Operation Manual 914
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.
Operation Manual 914 0312 0382 en 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. 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. 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.
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.
General DEUTZ Diesel Engines Care and Maintenance Service 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. Sound care and maintenance practices will ensure that the engine continues to meet the requirements placed on it.
1
Engine Description 2 Model Engine Illustrations Lube Oil Circuit Schematic Fuel System Plan Engine cooling © 2001 2.1 2.2 2.3 2.4 2.
Engine Description 2 2.1.1 Rating Plate 2.1.2 Position of the Rating Plate © 34 570 0 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. © 2001 2.1 Model © 34 571 0 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.
Engine Description 2.1 Model © 34 599 0 Cylinders are numbered consecutively, beginning at the flywheel. 2.1.5 Direct injection B/FL 914 2 © 35 215 0 Engines with direct injection are used if high output is required. © 2001 2.1.
Engine Description 2 2.2 Engine Illustrations 2.2.
Engine Description 2.2 Engine Illustrations 2.2.
Engine Description 2 2.2 Engine Illustrations 2.2.
Engine Description 2.2 Engine Illustrations 2.2.
Engine Description 2.2 Engine Illustrations 2 2.2.
Engine Description 2.2 Engine Illustrations 2.2.
Engine Description 2 2.2 Engine Illustrations 2.2.
Engine Description 2.2 Engine Illustrations 2.2.
Engine Description 2 2.3 Lube Oil Circuit Schematic 2.3.
Engine Description 2.3 Lube Oil Circuit Schematic 2.3.
Engine Description 2 2.4 Fuel System Schematic 2.4.
Engine Description 2.5 Engine cooling 2.5.
Engine Description 2 2.5 Engine cooling 2.5.
Engine Operation 3 Commissioning Starting Monitoring Operation Shutting off Operating Conditions © 2001 3.1 3.2 3.3 3.4 3.
Engine Operation 3 3.1.1 Pour in Engine Oil © 35 201 3.1.2 Oil Bath Air Filter with Engine Oil 0 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. © 2001 3.1 Commissioning © 24 980 3.1.3 Pour in Fuel 2 © 26 398 0 Fill oil cup 1 of the oil bath air cleaner with oil up to the arrow. For oil grade and viscosity, see 4.1. Use only commercial-grade diesel fuel. For fuel grade, see 4.2.
Engine Operation 3.1 Commissioning 3.1.4 Bleed Model: “Motorpal” model 3 © 35 212 0 © 2001 ● Position collecting tank below the injection pump. ● Unscrew ventilation valve 1 with screwdriver. ● 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.
Engine Operation 3 3.1 Commissioning 3.1.5 Other Preparations 3.1.6 Additional maintenance work ● Checking battery and cable connectors see 6.7.1 After 50-150 operating hours, the following maintenance work is to be carried out: ● Transport hooks Remove if fitted (see 6.7.3) ● Change lube oil, see 6.1.2 ● Trial run After the engine has been prepared, let it run for about 10 minutes without load. ● Change oil filter cartridge, see 6.1.3 During and after trial run – Check the engine for leaks.
© 2001 3
Engine Operation 3 3.2 Starting 3.2.1 Electric Starting without cold start assistance 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).
Engine Operation 3.2 Starting © 25 746 3 with cold start assistance/glow lamps FR 20/30 = 11 and 23 Volt 2 ● 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.
Engine Operation 3 3.3 Monitoring Operation 3.3.1 Engine Oil Pressure Oil Pressure Indicator Oil pressure pilot lights © 25 752 1 © 2001 ● 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 Gauge © 25 753 0 ● The pointer must remain in the green sector over the entire operating range. © 25 754 0 ● The pointer of the oil pressure gauge must display the minimum oil pressure (see 9.
Engine Operation 3.3 Monitoring Operation 3.3.2 Engine temperature 3 3.3.3 Cooling fan drive Engine Temperature Gauge 2 ● 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).
Engine Operation 3 3.4 Shutting Off 3.4.1 Mechanical shut-off © 2001 © 35 588 3.4.2 Electrical shut-off Ignition key 0 ● 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.
Engine Operation 3.5 Operating Conditions 3 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.
Engine Operation 3 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.
Operating Media 4 © 2001 4.1 Lube Oil 4.
Operating Media 4 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). 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.
Operating Media 4.1 Lube Oil 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.
Operating Media 4 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). 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).
