Deutz 9929en Operation Manual
C 2000
9929en
1
Operation Manual
2011
● Please read and observe the information
given in this Operation Manual. This will
enable you to avoid accidents, preserve the
manufacturer’s warranty and maintain the
engine in peak operating condition.
● This engine has been built exclusively for
the application specified in the scope of
supply, as described by the equipment manufacturer and is to be used only for the
intended purpose. Any use exceeding that
scope is considered to be contrary to the
intended purpose. The manufacturer will
not assume responsibility for any damage
resulting therefrom. The risks involved are
to be borne solely by the user.
● Use in accordance with the intended purpose also implies compliance with the conditions laid down by the manufacturer for
operation, maintenance and servicing. The
engine should only be operated by personnel trained in its use and the hazards involved.
● The relevant accident prevention guidelines
and other generally accepted safety and
industrial hygiene regulations must be observed.
● When the engine is running, there is a risk of
injury through:
- turning/hot components
- engines with positive ignition
- ignition systems (high electrical voltage)
You must avoid contact at all times!
● Unauthorized engine modifications will invalidate any liability claims against the manufacturer for resultant damage.
Manipulations of the injection and regulating
system may also influence the performance
of the engine, and its emissions. Adherence
to legislation on pollution cannot be guaranteed under such conditions.
● Do not change, convert or adjust the cooling
air intake area to the blower.
The manufacturer shall not be held responsible for any damage which results from
such work.
● When carrying out maintenance/repair operations on the engine, the use of DEUTZ
original parts is prescribed. These are specially designed for your engine and guarantee perfect operation.
Non-compliance results in the expiry of the
warranty!
● Maintenance and cleaning of the engine
should only be carried out when the engine
is switched off and has cooled down.
You must ensure that the electrical systems
have been switched off and the ignition key
has been removed.
Accident prevention guidelines concerning
electrical systems (e.g. VDE-0100/-0101/0104/-0105 Electrical protective measures
against dangerous touch voltage) are to be
observed.
When cleaning with fluids, all electrical components are to be covered impermeably.
Safety guidelines / Accident prevention
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Operation manual
2011
0297 9929 en
Engine Serial
Number:
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).
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.
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9929en
Foreword
Dear Customer,
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 fitted to your engine.
We have endeavoured to highlight any differences
so that you will be able to locate the operating and
maintenance instructions relevant to your engine
quickly and easily.
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
5
9929en
Contents
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 Fuel Delivery Lock
2.2 Engine Illustrations
2.2.1 Operation Side:
Example FL 2011
2.2.2 Exhaust Side:
Example FL 2011
2.2.3 Operation Side:
Example BF4L 2011
2.2.4 Exhaust Side:
Example BF4L 2011
2.2.5 Operation Side:
Example FM 2011
2.2.6 Exhaust Side:
Example FM 2011
2.2.7 Operation Side:
Example BFM 2011
2.2.8 Exhaust Side:
Example BFM 2011
2.3 Oil Circuit
2.3.1 Lube Oil Circuit Schematic
2.4 Fuel System Schematic
2.4.1 Fuel System
2.5 Coolant System
2.5.1 Coolant Plan
3. Engine Operation
3.1 Commissioning
3.1.1 Adding Engine Oil
3.1.2 Adding Fuel
3.1.3 Other Preperations
3.1.4 Additional Maintenance Work
3.2 Starting
3.2.1 Electric Starting
3.3 Monitoring Operation
3.3.1 Engine Oil Pressure
3.3.2 Engine Temperature
3.4 Shutting Off
3.4.1 Mechanical Shut-Off
3.4.2 Electric Shut-Off
3.5 Operating Conditions
3.5.1 Winter Operation
3.5.2 High Ambient Temperature, High Altitude
4. Operating Media
4.1 Lube Oil
4.1.1 Quality
4.1.2 Viscosity
4.2 Fuel
4.2.1 Quality
4.2.2 Winter-Grade Fuel
5. Service
5.1 Service Plan
5.2 Scheduled Maintenance Plan
5.3 Maintenance Chart
5.4 Maintenance Work Completed
6. Service and Maintenance
6.1 Lubrication System
6.1.1 Oil Change Intervals
6.1.2 Check Oil Level, Change Engine Oil
6.1.3 Changing Oil Filter
6.1.4 Clean/Replace Oil Filter (Cup)
6.2 Fuel System
6.2.1 Replace Fuel Filter
6.2.2 Clean/Replace Fuel Filter (Cup)
6.2.3 Clean Stainer of Fuel Filter
6.2.4 Change Fuel Leakage Line
6.3 Cooling System
6.3.1 Cleaning Intervals
6.4 Combustion Air Filter
6.4.1 Cleaning Intervals
6.4.2 Emptying Cyclone-Type Precleaner
6.4.3 Dry Type Air Cleaner
6.5 Belt Drives
6.5.1 Check V-belt
6.5.2 Tensioning Alternator Belts
6.5.3 Changing Alternator Belts
6.6 Adjustments
6.6.1 Check Valve Clearance, adjust if necessary
6.6.1.1 Valve Clearance Adjustment Schematic
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
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Contents
7. Faults, Causes and Remedies
7.1 Fault Table
8. Engine Preservation
8.1 Preservation
8.1.1 Preser ving Engine
8.1.2 Removing Engine Preser vatives
9. Technical Specification
9.1 Engine Specifications and Settings
9.2 Torque Wrench Settings
9.3 Tools
10. Service
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7 Gerade
7 Gerade
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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.
