Service Bulletin

0128 - 07 - 9397/0 EN
This Circular supersedes:

Date: 09.02.2006 DEUTZ AG

Author: Service Information Deutz-Mülheimer Straße 147-149
D-51063 Köln

Phone: +49 (0) 221 822-3635 www.deutz.com

Fax: +49 (0) 221 822-5358

BFM 2012 - Honing oversize piston / cylinder

The engines of the BFM 2012 series are high quality diesel engines which - like all engines
developed and produced by DEUTZ - allow reprocessing.
With regard to the application variety in the different devices, DEUTZ offers the repair con-
cept "Oversize piston" for the general overhaul of the engine.
Honing of the cylinder is necessary for using the oversize piston.

Part number
Designation Normal Oversize Remark
Piston 0425 8457 0428 4179 Piston complete, with piston
rings, piston pin and circlips
Nominal piston diameter 101.0 mm 101.5 mm without tolerances

© 40 213-0
A1 Piston, complete

Note: Copies to:

The part numbers indicated in this document are not subject to updating. - SM KM
Binding for the identification of spare parts is exclusively the spare parts documentation. - According to SIT 001
It is absolutely prohibited to multiply, publish or hand over this document - also excerpts of it.

Q - 2496

OBJ_DOKU-4900-001.fm 1/2 © 2006

 Service Bulletin
0128 - 07 - 9397/0 EN

The cylinder in the crankcase should be honed according to the enclosed job cards.
The job cards have been compiled for the honing machines of Gehring and Sunnen as ex-
amples. Use of equivalent honing machines is permissible.

z Job card I 03-03-08: Honing cylinders (honing machine made by Gehring)

z Job card I 03-03-08: Honing cylinders (honing machine made by Sunnen)

The cylinder may only be honed by your DEUTZ Service partner or a professional workshop
authorised by DEUTZ and appropriately equipped.

Enclosure: Job cards

Service Information

This document has been created digitally and is valid without a signature.

OBJ_DOKU-4900-001.fm 2/2 © 2006

 Crankcase
BFM 2012 I 03-03-08

Honing cylinders (honing machine made by Gehring)

Commercial available tools: – Workshop manual . . . . . . . . . . 03120361
8190

– Internal measuring device – Instructions . . . . . . . . . . . . . . . 02977765

– Hand deburrer – Production specification . . .FV01600050
– Roughness measuring unit
– Honing machine . . . . . . . . . Gehring Co. Honing cylinder with the honing machine
made by Sunnen, see "I 03-03-08 Honing
cylinders (honing machine made by Sun-
nen)“
This engine can be honed to the 1st repair
sizes of 0.5 mm.
It is fine drilled before honing.
Honing takes place in three stages:
1. Pre-honing with diamond stones 6
2. Intermediate honing with ceramic part
3. Finish honing with ceramic parts

Preparing the crankcase

z Disassembly the engine.
 Workshop manual
z Clean the crankcase.
z Check the crankcase.

© 30794-1

© 12/2005 1/12 4408-001

 Crankcase
I 03-03-08 BFM 2012

z Insert clamping bushing.

z Install main bearing cover (1).
Note assignment!
Gate (arrow) on the bearing cover faces
the manifold side.

6
© 30177-4

Attention!
Screws can be used a maximum 3 times
with written documentation.
z Tighten all screws (1).
 Pre-clamping value: 50 Nm
Re-tightening angle 1st step: 90°
Re-tightening angle 2nd step: 90°

© 30177-5

Clamping the crankcase

z Position the crankcase on the honing machine.
z Fix the crankcase with the clamps.
Attention!
See the honing machine manufacturer's
specification.

© 30794-3

© 12/2005 2/12 4408-001

 Crankcase
BFM 2012 I 03-03-08

Checking the cylinder running surface

z Prepare internal measuring device:
– Mount probe bolt for the appropriate measuring
range in the internal measuring device.
– Mount dial gauge with approx. 1 mm pre-tension in
the internal measuring device.
– Set micrometer gauge to 101 mm.
– Balance the internal measuring device between
the test surfaces of the micrometer gauge and set
the meter at the reversal point of the pointer to "0".

