Deutz Engine 914 Operation Manual Deutz Engine 914 Operation Manual

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User guide and maintenance

manual

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03120382

01/01/2002

33522910601_0_1

Operation Manual

914

validate any liability claims against the manu-

facturer 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 guaran-

teed under such conditions.

● Unauthorized engine modifications will in-

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.

Safety guidelines / Accident prevention

● Please read and observe the information

the application specified in the scope of

supply, as described by the equipment manu-

facturer and is to be used only for the

● This engine has been built exclusively for

air intake area to the blower.

The manufacturer shall not be held respon-

sible for any damage which results from

such work.

● Do not change, convert or adjust the cooling

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

erations on the engine, the use of DEUTZ

original parts is prescribed. These are spe-

cially designed for your engine and guaran-

tee perfect operation.

Non-compliance results in the expiry of the

warranty!

● When carrying out maintenance/repair op-

to be borne solely by the user.

pose also implies compliance with the con-

ditions laid down by the manufacturer for

operation, maintenance and servicing. The

engine should only be operated by person-

nel trained in its use and the hazards in-

● Use in accordance with the intended pur-

should only be carried out when the engine

is switched off and has cooled down.

You must ensure that the electrical systems

● Maintenance and cleaning of the engine

volved.

and other generally accepted safety and

industrial hygiene regulations must be ob-

● The relevant accident prevention guidelines

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 com-

ponents are to be covered impermeably.

served.

injury through:

- turning/hot components

- engines with positive ignition

- ignition systems (high electrical voltage)

You must avoid contact at all times!

● When the engine is running, there is a risk of

Operation Manual

914

0312 0382 en

Engine Serial Number

Technical modifications required to improve

our engines are reserved with regard to speci-

fication 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.

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).

Foreword

Dear Customer,

Air / liquid-cooled Deutz engines are designed

for a large number of applications. Conse-

quently, 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 Opera-

tion Manual are necessarily mounted to your

engine.

We have endeavoured to highlight any differ-

ences 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

Index

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

(adjust if necessary)

6.6 Adjustments

6.6.1 Check valve clearance

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

Altitude

6.9 Additional Maintenance Work

6.9.1 Check fastenings

6.9.2 Check functioning of glow plugs

Settings

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

9.2 Screw Tightening Torques

9.3 Tools

10 Service

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

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

3.4.2 Electrical shut-off

3.5 Operating Conditions

3.5.1 Winter Operation

3.5.2 High Ambient Temperature, High

4 Operating Media

4.1 Lube Oil

4.1.1 Quality

4.1.2 Viscosity

Intercooler over air-intake line

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

2.2.6 Air outlet side BF6L 914 C

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

Intercooler over flywheel

2.2.7 Operation side BF6L 914 C

2.2.8 Air outlet side BF6L 914

2.3 Lube Oil Circuit Schematic

2.3.1 Lube Oil Circuit Schematic

2.4 Fuel System Plan

2.4.1 Fuel System

exhaust thermostat

2.5 Engine cooling

2.5.1 Amount of cool air regulated by

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

exhaust thermostat and solenoid valve

2.5.2 Amount of cool air regulated by

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

General

Service

California

Proposition 65 Warning

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.

Diesel engine exhaust and some of its consti-

tuents are known to the State of California to

cause cancer, birth defects, and other repro-

ductive harm.

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

This symbol is used for all safety

warnings. Please follow them

demanding operating conditions.

Safety

carefully. The attention of operating

personnel should be drawn to these

safety instructions. General safety

and accident prevention regulations laid down by

law must also be observed.

Asbestos

DEUTZ original parts are asbestos-

free.

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 mainte-

nance 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.

Engine Description

2.1 Model

2.2 Engine Illustrations

2.3 Lube Oil Circuit Schematic

2.4 Fuel System Plan

2.5 Engine cooling

2.1.3 Engine Serial Number

Plate

The engine serial number is stamped on the

crankcase (arrow) as well as the rating

plate.

2.1.2 Position of the Rating

Engine Description 2.1 Model

2.1.1 Rating Plate

The rating plate C is attached to the crankcase.

The model A, the engine serial number B and

Depending on the model, a second rating

plate may be affixed to the air duct hood.

the performance data are stamped on the

rating plate.

The model and engine serial number must be

given when ordering parts.

B/FL 914

2.1.5 Direct injection

Engines with direct injection are used if high

output is required.

2.1 Model Engine Description

2.1.4 Cylinder numbering

Cylinders are numbered consecutively,

beginning at the flywheel.

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

11 Solenoid (shut-off magnet)

10 Fuel change filter

12 Lube oil filter

13 Full-stop depending on charge air pressure

14 Air duct hood

15 Cylinder head cover

BF3L 914

Engine Description 2.2 Engine Illustrations

2.2.1 Operation side

16 Air-intake line

17 Shielding plate

18 Flywheel

19 Oil drain screw

20 Starter

21 Exhaust turbocharger manifold

BF3L 914

2.2 Engine Illustrations Engine Description

2.2.2 Exhaust side

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

11 Shut-off magnet

10 Oil dipstick

12 SAE housing

13 Lube oil filter

14 Air duct hood

15 Cylinder head cove

F4L 914

Engine Description 2.2 Engine Illustrations

2.2.3 Operation side

16 Date plate

17 Flywheel

18 Oil drain screw

19 Starter

20 Oil pan

21 Air-intake manifold

22 Crankcase ventilation

F4L 914

2.2 Engine Illustrations Engine Description

2.2.4 Exhaust side

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

11 Oil dipstick

10 Shut-off lifting magnet

12 LDA

13 Lube oil filter cartridge

14 Engine oil cooler

15 Air duct hood

16 Cylinder head cover

BF6L 914 C- intercooler over air-intake line

2.2 Engine Illustrations Engine Description

2.2.5 Operation side

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

BF6L 914 C- intercooler over air-intake line

2.2 Engine Illustrations Engine Description

2.2.6 Exhaust side

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

11 Oil dipstick

10 Shut-off lifting magnet

12 LDA

13 Lube oil filter cartridge

14 Engine oil cooler

15 Air duct hood

16 Cylinder head cover

BF6L 914 C- intercooler over flywheel

Engine Description 2.2 Engine Illustrations

2.2.7 Operation side

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

BF6L 914 - intercooler over flywheel

2.2 Engine Illustrations Engine Description

2.2.8 Exhaust side

1 Oil pan

2 Intake manifold

3 Oil pump

4 Oil pressure regulating valve

5 Pressure oil line

rocker arm)

