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Workshop Manual
o 914
X
X
Hinweis f. Druckerei:
Farbe: weiB
Papier: Ikonofix 250 g/Qm
Workshop Manual
914
0312 0441 en
A
DEUTZ AG
Instandhaltungstechnik Motoren
Deutz-Mlilheimer Strafte 147-149
D-51063 Koln
Tel.: + 4 9 ( 0 ) 2 21-8 22-0
Fax: + 4 9 ( 0 ) 2 21-8 22-53 58
http://www.deutz.de
Printed in Germany
All rights reserved
1st edition, 10/2002
Order no. 0312 0441
0312 0 5 2 8 - 0 1 5 0 ©1002
A
DEUTZ
®
Foreword
• Please read carefully and observe the instructions given in this documentation. Thus you avoid
accidents, preserve the manufacturer's warranty and ensure that your engine always functions properly
and reliably.
• This engine is constructed solely for the use - as defined by the equipment manufacturer (intended use) -
designated in the scope of supply. Any use beyond this is contrary to the intended purpose. The
manufacturer is not responsible for any damage incurred on this account. That risk is borne solely by the
user.
• Intended use also includes compliance with the operating, maintenance and repair instructions issued by
the manufacturer. The engine may only be used, maintained and repaired by those who are familiar with
it and have received instruction about the hazards.
• Make sure that this documentation is readily available for all those carrying out operating, maintenance
and repair work and that the contents are well understood.
• Non-compliance with this documentation may result in malfunction and engine damage as well as
personal injuries for which the manufacturer shall not accept any liability.
• A prerequisite for successful maintenance and repair work is that all required equipment, hand and
special tools are available and in perfect working order.
) • Engine components such as springs, clamps, snap rings, etc. may cause injury if not handled with care.
• Accident prevention regulations and all other generally recognized regulations on safety and
occupational medicine are to be observed.
• Optimal operation economy, reliability and durability of the engine can only be ensured when
genuine parts of DEUTZ AG are used.
• Engine repairs must be carried out in accordance with intended use. For conversions, only parts
approved by DEUTZ AG for a specific purpose should be used. Unauthorised changes made to the
engine invalidate all liability on the part of the manufacturer for damage incurred as a result.
Non-compliance with this rule nullifies the warranty!
DEUTZ engines have been developed for a broad range of applications. The extensive range of models
available ensures that each particular requirement can be fulfilled.
The engine is equipped for the specific installation conditions, that means that not all parts and components
described in this documentation are actually built onto your engine.
We have tried to point out these differences so that can easily find the operating, maintenance and repair
specifications relevant to your engine.
Should you have any further questions, please do not hesitate to contact us.
Yours
DEUTZ AG
DEUTZ Engines
are the product of many years research and development work. Our broad-based expertise acquired over the
years, together with stringent quality requirements, ensures that the engines we produce have a long service
life, and are very reliable and economic in fuel consumption. It goes without saying that they also fulfil the high
requirements placed on environmental protection.
DEUTZ AG
In case of operating defects or inquiries for spare parts, please get in touch with one of our representative
service centres. Our trained personnel are able to repair any damage incurred promptly and professionally
using original parts.
Original parts made by DEUTZ AG are always state-of-the-art.
You can find notes on our back-up service at the end of this documentation.
Safety
A All safety instructions are marked by this symbol. Observe these carefully. Also pass on safety
instructions to your operating personnel. In addition, observe the "General Safety and Accident
Prevention Regulations" applicable by law.
Note
Notes of a general nature are marked by this symbol.
Observe these carefully.
Xr-y9 Asbestos
Fy\| The s e a l s u s e d with this engine do not contain asbestos. Please use corresponding spare parts when
|^Nj undertaking maintenance and repair work.
_____________™___
)
0 Introduction
Editorial, foreword, quick access, contents
1 User instructions
1.1 General
1.2 Regulations
1.3 Operating instructions and workshop manual
1.4 Work cards
1.5 Key to symbols
2 Technical Data
3 Work cards
3.1 Overview work cards, alphabetical
3.2 Overview work cards, numerical
1 User instructions
1.1 General
1.2 Regulations
1.3 Operating instructions and workshop manual
1.4 Work cards
1.5 Key to symbols
\y
<L S
*><£
1 User instructions
1.1 General
The maintenance work prescribed in the operating instructions and the work
shop manual must be performed to schedule and in the full scope.
Maintenance personnel must have the skills necessary to perform the work.
Any safety fixtures and protective equipment needing to be dismantled during
maintenance work must be refitted.
~~7~i Caution
Z!X it is essential to observe the safety and accident prevention regulati-
* ons during maintenance work.
In this context, also comply with the specific safety provisions for the
different maintenance groups which are described in detail as work
cards in the chapter on work cards (compare section 1.2). )
Maintenance intervals are contained in the maintenance schedules. These
also provide information on the work to be performed.
The work cards give technical advice on how to undertake the work.
The servicing documentation has been sub-divided into operating instructions 1.3 Operating
and workshop manual in order to structure the information in the best way for instructions
the users. and workshop
Among other things, the operating instructions contain a general description manual
of and a guide to all maintenance work required
They contain the following chapters:
1 General, table of contents
2 Engine description
3 Operating
4 Operating materials
5 Maintenance
6 Servicing and maintenance work
7 Troubleshooting
8 Engine conservation
9 Technical specifications
10 Service
The workshop manual requires prior knowledge of the contents of the
operating instructions, this applies in particular to the safety regulations.
