbidden to make marks on the mating surface between the bearing and the crankshaft, to avoid damaging the crankshaft if the bearing continues to be used.

 Install the connecting rod guide pin (part number 3376038) in the connecting rod bolt hole. Use a wooden dowel and a hammer to push the connecting rod away from the crankshaft, as shown in Figure 2-129. Continue pushing the connecting rod until the piston rings protrude from the cylinder block.

  

 Remove the piston and connecting rod assembly and mark it, as shown in Figure 2-130. If the removed piston and connecting rod assembly is still usable, it must be reassembled with the original cylinder number.

Remove the piston and connecting rod assembly and mark it, as shown in Figure 2-130. If the removed piston and connecting rod assembly is still usable, it must be reassembled with the original cylinder number. Place the piston and connecting rod assembly on a special test bench to prevent damage, as shown in Figure 2-131.

 

8. Mark the connecting rod and its mating connecting rod cap with special markings, as shown in Figure 2-132. During assembly, the markings on the connecting rod and connecting rod cap must match and be on the same side of the engine. 

 

Remove the upper connecting rod bearing and mark the cylinder number and the letter "u" on the flat surface of the locating tongue, as shown in Figure 2-133.

 

 

 

 

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Desmontagem da polia da cambota, do amortecedor e do conjunto da cambota do motor Cummins série M11 (8107).

(1) Removal of the oil pump: When removing the oil pump, it is strictly forbidden to pry the gear pump flange to avoid damaging the oil pump. Remove the three mounting bolts and two spacers, screw the two M8-

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1.25 bolts into the puller, and remove the oil pump from the engine, as shown in Figure 2-117.

(2) Camshaft Removal ① Rotate the camshaft until the camshaft gear hole aligns with the thrust bracket bolt hole. Remove the two thrust bracket bolts, then remove the three bolts, the rear cover plate, and the gasket, as shown in Figure 2-118. ② Install the camshaft installation guide tool (part number 3376388). Insert the expander (part number 3376923) through the opening in the rear cover plate into the camshaft. Rotate the bolt inside the expander clockwise to open the expansion plug, as shown in Figure 2-119.

 

 

③ Place the mandrel bushing onto the expander, and install the positioning guide extension rod on the expander, as shown in Figure 2-120. 

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 ④ Slowly rotate the camshaft by hand to pull it out of the cylinder block, as shown in Figure 2-121. Support the removed camshaft with your other hand and remove the camshaft guide tool. 

 

(3) Removal of the gear housing: Remove all bolts from the gear housing and the gear housing itself, as shown in Figure 2-122, and remove the rear rectangular seal ring.

 

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