6 Short-circuit line or alternative

7 Ribbed tube coil or alternative

8 Block oil cooler

9 Lube oil filter

11 Main oil channel

10 Safety valve

12 Crankshaft bearing

13 Con-rod bearing

14 Camshaft bearing

15 Tappet

16 Pushrod (hollow, for oil intake to lubricate

17 Rocker arm bearings

schematic

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

Please contact DEUTZ Service when

changing-over.

25 Connection option for oil heater **

** here the filter carrier must be exchanged.

FL 914

Engine Description 2.3 Lube Oil Circuit Schematic

2.3.1 Lube Oil Circuit Schematic

1 Oil pan

2 Intake line

3 Oil pump

arm)

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

11 Crankshaft bearing

10 Main oil channel

12 Con-rod bearing

13 Camshaft bearing

14 Tappet (with impulse lubrication of rocker

rocker arm)

15 Pushrod (hollow, for oil intake to lubricate

16 Rocker arm bearings

cylinder head to crankcase)

17 Rocker arm lubrication

18 Pushrod protective tube (oil return from the

19 Throttle bore (to lubricate cogwheels)

to crankcase

20 Spray nozzle for piston cooling

21 Oil line to lubricate turbocharger

22 Oil return line from exhaust turbocharger

23 Oil pressure gauge

24 Bypass lube oil fine filter

schematic

Please contact DEUTZ Service when

changing-over.

25 Connection option for oil heater **

26 Injection pump connected to lube oil circuit

** here the filter carrier must be exchanged.

BFL 914

2.3 Lube Oil Circuit Schematic Engine Description

2.3.2 Lube Oil Circuit Schematic

each other as possible

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

Engine Description 2.4 Fuel System Schematic

2.4.1 Fuel System

thermostat

1 Pressure oil line from engine to exhaust

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

2.5 Engine cooling Engine Description

2.5.1 Amount of cool air regulated by exhaust thermostat

thermostat

1 Pressure oil line from engine to exhaust

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

11 Adjusting screw with special seal ring

10 Ventilation line

12 Solenoid valve

2.5.2 Amount of cool air regulated by exhaust thermostat and soleno-

Engine Description 2.5 Engine cooling

id valve

Engine Operation

3.1 Commissioning

3.2 Starting

3.3 Monitoring Operation

3.4 Shutting off

3.5 Operating Conditions

Never fill the tank while the en-

gine is running.

Ensure cleanliness!

Do not spill fuel!

3.1.3 Pour in Fuel

Engine Oil

Use only commercial-grade diesel fuel. For

Fill oil cup 1 of the oil bath air cleaner with oil

fuel grade, see 4.2. Use summer or winter-

grade fuel, depending on the ambient tempera-

ture.

Do not fill the precleaner dust

collector (if fitted) with oil.

up to the arrow.

For oil grade and viscosity, see 4.1.

Engine Operation 3.1 Commissioning

3.1.1 Pour in Engine Oil 3.1.2 Oil Bath Air Filter with

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.

Model:

“Motorpal” model

3.1 Commissioning Engine Operation

3.1.4 Bleed

● Position collecting tank below the injection

pump.

driver.

arrow until bubble-free fuel escapes from

the ventilation valve 1.

● Unscrew ventilation valve 1 with screw-

● Move hand hump 2 in the direction of the

fuel in an environmentally-friendly manner.

● Tighten ventilation valve 1, still pumping.

● Remove collecting tank and dispose of the

heater

always be fixed to Pos.

heater, the change-over switch

should

For engines without an oil

2: closed.

3.1.7 Change-over switch for oil

work

see 6.1.2

3.1.6 Additional maintenance

After 50-150 operating hours, the following

maintenance work is to be carried out:

● Change lube oil,

see 6.1.3

● Change oil filter cartridge,

see 6.2.1

● Change fuel filter cartridge,

see 6.5.

●lCheck V-belts and retension as necessary,

Position of change-over switch for oil filter

consoles with an oil heater connected:

Pos. 1: open

Pos. 2: closed

sary) see 6.6.1

● Check valve clearance (adjust if neces-

● Check the engine for leaks

sary) see 9.2.

● Check engine mounts (retighten if neces-

see 6.7.1

Engine Operation 3.1 Commissioning

3.1.5 Other Preparations

● Checking battery and cable connectors

Remove if fitted (see 6.7.3)

● Transport hooks

● 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.

If necessary, top up oil, see 3.1.1

After the engine has been turned off

– Check the oil level, see 6.1.2

– Retension V-belts, see 6.5.

During the break-in phase, about 200 oper-

ating hours, check the oil level twice a day.

After the engine is broken in, checking once

a day will be sufficient.

● Breaking in

https://truckmanualshub.com/

without cold start assistance

z Insert key

– Position 0 = no operating voltage

– Position 1 = operating voltage

– Pilot lights illuminate

against spring pressure.

– Position 2 = no function

– Position 3 = start

z Turn key clockwise

z Push key in and turn further clockwise

– The pilot lights will go out.

z Release key as soon as engine fires

Engine Operation 3.2 Starting

Make sure that no-one is standing

in the danger area of the engine/

machine before switching on.

