Overhauling of a DEUTZ BF4M1013EC engine coupled with COMPAIR C115-12 portable air compressor

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 Type	BF4M1013EC, Vertical Inline, 4-Stroke diesel with Turbo charging and Direct Injection, Water Cooled.
Number of Cylinders	4
Bore	108 mm / 4.2 inch
Stroke	130 mm / 5.1 inch
Displacement	4.764 liters / 290 cu inch
Compression Ratio	17.5
Max. Rated Speed	2300 rpm
Mean Piston Speed	9.97 m/s / 32.71 ft/sec
Charge Air Cooler	Yes
Direction of Rotation	Counter-Clockwise
Valve Clearance with Cold Engine	Inlet 0.3 mm / Outlet 0.5 mm
Injector Opening Pressure	250 / 275 bar
Firing order of Engine	1-3-4-2
Oil Temperature in Oil Pan	125 degree Celsius
Oil Capacity (first fill up) without filter	13 liters
Oil Capacity (first fill up) with filter	14 liters

DESCRIPTION	PART NO.	QUANTITY	UNIT
CYLINDER LINER	01/30	04	NOS.
CYLINDER LINER WATER SEALS	01/31	04	SET
MAIN BEARING 0.025"	05/2	05	PAIR
BIG END BEARING 0.025"	05/4	04	PAIR
THRUST WASHER 0.025" (4 PCS)	05/3	01	SET
CONNECTING ROD BUSH	06/2	04	NOS.
PISTON, GUDGEON PIN, PISTON RINGS, RETAINER SPRINGS (FOR 01 CYL.)	07/1	04	SET
VALVE INLET	08/17	04	NOS.
VALVE EXHAUST	08/15	04	NOS.
VALVE SEAT INLET	08/16	04	NOS.
VALVE SEAT EXHAUST	08/14	04	NOS.
VALVE GUIDE	08/7	08	NOS.
FUEL INJECTOR NOZZLE	19/9	04	NOS.
TURBOCHARGER	43/1	01	NO.
OVERHAULING KIT	90/3	01	NO.
FUEL INJECTOR PUMP	17/1	04	NOS.
FRONT COVER	01/122	01	NO.
GASKET FRONT COVER	01/121	01	NO.
SEAL CRANK SHAFT FRONT	01/123	01	NO.
GASKET OIL PAN	02/1	01	NO.
SEAL CRANK SHAFT REAR	09/4	01	NO.
GASKET CYLINDER HEAD	08/22	01	NO.
GASKET VALVE COVER	08/2	01	NO.
WATER PUMP	39/209	01	NO.
GASKET EXHAUST MANIFOLD	41/82	04	NOS.
CONTROLLER	27/1	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