Deutz 914 Service Manual

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Page 1

Operation Manual

914

Page 2

Safety guidelines / Accident prevention

● Please read and observe the information given in this Operation Manual. This will enable you to avoid accidents, preserve the manufacturer’s warranty and maintain the engine in peak operating condition.

● This engine has been built exclusively for the application specified in the scope of supply, as described by the equipment manufacturer and is to be used only for the intended purpose. Any use exceeding that scope is considered to be contrary to the intended purpose. The manufacturer will not assume responsibility for any damage resulting therefrom. The risks involved are to be borne solely by the user.

● Use in accordance with the intended purpose also implies compliance with the conditions laid down by the manufacturer for operation, maintenance and servicing. The engine should only be operated by personnel trained in its use and the hazards involved.

● The relevant accident prevention guidelines and other generally accepted safety and industrial hygiene regulations must be observed.

● When the engine is running, there is a risk of injury through:

- turning/hot components

- engines with positive ignition

- ignition systems (high electrical voltage) You must avoid contact at all times!

● Unauthorized engine modifications will invalidate any liability claims against the manufacturer for resultant damage. Manipulations of the injection and regulating system may also influence the performance of the engine, and its emissions. Adherence to legislation on pollution cannot be guaranteed under such conditions.

● Do not change, convert or adjust the cooling air intake area to the blower. The manufacturer shall not be held responsible for any damage which results from such work.

● When carrying out maintenance/repair operations on the engine, the use of DEUTZ original parts is prescribed. These are specially designed for your engine and guarantee perfect operation. Non-compliance results in the expiry of the warranty!

● Maintenance and cleaning of the engine should only be carried out when the engine is switched off and has cooled down. You must ensure that the electrical systems have been switched off and the ignition key has been removed. Accident prevention guidelines concerning electrical systems (e.g. VDE-0100/-0101/0104/-0105 Electrical protective measures against dangerous touch voltage) are to be observed. When cleaning with fluids, all electrical components are to be covered impermeably.

Page 3

Engine Serial Number

Technical modifications required to improve our engines are reserved with regard to specification data and other technical information contained in this Operation Manual. No parts of this Manual may be reproduced in any form or by any means without our written approval.

Operation Manual

914

0312 0382 en

Please enter the engine serial number here. This number should be quoted when inquiring about Customer Service, Repairs or Spare Parts (see Section 2.1).

Page 4

Foreword

Dear Customer,

Air / liquid-cooled Deutz engines are designed for a large number of applications. Consequently, a wide range of variants is offered to meet the requirements of specific cases.

Your engine is appropriately equipped for the installation concerned, which means that not all of the components described in this Operation Manual are necessarily mounted to your engine.

We have endeavoured to highlight any differences so that you will be able to locate theses differences relevant to your engine.

Please read this Manual before starting your engine, and always observe the operating and maintenance instructions.

We are available to help with any additional inquiries

Sincerely,

DEUTZ AG

Page 5

Index

1 General 2 Engine Description

2.1 Model

2.1.1 Rating Plate

2.1.2 Position of the Rating Plate

2.1.3 Engine Serial Number

2.1.4 Cylinder numbering

2.1.5 Direct injection

2.2 Engine Illustrations

2.2.1 Operation side BF3L 914

2.2.2 Air outlet side BF3L 914

2.2.3 Operation side F4L 914

2.2.4 Air outlet side F4L 914

2.2.5 Operation side BF6L 914 Intercooler over air-intake line

2.2.6 Air outlet side BF6L 914 C Intercooler over air-intake line

2.2.7 Operation side BF6L 914 C Intercooler over flywheel

2.2.8 Air outlet side BF6L 914 Intercooler over flywheel

2.3 Lube Oil Circuit Schematic

2.3.1 Lube Oil Circuit Schematic

2.4 Fuel System Plan

2.4.1 Fuel System

2.5 Engine cooling

2.5.1 Amount of cool air regulated by exhaust thermostat

2.5.2 Amount of cool air regulated by exhaust thermostat and solenoid valve

3 Engine Operation

3.1 Commissioning

3.1.1 Pour in Engine Oil

3.1.2 Filling Oil Bath Air Filter with Engine Oil

3.1.3 Pour in Fuel

3.1.4 Bleed

3.1.5 Other Preparations

3.1.6 Additional maintenance work

3.1.7 Change-over switch for oil heater

3.2 Starting

3.2.1 Starting

3.3 Monitoring Operation

3.3.1 Engine Oil Pressure

3.3.2 Engine temperature

3.3.3 Cooling fan drive

3.4 Shutting off

3.4.1 Mechanical shut-off

3.4.2 Electrical shut-off

3.5 Operating Conditions

3.5.1 Winter Operation

3.5.2 High Ambient Temperature, High Altitude

4 Operating Media

4.1 Lube Oil

4.1.1 Quality

4.1.2 Viscosity

4.2 Fuel

4.2.1 Quality

4.2.2 Winter Fuel

5 Routine Maintenance

5.1 Maintenance Plan

5.2 Maintenance Diagram

5.3 Maintenance Work Completed

6 Service and Maintenance

6.1 Lube oil system

6.1.1 Oil change intervals

6.1.2 Check Oil Level / Change Engine Oil

6.1.3 Replace Oil Filter

6.1.4 Change bypass-oil filter use

6.2 Fuel System

6.2.1 Replace fuel filter

6.2.2 Precleaning fuel/clean fuel filter

6.3 Cooling system

6.3.1 Cleaning Intervals

6.4 Combustion Air Filter

6.4.1 Cleaning Intervals

6.4.2 Emptying Cyclone Type Precleaner

6.4.3 Clean Oil Bath Air Filter

6.4.4 Dry Type Air Cleaner

6.5 Belt Drives

6.5.1 Check V-belts

6.5.2 Change fan belt

6.5.3 Tension alternator belts

6.5.4 Change alternator belts

6.5.5 Check warning system

6.5.6 Tension/change air compressor belts

6.5.7 Air compressor model with dual belts

6.6 Adjustments

6.6.1 Check valve clearance (adjust if necessary)

6.7 Accessories

6.7.1 Battery

6.7.2 Rotary Current Alternator

6.7.3 Transportation Shackles

6.8 Engine cleaning

6.8.1 Engine cleaning

6.9 Additional Maintenance Work

6.9.1 Check fastenings

6.9.2 Check functioning of glow plugs

7 Faults, Causes and Remedies

7.1 Fault Table

8 Engine Preservation

8.1 Preservation

8.1.1 Preserve engine

8.1.2 Remove engine preservation

9 Technical Specification

9.1 Engine Specifications and

Settings

9.2 Screw Tightening Torques

9.3 Tools

10 Service

Page 6

General

DEUTZ Diesel Engines

are the product of many years of research and development. The resulting know-how, coupled with stringent quality standards, guarantee their long service life, high reliability and low fuel consumption. It goes without saying that DEUTZ Diesel Engines meet the highest standards for environmental protection.

Beware of Running Engine

Shut the engine down before carrying out maintenance or repair work. Ensure that the engine cannot be accidentally started. Risk of accidents. When the work is complete, be sure to refit any panels and guards that may have been removed. Never fill the fuel tank while the engine is running. Observe industrial safety regulations when running the engine in an enclosed space or underground.

Care and Maintenance

Sound care and maintenance practices will ensure that the engine continues to meet the requirements placed on it. Recommended service intervals must be observed and service and maintenance work carried out conscientiously. Special care should be taken under abnormally demanding operating conditions.

Safety

This symbol is used for all safety warnings. Please follow them

and accident prevention regulations laid down by law must also be observed.

carefully. The attention of operating personnel should be drawn to these safety instructions. General safety

Service

Please contact one of our authorized service representatives in the event of breakdowns or for spare parts inquiries. Our trained specialists will carry out repairs quickly and professionally, using only genuine spare parts. Original parts from DEUTZ AG are always produced in accordance with state-of-the-art technology. Please turn to the end of this manual for further service information.

California

Proposition 65 Warning

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Asbestos

DEUTZ original parts are asbestosfree.

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Page 8

Engine Description

2.1 Model

2.2 Engine Illustrations

2.3 Lube Oil Circuit Schematic

2.4 Fuel System Plan

2.5 Engine cooling

Page 9

Engine Description 2.1 Model

2.1.1 Rating Plate

The model A, the engine serial number B and the performance data are stamped on the rating plate. The model and engine serial number must be given when ordering parts.