Simple repairs and emergency action on components are described which
necessitate a larger scope of work and correspondingly skilled personnel.
Type of documentation
The first letter designates the type of documentation.
W = Workshop manual
I = Maintenance instructions
Sub-system (component)
The sub-systems are differentiated by maintenance group.
Generally applicable:
0 Meta sub-system level or safety regulation (SV)
1 System parameters or general inspections
Sequential number
Counting per sub-system (component)
Various work per sub-system (component)
Differences in version
• * •
W 3-3-3
|36613|0
Fig. 1 Numbering of work cards
©
Crankcase
Work cards
914 W3-3-3
<n =
©-
<D
13661210
Note
Should you have further questions on a work car, please always quote
the engine type (2), the number of the work card (4), the page number
(7), the date of issue (9) or alternatively the DEUTZ internal part
number (8).
Tools References
?| e.g. dial gauge 100 400 m| e.g. work card nr. W x-y-z
Technical Data
F3L F4L F5L F6L BF3L BF4L BF6L
/oooj General engine data
914 914 914 914 914/T 914/T 914 C/T
Bore
003 102
mm
Stroke
004 132
mm
Rated speed
006 2.500 to 2.800
max. min"1
Minimum
007 idle speed 650 to 700
min"1
© 1002 Page 1 of 42
Technical Data 914
A
F3L F4L F5L F6L BF3L BF4L BF6L
/o?o7 General engine data
914 914 914 914 914/T 914/T 914 C/T
Compression pressure
20 to 30
011 MPa
(20 to 30)
(bar)
Maximum length
021 1.012 1.012
mm
Maximum width
022 739 739
mm
Maximum height
023 1.176 1.176
mm
V-belt tension
045 First-time assembly 450 + 20
N
V-belt tension
Check after running 15 min
046 300 + 20
under load
N
V-belt tension
047 if re-used 300 + 20
N
Minimum pressure
which must be attained at
112 300 (300)
approx. 5 KW revolutions
MPa (bar)
2) Engine output, speed and commencement of delivery are stamped on the engine nameplate.
Adjustment start
152 1.200
min"1
Adjustment end
153 2.800
min"1
230 Valve
Valve stem
Diameter
231 7.945 to 7.960
Inlet
mm
Valve stem
Diameter
232 7.920 to 7.940
Exhaust
mm
Valve disc
diameter
237 42.9 to 43.10
Inlet
mm
Valve disc
diameter
238 36.90 to 37.10
Exhaust
mm
Length untensioned
253 normal 59 ±1.9
mm
Length untensioned
254 Wear limit 56.00
mm
Wear limit
272 5.50
mm
Wear limit
274 4.80
mm
Length
281 normal 217 ±0.5
mm
Length
282 limit value 218.50
mm
300 Cylinder
Bore
301 normal 102 u0 ++0.01
005
mm
Bore
302 Wear limit 0.1
mm
Number of
303 1
oversizes
400 Piston
Diameter
401 normal 102 101.89 " a 1 1
mm
Number of
402 1
oversizes
Piston pin
406 diameter 4 0 -0.006
mm
(1.)92.5
Piston ring groove diameter
410 (2.) 92.5
mm
(3.) 93.3
Wear limit
422 0.15
mm
Wear limit
424 0.15
mm
Wear limit
426 0.15
mm
Gap clearance
normal
429 0.3 to 0.5
1st ring
mm
Wear limit
430 0.80
mm
Gap clearance
normal
431 0.8 bis 1.0
2nd ring
mm
Wear limit
432 0.80
mm
Gap clearance
normal
433 0.25 to 0.4
3rd ring
mm
Wear limit
434 0.80
mm
1st ring
435 Double trapezoid ring 102x93.4x2.94 GV-MO
Size
2nd ring
436 Double trapezoid ring 102x93.4x3K-CR
Size
3rd Ring
437 Bevel-edge slotted oil ring 102x94.5x3OEVO
Size
500 Crankshaft
Journal width + 0 0 3
<5C
521 normal 36
+ 0
mm
Undersize stage
524 0.25
mm
Limit value
525 for undersize stage 73 5-°°1
°- -0.029
mm
Journal ovality
526 Wear limit 0.01
mm
True running
527 max. permissible 0.06 to 0.08
mm
Journal hardness
529 normal 55 min.