Service
Please contact one of our authorized service
representatives in the event of breakdowns or for
spare parts inquiries. Our trained specialists will
carry out repairs quickly and professionally, using
only genuine spare parts.
Original parts from DEUTZ AG are always produced
in accordance with state-of-the-art technology.
Please turn to the end of this manual for further
service information.
General
!
Care and Maintenance
Sound care and maintenance practices will ensure
that the engine continues to meet the requirements
placed on it. Recommended service intervals must
be observed and service and maintenance work
carried out conscientiously.
Special care should be taken under abnormally
demanding operating conditions.
Asbestos
DEUTZ original parts are asbestosfree.
Safety
This symbol is used for all safety
warnings. Please follow them
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.
Beware of Running Engine
Shut the engine down before carrying out maintenance or repair work. Ensure that the engine cannot
be accidentally started. Risk of accidents.
When the work is complete, be sure to refit any
panels and guards that may have been removed.
Never fill the fuel tank while the engine is running.
Observe industrial safety regulations when running
the engine in an enclosed space or underground.
California
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known to the State of California to
cause cancer, birth defects, and other reproductive harm.
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Engine Description
2.1 Model
2.2 Engine Illustrations
2.3 Lube Oil Circuit Schematic
2.4 Fuel System Schematic
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B
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Engine Description 2.1 Model
2.1.1 Rating Plate
The model A, the engine serial number B and the
performance data are stamped on the rating plate.
The model and engine serial number must be given
when ordering parts.
2.1.2 Position of the Rating Plate
The rating plate C is attached to the valve cover.
2.1.3 Engine Serial Number
The engine serial number B is stamped on the
crankcase D as well as the rating plate.
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2.1 Model Engine Description
2.1.4 Cylinder Numbering
Cylinders are numbered consecutively, beginning
at the flywheel.
2.1.5 Fuel Delivery Lock
The manufacturer shall not be held liable for damages resulting from adjustments made to the regulator by the operator.
The lock screws are protected in order to prevent
this:
1. with locking paint on model:
with torque balancer
2. with plastic protective cap on model:
without torque balancer.
Adjustments to the regulator are to
be carried out only by authorised
DEUTZ SERVICE specialists
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Engine Description 2.2 Engine Illustration
2.2.1 Operation Side
FL 2011
1 Oil filler neck (valve-gear housing cover)
2 Charge-air line / air-intake line
3 Fan with integrated generator
4 Narrow V-belt
5 Tractive electromagnet
6 Wheel-house cover
7 V-belt pulley on crankshaft
8 Oil pan
9 Shut-off lever
10 Speed control lever
11 Oil dipstick
12 Oil drain plug
13 Crankcase
14 Oil fill point (on side of crankcase)
15 Fuel pump
16 Easy-change fuel filter
17 Connecting facility for oil heater
18 Lube oil replacement filter
19 Removable coolant intake hood
20 Injection pumps
21 Oil cooler
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2.2 Engine Illustration Engine Description
2.2.2 Exhaust Side
FL 2011
22 Date plate
23 Optional attachment of an SAE housing
24 Flywheel with ring gear
25 Starter
26 Front cover
27 Crankcase
28 Exhaust manifold
29 Air intake pipe
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Engine Description 2.2 Engine Illustration
2.2.3 Operation Side
Example: BF4L 2011
1 Oil filler neck (valve-gear housing cover)
2 Charge-air line / air-intake line
3 Fan with integrated generator
4 Narrow V-belt
5 Tractive electromagnet
6 Wheel-house cover
7 V-belt pulley on crankshaft
8 Oil pan
9 Shut-off lever
10 Speed control lever
11 Oil dipstick
12 Crankcase
13 Oil fill point (on side of crankcase)
14 Fuel pump
15 Easy-change fuel filter
16 Connecting facility for oil heater
17 Charge-pressure-dependent full-load stop
(CPD)
18 Lube oil replacement filter
19 Removable coolant intake hood
20 Injection pumps
21 Oil cooler
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2.2 Engine Illustration Engine Description
2.2.4 Exhaust Side
Example: BF4L 2011
22 Cylinder head
23 Exhaust manifold line
24 Flywheel with ring gear
25 Starter
26 Crankcase
27 Lube oil feed line to turbocharger
28 Lube oil return line from turbocharger
29 Induction pipe
30 Turbocharger (TC)
31 Intake manifold
32 Charge-air line
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Engine Description 2.2 Engine Illustration
2.2.5 Operation Side
FM 2011
1 Oil filler neck (valve-gear housing cover)
2 Charge-air line / air-intake line
3 Alternator
4 Narrow V-belt