2.1.2 Position of the Rating Plate

The rating plate C is attached to the crankcase. Depending on the model, a second rating plate may be affixed to the air duct hood.

2.1.3 Engine Serial Number

The engine serial number is stamped on the crankcase (arrow) as well as the rating plate.

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2.1 Model Engine Description

2.1.4 Cylinder numbering

Cylinders are numbered consecutively, beginning at the flywheel.

2.1.5 Direct injection B/FL 914

Engines with direct injection are used if high output is required.

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Engine Description 2.2 Engine Illustrations

2.2.1 Operation side BF3L 914

1 Cooling fan 2 V-Belts (fan) 3 Optional attachment of hydraulic pumps 4 V-belt washer 5 Tension roller 6 Oil pan 7 Oil drain screw 8 Oil filler neck

9 Oil dipstick 10 Fuel change filter 11 Solenoid (shut-off magnet) 12 Lube oil filter 13 Full-stop depending on charge air pressure 14 Air duct hood 15 Cylinder head cover

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2.2 Engine Illustrations Engine Description

2.2.2 Exhaust side BF3L 914

16 Air-intake line 17 Shielding plate 18 Flywheel 19 Oil drain screw 20 Starter 21 Exhaust turbocharger manifold

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Engine Description 2.2 Engine Illustrations

2.2.3 Operation side F4L 914

1 Cooling fan 2 V-Belts (fan) 3 Optional attachment of hydraulic pumps 4 V-belt washer 5 Tension roller 6 Oil filler neck 7 Fuel pump 8 Fuel change filter

9 Injection pump 10 Oil dipstick 11 Shut-off magnet 12 SAE housing 13 Lube oil filter 14 Air duct hood 15 Cylinder head cove

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2.2 Engine Illustrations Engine Description

2.2.4 Exhaust side F4L 914

16 Date plate 17 Flywheel 18 Oil drain screw 19 Starter 20 Oil pan 21 Air-intake manifold 22 Crankcase ventilation

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2.2 Engine Illustrations Engine Description

2.2.5 Operation side BF6L 914 C- intercooler over air-intake line

1 Cooling fan 2 V-Belts (fan) 3 V-belt pulley on crankshaft 4 Tension roller 5 Oil filler neck 6 Oil drain screw 7 Fuel pump with fuel precleaning 8 Fuel filter cartridge

9 Injection pump 10 Shut-off lifting magnet 11 Oil dipstick 12 LDA 13 Lube oil filter cartridge 14 Engine oil cooler 15 Air duct hood 16 Cylinder head cover

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2.2 Engine Illustrations Engine Description

2.2.6 Exhaust side BF6L 914 C- intercooler over air-intake line

17 Intercooler 18 Air-intake line 19 Exhaust manifold line 20 Date plate 21 Flywheel 22 Starter 23 Oil drain screw 24 Turbocharger 25 Air-intake manifold to exhaust turbocharger 26 Alternator

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Engine Description 2.2 Engine Illustrations

2.2.7 Operation side BF6L 914 C- intercooler over flywheel

1 Cooling fan 2 V-Belts (fan) 3 V-belt pulley on crankshaft 4 Tension roller 5 Oil filler neck 6 Oil drain screw 7 Fuel pump with fuel precleaning 8 Fuel filter cartridge

9 Injection pump 10 Shut-off lifting magnet 11 Oil dipstick 12 LDA 13 Lube oil filter cartridge 14 Engine oil cooler 15 Air duct hood 16 Cylinder head cover

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2.2 Engine Illustrations Engine Description

2.2.8 Exhaust side BF6L 914 - intercooler over flywheel

17 Intercooler 18 Flywheel 19 Starter 20 Oil drain screw 21 Alternator 22 Exhaust connection supports 23 Exhaust manifold line 24 Air-intake manifold to exhaust turbocharger

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Engine Description 2.3 Lube Oil Circuit Schematic

2.3.1 Lube Oil Circuit Schematic FL 914

1 Oil pan 2 Intake manifold 3 Oil pump 4 Oil pressure regulating valve 5 Pressure oil line 6 Short-circuit line or alternative 7 Ribbed tube coil or alternative 8 Block oil cooler

9 Lube oil filter 10 Safety valve 11 Main oil channel 12 Crankshaft bearing 13 Con-rod bearing 14 Camshaft bearing 15 Tappet 16 Pushrod (hollow, for oil intake to lubricate

rocker arm) 17 Rocker arm bearings 18 Rocker arm lubrication 19 Pushrod protective tube 20 Throttle bore (to lubricate cogwheels) 21 Spray nozzle for piston cooling 22 Connection for oil pressure gauge 23 Oil pressure gauge 24 Injection pump connected to lube oil circuit

schematic 25 Connection option for oil heater **

** here the filter carrier must be exchanged.

Please contact DEUTZ Service when

changing-over.

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2.3 Lube Oil Circuit Schematic Engine Description

2.3.2 Lube Oil Circuit Schematic BFL 914

1 Oil pan 2 Intake line 3 Oil pump 4 Oil pressure regulating valve 5 Pressure oil line 6 Connection line to oil cooler 7 Block oil cooler 8 Lube oil filter

9 Safety valve 10 Main oil channel 11 Crankshaft bearing 12 Con-rod bearing 13 Camshaft bearing 14 Tappet (with impulse lubrication of rocker

arm)

15 Pushrod (hollow, for oil intake to lubricate

rocker arm) 16 Rocker arm bearings 17 Rocker arm lubrication 18 Pushrod protective tube (oil return from the

cylinder head to crankcase) 19 Throttle bore (to lubricate cogwheels) 20 Spray nozzle for piston cooling 21 Oil line to lubricate turbocharger 22 Oil return line from exhaust turbocharger

to crankcase 23 Oil pressure gauge 24 Bypass lube oil fine filter 25 Connection option for oil heater ** 26 Injection pump connected to lube oil circuit

schematic ** here the filter carrier must be exchanged.

Please contact DEUTZ Service when

changing-over.

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Engine Description 2.4 Fuel System Schematic

2.4.1 Fuel System

1 Fuel tank 2 Fuel line from tank to fuel pump 3 Fuel pump 4 Fuel change filter 5 Injection pump 6 Injection line 7 Injection valve 8 Fuel overflow pipe

A Distance: must be routed as far away from

each other as possible

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2.5 Engine cooling Engine Description

2.5.1 Amount of cool air regulated by exhaust thermostat

1 Pressure oil line from engine to exhaust

thermostat

2 Air line to exhaust thermostat 3 Exhaust manifold line 4 Exhaust thermostat 5 Control line to hydraulic coupling 6 Hydraulic coupling 7 Cooling fan 8 Cooling fan drive

9 Oil return line to crankcase 10 Ventilation line 11 Adjusting screw with special seal ring

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Engine Description 2.5 Engine cooling

2.5.2 Amount of cool air regulated by exhaust thermostat and solenoid valve

1 Pressure oil line from engine to exhaust

thermostat

2 Air line to exhaust thermostat 3 Exhaust manifold line 4 Exhaust thermostat 5 Control line to hydraulic coupling 6 Hydraulic coupling 7 Cooling fan 8 Cooling fan drive

9 Oil return line to crankcase 10 Ventilation line 11 Adjusting screw with special seal ring 12 Solenoid valve

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3.1 Commissioning

3.2 Starting

3.3 Monitoring Operation

3.4 Shutting off

3.5 Operating Conditions

Engine Operation

Page 25

Engine Operation 3.1 Commissioning

3.1.1 Pour in Engine Oil 3.1.2 Oil Bath Air Filter with Engine Oil

As a rule, engines are delivered without oil. Pour lube oil into the oil filler neck (arrow). For oil grade and viscosity, see 4.1.

Fill oil cup 1 of the oil bath air cleaner with oil up to the arrow. For oil grade and viscosity, see 4.1.

3.1.3 Pour in Fuel

Use only commercial-grade diesel fuel. For fuel grade, see 4.2. Use summer or wintergrade fuel, depending on the ambient temperature.

Do not fill the precleaner dust collector (if fitted) with oil.

Never fill the tank while the engine is running. Ensure cleanliness! Do not spill fuel!

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3.1 Commissioning Engine Operation

3.1.4 Bleed Model: “Motorpal” model

● Position collecting tank below the injection

pump.

● Unscrew ventilation valve 1 with screw-

driver.

