TRAINING DEUTZ
DEUTZ 2012 / 2013
Adjustment of the injection pumpe timing
Service Training
plug-in injection pump
Deutz diesel engines of product range 2012/1013 are equipped with plug-in injection pumps of series
PF 33 from Bosch.
The concept of the plug-in fuel injection pumps enables the realization of high injection pressures in
connection with extremely short injection lines, which contributes to a high hydraulic stiffness of the
injection system. This in turn provides the prerequisite for low exhaust emission values (soot) in
combination with a low fuel consumption.
Plug-in fuel injection pumps have the following plunger dimensions:
• Stroke 12 mm
• Diameter 9 mm
Cavitation in the injection lines and injection overrun, which is normally associated with high pressures,
is prevented by a return flow nozzle arranged after the pressure valve
The constant volume relief is 50 mm³.
Assembling the plug-type injection pumps
The adjustment of the injection pump timing (FB) affects:
• the fuel consumption,
• the power
• the exhaust emission
of the engine.
On engines of series 2012/1013 the start of delivery is adjusted without tolerance. The start of delivery
is entered in degree of crank angle measured from the top dead centre of the piston and depends on
application, power and speed setting of the engine.
The plug-in injection pump is in position of start of delivery when the plunger just closes the fuel supply
bore in the plunger sleeve.
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On engines with inline injection pumps the engine drive is turned to start of delivery position and closing
of the fuel supply bore is determined by means of a high pressure pump. Occurring tolerances are
compensated in the coupling of the injection pump drive, whereby the injection pump camshaft is turned
to start of delivery position against the fixed engine drive.
The injection pump cams on engines of series 2012/1013 are arranged on the camshaft of the engine.
For this reason the conventional adjustment method for the start of delivery cannot be used.
The start of delivery of the injection pump must be adjusted using the new method.
For this the conventional adjustment method is subdivided into length measurements of individual
engine parts and calculations.
The permissible manufacturing tolerances for the components
• cylinder crankcase,
• camshaft,
• plunger
• plug-in injection pump
are measured and eliminated by the adjustment of the start of delivery.
However, in cases of interest for BOMAG engineers the engine will not be overhauled completely, but
individual injection pumps will be replaced.
Crankcase, camshaft and plunger remain unchanged.
This results in a certain installation measurement for the engine drive, which is stamped on the engine
type plate.
In column „EP“ it is stamped as „CODE“ for each cylinder.
Note:
If an injection pump and/or nozzle is replaced, the respective high pressure line between pump and
nozzle must also be replaced..
1. Remove crankcase ventilation and cylinder
head cover.
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Service Training
Fig. 8:
2. Remove the engine solenoid
Fig. 9:
3. Insert the pressing device, WILBÄR No. 100
830 carefully into the groove in the governor
rod and tighten.
Fig. 10:
4. Turn the knurled fastening screw to press the
governor rod to stop position.
Note:
Tighten the knurled fastening screw by hand.
Fig. 11:
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Service Training
5. Set the cylinder of the injection pump to be
replaced to ignition top dead centre (valves
overlapping). Then turn the crankshaft
approx. 120° against the sense of rotation.
Note:
View on flywheel
Fig. 12:
6. Remove injection line and injection pump.
Fig. 13:
7. Take the compensation shim carefully out with
the rod magnet.
Fig. 14:
Determine the thickness of the new compensation shim:
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Service Training
Determination of the compensation shim thickness when replacing plug-in fuel injection
pumps
On the engine type plate column - EP – contains a code for the plug-in fuel injection pump for each
cylinder.
295
Each line represents 1 cylinder
e.g. 1st line = cylinder 1
2. line = cylinder 2 etc.
Fig. 15: Injection pump code BFM 2012/1013
The EP-code is used to determine the installation measurement to be corrected „Ek“ from table 1.