After repairs : Check whether all

3.2.1 Electric Starting

separate the engine from any driven parts.

z Where possible, disengage the clutch to

z Move speed control lever 1 into idle position.

protection devices are mounted

and all tools have been removed from the engine.

Do not use any additional starting aids (e.g.

injection with start pilot) when starting with glow/

heating plugs. Danger of accidents! Attention :

The engine may never be started with the speed

governor removed.

Disconnect the battery terminals! If the engine

does not start properly with automatic starting of

the heating flange (starter does not get any

current due to malfunction in the equipment/

customer side electrical control), the start proce-

dure must be aborted completely (set ignition

switch to OFF, interrupt power supply for the

heating flange).

Before restarting the engine, the fault must be

eliminated to avoid any overheating damage

start.

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

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

z Regarding electric starting with a solenoid,

to the heating flange/charge air hoses.

light go out.

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 at-

tempts, refer to the Diagnosis Chart (see 7.1).

0312 0382 en

Namenlos-1 02.02.2006, 10:3826

start

up phase.

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.

* Fuel particles not burnt during initial com-

with cold start assistance/glow

lamps

FR 20/30 = 11 and 23 Volt

● Insert key

– Position 0 = no operating voltage

– Position 1 = operating voltage

– Pilot lights illuminate

against spring pressure

● Turn key clockwise

● Push key in and turn further clockwise

secs., (holding key*)

– Preheat lamp comes on.

– Position 2 = preheat for approx. 20-30

– Preheat lamp extinguishes

– Position 3 = start

The pilot lights will go out

● Release key as soon as engine fires

with cold start assistance/glow

lamps

3.2 Starting Engine Operation

FR 60 = 9,5 and 19 Volt

– Position 0 = no operating voltage

– Position 1 = operating voltage

– Pilot lights illuminate

against spring pressure

– Preheat lamp comes on

– Position 2 = preheat for approx. 60 secs.

(holding key*)

– Preheat lamp extinguishes

– Position 3 = start

● Insert key

● Turn key clockwise

● Push key in and turn further clockwise

● Release key as soon as engine fires

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

The pilot lights will go out.

* Fuel particles not burnt during initial com-

display the minimum oil pressure (see 9.1).

● The pointer of the oil pressure gauge must

Oil Pressure Indicator Oil Pressure Gauge

Oil pressure pilot lights

Engine Operation 3.3 Monitoring Operation

3.3.1 Engine Oil Pressure

over the entire operating range.

● The pointer must remain in the green sector

operating voltage on and engine off.

● The oil pressure pilot light comes on with

when the engine is running.

● The oil pressure pilot light should go out

3.3.3 Cooling fan drive

Engine Temperature Gauge

3.3 Monitoring Operation Engine Operation

3.3.2 Engine temperature

of electrical switch is actuated by the ten-

● When the V-belt is torn, the pressure pin 1

should remain in the green sector most of

● The engine temperature gauge pointer

sion roller and an audio signal or a light signal

is emitted.

Switch off the engine immediately to avoid

overheating.

the time. It should rarely enter the yellow-

green sector. If the pointer enters the or-

ange sector, the engine is overheating. Turn

off and establish the cause from the Fault

Table (see 7.1).

Ignition key

and remove. The pilot lights will go out.

● Turn key counterclockwise (to position 0)

If possible, do not suddenly switch off the

engine when under full load.

Engine Operation 3.4 Shutting Off

3.4.1 Mechanical shut-off 3.4.2 Electrical shut-off

until the engine comes to a stop. The charge

pilot light and the oil pressure pilot light will

come on when the engine stops.

and remove. The pilot lights will go out.

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.

and remove. The pilot lights will go out.

● Move speed adjustment lever 1 to low idle.

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

● Turn key counterclockwise (to position 0)

● Concerning electrical shut-off or power

● Turn key counterclockwise (to position 0)

to be well-charged, see 6.7.1.

ered by 4-5 °C by heating the battery up to

and store in a warm place).

– Efficient cold starting requires the battery

● Battery

– Select the oil viscosity (SAE grade) ac-

cording to the ambient temperature when

3.5 Operating Conditions Engine Operation

3.5.1 Winter Operation

● Lube Oil Viscosity

about +20 °C. (To do so, remove the battery

– The starting limit temperatures can be low-

starting the engine, see 4.1.2.

– Increase oil change frequency when

operating below -10 °C, see 6.1.1.

– Use winter-grade diesel fuel for operation

● Diesel Fuel

week. (Unscrew the sludge drain plug)

cleaner and the engine oil to settle at the

ambient temperature.

if necessary, smear the ring gear on the

below 0 °C, see 4.2.2

– Drain the sludge from the fuel tank once a

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

● Additional Maintenance Work

fly wheel via the pinion bore from time to

– Below -20 °C, after removing the starter

time with cold-resistant grease (e.g. Bosch

FT 1 V 31 grease).

At temperatures near or below freezing

point, use sheathed glow plugs if neces-

sary, see 3.2.1. This not only lowers the

starting limit temperature, but provides easier

starting at temperatures normally not requir-

ing a starting aid.

● Cold Start Assistance

High Altitude

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 im-

peded. Under transient conditions, the en-

gine 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.

Engine Operation 3.5 Operating Conditions

3.5.2 High Ambient Temperature,

● Air density decreases as altitude or ambient

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.

● If you have any doubts about engine opera-

Operating Media

4.1 Lube Oil

4.2 Fuel

Only with engine preheating

Operating Media 4.1 Lube Oil

4.1.1 Quality 4.1.2 Viscosity

As the viscosity of the lube oil is dependent

on temperature, the choice of SAE grade

should be governed by the ambient tempera-

ture 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 be-

low 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. Multi-

grade oils, particularly light-flowing oils, also

reduce fuel consumption.