● Move hand hump 2 in the direction of the

arrow until bubble-free fuel escapes from the ventilation valve 1.

● Tighten ventilation valve 1, still pumping.

● Remove collecting tank and dispose of the

fuel in an environmentally-friendly manner.

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Engine Operation 3.1 Commissioning

3.1.5 Other Preparations

● Checking battery and cable connectors see 6.7.1

● Transport hooks Remove if fitted (see 6.7.3)

● Trial run After the engine has been prepared, let it run for about 10 minutes without load.

During and after trial run – Check the engine for leaks.

After the engine has been turned off – Check the oil level, see 6.1.2

If necessary, top up oil, see 3.1.1

– Retension V-belts, see 6.5.

● Breaking in During the break-in phase, about 200 operating hours, check the oil level twice a day. After the engine is broken in, checking once a day will be sufficient.

3.1.6 Additional maintenance work

After 50-150 operating hours, the following maintenance work is to be carried out:

● Change lube oil,

see 6.1.2

● Change oil filter cartridge,

see 6.1.3

● Change fuel filter cartridge,

see 6.2.1

●lCheck V-belts and retension as necessary,

see 6.5.

● Check valve clearance (adjust if neces-

sary) see 6.6.1

● Check the engine for leaks

● Check engine mounts (retighten if neces-

sary) see 9.2.

3.1.7 Change-over switch for oil heater

Position of change-over switch for oil filter consoles with an oil heater connected: Pos. 1: open Pos. 2: closed

For engines without an oil heater, the change-over switch should 2: closed.

always be fixed to Pos.

Page 28

Page 29

Engine Operation 3.2 Starting

3.2.1 Electric Starting

Before starting, make sure that nobody is standing in the immediate vicinity of the engine or driven machine. After repair work:

Check that all guards have been replaced and that all tools have been removed from the engine. When starting with glow plugs, do not use any other starter substance (e.g. injection with start pilot). Risk of accident!

Caution: If the speed regulator has been removed, the engine must not be tested under any circumstances: disconnect the battery!

Do not actuate the starter for more than 20 seconds. If the engine does not catch, wait a minute then try again. If the engine does not catch after two attempts, refer to the Diagnosis Chart (see 7.1).

● Where possible, disengage the clutch to separate the engine from any driven parts.

● Move speed control lever 1 into idle position.

● Move cut-out handle 2 in direction of “I” and

start.

● Regarding electric starting with a solenoid, the cut-out handle 2 is pulled in direction “I” and held when current is flowing. The charge pilot light and the oil pressure pilot light go out.

without cold start assistance

● Insert key – Position 0 = no operating voltage

● Turn key clockwise – Position 1 = operating voltage – Pilot lights illuminate

● Push key in and turn further clockwise against spring pressure. – Position 2 = no function – Position 3 = start

● Release key as soon as engine fires – The pilot lights will go out.

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3.2 Starting Engine Operation

with cold start assistance/glow lamps FR 60 = 9,5 and 19 Volt

● Insert key – Position 0 = no operating voltage

● Turn key clockwise – Position 1 = operating voltage – Pilot lights illuminate

● Push key in and turn further clockwise against spring pressure – Preheat lamp comes on – Position 2 = preheat for approx. 60 secs. (holding key*) – Preheat lamp extinguishes – Position 3 = start

● Release key as soon as engine fires The pilot lights will go out.

* Fuel particles not burnt during initial com-

bustion in the cylinder are subjected to a second stage combustion process for approx. 3 minutes in order to let the exhaust gases become more transparent in the

with cold start assistance/glow lamps FR 20/30 = 11 and 23 Volt

● Insert key – Position 0 = no operating voltage

● Turn key clockwise – Position 1 = operating voltage – Pilot lights illuminate

● Push key in and turn further clockwise against spring pressure – Preheat lamp comes on. – Position 2 = preheat for approx. 20-30

secs., (holding key*) – Preheat lamp extinguishes – Position 3 = start

● Release key as soon as engine fires The pilot lights will go out

* Fuel particles not burnt during initial com-

bustion in the cylinder are subjected to a second stage combustion process for approx. 3 minutes in order to let the exhaust gases become more transparent in the start-up phase.

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Engine Operation 3.3 Monitoring Operation

3.3.1 Engine Oil Pressure

Oil pressure pilot lights

● The oil pressure pilot light comes on with operating voltage on and engine off.

● The oil pressure pilot light should go out when the engine is running.

Oil Pressure Indicator Oil Pressure Gauge

● The pointer must remain in the green sector over the entire operating range.

● The pointer of the oil pressure gauge must display the minimum oil pressure (see 9.1).

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3.3 Monitoring Operation Engine Operation

3.3.2 Engine temperature

Engine Temperature Gauge

● The engine temperature gauge pointer should remain in the green sector most of the time. It should rarely enter the yellowgreen sector. If the pointer enters the orange sector, the engine is overheating. Turn off and establish the cause from the Fault Table (see 7.1).

3.3.3 Cooling fan drive

● When the V-belt is torn, the pressure pin 1 of electrical switch is actuated by the tension roller and an audio signal or a light signal is emitted. Switch off the engine immediately to avoid overheating.

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Engine Operation 3.4 Shutting Off

3.4.1 Mechanical shut-off 3.4.2 Electrical shut-off Ignition key

● Move speed adjustment lever 1 to low idle.

● Move shut-off lever 2 in the direction of “0”

until the engine comes to a stop. The charge pilot light and the oil pressure pilot light will come on when the engine stops.

● Turn key counterclockwise (to position 0)

and remove. The pilot lights will go out.

● Concerning electrical shut-off or power

failure, the shut-off lever 2 is disabled by the solenoids until the engine stops. The charge pilot light and the oil pressure pilot light illuminate when the engine stops.

● Turn key counterclockwise (to position 0)

and remove. The pilot lights will go out.

● Turn key counterclockwise (to position 0) and remove. The pilot lights will go out.

If possible, do not suddenly switch off the engine when under full load.

Page 34

3.5 Operating Conditions Engine Operation

3.5.1 Winter Operation

● Lube Oil Viscosity – Select the oil viscosity (SAE grade) according to the ambient temperature when starting the engine, see 4.1.2. – Increase oil change frequency when operating below -10 °C, see 6.1.1.

● Diesel Fuel – Use winter-grade diesel fuel for operation below 0 °C, see 4.2.2

● Additional Maintenance Work – Drain the sludge from the fuel tank once a

week. (Unscrew the sludge drain plug)

– If necessary, allow the oil in the oil bath air

cleaner and the engine oil to settle at the ambient temperature.

– Below -20 °C, after removing the starter

if necessary, smear the ring gear on the fly wheel via the pinion bore from time to time with cold-resistant grease (e.g. Bosch FT 1 V 31 grease).

● Battery – Efficient cold starting requires the battery

to be well-charged, see 6.7.1.

– The starting limit temperatures can be low-

ered by 4-5 °C by heating the battery up to about +20 °C. (To do so, remove the battery and store in a warm place).

● Cold Start Assistance At temperatures near or below freezing point, use sheathed glow plugs if necessary, see 3.2.1. This not only lowers the starting limit temperature, but provides easier starting at temperatures normally not requiring a starting aid.

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Engine Operation 3.5 Operating Conditions

3.5.2 High Ambient Temperature, High Altitude

● Air density decreases as altitude or ambient

temperature increase. As a result of this, the engine’s maximum output, the quality of the exhaust gas, the temperature level and, in extreme cases, starting behaviour, are impeded. Under transient conditions, the engine can be used at altitudes up to 1000 m and temperatures up to 30 °C. If the engine is to operate under more severe conditions (at higher altitudes or temperatures), it will be necessary to reduce the injected fuel quantity and thus, engine power.

● If you have any doubts about engine opera-

tion under these or similar conditions, ask your engine or equipment supplier whether the engine has been derated in the interests of reliability, service life and exhaust gas quality (smoke). Otherwise contact DEUTZ SERVICE.

Page 36

4.1 Lube Oil

4.2 Fuel

Operating Media

Page 37

Operating Media 4.1 Lube Oil

4.1.1 Quality 4.1.2 Viscosity

Lube oils are differentiated according to their performance and quality class. In common use are specifications named after the API (American Petroleum Institute) and ACEA (European Engine Oil Sequences).

Approved API Oils: At least: CF-4

Approved ACEA Oils: At least: E1-96

It is recommended to operate the engines with Deutz Oil TLX10W-40FE Europe. If this is not available, use the appropriate oil as described above.