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EK EP EK EP EK EP EK EP
(mm) code (mm) code (mm) code (mm) code
119,250 230 119,850 254 120,450 278 121,050 302
119,275 231 119,875 255 120,475 279 121,075 303
119,300 232 119,900 256 120,500 280 121,100 304
119,325 233 119,925 257 120,525 281 121,125 305
119,350 234 119,950 258 120,550 282 121,150 306
119,375 235 119,975 259 120,575 283 121,175 307
119,400 236 120,000 260 120,600 284 121,200 308
119,425 237 120,025 261 120,625 285 121,225 309
119,450 238 120,050 262 120,650 286 121,250 310
119,475 239 121,075 263 120,675 287 121,275 311
119,500 240 120,100 264 120,700 288 121,300 312
119,525 241 120,125 265 120,725 289 121,325 313
119,550 242 120,150 266 120,750 290 121,350 314
119,575 243 120,175 267 120,775 291 121,375 315
119,600 244 120,200 268 120,800 292
119,625 245 120,225 269 120,825 293
119,650 246 120,250 270 120,850 294
119,675 247 120,275 271 120,875 295
119,700 248 120,300 272 120,900 296
119,725 249 120,325 273 120,925 297
119,750 250 120,350 274 120,950 298
119,775 251 120,375 275 120,975 299
119,800 252 120,400 276 121,000 300
119,825 253 120,425 277 121,025 301
Table 1: Injection pump code table BFM 2012
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EK EP EK EP EK EP EK EP
(mm) code (mm) code (mm) code (mm) code
145.7 349 146.3 373 146.9 397
145.725 350 146.325 374 146.925 398
145.75 351 146.35 375 146.95 399
145.775 352 146.375 376 146.975 400
145.8 353 146.4 377 147.0 401
145.825 354 146.425 378 147.025 402
145.85 355 146.45 379 147.05 403
145.875 356 146.475 380 147.075 404
145.9 357 146.5 381 147.1 405
145.925 358 146.525 382 147.125 406
145.35 335 145.95 359 146.55 383 147.15 407
145.375 336 145.975 360 146.575 384 147.175 408
145.4 337 146.0 361 146.6 385 147.2 409
145.425 338 146.025 362 146.625 386 147.225 410
145.45 339 146.05 363 146.65 387 147.25 411
145.475 340 146.075 364 146.675 388 147.275 412
145.5 341 146.1 365 146.7 389 147.3 413
145.525 342 146.125 366 146.725 390 147.325 414
145.55 343 146.15 367 146.75 391 147.35 415
145.575 344 146.175 368 146.775 392 147.375 416
145.6 345 146.2 369 146.8 393 147.4 417
145.625 346 146.225 370 146.825 394 147.425 418
145.65 347 146.25 371 146.85 395 147.45 419
145.675 348 146.275 372 146.875 396
Table 2: Injection pump code table BFM 1013
Ek (mm) = corrected injection pump measurement, determined by EP-code on type plate and from
table 1 or 2.
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Service Training
During the manufacture of the plug-in fuel injection pump the high pressure method is used to determine
the wear in the fuel supply bore. In this position – injection pump plunger in start of fuel delivery position
- the distance between pump contact face and plunger foot contact face is measured.
Measurement "A" in 1/100 mm has been written on the pump with an electric marker.
64
Fig. 18: Plunger code inscription
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A=XXX
Fig. 19: Individual injection pump
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Measurement "A" specifies by how many 1/100 mm the gap between contact area on cylinder
crankcase and plunger foot is longer than the hydraulic base measurement Lo.
Lo
A = XX
A/100
Fig. 20: Presentation of measurement „A“
• Lo = 117,5 mm - BFM 2012
• Lo = 143 mm - BFM 1013
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Ek Lo+A/100
Z
Ts
Fig. 21: Drive in start of delivery position after determination of „Ts“
The plug-in fuel injection pump is now positively connected with the drive, which has been set to start
of delivery by inserting a compensation shim "Z" of calibrated thickness..
The illustration explains that according to calculation:
(Ek) - (Lo + A/100)
there is a gap „Ts“ between injection pump plunger foot and roller plunger. This gap has to be
compensated with a compensation shim "Z" of appropriate (calculated) thickness.