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

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).

At least: CF-4

Approved API Oils:

Approved ACEA Oils:

described above.

* Oil change intervals, see 6.1.1

Oil capacities, see 9.1

Argentina, Australia, South Africa

Argentina, Australia, South Africa,

engines with high output

Lube oil for engines with increased output and

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,

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

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 FX 10W-40 Europe

FUCHS DEA DEA Cronos Premium LD 10W-40 Germany, Europe

FUCHS DEA Fuchs Titan Cargo MC 10W-40 worldwide

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 Rimula Ultra country specific, various

Shell International

Shell Myrina TX / 10W-40 Europe, label

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.

definitions

listed in the following table are to be used.

4.1 Lube Oil Operating Media

4.1.2.1 Specific lube oil

Turbocharged engines with increased out-

put and engines with high capacity.

For the following engines, or applications:

● for engines with an output >141kW the oils

Firstly, these oils are of high quality in accord-

ance with ACEA or API. Additionally, these oils

EEC guidelines for commercial vehicles in

Europe,

mobile driven machines in Europe

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/

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

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)

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

I Summer-grade diesel fuel

I I Winter-grade diesel fuel

Legend:

A Ambient temperature

Mix in tank only! Fill with the

appropriate amount of kerosene

first, then add the diesel fuel.

B Percentage of kerosene added

diesel fuel should never be mixed

with petrol (normal or super

petrol)

Operating Media 4.2 Fuel

4.2.1 Quality 4.2.2 Winter Fuel

below -20 °C. The relevant percentages

are given in the adjacent diagram.

climatic zones up to -44 °C.

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 ad-

vance of the cold months).

● Kerosene must be added at temperatures

- DIN EN 590

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

● Special diesel fuels may be used in arctic

- BS 2869: A1 and A2

(with A2, take note of the sulphur content)

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

If summer-grade diesel fuel must be used at

temperatures below 0 °C, up to 60% kero-

sene can be added (see diagram).

- NATO Code F-54 and F-75

- ISO 8217 DMX

- ISO 8217 DMA

in accordance with DIN 51603

● Light fuel oils

In most cases, adequate resistance to cold

can be obtained by adding a flow improver

(additive). Please ask your DEUTZ partner.

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

ASTM D 396; 1 and 2

BS 2869 Class D

- F34/F35/F44 (Kerosene)

- F54 (corresponds to diesel fuel in accord-

ance with DIN EN 590)

- XF 63 (corresponds to F34+F35 with

additives)

● Jet fuel

- in accordance with DIN 51606- FAME

● Bio diesel fuel

approval test.

Routine Maintenance

5.1 Maintenance Plan

5.2 Maintenance Schedules

5.3 Maintenance Work Completed

Industrial engines

# Maintenance must only be carried out by

authorised service personnel

The specified engine maintenance values are

permissible recommended maximums. De-

pending on usage, reduced maintenance in-

tervals may be necessary, comply with the unit

manufacturer’s operating instructions.

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 #

years

Fuel pre-cleaner 4.2/ 6.2.2

Intake air cleaner/dry type air cleaner (If available, maintain according to

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

maintenance indicator) 6.4.3 /6.4.4

Basic overhaul #

■

■■■

In hours of operation (HO) every

every 10 hours of operation or daily

check = ● adjust = ❍ clean = ◆ replace = ■

prior to or during 1st trial run, check 2x daily during the breaking in phase or when

Routine Maintenance 5.1 Maintenance Schedule

commissioning new and overhauled engines

125 250 500 1000 12000 1 2

E10 E20 E30 E40 E50 E60 E70

■■■

●

●●

■

◆

❍❍

●

●◆

● ■

●

● ■

●

Additions and modifications

for engines with EPA approval

# Maintenance must only be carried out by authorised

service personnel

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.

Operation Section

Injection valve #

Intercooler (drain lube oil/condensation) #

CPD compressor outlet #

Basic overhaul of emission related parts #

years

■

◆

In hours of operation (HO) every

every 10 hours of operation or daily

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

5.1 Maintenance Schedule Routine Maintenance

commissioning new and overhauled engines

250 500 1000 2000 3000 4000 1 2

E10 E20 E30 E40 E50 E60 E70

daily E 20 daily inspection the user

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

Intervals Maintenance Activity Plan executed by: Comments

Maintenance 5.2 Routine maintenance work plan

5.2.1 Routine maintenance work plan

with/after levels

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

AIR

Std.

15 mm

0.6 in.

ca.

250

OIL

500

1000

1000500

FUEL

AIR

15 mm

0.6 in.

ca.

Std.

BF L 914/C

0,15 mm

0.006 in

a =

500

ex.

in.

250

125-

2000

250

500

OIL

500

1000 1000

OIL

max.

FUEL

0132 0359

FL 914

0,15 mm

0.006 in

1000

a =

in.

OIL

max.

125-

2000

ex.

500

OIL

0312 0360

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 accord-

ing to the schedule (see chapter 5.1).

Stop the engine before carrying

out any maintenance work.

–

250

500

750

1000

1250

1500

1750

2000

2250

2500

2750

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

125

50-150*

375

625

875

1125

1375

Routine Maintenance 5.3 Maintenance Work Completed

1625

1875

2115

2375

* following commissioning of new and overhauled engines.