HRc
Limit value - +-
530 HV10
HB 2.5/187.5
Core hardness
Journal width
011
541 normal I 35" 97"-0.243
ODi
mm
Journal width
542 normal II 36- ^4 ++0.00
0D °° 2
mm
Limit value
+0025
544 for oversize stage 38
mm
Bearing shell
Inner diameter
551
normal I 75.04 -°- 0 4 3
mm
Bearing shell
Inner diameter -0.01
552 ' d -0.029
normal II
mm
Radial clearance
555 normal 0.05
mm
Radial clearance
556 Wear limit 0.15
mm
Bearing bore in
crankcase JQ +0.019
561
normal
mm
Bearing bore
in crankcase +0019
562 79.5
Oversize stage
mm
Thrust bearing
570
(with thrust rings)
Limit value
574 for oversize stage 3 7 45-0.133
mm
Wear limit
576 0.4
mm
Wear limit
606 0.15
mm
Limit value
611 for undersize stage 64.530 to 64.569
mm
710 Camshaft
Camshaft bearing
Inner diameter 48 "a05
713 ^ ° -0.095
normal
mm
Radial clearance
714 normal 0.03 to 0.1
mm
Radial clearance
715 Wear limit 0.2
mm
Cam lift
716 Inlet 7.85 ±a1 8 ±0.1 - 7.1 ±a1
mm
Cam lift
717 Exhaust ±0.1 - ±a1
8
7.4
mm
Intermediate gear
Bearing journal 48 "°°5
730 ^ ° -0.066
Diameter
mm
Bearing bush
731 +0054
Inner diameterpressed 47.980
in mm
Radial clearance
of bearing journal in the bush
733 0.030 to 0.100
normal
mm
Wear limit
734 0.10
mm
Backlash
741 0.10to0.15
mm
80 l/min
800 Lube oil pump
with MAG - 70 l/min
Distortion backlash
803 Camshaft gear 0.02 to 0.1
mm
Safety valve on
lube oil pump
.813
hPa
(bar)
Bypass valve on
lube oil cooler
814
hPa
(bar)
Bypass valve on
filter housing
815
hPa
(bar)
Shaft seal
860 recess to support surface 0.10 to 0.50
mm
Schematic for valve clearance F3L F4L F5L F6L BF3L BF4L BF6L
adjustment 914 914 914 914 914/T 914/T 914 C/T
^ /
<* c = > /
CO
<==J
t = >
CM
B C=>
(0 " = = 3
m ==.
/
c==
1
) /
CO CO
■=.
870
c==
CM CM
" = 3 /
c 1 r-
12605510
• Crankshaft position 1:
Turn crankshaft until both valves overlap on the first cylinder. Adjust the valve clearance as shown
in the adjustment schematic (black designation). Mark each rocker arm with chalk to check the
adjustment performed.
Turn crankshaft by one further revolution (360°). Adjust the valve clearance as shown in the adjust
ment schematic (black designation).
M8 = 21 Nm
909 V-belt pulley nut
M10 = 40Nm
Sealing nut
919 50 Nm 90°
for hydraulic blower
Cylinder bolt
920 8.5Nm + 3Nm
for hydraulic blower
M28x1.5 = 100Nmto120Nm
925 Cap nut for oil suction pipe M33x2.0 = 145Nmto165Nm
M36 x 2.0 = 145 Nm to 165 Nm
Fastening bolts
926 for lube oil pumps 31.5 Nm to 38.5 Nm
Pressure scavenging pump
Blanking plug
936 80Nmto100Nm
with special sealing ring
Injection pump
942 22 Nm to 28 Nm
drive bolts
M6 = 7.5 Nm to 9.5 Nm
946 Bolts for oil suction pipe
M8 = 19Nmto23Nm
M8 = 20 Nm to 24 Nm
948 Cover on front cover
M10 = 3 8 N m t o 4 6 N m
M22x1.5 = 80Nm
952 Fastening bolt
M30x1.5 = 150 Nm
M6 = 7.5 Nm to 9.5 Nm
958 Bolts for cooling air ducting
M8 = 19Nmto23Nm
©1002
Technical Data 914
A
DEUTZ
®
M6 = 7 Nm to 9 Nm
971 Covering plate bolts
M8 = 17Nmto21 Nm
977 Elbow 21 Nm
Vibration damper
981 Hex, 8.8 19Nmto23Nm
Cylinder bolts, 10.9 25 Nm + 5 Nm
Air suction pipe, removing and refitting W 6-7-3 Exhaust system /charging
Change-over cock / filter carrier, removing and remounting W 8-11-7 Lube oil system
Commencement of delivery, with high-pressure pump, W 7-6-2 Fuel system
checking and setting
Commencement of delivery, with positioning bolt, checking W 7-6-1 Fuel system
and setting
Injection pump intermediate gear, removing and refitting W 4-4-7 Engine control
Oil cooler, removing, remounting and cleaning W 8-8-2 Lube oil system
Oil suction pipe, removing and refitting W 8-4-6 Lube oil system
Rocker arm and rocker arm bracket, removing and refitting W 1-2-2 Cylinder head
Valve seat inserts, removing, refitting and checking W 1-7-3 Cylinder head
W 1-7-3 Removing, refitting and checking valve seat inserts Cylinder head
W 1-7-8 Checking the valve recess Cylinder head
W 2-1-7 Checking the crankshaft Drive system
W 2-2-2 Renewing the crankshaft seal (coupling side) on complete Drive system
engine
W 2-2-4 Renewing the crankshaft seal (opposite end to coupling) Drive system
on complete engine
W 2-3-1 Checking the connecting rod Drive system
W 2-4-1 Removing and refitting the crankshaft Drive system
W 2-9-7 Checking the pistons Drive system
W 7-6-1 Checking and setting the commencement of delivery, with Fuel system
positioning bolt
W 7-6-2 Checking and setting the commencement of delivery, with Fuel system
high-pressure pump
W 7-7-1 Removing and refitting the injectors Fuel system
W 7-7-5 Checking and adjusting the injectors Fuel system
W 7-10-6 Removing and remounting the fuel lines Fuel system
W 8-4-5 Removing and remounting the oil pump Lube oil system
W 8-4-6 Removing and refitting the oil suction pipe Lube oil system
W 8-4-7 Removing and remounting the oil pan Lube oil system
W 8-8-2 Removing, remounting and cleaning the oil cooler Lube oil system
W 8-11-7 Removing and remounting the change-over cock / filter Lube oil system
carrier
W 9-11-1 Removing and remounting the blower Cooling system
W 9-11-2 Dismantling, reassembling and checking the blower Cooling system
W 9-11-3 Removing and remounting the cooling air ducting Cooling system
W 12-1-4 Removing and remounting the rotary vibration damper Other components
W 12-2-3 Checking the rotary vibration damper Other components
W 12-2-5 Disassembling and reassembling of V-belt idler pulley Other components
W 12-6-1 Removing and remounting flywheel Other components
W 12-6-3 Renew starter ring gear on flywheel Other components
W 13-2-3 Removing and remounting three-phase alternator and Electrical system
support
W 13-3-2 Removing and remounting the starter Electrical system
- Special tools Special tools
Disassembly
• Remove cooling air guide sheets.