6
© 30792-3

Diagram for measuring the cylinder run-

ning surface at the points "a" and "b" in the
levels "1" - "3".

a b
1

a b
2

a b
3

© 39100-1

z Measure cylinder diameter with internal measuring

device.
 101 + 0.02 mm
Wear limit: 101.1 mm
Attention!
If the cylinder diameter is outside the per-
missible wear limit, honing to the 1st repair
sizes of 101.5 mm is permissible.

© 42697-0

© 12/2005 3/12 4408-001

 Crankcase
I 03-03-08 BFM 2012

Fine drilling
z Determining the cylinder geometry.
z Mount fine drill.
z Fine drill all cylinders.
 max. 101.440 mm
Observe the setting parameters of the hon-
ing machine.

6
© 30813-3

z Check the diameter of the cylinder.

 101.420 to 101.440 mm
Roundness tolerance: 0.02 mm
Straightness tolerance: 0.02 mm

© 42697-0

z Connect roughness measuring unit

z Set roughness measuring unit
Measured with an oil-resistant roughness
measuring unit and printer.
Observe the manufacturer's instructions.
z Measure the roughness with the roughness measur-
ing unit.

© 30797-3

© 12/2005 4/12 4408-001

 Crankcase
BFM 2012 I 03-03-08

Diagram for measuring the roughness at

the points "a" and "b" in the
levels "1" and "2".
1 = 15 +10 mm and
2 = 85 +20 mm from the top edge of the
crankcase.
z Measure the roughness with the roughness measur-
ing unit.
 Average roughness depth Rz: 15.0 to 25 µm
 Instructions 0297 7765
- Company standard H 0203

6
© 37239-1

Pre-honing
z Mount honing tool.
z Set honing machine.
Observe the setting parameters of the hon-
ing machine.

z Prehone all cylinders.

 max. 101.485 mm
z Clean the crankcase.
z Clean all the cylinder running surfaces.

© 30795-1

z Check the diameter of the cylinder.

 101.465 mm to 101.485 mm
Roundness tolerance: 0.02 mm
Straightness tolerance: 0.02 mm

© 42697-0

© 12/2005 5/12 4408-001

 Crankcase
I 03-03-08 BFM 2012

Diagram for measuring the roughness at

the points "a" and "b" in the
levels "1" and "2".
1 = 15 +10 mm and
2 = 85 +20 mm from the top edge of the
crankcase.
z Measure the roughness with the roughness measur-
ing unit.
 Average roughness depth Rz: 10 to 20 µm
 Instructions 02977765
- Company standard H 0203

6
© 37239-1

Intermediate honing
z Mount honing tool.
z Set honing machine.
Observe the setting parameters of the hon-
ing machine.

z Intermediate hone all cylinders.

 max. 101.515 mm
z Clean the crankcase.
z Clean all the cylinder running surfaces.

© 30795-1

z Check the diameter of the cylinder.

 101.495 to 101.515 mm
Roundness tolerance: 0.02 mm
Straightness tolerance: 0.02 mm.

© 42697-0

© 12/2005 6/12 4408-001

 Crankcase
BFM 2012 I 03-03-08

Diagram for measuring the roughness at

the points "a" and "b" in the
levels "1" and "2".
1 = 15 +10 mm and
2 = 85 +20 mm from the top edge of the
crankcase.
z Measure the roughness with the roughness measur-
ing unit.
 Average roughness depth Rz: 10 -20 µm
 Instructions 0297 7765
- Company standard H 0203

6
© 37239-1

Finish honing
z Mount honing tool.
z Set honing machine.
Observe the setting parameters of the hon-
ing machine.

z Finish honing of all cylinders

 max. 101.520 mm
z Clean the crankcase.
z Clean all the cylinder running surfaces.