As the viscosity of the lube oil is dependent on temperature, the choice of SAE grade should be governed by the ambient temperature prevailing at the engine operating site. Optimum operating behaviour will be attained if you take the accompanying oil viscosity diagram as a guide. Should the temperature fall temporarily below the limits of SAE grade selected, cold starting may be affected but the engine will not be damaged. In order to keep wear to a minimum, do not exceed application limits for extended periods of time. Oil changes dictated by the seasons can be avoided by using multi-grade lube oils. Multigrade oils, particularly light-flowing oils, also reduce fuel consumption.

* Oil change intervals, see 6.1.1 Oil capacities, see 9.1

Only with engine preheating

Page 38

4.1 Lube Oil Operating Media

4.1.2.1 Specific lube oil definitions

Turbocharged engines with increased output and engines with high capacity. For the following engines, or applications:

● for engines with an output >141kW the oils

listed in the following table are to be used.

Firstly, these oils are of high quality in accordance with ACEA or API. Additionally, these oils are mainly partly synthetic, some even fully synthetic (5W-40) and thus achieve thermal stability if required for the application and sediments are less likely if the crankcase ventilation is closed in the turbocharger and in the air-intake lines.

Emission optimised engines for commercial vehicles from EURO II and mobile driven machines from position 2, corresponding to the following emission requirements:

a) from EURO II, the 88/77/EEC and 91/542/

EEC guidelines for commercial vehicles in Europe,

b) from position 2, the 97/68/EC guidelines for

mobile driven machines in Europe

c) from position 2, the US non-road engines

guidelines, only the following oil qualities are permitted:

-ACEA E3-96 and ACEA E4-98 for require ments a) and b)

-API CG-4 and API CH-4 for the require ments c)

Lube oil for engines with increased output and

engines with high output

Manufacturer Lube oil type SAE Class Availability

DEUTZ Deutz TLX Oil 10W-40FE Europe AGIP Agip Sigma Ultra TFE 10W-40 worldwide AGIP Autol Valve Ultra FE 10W-40 Germany ARAL GmbH Aral MegaTurboral 10W-40 worldwide ARAL GmbH Aral SuperTurboral 5W-30 worldwide BAYWA BayWa Super Truck 1040 MC 10W-40 South Germany BAYWA BayWa Turbo 4000 10W-40 South Germany Castrol GmbH Castrol SYNTRUCK 5W-40 Europe, North America, Brazil,

Argentina, Australia, South Africa,

Castrol GmbH Castrol DYNAMAX 7,5W-40 Europe, North America, Brazil,

Argentina, Australia, South Africa CHEVRON Chevron Delo 400 Synthtic 5W-40 North America ESSO Essolube XTS 501 10W-40 Europe FINA FINA KAPPA FIRST 5W-30 Europe FINA FINA KAPPA ULTRA 10W-40 Europe FUCHS DEA DEA Cronos Synth 5W-40 Germany, Europe FUCHS DEA DEA Cronos Premium LD 10W-40 Germany, Europe FUCHS DEA Fuchs Titan Cargo MC 10W-40 worldwide FUCHS DEA DEA Cronos Premium FX 10W-40 Europe FUCHS DEA Fuchs Titan Unic Plus MC 10W-40 worldwide MOBIL OIL Mobil Delvac 1 SHC 5W-40 Europe, South East Asia, Africa MOBIL OIL Mobil Delvac 1 5W-40 worldwide MOBIL OIL Mobil Delvac XHP Extra 10W-40 Europe, South East Asia BP OIL International BP Vanellus HT Extra 10W-40 Europe Shell International Shell Myrina TX / 5W-30 Europe, label

Shell Rimula Ultra country-specific, various Shell International Shell Myrina TX / 10W-40 Europe, label

Shell Rimula Ultra country specific, various TOTAL TOTAL RUBIA TIR 86000 10W-40 worldwide lube oil refinery Wintershall TFG 10W-40 Europe Salzbergen GmbH

The table can be extended if required.

Page 39

Operating Media 4.2 Fuel

4.2.1 Quality 4.2.2 Winter Fuel

Use commercially available diesel fuel with less than 0.5 % sulphur content. If the sulphur content is higher, oil change intervals should be reduced (see 6.1.1).

The following fuel specifications / standards are approved: (also see TR 0199-3002)

● Diesel fuel

- DIN EN 590

- BS 2869: A1 and A2 (with A2, take note of the sulphur content)

- ASTM D 975-88; 1-D and 2-D

- NATO Code F-54 and F-75

- ISO 8217 DMX

- ISO 8217 DMA

● Light fuel oils

in accordance with DIN 51603 ASTM D 396; 1 and 2 BS 2869 Class D

● Jet fuel

- F34/F35/F44 (Kerosene)

- F54 (corresponds to diesel fuel in accordance with DIN EN 590)

- XF 63 (corresponds to F34+F35 with additives)

Waxing may occur at low temperatures, clogging the fuel system and reducing engine efficiency. If the ambient temperature is less than 0 °C, winter-grade fuel (suitable down to -20 °C) should be used. (This fuel is available from the filling stations well in advance of the cold months).

● Kerosene must be added at temperatures below -20 °C. The relevant percentages are given in the adjacent diagram.

● Special diesel fuels may be used in arctic climatic zones up to -44 °C.

If summer-grade diesel fuel must be used at temperatures below 0 °C, up to 60% kerosene can be added (see diagram).

In most cases, adequate resistance to cold can be obtained by adding a flow improver (additive). Please ask your DEUTZ partner.

Legend:

I Summer-grade diesel fuel

I I Winter-grade diesel fuel

A Ambient temperature

B Percentage of kerosene added

● Bio diesel fuel

- in accordance with DIN 51606- FAME Exhaust emission values which may be determined in the case of type approval tests always refer to the reference fuel

prescribed by the authorities for the type approval test.

diesel fuel should never be mixed with petrol (normal or super petrol)

Mix in tank only! Fill with the appropriate amount of kerosene first, then add the diesel fuel.

Page 40

Routine Maintenance

5.1 Maintenance Plan

5.2 Maintenance Schedules

5.3 Maintenance Work Completed

Page 41

Routine Maintenance 5.1 Maintenance Schedule

check = ● adjust = ❍ clean = ◆ replace = ■ prior to or during 1st trial run, check 2x daily during the breaking in phase or when

commissioning new and overhauled engines

every 10 hours of operation or daily

In hours of operation (HO) every

■

years

Operation Section

Top up lube oil if necessary (also with separate container) 6.1.2/3.3.4 Lube oil (oil change intervals depending on engine use), see TR 0199-99-3002 6.1.1/6.1.2 Oil filter cartridge (at each lube oil change) Oil bath air filter 6.3 Bypass – oil filter 6.1.4 Fuel filter cartridge # Fuel pre-cleaner 4.2/ 6.2.2 Intake air cleaner/dry type air cleaner (If available, maintain according to

maintenance indicator) 6.4.3 /6.4.4

Battery and cable connectors 6.7.1 Engine monitoring system, warning system 3.3 # Valve clearance (set if necessary, earlier if noises occur) 6.6.1# V-belts (retension or replace if necessary) 6.5.1 Sheathed glow lamps 6.9.3 Check engine for leaks (visual inspection) – Engine suspension (replace if damaged) 9.2 Fastenings, hose connections / clamps 6.9.1 Basic overhaul #

E10 E20 E30 E40 E50 E60 E70

125 250 500 1000 12000 1 2

●●

■■■

●

■

◆

●◆

●

● ❍❍

● ■

●

Industrial engines

The specified engine maintenance values are permissible recommended maximums. Depending on usage, reduced maintenance intervals may be necessary, comply with the unit manufacturer’s operating instructions.

# Maintenance must only be carried out by authorised service personnel

Page 42

5.1 Maintenance Schedule Routine Maintenance

check = ● adjust = ❍ clean = ◆ replace = ■ max. recommended standard times in operating hours (HO) of all prior to or during 1st trial run, check 2x daily during the breaking in phase or when

commissioning new and overhauled engines

every 10 hours of operation or daily

In hours of operation (HO) every

years

E10 E20 E30 E40 E50 E60 E70

250 500 1000 2000 3000 4000 1 2

■

◆

■

Operation Section

Injection valve # Intercooler (drain lube oil/condensation) # CPD compressor outlet # Basic overhaul of emission related parts #

Additions and modifications

for engines with EPA approval

# Maintenance must only be carried out by authorised service personnel

Page 43

Maintenance 5.2 Routine maintenance work plan

5.2.1 Routine maintenance work plan

Intervals Maintenance Activity Plan executed by: Comments

with/after levels

50 [OH] E 10 after operation and E 50 - E 70 authorised specialised staff

daily E 20 daily inspection the user

250 [OH] E 25 Inspection authorised specialised staff

500 [OH] E 30 further inspection authorised specialised staff

1000 [OH] E 40 intermediate repair authorised specialised staff

3000 [OH] E 50 further intermediate repair authorised specialised staff

6 000 [OH] E 60 partial repair authorised specialised staff

12 000 [OH] E 70 major repair authorised specialised staff

Page 44

5.2 Maintenance Charts Routine Maintenance

The maintenance charts shown on this page are supplied as self-adhesive labels with each engine. They should be affixed where they can be seen clearly on the engine or driven equipment.

Check that this is the case.

If necessary, ask your engine or equipment supplier for a fresh supply of labels! Routine work should be carried out according to the schedule (see chapter 5.1).

in.

ex.

OIL

a =

0,15 mm

0.006 in

1000

1252000

500

FL 914

1000500

1000

Std.

ca.

15 mm

0.6 in.

250

500

AIR

OIL

Stop the engine before carrying out any maintenance work.

0312 0360

OIL

max.

FUEL

OIL

max.

in.

ex.

OIL

500

1252000

500

0.006 in

0,15 mm

a =

BF L 914/C

1000 1000

FUEL

Std.

ca.

15 mm

0.6 in.

250

500

AIR

OIL

0132 0359

Page 45

Routine Maintenance 5.3 Maintenance Work Completed

Date Signature/stamp Date Signature/stampOp. hoursOp. hours

50-150*

125

375

625

875

1125

1375

1625

1875

2115

–

250

500

750

1000

1250

1500

1750

2000

2250

2375

2625

* following commissioning of new and overhauled engines. Duly completed maintenance jobs can be recorded and signed off in the above chart.

2500

2750

Page 46

5.3 Maintenance Work Completed Routine Maintenance

Op. hours

2875

3125

3375

3625

3875

4125

4375

4625

Date Signature/stamp Date Signature/stampOp. hours

3000

3250

3500

3750

4000

4250

4500

4750

4875

5125

5375

5625

Duly completed maintenance jobs can be recorded and signed off in the above chart.

5000

5250

5500

5750

Page 47

Routine Maintenance 5.3 Maintenance Work Completed

Date Signature/stamp Date Signature/stampOp. hoursOp. hours

5875

6125

6375

6625

6875

7125

7375

7625

7875

8125

6000

6250

6500

6750

7000

7250

7500

7750

8000

8250

8375

8625

Duly completed maintenance jobs can be recorded and signed off in the above chart.

8500

8750

Page 48

5.3 Maintenance Work Completed Routine Maintenance

Page 49

Service and Maintenance

6.1 Lubrication System

6.2 Fuel System

6.3 Cooling system

6.4 Combustion Air Filter

6.5 Belt Drives

6.6 Adjustments

6.7 Accessories

6.8 Engine cleaning

6.9 Additional Maintenance Work

Page 50

Service and Maintenance

6.1.1 Oil change intervals

● The oil change intervals are dependent on the engine application and the quality of the lube oil.

● If the engine runs fewer hours during the year than stated in the table, the oil should be changed at least once a year.

● The table refers to the following conditions: – For diesel fuel: sulphur content max.

0.5% by weight.

– Continuous ambient temperatures down

to -10 °C (+14 °F).

● If the sulphur content is > 0.5 to 1% or the continuous ambient temperature below the oil change intervals must be halved.

Engines for installation

Lube oil quality

Normal oil requirement, e.g.:

Road vehicles, cranes, construction machines, ships electrical modules, pumps, railway vehicles.

High oil requirement, e.g.:

Combines, emergency pumps, underground mining units, sweeping machines, winter service vehicles, emergency power units.

API specification

ACEA-spezification

Vehicle engines

Lube oil change intervals in HO

Naturally aspirated

engines

CF-4/CH-4/ CG-4 CF-4 CG-4 / CH-4

E1+E2-96 E1+E2-96 E3-96/E4-98

500 250 500

250 125 250

Turbocharged engines

Lube oil change intervals in km

● In the case of fuels with a sulphur content higher than 1%, contact your Service representative.

Change the oil with the engine off but still warm (lube oil temperature approx. 80 °C).

Lube oil quality

Service group

I > 30 000 20

II 30.000 -100.000 40

III < 100 000 60

API specification

ACEA-spezification

Year’s kilometrage

medium driving speed

approx. km/h

Naturally aspirated

engines

CF-4/CH-4/ CG-4 CF-4 CG-4 / CH-4

E1+E2-96 E1+E2-96 E3-96/E4-98

10 000 5 000 10 000

20 000 10 000 20 000

30 000 15 000 30 000

Turbocharged engines

Page 51

6.1 Lubrication System Service and Maintenance

6.1.2 Checking Oil Level / Changing Engine Oil

6.1.2.1 Checking Oil Level 6.1.2.2 Changing Engine Oil

● Ensure that the engine or vehicle is on a level

surface.

● – Warm engine

● Switch off engine, wait 5 minutes and check the

oil level

● – Cold engine

Check the oil level

● Remove the dipstick

● Wipe off with a non-fibrous, clean cloth.

● Insert up to the stop and pull out again.

● Check oil level, if required top up to the

“MAX” level – If the oil level is just above the “MIN” mark, it should be topped up.

The oil level must not drop below the “MIN” mark.

● Run the engine warm

● Ensure that the engine or vehicle is on a level

surface – Lube oil temperature approx. 80°C.

● Switch off the engine.

26 022 0 25 729 0

● Place an oil tray beneath the engine

● Unscrew drain plug.

● Drain oil.

● Fit oil drain plug with new gasket and tighten

firmly (for torque, see 9.2).

● Fill with lube oil – For grade/viscosity, see 4.1. – For quantity, see 9.1.

● Check oil level, see 6.1.2.1

Be careful when draining hot oil - danger

of scalds! Do not let used oil run into the soil but catch it in a container ready for proper disposal.

26 023 0

Page 52

Service and Maintenance

6.1.3 Replace Oil Filter

6.1 Lubrication System

● Undo the lube oil filter cartridge using a commercial tool and spin off.

● Catch any escaping oil.

Caution is required in the case of hot oil: Risk of scalding! Please dispose of oil in an environmentally-friendly manner!

● Clean any dirt from the filter carrier sealing surface.

● Lightly oil the rubber gasket of the new lube oil filter cartridge.

● Manually screw in the new cartridge until the gasket is flush.

● Tighten the lube oil filter cartridge with another half-turn.

● Check the oil level, see 6.1.2

● Check oil pressure, see 3.3.1.

● Check lube oil filter cartridge seal for leaks.

Page 53

6.1 Lubrication System Service and Maintenanceen

6.1.4 Change bypass-oil filter use

● Remove oil drain screw 1 and let the oil run

out.

● Catch any escaping oil.

● Remove tensioning screw 2. Remove

cover.

● Remove soiled filter 3. Clean filter casing.

● Check cover 4 for leaks, and replace if

necessary.

● Screw in oil drain screw with a new seal

ring 5.

● Insert new filter.

● Screw on cover with seal ring 6.

● During trial, observe oil pressure and check

for leaks.

Page 54

Service and Maintenance 6.2 Fuel System

6.2.1 Replace Fuel Filter

● Close the fuel shut-off valve.

● Undo fuel filter cartridge with commercial

tool and spin off.

● Catch any escaping fuel.

Keep naked flames away when working on the fuel system. Do not smoke!

● Clean any dirt from the filter carrier sealing surface.

● Apply light film of oil or diesel fuel to the rubber gasket of the new fuel filter cartridge.

● Manually screw in the new cartridge until the gasket is flush.

● Tighten the fuel filter cartridge with a final half-turn.

● Open fuel shutoff valve.

● Check for leaks.

The fuel system does not need to be bled.

Page 55

6.2 Fuel System Service and Maintenance

6.2.2 Fuel precleaning Clean fuel filter “Motorpal” model

● Close the fuel shut-off valve.

● Screw out and remove filter cap 4.

● Catch any escaping fuel.

● Remove strainer 3 and clean with fuel.

● Remove seal ring 2.

● Clean filter casing 1 with fuel.

● Screw on filter cap 4 and strainer 3 with

new seal 2.

● Bleed fuel system (see 3.1.4).

● Open fuel shutoff valve.

● Check for leaks.

Keep naked flames away when working on the fuel system. Do not smoke!

Page 56

Service and Maintenance 6.3 Cooling System

6.3.1 Cleaning Intervals

● The amount of contamination in the cooling system depends on the engine application.

● Oil and fuel residues on the engine increase the risk of contamination. Therefore pay special attention to leaks if the engine is used in dusty environments.

● Serious contamination can occur, for example:

- On construction sites where there is a

high level of air-borne dust.

- In harvesting application where there are

high concentrations of chaff and chopped straw in the vicinity of the machine.

● Because applications vary, cleaning intervals have to be determined from case to case. The cleaning intervals given in the table on the right can be used as a guide.

Checking or cleaning intervals Engine application

Standard values

2000 1000

500 250

125

Ships, electrical modules in enclosed areas, pumps Vehicles on paved roads Tractors, fork-lift trucks, drivable electric units. Vehicles on construction sites and unpaved roads, construction machines compressors, underground mining units Agricultural machines, tractors in harvesting application

Page 57

6.4 Combustion Air Filter Service and Maintenance

6.4.1 Cleaning Intervals

● The amount of dirt in the air cleaner depends on the amount of dust in the air and the size of the air cleaner used. If a high level of dust is anticipated, a cyclone-type precleaner can be fitted to the air cleaner.

● Cleaning intervals will have to be determined from case to case.

● If dry type air filters are used, cleaning should only be carried out according to the service indicator or service switch.

● Air cleaner servicing is needed when

- Service indicator

the red signal 1 is fully visible when the engine is off.

- Service switch

the yellow pilot light comes on when the engine is running.

● After carrying out service work, reset the signal by pressing the button on the service indicator. The service indicator is now ready for operation again.

Page 58

Service and Maintenance 6.4 Combustion Air Filter

6.4.2 Emptying Cyclone Type Precleaner

● Undo wing nut 1 and remove cover 2.

● Remove collector bowl 3 from lower sec-

tion 4 and empty. Clean leaves, straw and other foreign matter from lower section of pre-cleaner.

● Reposition collector bowl 3 onto lower

section 4, fasten cover 2 in place by tightening wing nut 1.

6.4.3 Clean Oil Bath Air Filter

● Turn engine off and wait about 10 minutes for the oil to drain from filter housing 1.

● Loosen quick fasteners 2 and remove oil cup 3 with filter element 4; if necessary, loosen filter element with the aid of a screwdriver at the separating point. Do not damage rubber gasket 5!

● Remove dirty oil and sludge. Clean oil cup.

● Clean filter element 4 in diesel fuel and

allow to drip-dry.

● Clean filter housing 1 if very dirty.

● Inspect and replace rubber gasket 5 and 6

if necessary.

● Fill oil cup with engine oil up to the mark (arrow) (for viscosity, see 4.1.2).

● Refit oil cup and element to filter housing and secure with snap clips.

Never fill collector bowl with oil. Replace collector bowl if damaged.

Never clean filter with gasoline! Dispose of old oil in accordance with environmental regulations!

Page 59

6.4 Combustion Air Filter Service and Maintenance

6.4.4 Dry type air cleaner Dust discharge valvel

● Empty dust discharge valve 1 by pressing

apart lips of discharge slot as indicated by arrows.

● Clean discharge slot from time to time.

● Remove any caked dirt by pressing to-

gether the upper section of the valve.

Filter Cartridge

● Undo clip fasteners 1.

● Take off hood 2 and remove cartridge 3.

● Clean cartridge (replace at least once a

year).

● Clean cartridge 3. Blow out using dry compressed air (max. 5 bar), (or in difficult cases, tap out, taking care not to damage the cartridge, or wash according to manufacturer’s instructions).

● Through regular removal and replacement, the gaskets on the filter cartridge can become damaged. Check paper filter (light showing through) and gaskets for damage. Replace if necessary.

● After five cleaner services (or after two years at the latest), replace safety cartridge 4 (never clean). To do so:

- Undo hex. nut 5 and remove cartridge 4.

- Install new cartridge, insert and tighten

hex nut.

● Install cartridge 3, replace hood 2 and do up clip fasteners 1.

Never clean filter cartridge with gasoline or hot fluids.

Page 60

Service and Maintenance 6.5 Belt Drives

6.5.1 Check V-belts

● Visually inspect entire V-belt for damage.

● Replace damaged V-belts.

● After installing new belts, run engine for 15

minutes, then check belt tension.

● To check the tension of the V-belt, use a tension gauge (see 9.3).

- Place indicator arm 1 into gauge.

- Position guide 3 on V-belt 2, midway

between the pulleys, with flange 3 on bottom of gauge against the edge of belt.

- Push slowly on the black pad 4 at right

angles to V-belt 2 until the spring is heard or felt to trigger.

- Carefully remove the gauge without

altering the position of the indicator arm 1.

Read off the value where the indicator arm 1 intersects scale 5 (arrow). For settings, see 9.1.

- If necessary, retension belt and measure again.

Check, tension and change belts only with the engine off. Reinstall V-belt guard

6.5.2 Fan V-belt

● To replace the tension roller 1, press inwards with a commercial tool and remove the V-belt.

● Position new ribbed V-belt.

Retension V-belt after it has ran for 15 minutes.

Page 61

6.5 Belt Drives Service and Maintenance

6.5.3 Alternator belts 6.5.5 Check warning system6.5.4 Change alternator belt

● Loosen bolts 1, 2 and 3 slightly.

● Press alternator 4 outwards in direction

of arrow A until correct belt tension is achieved.

● Retighten bolts 1, 2 and 3.

● Remove fan belt, as shown in 6.5.2.

● Slacken off bolts 1, 2 and 3.

● Swing alternator inwards in the direction

of arrow B.

● Remove and replace belt.

● Swing alternator 4 outwards in direction

of arrow A until correct belt tension is achieved.

● Retighten bolts 1, 2 and 3.

● Fit fan belt.

● When the V-belt is torn, the pressure pin 1 of electrical switch is actuated by the tension roller and an audio signal or a light signal is emitted.

● Check the function by pressing pin 1.

Check, tension and change belts only with the engine off. Reinstall V-belt guard.

Retension V-belt after it has ran for 15 minutes.

Only check function when the engine is off!

Page 62

Service and Maintenance 6.5 Belt Drives

6.5.6 Tensioning or changing V-belts

● Unscrew hex screw 1.

● Remove outer belt pulley half 2.

● Replace V-belt if necessary.

● In order to retension, remove one or more inner washers 3. Place the removed washers on the outside on the removed belt pulley half 2.

● Tighten screw 1 again. Whilst tightening, turn engine over simultaneously in order to prevent crushing the V-belt.

After installing new belts, run engine for 15 minutes, then check belt tension.

Page 63

6.5 Belt Drives Service and Maintenance

6.5.7 Air compressor model with dual belts

● Undo hex nut 1, remove V-belt pulley half

2, V-belt 3 and inner washer kit 7.

● Remove inner washers 4, posterior V-belt

3, inner washer kit 6 and pulley half 5.

● To retension, remove one or more inner

washers from kits 6 and 7. Place removed washers in front of or behind pulley half 2 to ensure belt alignments. Always remove only the same number of washers from each kit.

● For installation, now proceed in the re-

verse order. Whilst tightening the nut 1, turn engine over simultaneously in order to prevent crushing the V-belt.

If one belt locks or is damaged, always replace both belts. The difference of length between the new belts may not exceed

0.15%.

Check and change belts only with the engine off. Reinstall V-belt guard, if necessary. Retension V-belt after it has ran for 15 minutes.

Page 64

Service and Maintenance 6.6 Adjustments

6.6.1 Check valve clearance, adjust if necessary

● Remove the cylinder head cover.

● Position crankshaft as per schematic, see

6.6.1.1.

● Before adjusting valve clearance, allow

engine to cool down for at least 30 minutes. The oil temperature should be below 80 °C.

● Check valve clearance 1 between rocker

arm / tappet contact face 2 and valve stem 3 with feeler gauge 6 (there should be only slight resistance when feeler blade is inserted). For permissible valve clearance, see 9.1.

● Adjust valve clearance if necessary:

- Release locknut 4.

- Use allen key 7 to turn setscrew 5 so that the correct clearance is attained after locknut 4 has been tightened.

● Check and adjust valve clearance on all cylinders.

● Reinstall cylinder head cover with new gasket if necessary.

For high output settings, the engines are fitted with an additional oil nozzle to lubricate bearings.

only be carried out in an authorised specialist workshop!

If necessary, readjustment may

Page 65

6.6 Adjustments Service and Maintenance

6.6.1.1 Schematic for Valve Clearance Adjustments

● Crankshaft Position 1:

Turn crankshaft until both valves in cylinder 1 overlap (exhaust valve about to close, inlet valve about to open). Adjust clearance of valves marked in black on schematic. Mark respective rocker arm with chalk to show that adjustment has been carried out.

● Crankshaft Position 2:

Turn crankshaft one full revolution (360°). Adjust clearance of valves marked in black on schematic.

Page 66

Service and Maintenance 6.7 Accessories

6.7.1 Battery

6.7.1.1 Checking battery and cable connectors

● Keep battery clean and dry.

● Undo dirty clamps.

● Clean terminal posts (+ and -) and clamps

of the battery, and grease with acid-free and acid-resistant grease.

● When reassembling, ensure that clamps

make good contact. Tighten clamp bolts hand-tight.

6.7.1.2 Check Electrolyte Level 6.7.1.3 Check electrolyte density

● Remove sealing caps 1.

● If testers 2 are present: Electrolyte level

should reach the base of these.

● Without testers:

The electrolyte level should be 10-15 mm above the top of the plates.

● If necessary, top up with distilled water.

● Screw sealing caps back in.

● Measure the electrolyte density of indi-

vidual cells with a commercial hydrometer.

The hydrometer reading (see table on following page) indicates the battery’s state of charge. During measurement, the temperature of the electrolyte should preferably be +20 °C.

Page 67

6.7 Accessories Service and Maintenance

in [kg/ l] in [°Bé (Baumé scale)*] Charge status

Normal Tropical Normal Tropical

1,28 1,23 32 27 well charged

1,20 1,12 24 16 semi-charged, re-charge

1,12 1,08 16 11 discharged, immediately charge

* Measurement of electrolyte density in ° Bé

(Baumé-scale) is out of date and rarely used today.

The gases emitted by the battery are explosive! Keep sparks and naked flames away from the battery! Do not allow battery

acid to come into contact with skin or clothing! Wear protective goggles! Do not rest tools on the battery!

Page 68

Service and Maintenance 6.7 Accessories

6.7.2 Rotary Current Alternator 6.7.3 Transportation Shackles

Notes on the three-phase system:

● Never disconnect the cables between battery, alternator and regulator while the engine is running.

● If, however, it is necessary to start and operate the engine without the battery, disconnect the regulator from the alternator before starting.

● Be sure not to confuse the battery terminals.

● Replace defective charge pilot lamp bulb immediately.

● When washing the engine, cover up the alternator and regulator.

● The habit of touching a lead against the frame to check whether it is live must under no circumstances be exercised with threephase electrical systems.

● In case of electric welding, connect the ground terminal on the welder directly to the piece being welded.

● Always use proper lifting tackle 1 when transporting the engine.

● After transportation and before commissioning of the engine:Remove attachment eyes 2.

Use only the correct lifting gear!

Page 69

6.8. Engine Cleaning Service and Maintenance

6.8.1 Engine cleaning

Using compressed air

● Switch off the engine.

● Remove engine covers and cooling air

hood. Replace them after cleaning and before the test run.

● Cover electrical / electronic components / connections (e.g. generator, starter, governor, solenoid).

● Blow air through the engine, taking particular care not to damage the cooler and cooling fins (begin to blow through air from the exhaust side). Remove the dirt which has blown into the interior space.

Using cold-cleaning compound

● Switch off the engine.

● Remove engine covers and cooling air

hood. Replace them after cleaning and before the test run.

● Cover electrical / electronic components / connections (e.g. generator, starter, governor, solenoid).

● Spray the engine with the commercial coldcleaning compound and allow to react for approx. 10 mins.

● Spray clean the engine with a strong water jet, repeat if necessary.

● Allow the engine to run warm so that the remaining water evaporates.

Using high pressure device

● Switch off the engine.

● Remove engine covers and cooling air

hood. Replace them after cleaning and before the test run.

● Cover electrical / electronic components / connections (e.g. generator, starter, governor, solenoid).

● Clean the engine with a steam jet (max. spray pressure of 60 bar, max. steam temperature of 90ºC).

● Allow the engine to run warm so that the remaining water evaporates.

Clean the engine only when the engine is switched off!

Page 70

Service and Maintenance 6.9 Additional Maintenance Work

6.9.1 Check fastenings 6.9.2 Checking the function of the glow plugs

● Cylinder head cover 1

● Air intake manifold 2

● Connection sockets

● Exhaust line 3

● Engine mounts 4

● With perfect function, the air-intake pipe 4

warms up near the glow lamps 2 from preglowing.

Test step 1

● Place speed control lever or shut-off lever in “stop” position.

● Insert key

-Position 0 = no operating voltage

● Key clockwise

-Position 1 = operating voltage

-Pilot lights illuminate

● Push key in and turn further clockwise against spring pressure.

-Position 2 = Preheat, hold for approx. 1 minute.

-Preheat lamp comes on

● Otherwise the glow lamps are defective or the transmission line interrupted.

Page 71

6.9 Additional Maintenance Work Service and Maintenance

Test step 2

● Loosen screw 1.

● Turn engine over with starter, key in switch-

ing position 3.

● Fuel must be present on the loosened pipe connection. Otherwise, the system and solenoid valve should be checked by a specialist!

Test step 3

● Loosen screw 1.

● Remove glow lamps 2

● Turn engine over with starter, key in switch-

ing position 3.

● Fuel must be present on the glow lamps 2, or replace glow lamps 2 if necessary.

● When fitting glow lamps 2, use DEUTZ DW 47 sealants.

● Reinstall glow lamps to fuel line.

Keep away from moving parts! Collect any escaping fuel and dispose of this in an environmentally-friendly manner.

Page 72

Page 73

7.1 Fault Table

Faults, Causes and Remedies

Page 74

Faults, Causes and Remedies 7.1 Fault Table

Faults Measures

Engine does not start or is difficult to start Check P

Engine starts, but runs irregularly or fails Adjust E

Engine overheats, temperature warning system responds Replace W

Engine output is deficient Clean R

Engine does not run on all cylinders Top up A

Engine oil pressure is non-existent or excessively low Reduce S

Engine oil consumption excessive

Engine smokes - blue

- white

- black

Cause Section

●

●●

●● ●●

●●●

●●

●●● ●●●

●● ●

●

●● ●

●●

●

●● ●

●●

●

Not declutched (where possible) Engine Operation P Below starting limit temperature P Engine shut-off lever still in stop position (shut-off magnet defective) P Oil level too low A Oil level too high S Excessive inclination of engine P/E Engine runs mainly with low load P Air cleaner clogged / turbocharger defective Combustion air W Air cleaner service switch / indicator defective P/W CPD defective (connection line leaks) only with turbocharged engines P/W Exhaust gas backpressure too high P Charge air line leaking, only with supercharged engines P/E Cooling fins soiled Cooling system P/R Intercooler soiled P/R Oil cooler soiled on the air and/or the oil side P/R Cooling fan or exhaust tension defective, torn or loose V-belt P/W Cooling air temperature rise / heating short circuit P Cooling air guide loose, torn or missing P

Page 75

7.1 Fault Table Faults, Causes and Remedies

Faults Measures

Engine does not start or is difficult to start Check P

Engine starts, but runs irregularly or fails Adjust E

Engine overheats, temperature warning system responds Replace W

Engine output is deficient Clean R

Engine does not run on all cylinders Top up A

Engine oil pressure is non-existent or excessively low Reduce S

Engine oil consumption excessive

Engine smokes - blue

- white

- black

Cause Section

●

●●●●● ●●

●● ●●

●

●● ●

●●●●● ●●

●● ●●

●●

●●●

●● ●● ●●

●

Battery defective or discharged Electrics P Cable connections, starter, electrical circuit loose or oxidised P Starter defective or pinion does not engage P Oil pressure switch / gauge defective P/W Incorrect valve clearance Engine P/E Injection line leaks P/R Ventilation line blocked P/R Glow plugs P/W Injection valve defective P/W Air in the fuel system P/W Fuel filter / fuel pre-cleaner soiled P/R/W Oil filter defective W Incorrect engine lube oil SAE class or quality W Compression too low P Oil in combustion chamber P/R

Page 76

Page 77

8.1 Preservation

Engine Preservation

Page 78

Engine Preservation 8.1 Preservation

8.1 Preservation

8.1.1 Preserve engine 8.1.2 Remove engine preservation

If the engine is to remain idle for an extended period of time, it is necessary to take protective measures to prevent the formation of corrosion. The preservative measures described here will protect the engine for up to approx. 6 months. The procedure will have to be reversed before the engine is recommissioned

● Anti-corrosion oils to specification:

- MIL-L 21260B

- TL 9150-037/2

- Nato Code C 640 / 642

● Recommended cleaning agent to remove preservatives:

- Petroleum benzine (hazardous materials

class A3)

● Clean engine (with cold cleansing agent if preferred) using high pressure equipment (see 6.8.1).

● Run engine until warm, then turn off.

● Drain engine oil, (see 6.1.2), and fill with

anti-corrosion oil.

● If necessary, clean oil bath cleaner (see

6.4.3), and fill with anti-corrosion oil.

● Drain fuel tank.

● Make up a mixture of 90 % diesel fuel and

10 % anti-corrosion oil, and refill fuel tank.

● Allow the engine to run for approx. 10 mins.

● Switch off the engine.

● Turn engine over manually several times to

preserve the cylinders and combustion chamber. When turning over with starter, set shutoff lever to stop position.

● Remove V-belts and store wrapped, dry and recumbent.

● Spray grooves on V-belt pulleys with anticorrosion spray.

● Close off intake ports and exhaust ports, possibly with plugs.

● Remove anti-corrosion agent from grooves in V-belt pulleys.

● Install V-belt, retension after brief operation if necessary (see 6.5).

● Remove covers from intake port and exhaust ports.

● Commission engine.

Page 79

Technical Specification

9.1 Engine Specifications and Settings

9.2 Screw Tightening Torques

9.3 Tools

Page 80

Technical Specification 9.1 Engine Specifications and Settings

Model

Number of cylinders

F3L 914 F4L 914 F5L 914 F6L 914

34 5 6 Cylinder arrangement Bore [mm] Stroke [mm] Total displacement [cm

]

3236 4314 5393 6472 Compression ratio [ε] Working cycle Combustion system Direction of rotation seen on flywheel Weight including cooling system to DIN 70020-A without starter or alternator [approx. kg]

270

Engine output [kW] Speed [rpm] Lubrication SAE oil Oil temperature in oil pan [°C] Min. oil pressure when warm (120 °C) and low idle [bar] ÖOil plate filling quantity without filter [approx. litres] Oil plate filling quantity with filter [approx. litres]

9,0

9,6

Valve clearance with cold engine [mm] Injector opening pressure [bar] Start of feed [°KW of TDC] Firing order of the engine

1–2–3 1–3–4–2 1–2–4–5–3 1–5–3–6–2–4 V-Belt tension: Alternator fan [N] Compressor [N]

1) Engine output, speed, start of delivery are stamped on engine rating plate, etc., (see also 2.1).

2) Re-tension 15 minutes after the engine has been operated under load.

3) Approx. values may vary depending on version. The upper oil dipstick mark is always authoritative.

4) Values for engines without engine oil heating.

5) Approx. values may vary depending on version.

vertical in line

102 132

4-stroke naturally aspirated diesel engine

Direct injection

counter-clockwise

300

380

Pressure lubrication

15W 40

135

0,4 12,0 13,0

13,5 15,0

Inlet 0,15 + 0,05 / exhaust 0,15 + 0,05

200 + 10

Pre-tension / re-tension

450 / 300 ± 20 550 / 400 ± 20

410

14,5 16,0

Page 81

9.1 Engine Specifications and Settings Technical Specification

914/C/CT Model

Number of cylinders

BF3L 914 BF4L 914 BF6L 914 BF6L 914 C

34 6 6 Cylinder arrangement Bore[mm] Stroke[mm] Total displacement [cm

]

3236 4314 6472 6472 Compression ratio [ε] Working cycle

4-stroke turbocharged diesel engine Combustion system Direction of rotation seen on flywheel Weight including cooling system to DIN 70020-A without starter or alternator [approx. kg]

320

360 Engine output [kW] Speed [rpm] Lubrication SAE oil Oil temperature in oil pan [°C] Min. oil pressure when warm (120 °C) and low idle [bar] Oil plate filling quantity without filter [approx. litres] Oil plate filling quantity with filter [approx. litres] Valve clearance with cold engine [mm]

9,6

12 13

Inlet 0,15 + 0,05 / exhaust 0,15 + 0,05 Injector opening pressure [bar] Start of feed [°KW of TDC] Firing order of the engine

1–2–3 1–3–4–2 1–5–3–6–2–4 1–5–3–6–2–4 V-Belt tension: Pretension / Retension Alternator fan [N] Compressor [N]

1) Engine output, speed, start of delivery are stamped on engine rating plate, etc., (see also 2.1).

2) Re-tension 15 minutes after the engine has been operated under load.

3) Approx. values may vary depending on version. The upper oil dipstick mark is always authoritative.

4) Values for engines without engine oil heating.

5) Approx. values may vary depending on version.

vertical in line

102 132

Direct injection

counter-clockwise

Pressure lubrication

15W 40

135

0,5

200 + 10

Pretension / Retension

400 / 250 ± 20 500 / 350 ± 20

485

16,0 17,5

510

16,0 17,5

Page 82

Technical Specification 9.2 Torque Wrench Settings

Installation Pretension Retension Total Comments

[Nm] 1

Securing the alternator 20 180° – – – 180° M10 x 180

30 180° – – – 180° M14 x 230

Cylinder head cover – – – – – 12 ± 1,2 Nm – Valve clearance adjusting screw – – – – – 22 ± 2 Nm –

Foot 30 60° 15° – – 75° M14 x 100

30 60° 45° – – 105° M14 x 110 30 60° 45° – – 105° M14 x 125

Intake manifold – – – – – 21 ± 2 Nm – Exhaust manifold – – – – – 40 ± 4 Nm –

position 2nd position 3rd position 4th position

Oil drain screw – – – – – 150 ± 10 Nm M30 x 1,5 Oil drain screw – – – – – 80 ± 10 Nm M22 x 1,5

Injection valve attachment – – – – – 25–30 Nm –

Page 83

9.3 Tools Technical Specification

V-belt tension gauge

The V-belt tension gauge can be obtained under order number 8115 from:

WILBÄR Postfach 14 05 80 D-42826 Remscheid

Page 84

Service

Knowing it’s DEUTZ

DEUTZ has always stood for excellence in motor construction, pioneering many developments in the industry. As an independent motor manufacturer, we offer — worldwide — a comprehensive range of diesel and gas motors spanning from 4kW to 7,400kW. Our products are perfectly tailored to meet our customers’ individual requirements.

Over 1.4 million DEUTZ motors do their job reliably all over the world. We are determined to preserve the high standard of performance and dependability of our motors, thus keeping our customers satisfied at all times. Therefore we are represented worldwide through a network of highly competent service partners who will meet the needs of our customers, wherever they are.

This is why DEUTZ is not only the name for motors which pack a lot of inventive genius. DEUTZ also means reliable service and comprehensive support to enhance your motor’s performance.

Order-No.: 0312 0806

This index Sales & Service offers you an overview of the DEUTZ partners in your vicinity, including the products for which they are responsible and the range of services provided. But even when no direct product responsibility is mentioned, your DEUTZ partner will be happy to help you with expert advice.

The Index is constantly updated. Please ask your DEUTZ service partner for the latest edition.

DEUTZ AG — at your service.

Obtainable from the local service Partner reponsible for you or from:

Order-No.: 0312 0807 (CD-ROM) DEUTZ AG

Deutz-Mülheimer Str. 147-149 D-51057 Köln

Phone: 0049-221-822-0 Telefax: 0049-221-822-5304 Telex: 8812-0 khd d http://www.deutz.de

Page 85

Imprint:

DEUTZ AG Service-Technik Instandhaltungstechnik Motoren Deutz-Mülheimer Straße 147-149 D - 51057 Köln Telefon: 0221 - 822 - 0 Fax: 0221 - 822 - 5358 http://www.deutz.de