Routine Maintenance 5 © 2001 5.1 Maintenance Plan 5.2 Maintenance Schedules 5.
Routine Maintenance 5.1 Maintenance Schedule check = ● adjust = ❍ clean = ◆ replace = ■ Industrial engines prior to or during 1st trial run, check 2x daily during the breaking in phase or when The specified engine maintenance values are commissioning new and overhauled engines permissible recommended maximums.
5.1 Maintenance Schedule Routine Maintenance 5 check = ● adjust = ❍ clean = ◆ replace = ■ Additions and modifications max. recommended standard times in operating hours (HO) of all for engines with EPA approval prior to or during 1st trial run, check 2x daily during the breaking in phase or when The specified engine maintenance values are permissible commissioning new and overhauled engines recommended maximums.
Maintenance 5 5.2 Routine maintenance work plan 5.2.
Routine Maintenance 5.2 Maintenance Charts 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. a= FL 914 0,15 mm 0.006 in h Std. 5 AIR 10 a in. 1000 ca. 15 mm 0.6 in. ex. Check that this is the case.
Routine Maintenance Op. hours 5 © 2001 50-150* Date Signature/stamp 5.3 Maintenance Work Completed Op. hours Date – 125 250 375 500 625 750 875 1000 1125 1250 1375 1500 1625 1750 1875 2000 2115 2250 2375 2500 2625 2750 * following commissioning of new and overhauled engines. Duly completed maintenance jobs can be recorded and signed off in the above chart.
Routine Maintenance Op. hours Date Signature/stamp Op. hours 2875 3000 3125 3250 3375 3500 3625 3750 3875 4000 4125 4250 4375 4500 4625 4750 4875 5000 5125 5250 5375 5500 5625 5750 Date Duly completed maintenance jobs can be recorded and signed off in the above chart. Signature/stamp 5 © 2001 5.
Routine Maintenance Op. hours © 2001 5 Date Signature/stamp 5.3 Maintenance Work Completed Op. hours 5875 6000 6125 6250 6375 6500 6625 6750 6875 7000 7125 7250 7375 7500 7625 7750 7875 8000 8125 8250 8375 8500 8625 8750 Date Duly completed maintenance jobs can be recorded and signed off in the above chart.
Routine Maintenance 5 © 2001 5.
Service and Maintenance 6 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.
Service and Maintenance 6 6.1.1 Oil change intervals Lube oil change intervals in HO Engines for installation Naturally aspirated engines ● 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.
Service and Maintenance 6.1 Lubrication System 6.1.2 6.1.2.1 6 Checking Oil Level / Changing Engine Oil Checking Oil Level 6.1.2.2 25 729 0 ● 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.
Service and Maintenance 6 6.1 Lubrication System 6.1.3 Replace Oil Filter © 25 880 0 © 25 881 0 © 25 882 0 ● Undo the lube oil filter cartridge using a commercial tool and spin off. ● Clean any dirt from the filter carrier sealing surface. ● Tighten the lube oil filter cartridge with another half-turn. ● Catch any escaping oil. ● Lightly oil the rubber gasket of the new lube oil filter cartridge. ● Check the oil level, see 6.1.2 ● Manually screw in the new cartridge until the gasket is flush.
6.1 Lubrication System 6.1.4 Change bypass-oil filter use © 24 511 1 ● 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.
Service and Maintenance 6 6.2 Fuel System 6.2.1 Replace Fuel Filter © 25 880 0 ● Close the fuel shut-off valve. ● Undo fuel filter cartridge with commercial tool and spin off. ● Catch any escaping fuel. © 25 881 0 © 25 882 0 ● Clean any dirt from the filter carrier sealing surface. ● Tighten the fuel filter cartridge with a final half-turn. ● Apply light film of oil or diesel fuel to the rubber gasket of the new fuel filter cartridge. ● Open fuel shutoff valve. ● Check for leaks.
Service and Maintenance 6.2 Fuel System 6.2.2 Fuel precleaning Clean fuel filter “Motorpal” model 6 © 35 213 0 ● 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.
Service and Maintenance 6.3 Cooling System 6.3.1 Cleaning Intervals 6 ● 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.
6.4 Combustion Air Filter Service and Maintenance 6.4.1 Cleaning Intervals 6 ● 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.
Service and Maintenance 6.4.2 Emptying Cyclone Type Precleaner 6 © 25 886 0 © 2001 ● Undo wing nut 1 and remove cover 2. ● Remove collector bowl 3 from lower section 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. Never fill collector bowl with oil. Replace collector bowl if damaged. 6.4 Combustion Air Filter 6.4.