© 30795-1

z Check the diameter of the cylinder.

 101.500 to 101.520 mm
Roundness tolerance: 0.02 mm
Straightness tolerance: 0.02 mm

© 42697-0

© 12/2005 7/12 4408-001

 Crankcase
I 03-03-08 BFM 2012

z Deburr top edges all around with hand deburrer.

z Clean the crankcase.

6
© 30799-1

z Check the honing structure of the cylinder.

 Instructions 02977765
-Test specification 01620002
"Honing structure of cylinder running surfaces“
-Test specification 01620008
"Fax-Film Technique for Assessment of Sur-
faces.“
Some coarse grooves (due to pre-honing)
and a lot of fine grooves (due to finish hon-
ing) must be detectable.
z Enter actual values in the measuring sheet.

© 30791-1

z Removing the main bearing cover.

Lay out components in the order in which
they should be installed.
Note order of cylinders.

© 30177-5

© 12/2005 8/12 4408-001

 Crankcase
BFM 2012 I 03-03-08

z Remove the crankcase.

z Remove the crankcase.
z Complete the crankcase.
 Workshop manual
z Complete the engine.
 Workshop manual

6
© 30794-1

© 12/2005 9/12 4408-001

 Crankcase
I 03-03-08 BFM 2012

Measuring sheet, measurement of diame-

ter and roundness
Order Engine type Engine No. Measurement Cyl. no. Date
BFM 2012

Distances of the measuring levels from the

top edge (o. t. Te) of the crankcase.

a b c d
Levels in mm
0° – 180° 45° – 225° 90° – 270° 135° – 315°
o. t. Te
1. 15
2. 50
3. 85
6 4. 120
5. 155
6. 190

Straight running (view from above)

0°= camshaft side
90°= gear side 0°
180°= camshaft opposite side 45° 315°
270°= gear opposite side

90° 270°

135° 225°
180°
© 39900-0

“1“ - “6“ = distances of measuring levels

“a“ - “d“ = measuring levels for straightness
measurement a
b
c
1
d
2

© 39901-0

© 12/2005 10/12 4408-001

 Crankcase
BFM 2012 I 03-03-08

Technical data
z Setting parameters of the honing machine
(Gehring Type 720/2934):
Pre-honing Intermediate honing Finish honing
Honing oil Shell Macron 5
Coolant lubricant temperature 18 °C to 25 °C
Honing tool type Blind hole/last Blind hole/shells
Honing tool manufacturer / type (Co. Hunger) /
(Co. Pleiger) / ø94
SHD ø94
Honing tool engagement hydraulic-mechanical
Hydraulic head surface 50 cm2
Honing tool cone angle 22,5°
Honing tool measurement device Air measurement
Distance of air measuring nozzle 6
from 34 mm
bottom edge of honing tool
Honing stone designation 70C100-4-160
D180/F/S11/1/75 70C1000-20-V002S
Ne-Ke-S
(Co. Hunger) (Co. Elsass)
(Co. Elsass)
Honing stone material Diamond Silicon carbide
Honing stone number 6 8
Honing stone dimensions approx. (b 6 mm x 6 mm x 80 mm 13 x 13 x 80 mm
x h x l) with 2 mm centre 13 x 13 x 80 mm with 3 mm centre
groove groove
Honing stone coating thickness 2.5 mm approx. 10 mm
Honing spindle direction of rotation alternating
Honing spindle speed 200 to 220 1/min 92 to 107 1/min
Stroke rate 46 to 50 pls./s 28 to 30 pls./s
Stroke distance potentiometer set-
ting 425/620 385/575
top / bottom
Honing stone stroke/cylinder length 190 mm/200 mm
Honing stone overrun: top / bottom 35 mm/35 mm 40 mm/30 mm
Honing tool engagement 6.8 to 7.2 bar 2.8 to 3.2 bar 1.8 to 2.2 bar
Honing angle 33° to 39° 41° to 49°
Processing time approx. 20 sec. per
after intermediate hon-
cyl.
ing
up to 10 µm before
intermediate hone dia-
approx. 30 sec. per cyl. meter, then
change direction
and approx. 7 sec. to
end
Time R3z
intermediate honing
Recommended values depending 2.0 sec. 5.0 - 6.2 µm
on the roughness depth - - 3.0 sec. 6.3 - 7.4 µm
after intermediate honing 4.0 sec. 7.5 - 8.5 µm
Honing stone pressure 4.5 N/mm2 0.45 N/mm2 0.3 N/mm2
Honing stone speed approx. 62 m/min approx. 29.5 m/min
Honing stone stroke rate approx. 20 m/min approx. 12.3 m/min
Honing stone cutting speed approx. 65 m/min approx. 32.0 m/min