Eain.-Ma.-nii
Note
HF1 If jammed, use extracting device 150 800
with extractor 110 030.
Note
If sealing ring is jammed, use extracting
device 120 630.
Assembly
• Insert connector with new sealing ring.
|©|35828|0
X
*L- I t *^*-
Note
O^ Do not bend the injection lines. Bending
them can create small rips which reduce
long-term durability.
<lr»«aii©l36206|0
[atcWAMtil
Auxiliary aids
6 - Hoist
- Sturdy rope
Note
Bores serve to take up clamping angles.
|©|35834|0
Note
Bores serve to take up clamping angles.
tj^-J'gfr-Jrkt'
i l l . •■"' . •> ':•'•, ,' p s s ^ sE?;
-^w
A ®
914 Work Card
W 1-1-1
Note
- Adjust valve clearance only with engine
cold. The engine must have cooled down
to ambient temperature.
Disassembly
• Remove cooling air guide sheets.
ESUcMacMEl
• Undo pipe.
• Remove cylinder head covers.
\ '4
Note
hwmmmmmmmmmmmmmiiEszz.zTJM
O^ Valve overlap means:
Exhaust valve is still not closed, inlet valve
about to open. The two push rods cannot be
turned in this position.
Note
The injection lines are removed here for a
clearer overview.
Note
O^ Graphitized gasket surface points towards
the cylinder head. Adhere new gasket onto
cylinder head cover using DEUTZ KL 8
adhesive.
• Fasten pipe.
5"
1S**~&
[§llcM:fcWm
Tools References
- Commercial tools CQ - w 1-1-1
Auxiliary aids
- DEUTZ KL 8
©REO-SH
Remove pipe.
s^m*0*^
•'^™B
2_S„ *
*2S5tf6^^WHti tiT
bin, ■£^ ^ ^ ^ " " " ' jB
f<£l|^
7©|35846|0
Note
cr Graphitized surface of the new gasket
(arrow) points towards the cylinder head.
• Fasten pipe.
NjtP?r
*''W
A ®
914 Work Card
W1-2-5
Note
KF" - After replacement of the V-belt pulley, the
"Top Dead Center" must be redetermined.
- The V-belt is removed in this work
process.
^**"?r
UEgSHH
Note
O^ Valve overlap means:
Exhaust valve is still not closed, inlet valve
about to open. The two push rods cannot be
turned in this position.
• Fit pointer.
Note
The piston coming upward thereby moves
the pressed-down valve.
'|©|36262|0
Note
KF 3 Graphitized gasket surface points towards
the cylinder head. Adhere new gasket onto
cylinder head cover using DEUTZ KL 8
adhesive.
A ®
914 Work Card
W 1-2-5
• Remount cooling air guide sheets.
Auxiliary aids
'A - DEUTZKL8
Note
C^ Lay the components down in their sequence
of assembly.
• Remove injectors
Note
O^ If the injectors are jammed
- see work card W 7-7-1.
|©135922|0
Note
The rounded side of the sealing ring points
upwards.
A ®
914 Work Card
W 1 -4-4
• Remount exhaust manifold and turbocharger
- see work card W 6-1-5.
casHagaBi
Disassembly
• Remove cylinder head and valves
- see work card W 1-5-1.
• Clean cylinder head and inspect visually for
damage.
• Mount cylinder head onto clamping fixture.
fzfzl /zfil
Note
O^ Before the cylinder heads are positioned all
pistons must be below the TDC.
Note
CF 3 Use a shim of appropriate thickness for cor-
recting piston crown clearance.
Shims are available in 3.0 - 3.9 mm thick-
ness at increments of 0.05 mm
Remove valves
• Dismount cylinder head
- see work card W 1 -4-4.
• Mount cylinder head on clamping plate
and clamping stand.
• Remove valves with valve spring compressor.
Note
O^ Support valve.
|©|35856|0
A ®
914 Work Card
W 1-5-1
Assemble cylinder head:
Install valve spring, valve spring cap and valve
collet.
Note
Position valve spring so that the closer
windings face the cylinder head.
"^ 'a^"©j35857T0
A ®
914 Work Card
W 1 -5-4
Note
E^ - All valves have been removed
and cleaned.
Note
C^ 3 Replace the valve if the wear limit has been
reached.
Note
KF* Replace the valve if the wear limit has been
reached.
Note
Replace the valve if the wear limit has been
reached.
<2Z7 /238i
Note
CF3 - Valve guides have been checked for wear.
|©|35223|0
Note
Reamers have a left-hand twist and must
be turned clockwise both in and out. Never
turn reamers backwards (anticlockwise).
The shavings created as material is
removed would otherwise become jammed
and destroy the cutters.
Note
irj^ - The cylinder head has been dismantled.
- New valves are reguired for testing.
Note
The complete rocker path must be taken
into account.
Replace valve guide if the limit of wear has
been reached
- see work card W 1-6-2.
'234/ /236j
A
DEUT2
914 Work Card
W 1-7-3
Removing, refitting and checking valve seat inserts
Tools Caution
- Commercial tools A The repaired cylinder heads must be
Lathe labelled as follows:
Valve reseating tool - Repair date (manufacturing date)
- Special tools according to works standard H0246 part 2
Clamping arbor 122 450
References
Drill jig
Pilot pin with drill-jig bushes
Hard metal special milling cutter
122 460
122 461
122 463
m - W 1-5-1
- W 1-7-8
Assembly mandrel exhaust 123 950
Assembly mandrel inlet 123 960
Clamping fixture 125 500
Note
Avoid material damage to the cylinder head.
Note
C^ Perform the cutting work on an upright drill
with a spindle diameter of at least 50 mm
and speed of 300 - 350 min rpm.
Note
Do not damage the valve seat insert seating
face.
if
,t* 4 -
j |'©|35816|0
Note
Do not damage the cylinder head.
Note
EF" Replace the valve seat inserts after heating
the cylinder head once to 220° C.
^3521710
' 2 4 1 / /242i
Note
CF 3 Replace valve seat inserts if the wear
limit have been reached.
A ®
914 Work Card
W 1-7-8
Note
EF 3 - Replace the valve seat insert or the
individual valves exceed the wear
limit, if necessary all together.
- External micrometer
internal dial gauge
Prisms
Hardness tester
- Special tools
Dial gauge 100 400
Note
Use the measuring device table to convert
the measured values.
Check crankshaft
• Schematic for gauging the bearing journals
at positions " 1 " and "2" in levels "a" and "b".
1 2>
b —
1
iJ 1 r f
a -—• •--
|©|36424|0
Crankpin diameter
• Gauge crankpins.
/512I / s i ! ) / i i s l / i i 6 l
True running
• Check crankshaft for true running.
/
54?l /542i
Example:
Dimension "a" = 37,50 mm
Dimension "b" = 37,30 mm
Axial end float = 0,20 mm
Visual inspection
• Visually inspect the running surface of the shaft
seal.
Note
If the crankshaft is worn, it is possible to
J
procure a replacement shaft or have the old
one repaired at our Service Centers.
Note
The punch mark of the gear is on the shorter
side of the notched pin.
Note
In case of existing run-in groove, displace
new shaft seal axially.
See marking on fitting device for installation
depth.
WteMM|8|^
* t
■L ^"^HST m. ^?|©|35864|0
j Einbautiefe 0 Q
i
! Einbautiefe ij^i
|©|35863|0
Note
Sealing lip faces the crankshaft.
Note
Hold against the V-belt pulley with the
retainer, if necessary.
|©|35869|0
pb - -^
V ' (*. 0
• Mount new shaft seal with fitting device.
Note
Sealing lip faces the crankshaft.
Note
Gauge small end bush at points " 1 " and "2"
in planes "a" and "b".
,\\\\v\
i1 i
(f\ ^
\J)
1 2
^
s\\\\V
|©|36348|0
"^l^iisL
|©|35874|0
v^ V)
( ( \ ^
1 2
C\\\\V
|©|36348|0
Note
ID-codes of connecting rod and big end
bearing cap must be identical.
Note
If the measured values deviate only slightly,
take further measurements with the new
bearing shells fitted.
Note
Gauge bearing shells at points " 1 " and "2" in
planes "a" and "b".
AWW
i t iL
ft\ :A\
\Y:VJ
1 2
wwv
|©|36348|0
/6087
A
DEUT2
914 Work Card
W 2-4-1
Remove crankshaft
• Remove front cover (opposite the coupling end)
and oil pan
- see work card W 3-8-1.
• Remove rear cover (coupling end)
- see work card W 3-9-1.
• Remove lube oil suction pipe and main
bearing cap.
• Remove big end bearing cap.
Note
Be careful with thrust ring. Lay down parts
of main bearing cap in their sequence of
removal.
..V . ^ 8Sf
■JaSb--:■*m
^IBSsJBt/am*.
[^HjHHigigy^jfet
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|©|36126|0
1
- see work card W 2-1-7.
• Install crankshaft.
|©|35904|0
Note
O^ The larger thrust ring half faces the flywheel
end.
Note
O^ The larger thrust ring half faces the flywheel
end.
Note
Bearing cap no. 1 is at the flywheel end.
Check piston
• Remove piston and cylinder
- see work card W 3-2-4.
• Use and set internal dial gauge with tracer pin for
measuring range 35 - 45 mm.
Note
CF 3 Gauge piston pin bore at points " 1 " and "2"
in planes "a" and "b".
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I© 13634810
^ - * - - -'
.• I©]36484I0
Note
E^ The piston diameter is gauged at the bottom
of the shank end, crosswise to the piston pin
bore.
'401// /402// / 4 0 3 j
|©|36485|0
' 4 3 1 / 7432/
'433/ /434i
1©|35911|0
1 ,1 1
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1 ' |ty|dbdt>d|u
Note
Sequence and position of piston rings seen
from piston crown:
1. Keystone ring, top facing combustion chamber.
2. Keystone ring, top facing combustion chamber.
3. Bevel-edged slotted oil control ring with hose
spring.
'425i
Tools References
- Commercial tools CD - W 1-4-4
External micrometer - W 8-4-6
- Special tools
Cylinder head wrench 120 040
Piston ring tensioning belt_ 130 600
Note
Pay attention to big end bearing shells.
Lay down parts in the order they were
disassembled.
P.
' ,1©|35918|0
• Remove circlips.
• Take out piston pin.
IMjMHB
P^L>'Si**^
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K '. ^ t.
|©|35883|0
Note
Lightly oil cylinder running surface.
Note
When refitting the piston and connecting
rod, ensure that the arrow on the piston
crown points to the exhaust end.
Note
CF5 A maximum of 3 shims with a total thickness
of 1.5 mm is permissible.
D Note
Ensure that connecting rod matches the
cap.
Note
EF* Pay attention to numbering.
A
DEUT;
914 Work Card
W 3-3-1
iS
a
--- r JL_J|U _a
JM Ull—l
(
b
|©|36425|0
and in planes 1 - 4
Note
O^ The surfaces must be clean and even.
If damaged, replace as necessary.
A ®
914 Work Card
W 3-3-1
• Inspect lower seating surface of cylinder for
damage.
Note
The surfaces must be clean and even. If
damaged, replace as necessary .
Note
Pay attention to compression spring and
cap for camshaft.
Note
Introduce angled spring end into bore of
camshaft.
Note
Engine is turned by 180°.
A ®
914 Work Card
W 3-9-1
Removing and refitting the rear cover (coupling end)
Tools References
- Commercial tools CP - W 8-4-7
Knife-edged ruler - W 12-6-1
- Special tools
Retainer plate 142 070
Assembly device 142 080
Centering device 143 110
• Tighten bolts.
Note
D ^ Installation depth possibilities:
Installation depth 0:
Standard dimension with perfect shaft seal
running surface.
Installation depth 1:
Offset installation with existing run-in groove
on shaft seal running surface.
Einbautiefe 0 Q
Einbautiefe 7 ) K f
|©|35863|0
• Refit flywheel
- see work card W 12-6-1.
• Refit oil pan
- see work card W 8-4-7.
A ®
914 Work Card
W 3-9-4
Removing and refitting the adapter housing
Tools
- Commercial tools
- Special tools
Tightening angle dial indicator _ 101 910
• Refit flywheel.
• Refit starter.
A ®
914 Work Card
W 3-10-1
Note
In case of traces of use in the bearing aisle,
it is possible to rework the outer diameter to
oversize in our Service Centers.
*ISP*^-I3
^ ^
!
mm
L '
i
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|©|36429|0
Note
Observe attached operation manual.
Note
Feed carefully. With a full turn of the knurled
nut (360°), the turning tool is fed by 1.5 mm.
©I35896I0
Note
Only remove enough material to obtain a
perfect seating surface.
Note
Schematic for gauging bearing bush and
bearing bores at points 1 and 2 in planes "a"
and "b".
A W WL
IL
:A
i
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1 2
^ :
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|©|36348|0
\ ^ ^
Note
H^ Make sure that the oil bores are in line.
1
Screw in all screw plugs and tighten.
Item 1 with new special sealing ring
Item 2 with new Cu sealing rings
Note
E5^ Screw plugs items 1 and 2 coated with
sealing compound.
Screw plugs coated with sealing compound
must always be renewed after disassembly.
'x
, X
, / • - ; . . • • • - . ■ ■ > !,_ "/■■ * ' ~ ~
\
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|©|36210|0
Note
CF5 Cylinder pin must point towards the cylinder
seating surface.
^ t •£
^•4M
Note
O^ Engine is turned through 180° in this picture.
Note
O^ Engine is turned through 180° in this picture.
Note
C^ Ensure that dowel sleeve is fitted, insert if
not.
Note
D ^ Engine is turned through 180° in this picture.
Note
KF* - These markings apply to 4, 5 and 6
cylinder engines.
- MAG is used for 4 cylinder engines. The
arrow marking applies to MAG.
- There is a further marking (arrow) on the
injection timing mechanism for 3 cylinder
engines.
Note
K^3 The bush is precision-bored in installed
condition.
A ®
914 Work Card
W 4-5-5
Remove camshaft
• Set engine to firing TDC cylinder 1.
• Remove rocker arm and rocker arm bracket
- see work card W 1-2-2.
• Remove push rods.
• Remove front cover
- see work card W 3-8-1.
• Remove compression spring and cap.
• Remove oil pump
- see work card W 8-4-5.
Refit camshaft
• Insert tappets.
Check camshaft
• Dismount camshaft
- see work card W 4-5-5.
• Visually check cams, bearing journals and gear
for wear, replace camshaft if necessary.
Refit camshaft
- see work card W 4-5-5.
Refit turbocharger
- see work card W 6-6-4.
Tighten bolts.
Auxiliary aids
a - DEUTZ S1
Remove turbocharger
• Undo hose clamp.
[1SMH0
• Remove turbocharger.
lei »**
\ Vi ■ " 1 * . 4
IK
WH'
. ■'- -_'■,..*KS&;J
^
|©|36249|0
1■
if necessary.
Note
UJ^ If the turbocharger is damaged / worn, it
is possible to have it reconditioned at our
Service Centers. |
H- :4 i
i "■
|©|36250|0
Refit turbocharger
• Refit oil return line and oil line with new gasket.
• Coat oil line bolts with DEUTZ S1 fitting lubricant
and tighten.
Note
Use spring-loaded clamp pliers.
HUPP?
tinaaweiBi
Note
- Utmost cleanliness is required when
working on the injection equipment.
Note
K^ Bending the injection lines can cause
small cracks which reduce the long-term
durability. Do not bend injection lines!
Note
- Utmost cleanliness is required when
working on the injection equipment.
- See repair instructions "Injection pump/
governor" for checks and repairs on the in
jection pump
• Fit pointer.
Note
The front cover has been removed here to
provide a clearer overview.
Note
Ensure Woodruff key is fitted.
Caution
A Do not turn the crankshaft after removing
the injection pump.
Note
This corresponds to commencement of
delivery of 1st cylinder.
Hinweis
C^ Ensure Woodruff key is fitted.
( m i l l <J
Note
KF" - The V-belt has been disassembled in
this work process to provide a clearer
overview.
Note
- Top Dead Center (TDC) marking has been
determined. Check TDC if necessary
- see work card W 1-2-5.
• Fit pointer.
Note
- The V-belt has been disassembled in
this work process to provide a clearer
overview.
^ngtSHaia
Note
ir^ 3 Top Dead Center (TDC) marking has been
determined. Check TDC if necessary
- see work card W 1-2-5.
• Fit pointer.
* v3***Mw»™. «!»"'*
0312 0572-0150
Page 3 of 8
©1002
Fuel System
Work Card
W 7-6-2
914
A
• Connect delivery line of H.P. hand feed pump to
injection pump and suction line on reservoir tank.
• Fill reservoir tank with clean fuel.
Note
E^ Apply current to stop magnet and remove
start magnet.
Note
If commencement of delivery does not
agree with the data on the engine
nameplate, reset commencement of
delivery as follows.
Note
Recheck commencement of delivery, if
necessary repeat the setting work.
sd^s
ip
A ®
914 Work Card
W 7-6-2
• Remove high-pressure pump, reservoir tank and
pipe elbow.
Note
Reinstall stop magnet and start magnet.
Note
O^ - Utmost cleanliness is required when
working on the injection equipment.
Dismount injectors
• Remove cooling air guide sheets.
E5lM.-fcM.1Iil
• Dismount injectors.
;i
* \ *
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©13601010
B£74H&T*'^
Adjust injector
• Remove injectors
- see work card W 7-7-1.
• Insert injector into assembly device and undo
the nozzle tensioning nut approx. 180° (release
pressure) and then retighten.
• - — • ■ » — * . - * - -
Caution
A Keep hands away from the fuel jet. The fuel
penetrates deeply into the skin and may
cause blood poisoning.
\ 3f«S
araF-# moo «»r%-^|
• sm-jf.
Note
A „ *
^ H ^
tolti
bat
mtwi
Ci After actuating the hand lever on the
nozzle tester 3 or 4 times, the pressure
builds up again in the spring chamber. Undo
the tensioning nut again and retighten
before repeating the test.
|©|36293|0
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[©13627010
A
DEUT2
914 Work Card
W 7-7-5
Sequence of part assembly
Note
A thicker shim increases the opening
pressure.
Note
Reworking is not permissible.
Note
The buzzing test permits an audible check
to be made whether the nozzle needle
moves easily in the nozzle body. New i
njectors emit a different buzzing sound
compared to used injectors. It deteriorates
due to wear around the needle seat. If an
injection nozzle does not buzz despite
cleaning, it must then be replaced. A clear
buzz should be heard from a used injector
when the hand lever is actuated rapidly,
while exhibiting a well atomised spray
pattern. The spray pattern may differ
noticeably from that of a new injector.
Note
Catch fuel and dispose of properly.
Note
Turn engine 180°.
/ 9 2 5 | /946^
A ®
914 Work Card
W 8-4-6
A ®
914 Work Card
W 8-4-7
Auxiliary aids
- DEUTZ DW 47
©13621910
j iiilMMIMMlMlMlllHliinill^ill«Hilliilill»MrtlMWftlli<WMa
v.
'iVi'\£kJL«<* ±b*
Note
The injection lines und cooling air guide
sheets have been removed in this work
process to provide a clearer overview.
Note
Screw bolts in loosely.
EJItcWfifcWtil
A ®
914 Work Card
W 8-11-7
[§]fcM:M.ira
A ®
914 Work Card
W 8-11-7
• Check level of engine oil, replenish if necessary.
• Refit oil filling cap with new gasket.
• Refit oil dipstick with new sealing ring.
[HicbftM.-lBl
Remove blower
• Remove cooling air guide sheets.
? i i 7^r«
' I'.
Note
Pay attention to spacer sleeve.
• Remove blower.
Note
E^ Pay attention to spacer sleeve.
/<mj /985~jl
Dismantle blower
• Hold V-belt pulley and bolt together.
Undo sealing nut.
Note
Clean and oil the bolt thread.
' ^- |©136303|0
Note
CF3 Clean and oil the bolt thread.
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W ^ 3 © 13631010
A
DEUT;
®
914 Work Card
W 9-11-2
• Prise out shaft seal.
-*..»•,.
©13631410
Reassemble blower
• Assemble cover
- 1 Circlip
- 2 Ball bearing
- 3 Shaft
- 4 Inner circlip
- 5 Needle bearing
- 6 Outer circlip
- 7 Shaft seal
- 8 Cover
©13631910
• Insert circlip.
Note
Support cover on inner race of ball bearing.
©|36323|0
A ®
914 Work Card
W 9-11-2
- Assemble blower casing
1 Blower casing
2 Circlip
3 Ball bearing
4 Shaft
5 Sleeve
6 Inner circlip
7 Needle bearing
8 Outer circlip
9 Shaft seal
• Insert sleeve.
A ®
914 Work Card
W 9-11-2
Press in ball bearing over the outer race.
• Insert circlip.
Note
Support blower casing on the inner race of
the ball bearings.
Reassemble blower
• Insert coupling.
Note
tiW Oil deflector boss must face oil return bore.
Note
E^ Oil bolt thread.
Note
E^ For tightening angle apply a 90° mark
relative to bolt.
• Insert rotor.
A ®
914 Work Card
W 9-11-2
• Screw on new sealing nut.
Note
DS^ Oil bolt thread.
Note
CF= For tightening angle apply a 90° mark
relative to bolt.
Tools References
- Commercial tools - W 6-1-5
- W 9-11-1
• Dismount shield.
r\ n,.^.T"
s
^,i ' - * '- ■- '-
\j
• Refit blower
- see work card W 9-11 -1.
• Remount pipe.
|©|36268|0
A ®
914 Work Card
W 12-1-4
Tools
- Commercial tools
- Special tools
Tightening angle dial indicator _ 101 910
Retainer 143 400
Auxiliary aids
6 - Molykote-Paste-Rapid
Note
Bolt has a left-hand thread.
Note
O^ Bolt has a left-hand thread.
Note
O* Bolt has a left-hand thread.
/
968J' /045// /046// /0471
Tools References
- Commercial tools - W 12-1-4
Note
D ^ Pay attention to number and thickness of
shims.
Note
Pay attention to number and thickness of
shims.
Note
B^ Centering of ring must point towards ball
bearing.
Note
KF* Schematic for pressing-in bearing bushes:
The oil bores "A" must be in line with oilduct
"B". The inside bearing bush must be flush.
There must be no axial end float between
spacer ring and bearing bushes.
Note
KF 3 Centering of the disc must point towards
idler pulley housing. Centering serves to fix
the shaft.
Note
K^ Coated side of item 1 must point towards
steel washer, item 2.
Note
Pay attention to position towards long
spring end.
Note
Ensure bores are in line.
Note
HP 3 Use the same number and thickness of
circlips as with disassembly.
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|©|35798|0
A ®
914 Work Card
W 12-6-1
Tools
- Commercial tools
- Special tools
Guide mandrel (self-made)
Retainer 143 400
Dismount flywheel
• Hold flywheel against V-belt pulley with retainer
and dismount.
Mount flywheel
O Position flywheel using a self-made guide
mandrel.
Note
Pay attention to centering sleeve.
Tools References
- Commercial tools - W 12-6-1
T - ;„i
H ^ ^JH| I B S S H B ^ K "
1
M
VBHB PJE^^awE.-' nrfE^^"*""^ iifiwtiWIfflMHfilliBffffl'i
I H H H H H H H i l ^ |35yu2 iu
Note
CF3 Chamfered teeth point away from flywheel.
• Mount flywheel
- see work card W 12-6-1.
Six.
|©|36165|0
Note
E^ Use the same type of bushes and shims as
disassembled.
Note
Use the same type of bushes and shims as
disassembled.
©136201101
Remove starter
• Take out bolts and remove starter.
Remount starter.
• Tighten bolts.
consists of:
2 angled clamping plates 6066/154
1 angled clamping plate 6066/155
1 angled clamping plate 6066/156
/- ^
Jl ll
^ ^
l©|36457|0
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|©|35441|1
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