Deutz 9929en User 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 manu-
facturer 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 pur-
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-
volved.
●The relevant accident prevention guidelines
and other generally accepted safety and
industrial hygiene regulations must be ob-
served.
●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 in-
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.
●Do not change, convert or adjust the cooling
air intake area to the blower.
The manufacturer shall not be held respon-
sible for any damage which results from
such work.
●When carrying out maintenance/repair op-
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!
●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 com-
ponents are to be covered impermeably.
Safety guidelines / Accident prevention
00_GB.p65 04.02.2002, 14:232

C 2000
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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.

4 9929en
Foreword
Dear Customer,
Liquid-cooled Deutz engines are designed for a
large number of applications. Consequently, a wide
rangeofvariantsisofferedtomeettherequirements
of specific cases.
Your engine is appropriately equipped for the
installation concerned, which means that not all of
the components described in this Operation Manu-
al 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 Preserving Engine
8.1.2 Removing Engine Preservatives
9. Technical Specification
9.1 Engine Specifications and Settings
9.2 Torque Wrench Settings
9.3 Tools
10. Service

C 2000
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7Gerade
7Gerade
1
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 asbestos-
free.
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 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.
California
Proposition 65 Warning
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.
9689en_K01_neu 30.09.1999, 15:45 Uhr7

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9689en_K01_neu 30.09.1999, 15:45 Uhr8

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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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C
© 31 864 0© 26 332 2
AB
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Engine Description 2.1 Model
2.1.1 Rating Plate
The model A, the engine serial number Band 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 Cis attached to the valve cover.
2.1.3 Engine Serial Number
The engine serial number Bis stamped on the
crankcase Das well as the rating plate.

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!
1234
© 26 431 0 © 26 387 0
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 dam-
ages resulting from adjustments made to the regu-
lator 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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© 31 873 1
1
2
3
4
5
7
6
16
15
21
20
19
18
17
9 81214 13 11 10
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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© 31 874 1
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
22
24
23
29
28
27
26
26

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3
4
7
6
15
14
20
19
18
17
16
21 1 2
9 810111213
5
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

2
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© 31 868 1
22
23
24
26
28
30
27
29
31
32
25
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)
1
2
3
4
5
7
6
16
15
21
20
19
18
17
9 814 13 12 11 10

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2.2 Engine Illustration Engine Description
2.2.6 Exhaust Side
FM 2011
22
23
24
28
27
26 25
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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© 31 861 0
1
2
4
3
12
11
18
17
16
15
14
13
7 6 510 9 8
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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19
28
20
21
24
22
23
27
26
25
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