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Theoretical Compensation Theoretical Compensation
thickness shim thickness shim
„Ts“ thickness „Ss“ „Ts“ thickness „Ss“
(mm) (mm)
(mm) (mm)
0.95 - 1.049 1.0 2.45 - 2.549 2.5
1.05 - 1.149 1.1 2.55 - 2.649 2.6
1.15 - 1.249 1.2 2.65 - 2.749 2.7
1.25 - 1.349 1.3 2.75 - 2.849 2.8
1.35 - 1.449 1.4 2.85 - 2.949 2.9
1.45 - 1.549 1.5 2.95 - 3.049 3.0
1.55 - 1.649 1.6 3.05 - 3.149 3.1
1.65 - 1.749 1.7 3.15 - 3.249 3.2
1.75 - 1.849 1.8 3.25 - 3.349 3.3
1.85 - 1.949 1.9 3.35 - 3.449 3.4
1.95 - 2.049 2.0 3.45 - 3.549 3.5
2.05 - 2.149 2.1 3.55 - 3.649 3.6
2.15 - 2.249 2.2 3.65 - 3.749 3.7
2.25 - 2.349 2.3 3.75 - 3.850 3.8
2.35 - 2.449 2.4
Table 3: Compensation shims 2012/1013
For the determination of the theoretical shim thickness „Ts“ it is also necessary to determine
measurement Lo + A/100 of the new fuel injection pump, which must then be subtracted from the
corrected injection pump measurement Ek.
Ts = Ek - (Lo + A/100) [mm]
The real compensation shim thickness „Ss“ is determined with the help of table 1 or 2 and 3.
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Exemplary calculation for BFM 2012
EP-code read off engine type plate: 295
• see table 1
corrected injection pump measurement „Ek“: 120,875 mm
Lo = 117,5 mm (fixed measurement)
Value for A/100 read off new injection pump A/100 = 42
• Ts = Ek - (Lo + A/100)
Ts = 120,875 mm - (117,5 + 42/100 mm)
Ts = 2.955 mm
• see also table 3
Ts = 3,0 mm
Exemplary calculation for BFM 1013
EP-code read off engine type plate: 397
• see table 2
corrected injection pump measurement „Ek“: 146.9 mm
Lo = 143 mm (fixed measurement)
Value for A/100 read off new injection pump A/100 = 133
• Ts = Ek - (Lo + A/100)
Ts = 146,9 mm - (143 + 133/100 mm)
Ts = 2.57 mm
• see also table 3
Ts = 2,6 mm
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8. P?lace the new calculated compensation shim
on the roller plunger.
Fig. 22:
9. Turn the injection pump control lever to
approx. middle position.
Fig. 23:
10. Apply some oil to the locating bore in the
crankcase and the O-rings on the injection
pump. Carefully insert the injection pump
control lever into the governor rod.
Fig. 24:
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11. Attach the flange.
Note:
The chamfer must face towards the injection
pump body
Fig. 25:
12. Slightly oil the screws and tighten them
evenly with 5Nm.
Fig. 26:
13. Loosen the screws again for 60°.
Fig. 27:
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14. Carefully turn the injection pump with and
open end spanner in anti-clockwise direction
against the noticeable stop
Fig. 28:
15. Tighten the screws again for 60° and
continue in stages with tightening torques of
7 Nm, 10 Nm and 30 Nm.
Note:
Start with the outer screw, viewed from the
flywheel. (see arrow).
Fig. 29:
16. Back out the knurled screw of the pressing
device, remove the pressing device.
17. Reinstall the engine solenoid with a new O-
ring.
18. Reinstall the cylinder head cover. Tightening
torque: 9 +/-1 Nm.
Note:
If necessary replace the gasket.
Fig. 30:
19. Slightly oil the O-ring of the crankcase ventilation. Reassemble the crankcase ventilation. Tightening
torque 9 +/- 1Nm
Note: If necessary replace the gasket.
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BFM 2012 Injection pump adjustment
Exemplary calculation for BFM 2012
Lo = 117,5 mm (fixed measurement)
Value for A/100 read off new injection pump A/100 = 64
EP – code read off engine type plate: 295
see table 1
corrected injection pump measurement “Ek” 120,875 mm
fixed measurement Lo 117,5 mm
read off injection pump + A/100 0,64 mm
118,14 mm
Ek = 120,875 mm
– l18,14 mm
Ts 2,735 mm
see table 3
Ts = 2,735 mm
Compensation shim thickness Ss = 2,7 mm
Service Training
Tools
The following tools can be ordered from the respective supplier (in brackets) under the stated part-
number.
For tools from Hazet and Bosch you should consult your nearest representative, orders to Wilbär should
be addressed to:
Co. Wilbär
P.O. box 140580
D - 42826 Remscheid
Fig. 31
• Pressing device for governor rod 100 830 (Wilbär)
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