2625

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

3250

3000

3500

3750

4000

4250

4500

4750

5000

5250

5500

5750

Date Signature/stamp Date Signature/stampOp. hours

5.3 Maintenance Work Completed Routine Maintenance

Op. hours

2875

3125

3375

3625

3875

4125

4375

4625

4875

5125

5375

5625

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

6250

6000

6500

6750

7000

7250

7500

7750

8000

8250

8500

8750

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

5875

6125

6375

6625

6875

7125

7375

Routine Maintenance 5.3 Maintenance Work Completed

7625

7875

8125

8375

8625

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

5.3 Maintenance Work Completed Routine Maintenance

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

Turbocharged engines

Lube oil change intervals in HO

engines

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

Naturally aspirated

API specification

Engines for installation

500 250 500

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

ACEA-spezification

Normal oil requirement, e.g.:

250 125 250

High oil requirement, e.g.:

Lube oil change intervals in km

engines

Naturally aspirated

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

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

medium driving speed

API specification

ACEA-spezification

Year’s kilometrage

10 000 5 000 10 000

approx. km/h

20 000 10 000 20 000

30 000 15 000 30 000

Vehicle engines

I > 30 000 20

II 30.000 -100.000 40

III < 100 000 60

Lube oil quality

the engine application and the quality of the

lube oil.

Service and Maintenance

6.1.1 Oil change intervals

● The oil change intervals are dependent on

Road vehicles, cranes, construction machines,

ships electrical modules, pumps, railway

vehicles.

year than stated in the table, the oil should

be changed at least once a year.

● If the engine runs fewer hours during the

0.5% by weight.

– For diesel fuel: sulphur content max.

● The table refers to the following conditions:

Combines, emergency pumps, underground mining

units, sweeping machines, winter service

vehicles, emergency power units.

to -10 °C (+14 °F).

– Continuous ambient temperatures down

● If the sulphur content is > 0.5 to 1% or the

Service group

Lube oil quality

continuous ambient temperature below

the oil change intervals must be halved.

higher than 1%, contact your Service

representative.

● In the case of fuels with a sulphur content

Change the oil with the engine off but still

warm (lube oil temperature approx. 80 °C).

26 023 0

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.

26 022 0 25 729 0

firmly (for torque, see 9.2).

– For grade/viscosity, see 4.1.

– For quantity, see 9.1.

● Place an oil tray beneath the engine

● Unscrew drain plug.

● Drain oil.

● Fit oil drain plug with new gasket and tighten

● Fill with lube oil

surface

– Lube oil temperature approx. 80°C.

● Run the engine warm

● Ensure that the engine or vehicle is on a level

● Switch off the engine.

● Check oil level, see 6.1.2.1

Changing Engine Oil

6.1 Lubrication System Service and Maintenance

6.1.2 Checking Oil Level /

6.1.2.1 Checking Oil Level 6.1.2.2 Changing Engine Oil

surface.

● Ensure that the engine or vehicle is on a level

oil level

Check the oil level

● – Warm engine

● Switch off engine, wait 5 minutes and check the

● – Cold engine

● Remove the dipstick

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

“MAX” level

– If the oil level is just above the “MIN” mark,

it should be topped up.

● Insert up to the stop and pull out again.

● Check oil level, if required top up to the

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

6.1 Lubrication System

● 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.

Service and Maintenance

6.1.3 Replace Oil Filter

surface.

● Clean any dirt from the filter carrier sealing

commercial tool and spin off.

● Undo the lube oil filter cartridge using a

oil filter cartridge.

● Lightly oil the rubber gasket of the new lube

● Catch any escaping oil.

the gasket is flush.

● Manually screw in the new cartridge until

Caution is required in the case

of hot oil: Risk of scalding!

Please dispose of oil in an

environmentally-friendly

manner!

use

6.1 Lubrication System Service and Maintenanceen

6.1.4 Change bypass-oil filter

out.

● Remove oil drain screw 1 and let the oil run

cover.

● Catch any escaping oil.

● Remove tensioning screw 2. Remove

necessary.

ring 5.

● Remove soiled filter 3. Clean filter casing.

● Check cover 4 for leaks, and replace if

● Screw in oil drain screw with a new seal

● Insert new filter.

for leaks.

● Screw on cover with seal ring 6.

● During trial, observe oil pressure and check

● 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.

Service and Maintenance 6.2 Fuel System

6.2.1 Replace Fuel Filter

surface.

● Clean any dirt from the filter carrier sealing

● Close the fuel shut-off valve.

rubber gasket of the new fuel filter

cartridge.

● Apply light film of oil or diesel fuel to the

tool and spin off.

● Undo fuel filter cartridge with commercial

● Catch any escaping fuel.

the gasket is flush.

● Manually screw in the new cartridge until

Keep naked flames away when

working on the fuel system. Do

not smoke!

Clean fuel filter

“Motorpal” model

6.2 Fuel System Service and Maintenance

6.2.2 Fuel precleaning

Keep naked flames away when

new seal 2.

● 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

● Bleed fuel system (see 3.1.4).

● Open fuel shutoff valve.

● Check for leaks.

working on the fuel system. Do

not smoke!

Ships, electrical modules in enclosed areas, pumps

2000

Standard values

Checking or cleaning intervals Engine application

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

500

1000

250

125

system depends on the engine application.

Service and Maintenance 6.3 Cooling System

6.3.1 Cleaning Intervals

● The amount of contamination in the cooling

crease the risk of contamination. There-

fore pay special attention to leaks if the

engine is used in dusty environments.

● Oil and fuel residues on the engine in-

high level of air-borne dust.

high concentrations of chaff and chopped

ample:

- On construction sites where there is a

● Serious contamination can occur, for ex-

straw in the vicinity of the machine.

- In harvesting application where there are

vals have to be determined from case to

case. The cleaning intervals given in the

table on the right can be used as a guide.

● Because applications vary, cleaning inter-

pends 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.

6.4 Combustion Air Filter Service and Maintenance

6.4.1 Cleaning Intervals

● The amount of dirt in the air cleaner de-

mined from case to case.

● Cleaning intervals will have to be deter-

should only be carried out according to the

service indicator or service switch.