© 12/2005 11/12 4408-001

 Crankcase
I 03-03-08 BFM 2012

z Permissible roughness values:

Measuring variable intermediate
Sign Unit Finish honing
honing
Profile depth Pt µm max. 22.0 max. 22.0
Average roughness depth Rz µm 7.0 to 13.5 4.0 to 10.5
Maximum roughness depth Rmax µm max. 20.0 max. 20.0
Average roughness depth Ra µm 1.0 to 2.0 0.6 to 1.5
Reduced roughness depth R3z µm 5.0 to 8.5 3.0 to 6.0
Wave depth (GS) Wt µm max. 5.0 max. 3.0
Profile skew Sk - -3.0 to 0.2 -4.0 to -0.8
Peak profile C (5 - 20) µm 0.6 to 2.4 0.05 to 0.6
Core profile C (20 -80) µm 2.1 to 4,3 0.7 to 2.9
Depth profile C (80 -95) µm 1.0 to 3.7 1.0 to 3.7
max. profile peak height, average rpm µm 2.8 to 6.0 0.7 to 2.4
6 Peak number S (-1) 1/cm 100 to 200 60 to 160

© 12/2005 12/12 4408-001

 Crankcase
BFM 2012 I 03-03-08

Honing cylinders (honing machine made by Sunnen)

Commercial available tools: – Workshop manual . . . . . . . . . 0312 0361
8190

– Internal measuring device – Instructions . . . . . . . . . . . . . . 0297 7765

– Hand deburrer
– Roughness measuring unit This engine can be honed to the 1st repair
– Honing machine . . . . . . . . . . . . . Sunnen sizes of 0.5 mm.
Type: CK - 21
Honing takes place in three stages:
1. Pre-honing with diamond stones
2. Finish honing with ceramic stones
3. Plateau honing with ceramic stones

Preparing the crankcase

z Disassembly the engine.
 Workshop manual
z Clean the crankcase.
z Check the crankcase.

© 30794-1

z Insert clamping bushing.

z Install main bearing cover (1).
Note assignment!
Gate (arrow) on the bearing cover faces
the manifold side.

© 30177-4

© 12/2005 1/10 4404-001

 Crankcase
I 03-03-08 BFM 2012

Attention!
Screws can be used a maximum 3 times
with written documentation.
z Tighten all screws.
 Pre-clamping value: 50 Nm
Re-tightening angle 1st step: 90°
Re-tightening angle 2nd step: 90°

6
© 30177-5

Clamping the crankcase

z Position the crankcase on the honing machine.
z Fix the crankcase with the clamps.
Attention!
See the honing machine manufacturer's
specification.

© 30794-3

Checking the cylinder running surface

z Prepare internal measuring device:
– Mount probe bolt for the appropriate measuring
range in the internal measuring device.
– Mount dial gauge with approx. 1 mm pre-tension in
the internal measuring device.
– Set micrometer gauge to 101 mm.
– Balance the internal measuring device between
the test surfaces of the micrometer gauge and set
the meter at the reversal point of the pointer to "0".

© 30792-3

© 12/2005 2/10 4404-001

 Crankcase
BFM 2012 I 03-03-08

Diagram for measuring the cylinder run-

ning surface at the points "a" and "b" in the
levels "1" - "3".

a b
1

a b
2

a b
3

6
© 39100-1

z Measure cylinder diameter with internal measuring

device.
 101 + 0.02 mm
Wear limit: 101.1 mm
Attention!
If the cylinder diameter is outside the per-
missible wear limit, honing to the 1st repair
sizes of 101.5 mm is permissible.

© 42697-0

Pre-honing
z Mount honing tool.
z Set honing machine.
Due to the centre connection of the cylin-
ders in the crankcase, the pre-honing must
take place in 2 stages with a low honing
pressure and a material removal of
about ø 0.2 mm.
Observe the setting parameters of the hon-
ing machine.

© 30813-3

© 12/2005 3/10 4404-001

 Crankcase
I 03-03-08 BFM 2012

z Pre-honing of all cylinders in two stages.

 1. stage ø: approx. 101.20 mm
2. stage ø: approx. 101.40 mm
z Clean the crankcase.
z Clean all the cylinder running surfaces.

6
© 30795-1

z Measure the diameter of the cylinder.

 101.20 to 101.40 mm
Roundness tolerance: 0.02 mm
Straightness tolerance: 0.02 mm and
0.005 mm to 30 mm

© 42697-0

z Connect roughness measuring unit

z Set roughness measuring unit
Measured with an oil-resistant roughness
measuring unit and printer.
Observe the manufacturer's instructions.
z Measure the roughness with the roughness measur-
ing unit.

© 30797-3

© 12/2005 4/10 4404-001

 Crankcase
BFM 2012 I 03-03-08

Diagram for measuring the roughness at

the points "a" and "b" in the
levels "1" and "2".
1 = 15 +10 mm and 
2 = 85 +20 mm from the top edge of the
crankcase.
z Measure roughness with the measuring unit.
 Average roughness depth Rz: 7.0 - 13.5 µm
 Instructions 0297 7765
- Company standard H 0203

6
© 37239-1

Finish honing
z Mount honing tool.
z Set honing machine.
Observe the setting parameters of the hon-
ing machine.

z Finish honing of all cylinders

z Clean the crankcase.
z Clean all the cylinder running surfaces.

© 30795-1

z Check the diameter of the cylinder.

 101.500 to 101.520 mm
Roundness tolerance: 0.02 mm
Straightness
tolerance: 0.02 mm and 0.005 mm to 30 mm

© 42697-0

© 12/2005 5/10 4404-001

 Crankcase
I 03-03-08 BFM 2012

Diagram for measuring the roughness at

the points "a" and "b" in the
levels "1" and "2".
1 = 15 +10 mm and 
2 = 85 +20 mm
Measured respectively from the top edge
of the crankcase.
z Measure roughness with the measuring unit.
 Average roughness depth Rz: 4.0 -10.5 µm
 Instructions 0297 7765
- Company standard H 0203

6
© 37239-1

Plateau honing
z Mount honing tool.
z Set honing machine.
Observe the setting parameters of the hon-
ing machine.

z Plateau hone all cylinders.

© 30795-1

z Check the diameter of the cylinder.

 101.500 to 101.520 mm
Roundness tolerance: 0.02 mm
Straightness tolerance: 0.02 mm and
0.005 mm to 30 mm

© 42697-0

© 12/2005 6/10 4404-001

 Crankcase
BFM 2012 I 03-03-08

z Deburr top edges all around with hand deburrer.

z Clean the crankcase.

6
© 30799-1

z Check the honing structure of the cylinder.

 Instructions 0297 7765
-Test specification 0162 0002
"Honing structure of cylinder running surfaces“
- Test specification 0162 0008
"Fax-Film Technique for Assessment of Sur-
faces.“
Some coarse grooves (due to pre-honing)
and a lot of fine grooves (due to finish hon-
ing) must be detectable.
z Enter actual values in the measuring sheet.

© 30791-1

z Removing the main bearing cover.

Lay out components in the order in which
they should be installed.
Note order of cylinders.

© 30177-5

© 12/2005 7/10 4404-001

 Crankcase
I 03-03-08 BFM 2012

z Remove the crankcase.

z Remove the crankcase.
z Complete the crankcase.
 Workshop manual
z Complete the engine.
 Workshop manual

6
© 30794-1

© 12/2005 8/10 4404-001

 Crankcase
BFM 2012 I 03-03-08

Measuring sheet, measurement of diame-

ter and roundness
Order Engine type Engine No. Measurement Cyl. no. Date
BFM 2012

Distances of the measuring levels from the

top edge (o. t. Te) of the crankcase.

a b c d
Levels in mm
0° – 180° 45° – 225° 90° – 270° 135° – 315°
o. t. Te
1. 15
2. 50
3. 85
4. 120 6
5. 155
6. 190

Straight running (view from above)

0°= camshaft side 
90°= gear side  0°
180°= camshaft opposite side  45° 315°
270°= gear opposite side

90° 270°

135° 225°
180°
© 39900-0

“1“ - “6“ = distances of measuring levels

“a“ - “d“ = measuring levels for straightness
measurement a
b
c
1
d
2

© 39901-0

© 12/2005 9/10 4404-001

 Crankcase
I 03-03-08 BFM 2012

Technical data
z Setting parameters of the honing machine
(e. g. Sunnen, type CK - 21):
Pre-honing Finish honing Plateau honing
Honing oil Sunnen MB - 30
Honing oil temperature 18° C to 25° C
Honing tool type Last
Honing tool type GHSS CK
Honing tool engagement mechanical
Honing stone designation GH 233 - DMB - 55 C 30 - J 24 C 30 - J 95
Honing stone material Diamond Silicon carbide
Honing stone number 8 2
Honing stone dimensions 
8 mm x 8 mm x 76 mm 10 mm x 10 mm x 89 mm
6 approx. (w x h x l)
Honing stone coating minimum
approx. 1 mm
thickness
Honing spindle direction of rotation clockwise
Honing spindle speed 200 rpm
Stroke rate 5 - 6 strokes with low
50 strokes/min
pressure
Stroke length approx. 144 mm
Honing stone overrun: top / bottom approx. 12 mm/12 mm approx. 22 mm/10 mm
Honing tool engagement mech. 0.1 mm/min. mech. 0.02 mm/min.
Honing angle 41° to 49°
Processing time approx. 450 sec. per approx. 60 sec. per approx. 10 sec. per
cyl. cyl. cyl.
z Permissible roughness values:
Measuring variable Sign Unit Pre-honing Finish honing
Profile depth Pt µm max. 22.0 max. 22.0
Average roughness depth Rz µm 7.0 to 13.5 4.0 to 10.5
Maximum roughness depth Rmax µm max. 20.0 max. 20.0
Average roughness depth Ra µm 1.0 to 2.0 0.6 to 1.5
Reduced roughness depth R3z µm 5.0 to 8.5 3.0 to 6.0
Wave depth (GS) Wt µm max. 5.0 max. 3.0
Profile skew Sk -3.0 to 0.2 -4.0 to -0.8
Peak profile C (5 - 20) µm 0.6 to 2.4 0.05 to 0.6
Core profile C (20 -80) µm 2.1 to 4.3 0.7 to 2.9
Depth profile C (80 -95) µm 1.0 to 3.7 1.0 to 3.7
max. profile peak height, average Rpm µm 2.8 to 6.0 0.7 to 2.4
Peak number S (-1) 1/cm 100 to 200 60 to 160

© 12/2005 10/10 4404-001