Service and Maintenance 6.4 Combustion Air Filter © 25 888 1 ● 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 together the upper section of the valve. 6 Filter Cartridge © 25 889 0 ● 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.
Service and Maintenance 6.5 Belt Drives 6.5.1 Check V-belts 6 6.5.2 Fan V-belt © 2001 © 35 209 0 ● 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.
Service and Maintenance 6.5.3 Alternator belts 6.5.4 Change alternator belt © 35 207 0 ● 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. Check, tension and change belts only with the engine off. Reinstall V-belt guard. © 35 208 0 6.5.5 Check warning system 6 © 35 202 0 ● Remove fan belt, as shown in 6.5.2. ● Slacken off bolts 1, 2 and 3.
Service and Maintenance 6.5 Belt Drives 6.5.6 Tensioning or changing V-belts 6 © 24 598 1 © 2001 ● Unscrew hex screw 1. ● Remove outer belt pulley half 2. ● Replace V-belt if necessary. © 24 599 1 ● 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.
Service and Maintenance 6.5 Belt Drives 6.5.7 Air compressor model with dual belts 6 ● 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.
Service and Maintenance 6.6 Adjustments 6.6.1 Check valve clearance, adjust if necessary 6 © 19 691 2 © 2001 ● 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).
6.6 Adjustments 6 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. © 26 055 1 © 2001 6.6.1.
Service and Maintenance 6.7.1 6.7.1.1 6 Battery Checking battery and cable connectors © 25 895 0 © 2001 ● 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 6.7 Accessories Check Electrolyte Level © 24 232 3 ● Remove sealing caps 1.
Service and Maintenance 6.
Service and Maintenance 6.7.2 Rotary Current Alternator 6 © 2001 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.
6.8. Engine Cleaning Service and Maintenance 6.8.1 Engine cleaning 6 © 35 206 0 ● 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).
Service and Maintenance 6.9.1 Check fastenings 6 6.9.2 Checking the function of the glow plugs © 26 111 0 © 2001 ● Cylinder head cover 1 ● Air intake manifold 2 ● Connection sockets ● Exhaust line 3 ● Engine mounts 4 6.9 Additional Maintenance Work © 24 717 1 ● With perfect function, the air-intake pipe 4 warms up near the glow lamps 2 from preglowing. © 25 746 2 Test step 1 ● Place speed control lever or shut-off lever in “stop” position.
6.9 Additional Maintenance Work Service and Maintenance 6 Test step 2 ● Loosen screw 1. ● Turn engine over with starter, key in switching position 3. ● Fuel must be present on the loosened pipe connection. Otherwise, the system and solenoid valve should be checked by a specialist! © 24 717 1 Test step 3 ● Loosen screw 1. ● Remove glow lamps 2 ● Turn engine over with starter, key in switching position 3. ● Fuel must be present on the glow lamps 2, or replace glow lamps 2 if necessary.
© 2001 6
Faults, Causes and Remedies 7 © 2001 7.
Faults, Causes and Remedies 7 Faults 7.
Faults, Causes and Remedies 7.
© 2001 7
Engine Preservation 8 © 2001 8.
Engine Preservation 8.1 8 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.
Technical Specification 9 © 2001 9.1 Engine Specifications and Settings 9.2 Screw Tightening Torques 9.
Technical Specification Model Number of cylinders Cylinder arrangement Bore Stroke Total displacement Compression ratio Working cycle Combustion system Direction of rotation seen on flywheel Weight including cooling system to DIN 70020-A without starter or alternator Engine output Speed Lubrication SAE oil Oil temperature in oil pan Min.
Technical Specification 914/C/CT Model BF3L 914 BF4L 914 BF6L 914 BF6L 914 C Number of cylinders 3 4 6 6 Cylinder arrangement vertical in line Bore[mm] 102 Stroke[mm] 132 Total displacement [cm3] 3236 4314 6472 6472 Compression ratio [ε] 18 Working cycle 4-stroke turbocharged diesel engine Combustion system Direct injection Direction of rotation seen on flywheel counter-clockwise Weight including cooling system to DIN 70020-A without starter or alternator [approx.
Technical Specification 9.
Technical Specification 9.
Service en Order-No.: 0312 0806 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.
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 Allrights reserved 1st edition, 01/2002 © Order no.