● If dry type air filters are used, cleaning

the red signal 1 is fully visible when the

- Service indicator

● Air cleaner servicing is needed when

engine is off.

the yellow pilot light comes on when the

engine is running.

- Service switch

signal by pressing the button on the serv-

ice indicator. The service indicator is now

ready for operation again.

● After carrying out service work, reset the

● Clean filter housing 1 if very dirty.

Never clean filter with gasoline!

Dispose of old oil in accordance

with environmental regulations!

if necessary.

(arrow) (for viscosity, see 4.1.2).

and secure with snap clips.

● Inspect and replace rubber gasket 5 and 6

● Fill oil cup with engine oil up to the mark

● Refit oil cup and element to filter housing

6.4.3 Clean Oil Bath Air Filter

Precleaner

Service and Maintenance 6.4 Combustion Air Filter

6.4.2 Emptying Cyclone Type

● Turn engine off and wait about 10 minutes

● Undo wing nut 1 and remove cover 2.

for the oil to drain from filter housing 1.

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!

● Loosen quick fasteners 2 and remove oil

tion 4 and empty. Clean leaves, straw and

other foreign matter from lower section of

pre-cleaner.

section 4, fasten cover 2 in place by

● Remove collector bowl 3 from lower sec-

● Reposition collector bowl 3 onto lower

allow to drip-dry.

● Remove dirty oil and sludge. Clean oil cup.

● Clean filter element 4 in diesel fuel and

tightening wing nut 1.

Never fill collector bowl with oil. Replace

collector bowl if damaged.

Never clean filter cartridge with

gasoline or hot fluids.

Filter Cartridge

years at the latest), replace safety car-

tridge 4 (never clean).

To do so:

● After five cleaner services (or after two

year).

● Undo clip fasteners 1.

● Take off hood 2 and remove cartridge 3.

● Clean cartridge (replace at least once a

hex nut.

- Undo hex. nut 5 and remove cartridge 4.

- Install new cartridge, insert and tighten

Blow out using dry compressed air (max.

● Clean cartridge 3.

clip fasteners 1.

● Install cartridge 3, replace hood 2 and do up

5 bar), (or in difficult cases, tap out, taking

care not to damage the cartridge, or wash

according to manufacturer’s instructions).

the gaskets on the filter cartridge can

become damaged. Check paper filter (light

showing through) and gaskets for dam-

age.

Replace if necessary.

● Through regular removal and replacement,

Dust discharge valvel

6.4 Combustion Air Filter Service and Maintenance

6.4.4 Dry type air cleaner

apart lips of discharge slot as indicated by

arrows.

● Empty dust discharge valve 1 by pressing

gether the upper section of the valve.

● Clean discharge slot from time to time.

● Remove any caked dirt by pressing to-

6.5.2 Fan V-belt

● To replace the tension roller 1, press in-

Read off the value where the indicator

wards with a commercial tool and remove

the V-belt.

● Position new ribbed V-belt.

arm 1 intersects scale 5 (arrow). For

settings, see 9.1.

again.

- If necessary, retension belt and measure

Retension V-belt after it has ran for 15 min-

utes.

Check, tension and change belts

only with the engine off. Rein-

stall V-belt guard

Service and Maintenance 6.5 Belt Drives

6.5.1 Check V-belts

● Visually inspect entire V-belt for damage.

between the pulleys, with flange 3 on

bottom of gauge against the edge of belt.

angles to V-belt 2 until the spring is heard

or felt to trigger.

minutes, then check belt tension.

tension gauge (see 9.3).

- Place indicator arm 1 into gauge.

- Position guide 3 on V-belt 2, midway

● Replace damaged V-belts.

● After installing new belts, run engine for 15

● To check the tension of the V-belt, use a

- Push slowly on the black pad 4 at right

altering the position of the indicator arm 1.

- Carefully remove the gauge without

Only check function when the

engine is off!

of electrical switch is actuated by the

tension roller and an audio signal or a light

signal is emitted.

● When the V-belt is torn, the pressure pin 1

● Check the function by pressing pin 1.

● Remove fan belt, as shown in 6.5.2.

of arrow B.

● Slacken off bolts 1, 2 and 3.

● Swing alternator inwards in the direction

of arrow A until correct belt tension is

achieved.

● Remove and replace belt.

● Swing alternator 4 outwards in direction

● Retighten bolts 1, 2 and 3.

● Fit fan belt.

Retension V-belt after it has ran for 15 min-

utes.

6.5 Belt Drives Service and Maintenance

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

Check, tension and change belts

only with the engine off. Rein-

of arrow A until correct belt tension is

achieved.

● Loosen bolts 1, 2 and 3 slightly.

● Press alternator 4 outwards in direction

● Retighten bolts 1, 2 and 3.

stall V-belt guard.

● In order to retension, remove one or more

inner washers 3. Place the removed wash-

ers on the outside on the removed belt

pulley half 2.

turn engine over simultaneously in order to

prevent crushing the V-belt.

After installing new belts, run engine for 15

● Tighten screw 1 again. Whilst tightening,

minutes, then check belt tension.

or changing V-belts

Service and Maintenance 6.5 Belt Drives

6.5.6 Tensioning

● Unscrew hex screw 1.

● Remove outer belt pulley half 2.

● Replace V-belt if necessary.

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.

dual belts

6.5 Belt Drives Service and Maintenance

6.5.7 Air compressor model with

If one belt locks or is damaged, always

replace both belts. The difference of length

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

3, inner washer kit 6 and pulley half 5.

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.

verse order. Whilst tightening the nut 1, turn

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

● Remove inner washers 4, posterior V-belt

● To retension, remove one or more inner

● For installation, now proceed in the re-

between the new belts may not exceed

0.15%.

engine over simultaneously in order to

prevent crushing the V-belt.

● Adjust valve clearance if necessary:

the correct clearance is attained after

- Release locknut 4.

locknut 4 has been tightened.