5 Tractive electromagnet
6 Timing belt cover
7 V-belt pulley on crankshaft
8 Oil pan
9 Shut-off lever
10 Speed control lever
11 Oil dipstick
12 Oil drain plug
13 Oil fill point (on side of crankcase)
12 Crankcase
14 Fuel pump
15 Easy-change fuel filter
16 Connecting facility for oil heater
17 Lube oil replacement filter
18 Injection pump(s)
19 Oil cooler connection
20 Fuel leakage line
21 Injection valve(s)
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2.2 Engine Illustration Engine Description
2.2.6 Exhaust Side
FM 2011
22
23
24
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22 Cylinder head
23 Exhaust manifold
24 Flywheel with ring gear
25 Starter
26 Starter guard (optional)
27 Crankcase
28 Air intake pipe
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Engine Description 2.2 Engine Illustration
2.2.7 Operation Side
BFM 2011
1 Air-intake pipe
2 Fan wheel
3 V-belt pulley on crankshaft
4 Narrow V-belt
5 Tractive electromagnet
6 Timing belt cover
7 Shut-off lever
8 Speed control lever
9 Oil fill point (on side of crankcase)
10 Oil dipstick
11 Fuel pump
12 Easy-change fuel filter
13 Connecting facility for oil heater
14 Lube oil replacement filter
15 Injection pump(s)
16 Oil cooler connection
17 Injection valve(s)
18 Fuel leakage line
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2.2 Engine Illustration Engine Description
2.2.8 Exhaust Side
BFM 2011
19 Crankcase ventilation (optional)
20 Cylinder head cover
21 Exhaust manifold
22 SAE housing
23 Starter
24 Crankcase
25 Turbocharger
26 Generator with cover
27 Charge-air line
28 Oil filler neck
© 31 862 0
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Engine Description 2.3 Oil Circuit
2.3.1 Lube Oil Circuit Schematic
1 Oil pan
2 Oil-intake pipe
3 Oil pump
4 Main oil duct
5 Oil-cooled cylinders
6 Cylinder head cooling neck
7 Oil duct for rocker arm lubrication
8 Rocker arm
9 Oil manifold for the thermostat
10 Intake to external engine oil cooler
11 Return from external engine oil cooler
12 Thermostat housing with slide thermostat
13 Oil duct to oil filter
14 Oil filter
15 Oil duct to cam, con-rod and crankshaft bear
ings
16 Spray nozzle for piston cooling
17 Oil return via crankcase to oil pan
18 Lube oil intake to turbocharger
19 Turbocharger
20 Return from turbocharger to oil pan
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2.4 Fuel System Schematic Engine Description
2.4.1 Fuel System
1 Fuel line from tank to fuel pump
2 Fuel pump
3 Fuel line from fuel pump to easy-change fuel
filter
4 Easy-change fuel filter
5 Fuel line from filter to injection pump
6 Injection pump
7 Fuel distributor line
8 Injection line
9 Injection valves
10 Fuel leakage line
11 Fuel overflow pipe
12 Fuel return line to tank
The installation of a fuel pre-filter/
hand pump between the fuel tank
and the engine is prescribed to
protect the engines against dirt in
the fuel.
!
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Engine Operation
3.1 Commissioning
3.2 Starting
3.3 Monitoring Operation
3.4 Shutting Off
3.5 Operating Conditions
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OIL
3.1.1.2 Initial Engine Oil Fill-Up
B/FM 2011
© 26 432 0
Engine Operation 3.1 Commissioning
3.1.1 Adding Engine Oil
As a rule, engines are delivered without oil.
Pour lube oil into the oil filler neck (arrow).
For oil grade and viscosity, see 4.1.
● Fill oil into oil pan up to "Max." mark on engine
dipstick (for oil quantity see 9.1).
● Start engine and allow to run at low idling speed
for approx. 2 mins.
● Switch off engine.
● Check oil level, if necessary, top up oil to "Max."
mark.
● Fill oil into oil pan up to "Min." mark on engine
dipstick.
● In addition, top up oil quantity of supply hoses
and of external oil cooler (according to manufacturer’s specifications).
● Allow engine to run warm until thermostat opens
(at approx. 95°C).
● Allow engine to run for approx. 2 mins.
● Switch off engine.
● Check oil level, and if necessary, top up oil to
"Max." mark.
3.1.1.1 Initial Engine Oil Fill-Up for
B/FL 2011
If the person operating the engine does not run up
the engine until the thermostat opens, the oil level
may lie above the "Max." mark on the engine
dipstick when delivered. The level can then only be
assessed after the engine has been run up.
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!
FUEL
© 26 398 0
3.1 Commissioning Engine Operation
3.1.1.3 Initial Engine Oil Fill-Up
B/FM 2011 Genset Engine
● Fill oil into oil pan up to "Max." mark on engine
dipstick (for oil quantity see 9.1).
● Start engine and allow to run at low idling speed
for approx. 2 mins.
● Switch off engine.
● Check oil level and fill up with oil up to upper
"Max." mark.
3.1.2 Adding Fuel
Use only commercial-grade diesel fuel. For fuel
grade, see 4.2. Use summer or winter-grade fuel,
depending on the ambient temperature.
Never fill the tank while the engine
is running.
Ensure cleanliness!
Do not spill fuel!
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