- Use allen key 7 to turn setscrew 5 so that

cylinders.

gasket if necessary.

● Check and adjust valve clearance on all

● Reinstall cylinder head cover with new

Service and Maintenance 6.6 Adjustments

adjust if necessary

6.6.1 Check valve clearance,

If necessary, readjustment may

6.6.1.1.

engine to cool down for at least 30 minutes.

The oil temperature should be below 80 °C.

arm / tappet contact face 2 and valve stem

3 with feeler gauge 6 (there should be only

slight resistance when feeler blade is in-

serted).

For permissible valve clearance, see 9.1.

● Remove the cylinder head cover.

● Position crankshaft as per schematic, see

● Before adjusting valve clearance, allow

● Check valve clearance 1 between rocker

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!

Turn crankshaft until both valves in cylin-

der 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 1:

Turn crankshaft one full revolution (360°).

Adjust clearance of valves marked in

black on schematic.

● Crankshaft Position 2:

Valve Clearance Adjustments

6.6 Adjustments Service and Maintenance

6.6.1.1 Schematic for

density

vidual cells with a commercial hydrometer.

The hydrometer reading (see table on fol-

lowing page) indicates the battery’s state

of charge.

During measurement, the temperature of

the electrolyte should preferably be +20 °C.

● Measure the electrolyte density of indi-

6.7.1.2 Check Electrolyte Level 6.7.1.3 Check electrolyte

cable connectors

Service and Maintenance 6.7 Accessories

6.7.1 Battery

6.7.1.1 Checking battery and

● Remove sealing caps 1.

● Keep battery clean and dry.

should reach the base of these.

The electrolyte level should be 10-15 mm

above the top of the plates.

● If testers 2 are present: Electrolyte level

● Without testers:

of the battery, and grease with acid-free

● Undo dirty clamps.

● Clean terminal posts (+ and -) and clamps

● If necessary, top up with distilled water.

● Screw sealing caps back in.

and acid-resistant grease.

make good contact. Tighten clamp bolts

hand-tight.

● When reassembling, ensure that clamps

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

1,28 1,23 32 27 well charged

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

Normal Tropical Normal Tropical

6.7 Accessories Service and Maintenance

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

(Baumé-scale) is out of date and rarely

used today.

* Measurement of electrolyte density in ° Bé

The gases emitted by the bat-

tery 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!

Use only the correct lifting gear!

transporting the engine.

sioning of the engine:Remove attachment

eyes 2.

● Always use proper lifting tackle 1 when

● After transportation and before commis-

battery, alternator and regulator while the

engine is running.

Notes on the three-phase system:

Service and Maintenance 6.7 Accessories

6.7.2 Rotary Current Alternator 6.7.3 Transportation Shackles

● Never disconnect the cables between

operate the engine without the battery,

disconnect the regulator from the alterna-

tor before starting.

nals.

immediately.

alternator and regulator.

frame to check whether it is live must under

no circumstances be exercised with three-

phase electrical systems.

● If, however, it is necessary to start and

● Be sure not to confuse the battery termi-

● Replace defective charge pilot lamp bulb

● When washing the engine, cover up the

● The habit of touching a lead against the

● In case of electric welding, connect the

ground terminal on the welder directly to

the piece being welded.

Using high pressure device

Clean the engine only when the

engine is switched off!

hood. Replace them after cleaning and

before the test run.

connections (e.g. generator, starter, gov-

ernor, solenoid).

spray pressure of 60 bar, max. steam

temperature of 90ºC).

remaining water evaporates.

● Switch off the engine.

● Remove engine covers and cooling air

● Cover electrical / electronic components /

● Clean the engine with a steam jet (max.

● Allow the engine to run warm so that the

Using cold-cleaning compound

6.8. Engine Cleaning Service and Maintenance

6.8.1 Engine cleaning

Using compressed air

● Switch off the engine.

hood. Replace them after cleaning and

before the test run.

connections (e.g. generator, starter, gov-

ernor, solenoid).

cleaning compound and allow to react for

approx. 10 mins.

jet, repeat if necessary.

remaining water evaporates.

● Remove engine covers and cooling air

● Cover electrical / electronic components /

hood. Replace them after cleaning and

before the test run.

● Cover electrical / electronic components /

● Spray the engine with the commercial cold-

connections (e.g. generator, starter, gov-

ernor, solenoid).

● Blow air through the engine, taking particu-

● Spray clean the engine with a strong water

● Allow the engine to run warm so that the

lar 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.

the glow plugs

in “stop” position.

-Position 0 = no operating voltage

-Position 1 = operating voltage

-Pilot lights illuminate

against spring pressure.

-Position 2 = Preheat, hold for approx. 1

minute.

-Preheat lamp comes on

the transmission line interrupted.

Test step 1

● Place speed control lever or shut-off lever

● Insert key

● Key clockwise

warms up near the glow lamps 2 from pre-

glowing.

● With perfect function, the air-intake pipe 4

● Push key in and turn further clockwise

● Otherwise the glow lamps are defective or

Service and Maintenance 6.9 Additional Maintenance Work

6.9.1 Check fastenings 6.9.2 Checking the function of

● Cylinder head cover 1

● Air intake manifold 2

● Connection sockets

● Exhaust line 3

● Engine mounts 4

Test step 3

ing position 3.

or replace glow lamps 2 if necessary.

47 sealants.

● Loosen screw 1.

● Remove glow lamps 2

● Turn engine over with starter, key in switch-

● Fuel must be present on the glow lamps 2,

● When fitting glow lamps 2, use DEUTZ DW

Keep away from moving parts!

Collect any escaping fuel and

dispose of this in an environ-

mentally-friendly manner.

● Reinstall glow lamps to fuel line.

6.9 Additional Maintenance Work Service and Maintenance

Test step 2

ing position 3.

connection. Otherwise, the system and

● Loosen screw 1.

● Turn engine over with starter, key in switch-

● Fuel must be present on the loosened pipe

solenoid valve should be checked by a

specialist!

Faults, Causes and Remedies

7.1 Fault Table

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

Faults, Causes and Remedies 7.1 Fault Table

Engine starts, but runs irregularly or fails Adjust E

Engine does not start or is difficult to start Check P

Faults Measures

Engine overheats, temperature warning system responds Replace W

Engine oil consumption excessive

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

Engine does not run on all cylinders Top up A

Engine output is deficient Clean R

●●

●● ●●

●

●●

●●●

●●

●● ●●●● ●

●

●●● ●●●

●● ●

●●

●

- 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

Engine smokes - blue

Engine oil consumption excessive

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

Engine does not run on all cylinders Top up A

Engine output is deficient Clean R

Engine overheats, temperature warning system responds Replace W

Engine starts, but runs irregularly or fails Adjust E

7.1 Fault Table Faults, Causes and Remedies

Faults Measures

Engine does not start or is difficult to start Check 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

●

●●●

●● ●● ●●

Engine Preservation

8.1 Preservation

preservation

in V-belt pulleys.

● Remove anti-corrosion agent from grooves

preferred) using high pressure equipment

8.1.1 Preserve engine 8.1.2 Remove engine

● Clean engine (with cold cleansing agent if

tion if necessary (see 6.5).

● Install V-belt, retension after brief opera-

(see 6.8.1).

● Run engine until warm, then turn off.

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

haust ports.

● Remove covers from intake port and ex-

anti-corrosion oil.

● If necessary, clean oil bath cleaner (see

● Commission engine.

6.4.3), and fill with anti-corrosion oil.

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

● Drain fuel tank.

● Make up a mixture of 90 % diesel fuel and

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

preserve the cylinders and combustion

chamber.

When turning over with starter, set shut-

off lever to stop position.

and recumbent.

● Switch off the engine.

● Turn engine over manually several times to

● Remove V-belts and store wrapped, dry

● Spray grooves on V-belt pulleys with anti-

corrosion spray.

possibly with plugs.

● Close off intake ports and exhaust ports,

If the engine is to remain idle for an extended

period of time, it is necessary to take protec-

tive measures to prevent the formation of

Engine Preservation 8.1 Preservation

8.1 Preservation

corrosion. The preservative measures de-

- MIL-L 21260B

- TL 9150-037/2

- Nato Code C 640 / 642

scribed 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:

● Recommended cleaning agent to remove

class A3)

preservatives:

- Petroleum benzine (hazardous materials

Technical Specification

9.1 Engine Specifications and Settings

9.2 Screw Tightening Torques

9.3 Tools

102

vertical in line

34 5 6

F3L 914 F4L 914 F5L 914 F6L 914

132

410

380

1) 135

15W 40

Direct injection

counter-clockwise

4-stroke naturally aspirated diesel engine

Pressure lubrication

300

3236 4314 5393 6472

270

0,4

14,5

13,5

12,0

9,0

16,0

15,0

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

13,0

9,6

200 + 10

1–2–3 1–3–4–2 1–2–4–5–3 1–5–3–6–2–4

450 / 300 ± 20

550 / 400 ± 20

Pre-tension / re-tension

]

Model

Number of cylinders

Cylinder arrangement

Bore [mm]

Stroke [mm]

Total displacement [cm

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]

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]

Valve clearance with cold engine [mm]

Technical Specification 9.1 Engine Specifications and Settings

Injector opening pressure [bar]

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

Start of feed [°KW of TDC]

Firing order of the engine

V-Belt tension:

Alternator fan [N]

Compressor [N]

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.

102

vertical in line

34 6 6

BF3L 914 BF4L 914 BF6L 914 BF6L 914 C

132

510

485

Direct injection

counter-clockwise

4-stroke turbocharged diesel engine

Pressure lubrication

360

3236 4314 6472 6472

320

135

15W 40

0,5

16,0

17,5

200 + 10

400 / 250 ± 20

500 / 350 ± 20

Pretension / Retension

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

9,6

1–2–3 1–3–4–2 1–5–3–6–2–4 1–5–3–6–2–4

]

9.1 Engine Specifications and Settings Technical Specification

914/C/CT Model

Number of cylinders

Cylinder arrangement

Bore[mm]

Stroke[mm]

Total displacement [cm

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]

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]

Injector opening pressure [bar]

Start of feed [°KW of TDC]

Firing order of the engine

V-Belt tension: Pretension / Retension

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.

Alternator fan [N]

Compressor [N]

5) Approx. values may vary depending on version.

position

position 4

position 3

position 2

[Nm] 1

Technical Specification 9.2 Torque Wrench Settings

Installation Pretension Retension Total Comments

30 180° – – – 180° M14 x 230

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

Cylinder head cover – – – – – 12 ± 1,2 Nm –

30 60° 45° – – 105° M14 x 110

Valve clearance adjusting screw – – – – – 22 ± 2 Nm –

Foot 30 60° 15° – – 75° M14 x 100

30 60° 45° – – 105° M14 x 125

Intake manifold – – – – – 21 ± 2 Nm –

Exhaust manifold – – – – – 40 ± 4 Nm –

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 –

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

Service

Order-No.: 0312 0806

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

Obtainable from the local service Partner reponsible

for you or from:

http://www.deutz.de

Knowing it’s DEUTZ

DEUTZ has always stood for excellence in motor

construction, pioneering many developments in

the industry. As an independent motor manu-

facturer, we offer — worldwide — a com-

prehensive 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.

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

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partner will be happy to help you with expert advice.

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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

Printed in Germany

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Order no. 0312 0382 en

Deutz Engine 914 Operation Manual Deutz Engine 914 Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual