Asu 160 Ppm - 2165 Technical Manual

OPERATION / MAINTENANCE MANUAL ASU 160 PPM

Air+MakIndustries, Inc.

OPERATION, MAINTENANCE & TROUBLE

SHOOTING MANUAL 160 PPM AIR START UNIT

DESIGNED & MANUFACTURED BY:

AIR + MAK INDUSTRIES INC. 11154, WILDWOOD DRIVE, OLIVE BRANCH, MS 38654

PHONE: (662) 893 3444, FAX: (662) 893 3476 E-mail: [email protected]

www.airmak.com

CLIENT: AIR ASIA BHD, MALAYSIA

THIS MANUAL SHOULD BE REFERRED FOR THE ASU SL.No. 2165



TABLE OF CONTENTS

SUBJECT CHAPTER / SECTION PAGE

GENERAL SAFETY INSTRUCTIONS

DEFINITIONS OF TERMS.

NOTES

DESCRIPTION AND OPERATION I / I

1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2. Special features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3. Detailed Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4. G.A Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

5. Controls, Monitoring and Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

6. Specification & capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

ELECTRONICS AND ELECTRICAL MODULE I / II

1. Pre-commissioning check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2. DO’s & Don’ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . 2

3. Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

4. General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

5. Pneumatic block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

6. Compressor lubrication circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

7. ASU Panel Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

I. Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

8. Electro Pneumatic Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

9. Electronic Pressure Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

10. Pressure Regulating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

11. Control System Display Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

12. Warning Indications in Control Panel Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

13. ASU Protection Systems and set limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

14. Special Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38



15. Electrical Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

I. Control panel I Wiring details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

II.Control panel II Wiring details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

III.EMR Wiring details . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . 42

16. PCB Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 43

17. ASU Remote Monitoring System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

MAINTENANCE & TROUBLE SHOOTING II

MAINTENANCE II / I

1. Engine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2. Compressor maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

TROUBLE SHOOTING II / II

1. Trouble Shooting Procedures & Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2. Engine Trouble Shooting Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3. Compressor Trouble Shooting Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4. ASU Trouble Shooting Procedures & Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

OVERHAUL AND MAJOR REPAIR – III

ILLUSTRATED PARTS CATALOGUE - IV

RECOMMENDED SPARES – V

MANUFACTURER APPENDIX – VI

1. Compressor Manual

2. Engine Manual



GENERAL SAFETY INSTRUCTIONS

WARNING Improper practices or carelessness can cause burns, cuts, mutilation or other

bodily injury or death.

Read and understand all the safety precautions and warnings before performing any repair. This list

contains the General Safety Precautions that must be followed to provide personal safety. Special

safety precautions are included in the procedures when they apply.

Make sure the work area surrounding the product is dry, well lit, ventilated, free from clutter,

loose tools, parts, ignition sources and hazardous substances. Be aware of hazardous conditions

that can exist.

Always wear protective glasses and protective shoes when working.

Rotating parts can cause cuts, mutilation or strangulation.

Do not wear loose – fitting or torn clothing. Remove all jewelry when working.

Disconnect the battery (negative (-) first) and discharge any capacitors before beginning any

repair work.

Disconnect the starting motor if equipped to prevent accidental engine starting.

Put a “ DO NOT OPERATE ” tag in the operator’s compartment. When the unit is left

unserviceable

If the equipment has been operating and is hot, allow cooling before starting any maintenance

work.



Do not work on anything that is supported ONLY by lifting jacks or a hoist. Always use blocks

or proper stands to support the product before performing any service work.

Relieve all pressure in the storage tank air, oil, and fuel and water in cooling system assembly

before any lines, fittings, or related items are removed or disconnected. Be alert for possible

pressure when disconnecting any device from a system that utilizes pressure.

Do not check for pressure leaks with hand. High-pressure oil or fuel can cause personal injury.

To avoid personal injury, use a hoist or get assistance when lifting components that weigh more

than 50 lbs. Check and make sure that the lifting tackles are in good condition. Make sure hooks

are positioned correctly. Always use a spreader bar when necessary. The lifting hooks must not

be side-loaded.

To avoid burns, be alert for hot parts on products that have just been turned off, and hot fluids in

lines, tubes, and compartments.

Always use correct tools that are in good condition.

Do not perform any repair when fatigued or after consuming alcohol or drugs that can impair

your functioning.

Corrosion inhibitor, a component of SCA and lubricating oil, contains alkali. Do not get the

substance in your eyes. Avoid prolonged or repeated contact with skin. Do not swallow

internally. In case of contact, immediately wash skin with soap water.

Do not fill the fuel, Coolant, Engine Oil & Compressor Oil while the Engine is running.



DEFINITION OF TERMS

ASU Air start unit CAmps Amperes

AST Air start mode CCA Cold Cranking Ampere

ACP AC Pack mode Cfm Cubic feet per minute

BHP Brake Horse Power DC Direct Current

CFM Cubic Feet Per Minute Deg C Degree Celsius

EMI Electro Magnetic Interference F Fahrenheit

EMC Electro Magnetic Compatibility Gal Gallons

EMR Electronic Motor Regulator G/kw – hr Grams Per Kilowatt Hour

E-P Voltage to pressure Gpm Gallons per minute

HCT High Coolant Temperature KW Kilowatt

HDT High Discharge Temperature Kgs Kilograms

HCOT High Compressor Oil Temperature KN Kilo Newton

LLOP Low Lube Oil Pressure Ltrs Litres

LCOP Low Compressor Oil Pressure Mm Milli metre

OEM Original Equipment Manufacturer Mph Miles Per Hour

PCB Printed Circuit Board PSIa Pounds per Square Inch - Absolute

P-I Pressure to current PSIg Pounds per Square Inch – Gauge

RPM Revolutions Per Minute PPM Pounds Per Minute

FI Radio Frequency Interference VBAT Battery Voltage



NOTES



DESCRIPTION AND OPERATION

CHAPTER I

SECTION I


CHAPTER I / I PAGE 1


DESCRIPTION

1. INTRODUCTION MAK Air Start Units are available in standard model that ranges from 90 PPM - 450 PPM. The Air

Start Unit is a rotary machine comprising of an oil free dry Screw Compressor with an integral gearbox

and driven by a suitable Diesel Engine.

These units provides regulated, dry, oil free air at a pressure of 40 PSIg, with determined flow required

to start the aircraft jet engines, while the onboard APU is unserviceable.

2. SPECIAL FEATURES • User friendly and unattended wake away system

• Monitoring and control through digital systems

• Operation made simple through push button controls

• Engine speed control is achieved by EMR

• USB Interface for data log and analysis in addition to RS-232.

• Better readability of output through Digital high intensity 2x16 LCD’s.

• Accessibility for routine check and maintenance made easy through side hinged doors

• RFI - EMC is achieved through appropriate design and shielding technique. Essential for

Military Aircraft.

• Compact size, Minimum weight and easy Maneuverability achieved through appropriate design

and layout configuration of components on a specially designed base frame.

• Exhaust emission (optional) conformance to EEC law EG - RL 91 / 542. EEC and EPA

Standards




3. DETAILED DESCRIPTION A. Engine The Engine used in the Air Start Unit is a DEUTZ make and Model BF 6M 1015 C rated for Gross

power output of 286 kW @ 2100 rpm.

Kindly refer the Engine Manual provided separately

MAJOR COMPONENT LOCATIONS (FRONT VIEW)

OIL FILTER




MAJOR COMPONENT LOCATIONS (REAR VIEW)

SAE HOUSING

FLY WHEEL

TURBO CHARGER




AIR INLET SYSTEM (TOP VIEW)

EXHAUST TURBO

CHARGER




B. Compressor

The Compressor used in the Air Start Unit is a GHH - RAND make and Model CD-26S with a flow

rate of 160 PPM @ 2100 rpm. This is a Screw type Compressor for absolutely oil - free compression of

atmospheric air.

Kindly refer the Compressor Manual provided separately in CHAPTER V

DELIVERY POINT

SUCTION POINT




C. Towable Base Frame

The Tow able Base frame is a fabricated structure consisting of standard commercial sections like

channels, angles etc., incorporating solid rubber tyres and a turntable arrangement with tow bar for

towing the equipment by means of a towing vehicle. Four stabilized jacks with adjustable screw rods

and anti-vibration mounts are provided in the base frame for placing the unit in a particular place.

All the major components like

• Engine

• Screw compressor

• Radiator

• Air filters

• Oil coolers

• Oil filter

• Diesel filter

• Diesel tank

• Pneumatic tank

• Control panel

• Batteries

• By-pass valve

• Engine silencer

• By-pass Silencer

Auxiliary compressors are assembled on to the base frame at accessible locations for any routine

checks and maintenance.


CHAPTER I / I

PAGE 7


4. G.A Drawing




INTERNAL LAYOUT - MAJOR COMPONENTS

LEFT SIDE VIEW

FRONT VIEW

1 5432 7

11

6

7

9

28

27 8

29

30

20




OBS TR UCTION

LAMP S WITCHES

F USE

HOOTER CONTROL

S TOP C HECK

ENGINE

HOS E 3

OUTPUT S ELECTION

HOSE 1 HOS E 2

ON ON

C AB IN

ON

OP EN

HOOTER

OPEN

OP TIONAL

OPEN

DIAGNOSIS

OP EN

SYSTEM OK

ON

PANEL

RIGHT SIDE VIEW

REAR SIDE VIEW

14 1816

19201511 1710 32

26

24

26

18

23

1922

25

1312




TOP VIEW

30

21

31

21




LIST OF COMPONENTS

1. ENGINE.

2. ENGINE AIR FILTER.

3. SCREW COMPRESSOR.

4. COMPRESSOR AIR FILTER.

5. RADIATOR.

6. BYPASS VALVE ASSEMBLY.

7. MUFFLER SILENCER.

8. MUFFLER SILENCER PIPE LINE.

9. ENGINE SILENCER.

10. ENGINE SILENCER PIPE LINE.

11. TOW BAR ASSEMBLY.

12. AIR RESERVOIR TANK.

13. DRYER.

14. CONTROL PANEL.

15. PNEUMATIC PANEL.

16. EMR PLATE.

17. PNEUMATIC PANEL & CONTROL PANEL MAIN FRAME.

18. OIL COOLER.

19. OIL COOLER MAIN FRAME.

20. FIFTH WHEEL ASSEMBLY.

21. REAR WHEEL ASSEMBLY.




22. OUTPUT HOSE ASSEMBLY.

23. HOSE STOWAGE.

24. BATTERY.

25. BATTERY TRAY.

26. LIFTING HOOK.

27. TOWING HOOK.

28. ENGINE SILENCER CLAMP.

29. MUFFLER SILENCER CLAMP.

30. SILENCER FRAME.

31. RADIATOR FAN.

32. FUEL TANK.




A. Canopy This is a metallic enclosure to cover the components against any kind of environments and to

withstand any external damages to protect the unit. This enclosure is also insulated for thermal and

sound absorption resulting in reduction of heat & sound on the canopy walls.

The canopy is fabricated out of MS sheet metal profiles and is mounted on to the base frame through

fasteners. The entire canopy is detachable from the base frame to have full access during major

overhaul of the equipment.

The canopy has hinged doors on the sides to facilitate access to the routine checks and maintenance.

The top doors are bolted to the canopy top member and it can be dismantled when in need. Cross

channels are provided inside the canopy to collect the water.

B. Fuel Tank

The Fuel tank is fabricated out of SS sheet metal profiles and is mounted on to the base frame through

fasteners. Two individual tanks are fabricated and interconnected to form the total capacity of the tank

is 285 liters (75 gallons).

Provisions are available for manual fuel filling, suction port, return line port, dipstick, breather and

fuel float. An external overfill port is provided for physical identification.

To take care of the raise in fuel temperature an additional fuel cooler has been included in fuel tank

assembly for the fuel return line circuit. Control circuits are designed such that the cooler is made to

ON when any one of the pressure modes (AST / ACP) is selected.




CONTROL PANEL AND PNEUMATIC PANEL

DOOR

RADIATOR ANDENGINE SIDE DOOR

`

ENGINE AIR FILTER CUTOUT TOP DOOR

RADIATOR CUTOUT TOP DOOR




OIL COOLER SIDE DOOR

SILENCER SIDE FRONT DOOR




C. Coupling of Engine & Compressor The Engine and the Compressor is coupled directly by means of a flexible coupling. The flywheel end

of the engine has the male part of the coupling and the compressor shaft has the female part of the

coupling with rubber pads. These rubber pads are provided for achieving flexibility. A fabricated

housing is provided to interconnect the engine flywheel housing and the compressor flange to avoid

any possibility of misalignment.

The Engine & Compressor Coupling drawing shown below illustrates the assembly, for easy

identification.

ENGINE & COMPRESSOR COUPLING DETAILS




5. Controls, Monitoring and Protection

This section list out the control system parameters, monitoring the Engine &Compressor parameters

and other protection Indicators.

5A. AVAILABLE CONTROLS i. Control Panel

DISPLAY FUNCTION NORMAL VALUES

Engine RPM Engine Speed Idle – 1300

Full Speed – 2100

Mode AST – IDLE - ACP Idle – No load mode

Air Pressure Output Air Pressure 0 - 10 PSIg

ii. Relay Module

LAMPS INDICATION COLOUR

Hose 1 selection When Air output hose 1 on / off

ball valve selected Green colour

Stop Engine lamp When Engine is stopped Red colour

Check Engine lamp When there is any warning Yellow colour

iii. Pneumatic Panel

GAUGES FUNCTION NORMAL VALUES

Regulator Pr. Gauge Regulation Tank Pressure 40 - 70 PSI

E-P output air Pr. Gauge Control Air 0 – 30 PSI

Tank Pr. Gauge Pneumatic tank pressure 6 – 10 bar

Pressure – Comp. Lube oil Comp. Lube oil pressure 1 – 3 bar




5B. WARNING INDICATIONS IN CONTROL PANEL DISPLAY

On Healthy condition Ready to start

Engine lube oil pressure low LOW E.OIL PR

Engine coolant temperature high HI.COOL.TEMP

Coolant level low LOW COOLANT

Engine speed Low (RPM) UNDER SPEED

Compressor lube oil pressure low COMP. LLOP

Compressor lube oil temperature high COMP. HOT

Output Discharge Air temperature high HIGH DT

If Regulation pressure is low in Idle mode REG LOW PRE

If Regulation pressure is low and AST/ACP applied

Reg pressure low

Change to IDLE

If P-I pressure signal lost /input wire open Pressure Signal

Lost, Check P-I

If Engine RPM Lost/input wire open RPM Lost

If EMR Communication Failure EMR Connection Failed

If unit does not cranks Crank Failed

Reset & Try

Engine cranks but no RPM input available OUTPUT: 00.0 PSIg

Check RPM Input

Fuel level low LOW FUEL

If Engine air filter clogged E.AF CLOG

If Compressor air filter clogged COMP.AF CLOG




5C. PROTECTIONS IN THE EQUIPMENT

The abnormal operating conditions described in Chapter1- Section 2 - ASU Protection System and set

limits will cause automatic engine shut down*.

Any rectification for the faults should be checked in accordance with the trouble-shooting chart

provided in CHAPTER II / II - ASU Trouble Shooting Procedures & Techniques

*Note: No Protections will trip the Engine in AST mode contact is kept in close condition. This interlock is provided to avoid Hot Start of the Aircraft Engine.

PROTECTIONS FOR COMPRESSOR

The Compressor is protected from High pressure by incorporating two spring loaded Safety valves

mounted on the output discharge line.




6. SPECIFICATIONS AND CAPABILITY Model : ASU 160

Unit capacity : 160 PPM

Discharge Pressure : 40 PSIG at AST mode

: 30 PSIG at ACP mode

Discharge Temperature : 200 Deg C

Regulation : Microcontroller base System & Bypass setup

Fuel tank capacity : 285 ltrs ( 75 Gal )

Front Wheel track : 585 mm ( 23”)

Rear Wheel track : 1510 mm ( 59”)

Wheel Base : 2900mm (114.2”)

Towing speed : 20 kmph

Towing angle : 160 Deg

Tyre : Solid cushion tyre

Length (Tow bar folded condition) : 4475 mm (176.2”)

Length (Tow bar unfolded condition) : 5610 mm (220.9”)

Width : 1920 mm (75.6”)

Height : 2250mm ( 88.6”)

Weight : 4400 kgs (approx.)

PRIMEMOVER DIESEL ENGINE

Make : Deutz

Model : BF 6M 1015 C

Gross power kW / BHP @ rpm : 286kW @ 2100 RPM (INT DUTY)

No of cylinders : 6

Aspiration : Turbocharged & After cooled

After cooling system : 1 - Pump 2 - Loop

Displacement : 14.0 ltr ( 855 cu.in )

Bore : 132 mm ( 5.2 in )




Stroke : 145 mm ( 5.7 in )

Compression ratio : 17 : 1

Firing order : 1 - 6 - 3 - 5 - 2 - 4

Crankshaft rotation (viewed from front) : Clockwise

Emission control : ETC

Fuel consumption : 220 g / kW -HR

Oil Pan capacity (high – low) : 34-26 liters

Coolant Capacity : 17 liters

Weight with radiator ( dry ) : 1050 kgs

Engine Speed : 2100 1/min

Voltage : 24V DC

Kindly refer the Engine Manual provided in chapter VI - Manufacturer Appendix

COMPRESSOR

SCREW COMPRESSOR FOR AIR START

Make : GHH - RAND

Model : CD - 26S

Gear ratio : 4.038

Screw compressor flow rate : 1633 cfm

Air quality : Oil free Dry

By-pass valve setting : Automatic (As per demand)

Safety Valve setting : 60 PSIg

Shutoff Valve type : Butterfly valve

Shutoff Valve actuation : Manual

Air hose length : 30’

Discharge temperature : 200 Deg C

Weight : 750 kgs




Kindly refer the Compressor Manual provided in chapter VI - Manufacturer Appendix

ELECTRICAL SYSTEM

Batteries : 2 x 12V - 150 AH

Charging Alternator Make : Detuz

Charging Alternator : 55Amps

COMPRESSOR LUBRICATING SYSTEM

Lube oil capacity : 40 ltrs

Lube oil grade : ISO VG 46 ULTRA LUBE

Oil cooler Make : AKG Thermotechnik International

Oil cooler Part No : 5203.202.0000

Max. internal pressure : 26 Bar

Max Oil temperature : 110 Deg C

Volume : 2.9 ltrs

Fan rpm : 2950

Fan voltage : 24 V DC

Quantity : 1 Nos

Weight : 23 kgs

SAFETY RELIEF VALVE

Make : SPENCE

Model : 0042A-JHA

Type : Spring loaded

Set Pressure : 60 PSIg

Quantity : 2 Nos

Max flow handling capacity : 1586 SCFM

Weight : 8 kgs x 2




ENGINE SILENCER

Make : MAK

Type : Residential

Quantity : 1 No.

BYPASS SILENCER

Make : MAK

Type : Residential

Quantity : 1 No.

Temperature : 200°C ( 392 F)

Pressure : 40 PSIg

BY PASS VALVE

Make : MAK

Control Range : 90 - 400 PPM

Valve Type : Slotted pipe

Quantity : 1 No

Weight/unit : 61 kgs

ACTUATOR

Make : BELLOFRAM

Model : SS-24-F-BP-HFM

Type : Spring return

Stroke : 132 mm ( 5.20” )

Cylinder dia : 140 mm ( 5.51” )

Quantity : 1 No

Weight/unit c : 10 kgs




ACTUATOR SOLENOID

Make : ASCO

Model : WT8551A001MS

Ratings : 24 VDC

Function : 5/2

Quantity : 1 Nos

LIMIT SWITCH

Make : STONEL

Model : QZM2VE2R

Mounting kit Part No. : XRPXS025

Quantity : 1 Nos

QUICK EXHAUST SOLENOID & COIL

Make : FESTO

Model : MN1H-2-3/8-MS

Coil Model : MSN1G-24VDC-OD

Ratings : 24 VDC

Quantity : Each 1 Nos PNEUMATIC PANEL COMPONENTS PRESSURE SWITCH

Make : DANFOSS

Model : KP135

Part no : 060-121766

Quantity : 2 Nos




E-P FILTER CUM REGULATOR

Make : FESTO

Model : LFR-1/4-D-MINI-A

Part no. : 159635

Quantity : 1 Nos

P-I INPUT FILTER

Make : FESTO

Model : LF-1/4-D-MINI-A

Part no. : 159617

Quantity : 1 Nos

E-P TRANSDUCER

Make : CONTROL AIR

Model : 900-CIA

Quantity : 1 Nos

P-I TRANSDUCER

Make : BELLOFRAM

Model : 964-501-001

Quantity : 1 Nos

COMPRESSOR OILPRESSURE GAUGE

Make : WIKA

Model : 0-4 Bar

Quantity : 1 Nos




PNEUMATIC TANK PRESSURE GAUGE

Make : WIKA

Model : 0-10 Bar

Quantity : 1 Nos

CONTROL PANEL COMPONENTS: STARTING KEY

Make : TIGER

Model : ACC-BAT- IGN-ST

Part No. : 429 2483

Quantity : 1 Nos

EMERGENCY STOP

Make : IDEC

Model : Normally Closed

Part No. : AVW402ERP

Quantity : 1 Nos

RELAYS

Make : FINDER

Model : 4 Changeover

Ratings : 24V DC – 7A

Part no. : 55.34.9.024.0074

Quantity : 6 Nos




TIMER RELAY

Make : FINDER

Model : 4 Change over

Ratings : 24V DC

Part no : 85.04.0.024.0.000

Quantity : 1 Nos

STARTING & COOLER FAN RELAYS

Make : O/E/N

Model : Single change over

Ratings : 24 VDC / 30A

Part No. : 531-1A-24-T-1

Quantity : 2 Nos.

RESETTABLE FUSE

Make : TYCO ELECTRONICS

Model : W58-XB1A4A-5, 15 & 30

Ratings : 5, 15 & 30Amps

Quantity : Each 2 Nos & 1 Nos

HOSE SELECTION SWITCHES

Make : OTTO

Model : T7-231B5 / ON-ON

Quantity : 3 Nos

MODE SELECTOR SWITCH

Make : OTTO

Model : T7-231F5 / ON-OFF-ON

Quantity : 1 Nos




LAMP SWITCHES

Make : OTTO

Model : T7-231A5 / ON-OFF

Quantity : 3 Nos

ALARM & OPTIONAL SWITCH

Make : OTTO

Model : T7-231A5 / ON-OFF

Quantity : Each 1 Nos

DIAGONSIS & BYPASS SWITCH

Make : OTTO

Model : T7-231E5 / Spring Return

Quantity : Each 1 Nos

HOSE INDICATION LAMP

Make : IDEC

Model : Green colour / 24 VDC

Part No. : AL6M-P4G

Quantity : 3 Nos

ENGINE STOP LAMP

Make : IDEC

Model : Red colour / 24 VDC

Part No. : AL6M-P4R

Quantity : 1 Nos




ENGINE CHECK LAMP

Make : IDEC

Model : Yellow colour / 24 VDC

Part No. : AL6M-P4Y

Quantity : 1 Nos

SYSTEM OK & AIR ON LAMP

Make : IDEC

Model : Green colour / 24 VDC

Part No. : AL6M-P4G

Quantity : each 1 Nos

10 PIN ALLIED CONNECTOR

Make : ALLIED ELECTRONICS CORPORATION

Model / Type : Female Connector / Special - Lock Type

Part No. : MG 00F 18-1S

Quantity : 1 Nos

35 PIN ALLIED CONNECTOR

Make : ALLIED ELECTRONICS CORPORATION

Model / Type : Female Connector / Special - Lock Type

Part No. : MG 00F28-15S

Quantity : 1 Nos

PANEL LOCK

Make : DHARSAN

Model : DMCL-4-F

Quantity : 2 Nos




SENSORS CHARGING AMMETER

Make : MURPHY

Model : -60-0+60 AMPS

Part No. : EGS21

Quantity : 1 Nos

FUEL FLOAT

Make : MURPHY

Model : ES2F

Part No. : 05-70-5668

Quantity : 1 Nos

COMPRESSOR OIL PRESSURE SENSOR

Make : MURPHY

Model : ESP-100

Quantity : 1 Nos

COMPRESSOR OIL TEMPERATURE SENSOR

Make : DETRIV. INSTRUMENTS

Model : PT-1000

Quantity : 1 Nos

OUTPUT AIR TEMPERATURE SENSOR

Make : DETRIV. INSTRUMENTS

Model : PT-1000

Quantity : 1 Nos




COMPRESSOR AIR FILTER CLOG INDICATOR

Make : MANN

Model / Part no. : 50 mBar / 3900062959

Quantity : 1 Nos HOSE COUPLING ADAPTOR SENSOR

Make : OMRON

Model : Proximity Switch

Part No. : E2A-M18KN16-M1-C1

Quantity : 1 Nos

PNEUMATIC TANK COMPONENTS PNEUMATIC TANK

Make : FESTO

Model / Part no. : CRVZ-20

Quantity : 1 Nos AIR FILTER

Make : SMC

Model / Part no. : I-AF40-04

Quantity : 1 Nos MIST SEPEARTOR

Make : SMC

Model / Part no. : AFM40-04

Quantity : 1 Nos




AUTODRAIN VALVE

Make : SMC

Model / Part no. : 1-AD402-04

Quantity : 1 Nos

AIR DRYER INSULATION KIT

Make : TVS

Model : M1K26/1

Quantity : 1 Nos

RELIEF VALVE

Make : BENDIX

Model / Part no. : VAR VALVE_SAFTEY / 284142N

Quantity : 1 Nos

SAFTEY COMPONENTS BATTERY ISOLATOR

Make : CURTIS

Model : ED-125

Quantity : 1 Nos PILOT PROCESS VALVE

Make : SMC

Model / Part no. : 1-VND202D-15A-B

Quantity : 1 Nos




LAMPS CORNER LAMP

Make : VITRONICS

Model : Amber Colour -24 V

Quantity : 6 Nos

CABIN & PANEL LAMP

Make : VITRONICS

Model : White Colour -24 V

Type : Rectangle

Quantity : 4 Nos

OBSTRUCTION LAMP

Make : ALTOS

Model : Orange Colour -24 V

Quantity : 1 Nos


CHAPTER I / II


CHAPTER I SECTION II

ELECTRONICS AND ELECTRICAL MODULE


CHAPTER I / II PAGE 1


DESCRIPTION AND OPERATION 1. Pre-Commissioning Check When preparing to start the equipment, which has been in storage, for a long period, perform all the

checks listed in Engine maintenance procedure at Daily Intervals in the Operation and Maintenance

manual.

INSPECTION

Visually inspect if any components have been damaged during transit.

WARNING

If any damage is found in a component do not attempt to start the equipment unless the damage is rectified or the component is replaced.

CAUTION

Do not attempt to start the equipment unless all the fasteners are checked for Proper tightness. Note: Prolonged cranking of the starting motor can result in damage to the starter.




2. Do’s & Don’t s

Do’s

Only authorized personal should handle the system.

Check for the fuel availability in the tank before starting the system in the beginning of the day.

Engine oil level, coolant level, Compressor oil level should be checked before the 1st start of the

unit on that day.

Free passage at Air Intake, Radiator fan output to be ensured.

Engine should be allowed to run at IDLE speed in no load condition before shutting down.

In case of deficiency in the output parameters, only authorized person should go through the

trouble-shooting chart for any adjustments.

Any adjustment in the system should be done with the help of the Manual and detailed circuit

diagrams.

Disconnect the batteries if there is any welding to be carried out on the unit.

Don’ts:

The unit should not be towed in running condition.

Never open the output valve before the unit is cranked and the output parameters are within

acceptable limits.

Never bypass any protection system for starting the unit, without rectifying the fault.

Never Shutoff the unit with load.

Never fill fuel or Coolant or Oil while engine in running condition.




3. OPERATING INSTRUCTIONS

A. Starting of ASU Ensure that the mode selector switch is in “IDLE” position.

Ensure that the output hose selection switches (Hose1, Hose2 & Hose3) are in “OFF” position.

Ensure that the Air output hose ball valves (Hose1, Hose2 & Hose3) are in “CLOSE” position.

Ensure that the output hoses (Hose1, Hose2 & Hose3) are in Hose stowage coupling adaptor.

Switch “ON” the Battery Isolator.

Turn the Starting key from “ OFF ” position to “RUN” position and ensure the system is “READY

TO START”.

Check for the Battery Voltage & Fuel availability in the LCD display.

Turn the Starting key from “ RUN ” position to “START” position and Release once the Engine

gets Cranked. Do not keep cranking more than 5 seconds.

Let the Engine to run at the idle speed for a minimum of three minutes. The Unit is now Ready for “AST” or “ACP” operation.

INSPECTION

Visually inspect whether all the parameters are within limit and all the gauges are functioning.

WARNING

Do not open the Output valve unless all the parameters are under control.

CAUTION Before working on or near the unit remove loose items of clothing or Jewels that could get caught in a moving part of the engine and cause personal Injury. Safety glasses and hearing protection should also be worn.




B. Jet Start Operation (AST mode)

Uncoil the output hose (s) as required, connect to the Aircraft coupling & check for proper connection.

Check for any twist in the Hose(s), if so rectify the same.

Ensure that the Hose selection switches (Hose1, Hose2 & Hose3) is in “OFF” position.

Change the mode selector switch from “IDLE” mode to “AST” mode.

Check whether all output parameters are within acceptable limits.

For air bleeding, manually open the corresponding Air output hose ball valve (s) and observe the hose selected indication lamp provided in the operating panel.

Change the selected hose switches (Hose1, Hose2 & Hose3) to “ON” position.

Await further instructions from the crew.

C. Air Conditioning Operation (ACP mode)

Uncoil the output hose (s) as required, connect to the Aircraft coupling & check for proper connection.

Check for any twist in the Hoses, if so rectifies the same.

Ensure that the Hose selection switches (Hose1, Hose2 & Hose3) are in “OFF” position.

Change the mode selector switch from “IDLE” mode to “ACP” mode.

Check whether all output parameters are within acceptable limits.

For air bleeding, manually open the corresponding Air output hose ball valve (s) and observe the hose selected indication lamp provided in the operating panel.

Change the selected hose switches (Hose1, Hose2 & Hose3) to “ON” position.

Await further instructions from the crew.




INSPECTION

Visually inspect whether the “AIR ON” lamp glows when the output valve is opened for Air bleeding.

WARNING Always be cautious whenever the operator is near the output valve, since in the event of any coupling failure, contact with high pressure / high temperature could be dangerous.

CAUTION

Note: No Protections will trip the Engine in Air start mode. This Interlock is provided to avoid Hot Start of the Aircraft Engine. Operator’s attention is required during this situation to save the system getting damaged.




D. ASU Shut down Procedures

After the completion of one Engine start, the following sequences of procedures are to be carried out to

accomplish “ASU Shut down”.

• Change the mode selector switch from “AST or ACP” to “IDLE” mode.

• Change the hose selection switches (Hose1, Hose2 & Hose3) to “OFF” position.

• Change the Air output hose ball valves (Hose1, Hose2 & Hose3) to “CLOSE” position.

• Ensure that the output hose gets De-pressurized.

• Disconnect the output hoses and stow in the hose stowage coupling adaptor.

• Turn the starting key from “RUN” position to “OFF” position.

• Allow the unit to run at the idle speed for the predetermined time.

• Switch “OFF” the Battery isolator.

In case of any Emergency Shut off, hit the “EMERGENCY OFF” mushroom actuator on the ASU

Control panel.

Perform the After Operation Procedures of the daily services (see Chapter on Maintenance II / 1)

INSPECTION Visually inspect all the assemblies are in good condition.

WARNING Do not attempt to restart the Unit without rectifying the fault. Kindly refer CHAPTER II / II in this manual for Trouble shooting and rectification




4. General Description Principle of Operation

The ASU 160 PPM air compressor package consists of various components and assemblies. The

Diesel Engine acts as a prime mover to rotate the secondary Screw Compressor. Other major

components / assemblies are as follows,

Compressor air suction filter assembly

Compressor oil tank and output assembly

Output air Pressure Regulating assembly

Electronic control panel assembly

Pneumatic Panel assembly

Compressor Oil coolers assembly

Output Header / Hose assembly

Engine Fuel tank assembly

Engine air filter assembly and

Bye-pass assembly.

Once the engine gets cranked and started, it rotates the coupled compressor to deliver the output flow

irrespective of the load. At idle (no load) condition the engine run at 1300 RPM (set speed) and the

output air thus produced is let out to the atmosphere through bye-pass muffler. This idle mode has

been designed to run the engine with minimum load all the time except when connecting the loads

(ACP – 30 Psig or AST – 40 Psig line pressure). This feature increases the overall life of the diesel

engine and also reduces the fuel cost to the maximum.

The Compressor air suction filter assembly consists of specially designed double stage (noise

reduction) industrial suction filter fixed inside a metallic hood to prevent from any external damages. It

is directly connected to the Compressor’s suction port through 10” MS pipe and flanges. It sucks the

atmospheric air at a pressure of 14.7 PSIg and supplies it to the Compressor, where it gets compressed

by means of dry screw rods present inside the compression chamber. Thus compressed Oil free, dry air




is regulated to the required pressure of 40 PSIg and can bleed through the hose provided in the unit to

handle the entire 160-PPM (maximum) flow rate.

The Compressor oil tank forms the integrated part of the compressor and consists of

• Filling point,

• Sight glass,

• Injection points,

• Return line filter

An integrated oil pump lubricates the Compressor. A pipeline fitted with a ball valve provides

compressor oil drain. The lube oil is taken from the tank by the pump and passes through 24 V DC

operated oil cooler. The oil cooler is mounted separately and it controlled by power relay that is fixed

on the same for easy monitoring/accessing and troubleshooting. The electrical connections are wired

such a way that after the engine gets cranked, at the time oil cooler will be in running condition (Oil

cooler-1). The PT-1000 (Temperature sensor) is used to sense the compressor oil temperature and

mounted at the outlet of the oil cooler. The cooler is configured such a way that they suck the

atmospheric air, inline with the Engine radiator fan and thus maintain the compressor lube oil

temperature under control. The oil from the cooler is passed to the injection points and returns back to

the oil tank.

The Output air Pressure Regulation is achieved by means of Electronic control panel, Pneumatic panel

and Pressure Regulating valve assembly.

The ECP - Electronic control panel controls the entire system with the help of a powerful Micro

Controller based PID Closed loop algorithm. It takes care of all monitoring, warning, indication,

protection circuits and fine regulation.




Kindly refer page no: 13 for the completed description of the electronic control panel assembly.

Electro-Pneumatic panel is constructed with the help of the following components,

• P-I (Pressure to Current) Transducer,

• E-P (Voltage to Pressure) Transducer,

• Pneumatic gauges,

• Pressure Switch and Gauges

The P-I Transducer with very high response time continuously senses the output air pressure in the

output header and gives the signal to the ECP. This pressure signal is compared with the set values of

AST / ACP modes and a corrective signal is applied to control the E-P Transducer there by

venting/blocking the excess air to the atmosphere via bypass muffler and to vary the electronic demand

throttle to nullify the error and achieve the required flow rate.

The Pilot pneumatic pressure used to control the pressure-regulating valve is generated from an engine

mounted auxiliary compressor. The output air from the auxiliary compressor is collected in a small

storage (Pneumatic) tank and then passes through air Dryer (along with un-loader) assembly, to

produce the moisture free dry air.

A 40-micron filter cum regulator with an auto drain valve, in the pneumatic panel is used to filter the

dried air and regulate the same before supplying to the E-P Transducer. The E-P input pressure is to be

normally set at 40 – 70 Psig. The Pressure Switch (PS) mounted at the output of the regulator, senses

the regulated Pilot air pressure and sends the signal to the Control Panel. When there is no pressure

buildup in the tank, the electronic control panel gives a warning signal as “ Regulation pressure low”.

And during such condition, if any mode (AST / ACP) is selected, the intelligent system will sense the

situation and gives another warning message as “Regulation pressure low – Change to IDLE”. This

safety interlock has been incorporated to make sure that there will not be any control/regulation taking

place in order to protect jet engine from hot start.




Kindly refer page no: 20 for the completed description of the Electro-pneumatic panel assembly.

The pressure-regulating system has been provided to regulate the output pressure as per the

requirement (Type of Aircrafts say, narrow body, wide body, jets, jumbo jets, etc.). It consist of

1. Pneumatic actuator,

2. Bye-pass valve,

3. Shut off valve,

4. Quick exhaust solenoid,

The output of the E-P transducer is supplied to the pneumatic cylinder to control the movement of the

pressure-regulating valve and there by controlling the output flow. A quick exhaust solenoid valve is

mounted at the top of the pneumatic cylinder for quick release of pressure during excess pressure

build-up (when line pressure exceeds 47.0 Psig).

Two Safety relief valves set @ 60 PSIg are mounted at the compressor output discharge line to let the

entire air to the atmosphere, in case of any excess pressure build-up and there by avoiding any physical

damage. A High Discharge Temperature sensor (HDT) mounted at the discharge line will sense the

output air temperature and sends to the control and the panel trips the engine when it exceeds the set

value (250 Deg C and above)

Two gauges are provided below the Pneumatic panel, to indicate/monitor Compressor oil pressure and

Pneumatic tank pressure.




5. Pneumatic Block Diagram




6. Compressor Lubrication circuit diagram

1.COMPRESSOR

2.OIL COOLER

3.PRESSURE GAUGE

4.COMPRESSOR OIL TEMPERATURE SENSOR

2

4

1

3




7. ASU Panel Descriptions I. Control Panel Module

The ASU Control Panel takes care of protection, monitoring, electro pneumatic control circuits, EMR

fault diagnosis, output hose selection and control operations of the MAK ASU 160PPM. This module

comprises of the two printed circuit boards and the following Panel components.

• ASU Controller Card (CPU) – MAK PCB No.472-A

• LCD Display Card – MAK PCB No. 475

• Digital high intensity LCD – 2 X 16

• Starting key – Tiger key

• Mode Selector switch (AST – IDLE – ACP)

• Air ON indicating lamp - Green

• Manual Re-settable fuse – 15 Amps

• Emergency push button switch

• Key board

• Indication Lamps

• Switches

• Re-settable fuse

• Electrical Relays

ASU Controller Card:

ASU controller board marked as MAK PCB no: 472A (Printed circuit board) is a four-layered board

compiled to NEMA FR4 standard forms the heart of the MAK ASU 160 PPM. It uses the powerful

micro controller based PID algorithm that senses, monitors and controls all Electronic, Electrical,

Electro-Mechanical & Electro-Pneumatic controls for Protection and Pressure Regulation.

LCD Display Card:

LCD display board marked as MAK Pcb no: 475 used for interfacing 2 nos of 16x2 High Intensity

LCD module with the ASU Controller card by through miniature FRC cable.




LCD Module:

Two 16x2 high intensity LCD modules are used to display all the Output, Engine, Compressor and

other parameters, Warning messages as well as the Fault Indications of the ASU 160 PPM. They are

mounted on the LCD Display card. A clear transparent window has provided in the control panel to

monitor and prevent the LCD module from external damages.

Starting Key:

It is a four-position key (ACC – OFF – RUN – START) used for starting the Engine. In the 4th position

it is a spring return. The positions and their operations are listed below:

• ACC mode: All the accessories such as panel lamps, cabin lamps & obstruction lamps used in

the unit gets powered by keeping the starting key in this position.

• OFF mode: This mode is used to keep the starting key in OFF position; it disconnects the

electrical supply to the control panel. When the unit is not put into operation the starting key

should always be kept in this position to prevent the drainage of the batteries.

• RUN mode: By turning the Starting key from OFF position to RUN position all the systems,

gauges and transducers used in the unit gets energized. A Welcome message is displayed in the

LCD, followed by “Ready To Start” display on healthy condition.

• START mode: In this position the engine can be cranked if there is no fault exists. The supply

from this terminal has taken through starter interlock relay (for disabling engine cranking when

the engine is already running), engine fault RLEF (for disabling engine cranking if there is any

existing fault) and actuates starter relay RLS. This relay in turn actuates the starter solenoid

there by energizing starter motor.




Air ON Indication Lamp:

A green coloured LED lamp has provided in the ASU control panel for indicating the Air ON status on

selecting any mode (AST / ACP).

Re-settable Fuse:

A manual re-settable fuse of rating 15 Amperes has provided in the control panel to protect all

electronic circuits and components from any short circuit or unit/component failures.

Emergency shut OFF push button:

A red coloured mushroom head actuator has provided to shut down the engine in the emergency

conditions. This is a push to lock switch, which needs to be released before need next start.

Keyboard

Five soft touch keys with a system OK LED forms the keyboard. Each keys performs various special

functions that makes the operator task so easier. The functions of the keys are classified into normal

operation mode and programming / debugging mode. The programming mode is used for factory set

parameters only.

Normal mode operation:

1. Test key – No operation

2. Digit select key – No operation

3. Increment / Page up key – To move to next page display

4. Set / Menu key – This page is used to display ASU maintenance schedule.

5. Fault clear - Every fault that occurs are displayed on the LCD and gets latched, hence the

display remains the same even if the fault gets rectified. Clearing of the fault in the display can

be accomplished by pressing Fault Clear key.




Indication Lamps:

ASU module consists of six panel mountable LED lamps used for indicating various conditions.

• Output Hose selection – Hose1

Green coloured lamps are provided to indicate the hose selected status.

• Engine Diagnosis

Stop – Red coloured lamp to indicate engine stopped due to EMR protection.

Warning – Yellow coloured lamp to indicate the EMR warning status.

• System OK

A green coloured lamp is used to indicate the overall system performance. This lamp will be

illuminated on any healthy condition and will be flashing on any fault condition.

Switches:

Nine switches of different types are provided in the control panel to perform various functions such as

output hose selection, lamp on/off, Alarm on/off and engine EMR diagnosis (optional) etc.

Hose selection Switches – Hose1

For output air bleeding, three individual toggle switches (DPDT) for Hose1 to energize the actuator

solenoid and there by to actuate the pneumatic actuator fixed to the output butterfly valves.

Bypass Mode Selector Switch: It is a DPDT (Double Pole Double Through) spring return switch used

to select the bypass mode. In this mode used, when output hose adaptor sensor is failure.

Lamp Switches a) Panel Lamp Switch: This switch is used to power ON the Panel lamp fixed inside the Panel

compartment.

b) Cabin Lamp Switch: This switch is provided to power ON all the Cabin lamps fixed inside the

Unit at various locations. These lamps provide light all through out the unit for easy accessibility and

maintenance aspect.




c) Obstruction Lamp Switch: This switch is used to power ON the Amber coloured Obstruction lamp

fixed on the top of the unit. This is a 24V high intensity LED lamp with flashing light and can be

viewed at maximum angle even from a longer distance.

Alarm switch: It is a SPDT (Single Pole Double Through) switch used to switch ON /OFF the Hooter,

provided for giving Audio alarm indication during faulty condition

Diagnosis Switch (Optional): It is a DPDT (Double Pole Double Through) spring return switch used

to select the EMR fault diagnosis mode.

Optional Switch: A SPDT (Single Pole Double Through) switch is provided in the unit for any future

application.

Re-settable Fuse:

Two easy to operate manual re-settable type fuse of rating 15 Amperes capacity for all control circuits

and 5 Amperes fuse to control Alarm are mounted in the Relay module.

Re-settable Fuse – Charging ammeter:

Battery charging wire had taken through 30 Amps Re-settable fuse to protect the battery charging

circuit, which has placed, back to the charging ammeter.

Electrical Relays:

The ASU Relay module consists of eight-24V DC operated relays for various control actions. In which

six of them are 4 changeover rail mountable relays, one heavy-duty single changeover panel mountable

relay and a timer-based ON/OFF relay. For all the relays snubbers are provided for filtering and

protection aspects.

• RLEF: This relay is abbreviated as Engine Fault relay and gets energized only on healthy or NO

fault condition and remains in that state until any fault occurs in the system.




• RLST: This relay is known as Starting Interlock relay that energizes when the Engine is in OFF

state before cranking and gets de-energizes once the engine gets fired. Hence it prevents the engine

being engaged for the second time during running condition.

• RLER: This is an Engine run relay that energizes only when the Engine gets cranked and runs at

or above the rated idle speed and remains in that state until Engine gets stopped.

• RLQX: This relay is used for energizing the Quick-exhaust solenoid mounted on the top of the

Pneumatic cylinder to retract quickly when there is excess pressure build up (>47 Psig) in the

compressor output discharge pipe line and there by venting the air to atmosphere.

• RLS: This is a single changeover heavy-duty relay mounted vertically on the relay module. It is

used for energizing the Starter motor solenoid, only during the time of cranking. Thus it prevents

the starter being damaged.

• IDLE RUN TIMER RELAY: This is an OFF delay timer based relay with four changeover used

for idle run of the unit during shutdown periods. The unit will run at the rated idle speed of 1200

for the predetermined time interval and gets off.

• RLOVR: Abbreviated as auto shutdown override relay is provided in the relay module to override the

auto shutdown of the EMR during AST mode to prevent the hot start of the aircraft engine.

• RLFLT: Abbreviated as fault relay is provided in the relay module used to energize the 24V

vibrosonic Alarm on occurrence of any fault if the Alarm ON/OFF switch is kept in ON position.

USB Interface Card-PCB No: 477

This card marked as MAK Pcb no: 477 is a double sided board compiled to NEMA FR4 standard and

used to get the RS-232 data from the cpu card and provides in the high speed USB bus for data

logging, event capturing and remote diagnosis.




Integrated relay card – PCB no: 500

This card marked as Pcb no: 500 is a double sided board compiled to NEMA FR4 standard and used to

energize the actuator solenoid thro’ onboard relay and idle run of the ASU. Compiled to NEMA FR4

standard forms the heart of the MAK ASU 160 PPM. It uses the powerful micro controller based PID

algorithm that senses, monitors and controls all Electronic, Electrical, Electro-Mechanical & Electro-

Pneumatic controls for Protection and Pressure Regulation.

CONTROL PANEL




8. ELECTRO PNEUMATIC PANEL The electro-pneumatic panel consists of the following components,

• P-I Transducer

• Filter

• E-P Transducer

• Filter cum Regulator

• Pressure Switches

• Gauges

P-I TRANSDUCER

It is a two-wire electro-pneumatic transmitter designed for industrial field service. This instrument

converts a signal pressure input into a precise 4-20 mA output. This type uses a unique, temperature

compensated piezoresistive sensor suitable for gauge pressure measurement of non-corrosive liquids

and gases. The sensor has excellent dynamic response and is virtually insensitive to mounting

orientation and ordinary industrial vibration. The industrial standard 4-20 mA current loop is used to

represent 0-100 psig line pressure. This is transmitted to the electronic control system.

FILTER

This is a micro filter that filters the main compressor’s output air and passes it to the P – I Transducer.

The filtrations rate is 5 mic and features a centrifugal separator for water removal and has an auto

drain.

E-P TRANSDUCER

This is also an electro pneumatic transducer that reduces a supply pressure to a regulated output

pressure, which is directly proportional to a three-wire voltage input. This design incorporates closed

loop sensing of the output pressure to achieve excellent accuracy and vibration stability. It also

features a unique damping circuit, which can be adjusted to prevent overshoot and actuator ‘hunting’.

The industrial standard 0 – 5 Volt DC is used to convert 0 - 30 psig air pressure signal used to drive the

cylinder. The input voltage signal is conditioned to provide a normalized control signal directly




proportional to the desired pressure output. The input pilot pressure for this transducer is supplied from

a pneumatic tank by means of the Engine mounted auxiliary compressor. For proper operation of E-P

transducer regulator input is set between 40 - 70 psig.

FILTER CUM REGULATOR

This assembly consists of a micro filter, pressure regulator and a pressure gauge to indicate the

regulated pressure value. The pilot pressure for the E-P transducer is directly fed to this filter to get

filtrated. And by using the Regulator one can regulate the inlet pressure to the desired range of 40 – 70

PSIg. The filtrations rate is 5 mic and features a centrifugal separator for water removal and has an

automatic drain. A gauge of range 0 to 10 bar is mounted on the outlet port of the regulator to monitor

the output pressure.

PRESSURE SWITCH – Regulation pressure

A pressure Switch of range from 0 to 10 bar with adjustable set point is mounted at the outlet of the

regulator. It continuously monitors the inlet pressure applied to the E-P transducer and sends the low

signal to the control panel to check for regulation pilot pressure. And it is set @ 4 bar.

GAUGES

Three different types of pressure gauges are used in the pneumatic panel for various

monitoring/control actions.

• Regulator output gauge

This gauge is mounted at the outlet port of the filter cum regulator and used to determine the amount of

pilot pressure regulated to E-P transducer. It offers a higher accuracy class and has a Bar/PSI scale

with fine divisions. It is silicon free. In continuous operation gauges may only be loaded up to 3 / 4 of

their full-scale value.




• Pressure gauge – Pneumatic tank

This gauge is used to monitor the pressure at the pneumatic tank. It ranges from 0 to 10 bars. This

gauge is provided for easy trouble shooting when there is no pressure built up in the system. It offers a

higher accuracy class and has a Bar/PSI scale with fine divisions. It is silicon free and glycerin filled

one.

• Pressure gauge – Compressor lube oil

This gauge is provided for indicating the compressor lube oil pressure considering the oil coolers and

pump return aspects. It ranges from 0 to 4 bars. It offers a higher accuracy class and has a Bar/PSI

scale with fine divisions. It is silicon free and glycerin filled one.

PNEUMATIC PANEL




9. Electronic Pressure Control System This is a unique and sophisticated smart Embedded system, based on powerful high-speed micro

controller. This is the heart of the system, which controls and monitors all the functions. It accepts the

transducer input and various switch inputs to take care of all the output controls.

The signal from P-I transducer is taken and processed through a powerful PID algorithm to provide

control output. This control output is a voltage signal that varies from 0-5V, which is transmitted to the

E-P converter, to provide a pressure output of 0-30 psig. This pneumatic signal is used to drive the

cylinder to control the amount of air let to the atmosphere and thus regulates the output pressure.

Apart from pressure regulating valve position control the control system also provides a control output

to vary the engine speed from idle to full speed. Based on the load requirement (determined by Aircraft

type) automatically. This will enhance the fuel efficiency and wear and tear of the machine when the

system used for lower requirements.

This is one of the unique features of MAK ASU system. By employing this system, the fuel efficiency

is guaranteed since the engine is run at its optimum speed. For 160 PPM, idle speed is set at 1300 rpm

and full speed is 2100 rpm.

This smart system always watches for any abnormality in the system operation. If anything found, it

immediately takes the necessary corrective action.

In the case of any engine/compressor protection faults, the system automatically shuts the engine with

the fault indication on the LCD display. And if the mode selected is AST the system will continuous to

run and provides the respective Fault indication in the LCD display as well as by flashing the corner

for easy identification (normally all the corner lamps will be in on condition to indicate the running

condition of the unit). In addition to the visual alarm an audio alarm circuit is also included and can be

controlled by means of the Alarm on/off switch provided in the relay module.




10. Pressure Regulating System Whenever the pressure control and regulation is required, the control algorithm goes through the

following sequence.

i. System reads the line pressure.

ii. Compares the line pressure with the reference value based on mode.

iii. Based on the error, corrective signal is generated and issued

iv. The above given sequence is repeated continuously to achieve better stability at the output, i.e.,

the controller continuously tries to make the error zero

The Pressure regulating system is the combination of the following systems and components,

• Electronic Pressure Control System

• Regulating Cylinder

• Pressure Regulating (Bypass) Valve

• Quick Exhaust Solenoid

• Safety Valves

• Bypass muffler

(Refer component description for more details)

Electronic Control System

Kindly refer the above description of the electronic control system.

Regulating Cylinder

The regulating cylinder is basically a diaphragm based piston-operated system and acts as an actuator.

The pneumatic actuator is driven by the pressure signal from the E - P Transducer depending upon the

output discharge pressure signal.




Pressure Regulating Valve

By positioning the pressure-regulating valve at an appropriate position, the system regulates the output

discharge air pressure. In other words, depending on the requirement, certain amount of air is bypassed

by actuating the pressure-regulating valve, which is carried out by the pneumatic actuator. Hence it is

also called as Bypass valve assembly.

Quick Exhaust Solenoid

A normally open quick exhaust solenoid is provided at the inlet port of each pneumatic actuator. It is

used to quickly exhaust the excess pressure produced inside the cylinder, when an overshoot condition

arises in the compressor output discharge line. It is controlled by the ASU electronic control system.

Safety Valves:

The ASU 160 PPM is equipped with two safety valves of identical type to let out the total flow with

set pressure of 60 psig. If there is any excess pressure built occurs, these safety valves opens

immediately in order to let the air to the atmosphere and they’re by avoiding any physical damage.




11. Control System Display Parameters System Informative Information: Once the system is powered by switching on the starting key from OFF position to RUN position. A welcome message is displayed in the LCD as, On healthy condition (No fault status) this message is followed by the “READY TO START” display,

If the output Hose selection switches to control the output butterfly valves are kept in open position before cranking, the following warning message will be displayed and cranking of the Engine will not be allowed, 1. a) If one of the output Hose selection switches (Hose1) is kept in open position,

MAK Air Start Unit

Thanks for Choosing

Turn Hose Switch 1 To Close

EOP: 0.0 Bar ECT: 000 °C

System OK Ready to START





b) If one of the output Butterfly valves (Hose1) is kept in open position, Note: The above all warning messages will be displayed, if the Output butterfly valve(s) used to bleed control the discharge air are kept open by any means will be detected by the Control module and will not allow the operator to crank the unit. This interlock has been included to incorporate personnel safety. If the operator by mistake leaves the ball valves to manually control the output hoses in Open position before starting the ASU. The ASU control panel automatically deducts the situation and displays a warning and disables starting of ASU. 1. If one of the output Hose selection ball valves (Hose1) is kept in open position, Similarly if any one of the pressure-regulating modes (ACP-30Psig / AST-40Psig) has been selected before starting the unit, the control system will not allow the operator to start the ASU and a warning message will be displayed as,

COP: 0.0 Bar COT: 000 °C

Close Ball valve 1 Then crank

FL: 80 % BV: 26 V

FL: 80 % BV: 26 V

Selected – AST Change to IDLE

Selected – ACP Change to IDLE

Close O/P Valve 1 Then Crank





When all the above safety precautions are taken care by the operator and the entire unit is on healthy condition and if the operator try to Crank, by turning the starting key from run mode to start mode. Crank Sense is applied to the Engine, and the “READY TO START” display changes to, And once the Engine gets cranked, the display changes to the operational/default display. This indicates the Output Discharge pressure in PSIG, RPM of the Prime mover and the current mode. Under any circumstances, if the Engine does not gets started then the following message will be displayed as, In case of any loose connection/disconnect of the EMR communication wiring harness has happened, but the Engine is in running condition, ECP detects this and displays the following warning message as,

5.0PSIG IDLE 198°C RPM LOST

Panel Temp :30°C H:00016:30

5.0PSIG IDLE 168°C RPM:1300

Date: 06/12/2007 Time: 10:10:09AM

Crank Failed Reset & Try

Date: 06/12/2007 Time: 10:10:09PM

Start Progress Please Wait

EOP: 0.0 bar ECT: 000 °C




In case of any loose connections/malfunction of the P-I transducer and its wiring, the following warning message is displayed as, Real time Clock Display:

Note: It displays the real time date, month, year and hour, minute, seconds with 12 / 24 hour format. On occurrence of any of the below described faults, Clear Fault message will be displayed in the first line and the respective Fault will be displayed on the second line of the first LCD. Unit will be Trip/Shut down in IDLE as well as ACP mode.

Where as it will continue to run on AST mode irrespective of the fault occurred.

Date: 06/12/2007 Time: 10:10:09AM

SYSTEM FAULT HIGH DT 1/1


Clear faults & TRY again

Pressure signal Lost, check P-I


40.0PSIG AST 198°C RPM:1300





If more than one fault occurs at a time the Faults will be toggled and listed as, If the output hose couplings are not kept in adaptor after cranking, ECP automatically detects this and displays will be toggled the following as, 1. If one of the output Hose couplings (Hose1) is not kept in adaptor, To control the Pressure regulating valve, a minimum amount of pilot pressure is required through out the entire test cycle. To ensure this healthy condition, the control panel continuously monitors the pneumatic tank pressure. In case of Low Regulation Pilot Pressure, a warning message will be displayed as, In any case when the regulation pressure is low and any mode is selected. All the control action carried out by the Control module will be immediately stopped and displays the mode selected along with a warning message as,

SYSTEM FAULT HI.COOL.TEMP 2/2




SYSTEM FAULT REG LOW PRE. 1/1


Place Aircraft Coupling 1


In Adaptor & Try





Note: If this is noticed, verify the tank pressure and its pipeline for any leakage or damage. If the outputs of the Hose selection switches are kept in open position during the hose couplings are inserted in adaptor after running, the following warning message will be displayed and opening of the hose will not be allowed,

1. If one of the output Hose selection switches (Hose1) is kept in open position, In Bypass Mode Display: When in any case if there occurs any error in the Communication between the Engine EMR and ASU control panel the following warning message will be toggled,

Reg pressure low Change to IDLE

EMR Comm. Fail Check EMR to CPU


SYSTEM FAULT REG LOW PRE. 1/1

Turn Hose Switch 1 To Close


Remove Coupling From Adaptor& Try


5.0PSI BYP IDLE 198°C RPM:1300



EMR Comm. Fail Connector




When you press and hold the menu key for 3 sec ASU maintenance information will be displayed as,

i) Normal Condition

ii) If any one of the maintenance days or engine hours elapsed the following message will be displayed,

Fuel Filter Rep. Due in 0250 Hrs

ASU maintenance Information

Fuel Filter Rep. Due in 0160 Days


E.Oil&Filter Rep. Due in 0250 Hrs


E.Oil&Filter Rep. Due in 0160 Days


Warning! Replace Fuel Filter

Due in 050 Hrs/ 0010 Days

Warning! Replace E.Oil&Filter





E.Air Filter Rep. Due in 1000 Hrs


E.Air Filter Rep. Due in 0365 Days

ASU maintenance Informatio

C.Oil&Filter Rep. Due in 0250 Hrs


Warning! Replace E.Air Filter


Warning! Replace C.Oil&Filter



C.Oil&Filter Rep. Due in 0160 Days




Use page up key to view next pages, if eleven pages completed then it returns to main page. If any key isn’t pressed for 5 sec LCD message returns to main page.


Check battery Weekly Once

Warning! Replace C.Air Filter



C.Air Filter Rep. Due in 1000 Hrs


C.Air Filter Rep. Due in 0365 Days




If the maintenance of the engine or compressor days or hours elapsed before cranking, the following warning message will be displayed and cranking of the Engine will be allowed, (press Fault clr key and then crank the unit.)



Warning! Replace E.Oil&Filter


Warning! Replace E.Air Filter


Warning! Replace C.Oil&Filter


Warning! Replace C.Air Filter





12.WARNING INDICATIONS IN CONTROL PANEL DISPLAY

On Healthy condition Ready to start

Engine lube oil pressure low LOW E.OIL PR

Engine coolant temperature high HI.COOL.TEMP

Engine speed low (RPM) Under speed UNDER SPEED

Engine cranks but no RPM input available RPM LOST

Engine air filter restriction is very high E. AF CLOG

Engine coolant level is low LOW COOLANT

Compressor lube oil pressure low COMP. LLOP

Compressor lube oil temperature high COMP. HOT

Output Discharge Air temperature high HIGH DT

If Regulation pressure is low in Idle mode REG LOW PRE

If Regulation pressure is low and AST/ACP

applied

Reg pressure low

Change to IDLE

Compressor air filter restriction is very high C. AF CLOG

When fuel level is less than 25% LOW FUEL

When fuel level is less than 10% Unit tripped with LOW FUEL

When fuel level is less than 20% (Before starting

the unit)

Cannot be cranked.




13. ASU Protection System and set limits ASU electronic control module protects the engine and compressor against the following faults

S# Fault Description Set Limits Action Delay Time Remarks

1 Engine Low Lube Oil Pressure < 2.5 bar Trip 2 Second

2 Engine High Coolant Temp. > 105 ° C Trip 2 Second

3 Under Speed < 800 rpm Trip 30Second

4 Engine Air filter clogging < 30 mbar Warning 2 Second

5 Low Compressor Oil Pressure < 1.0 bar Trip 2 Second

6 High Compressor Oil Temp. Above 80 ° C Trip 2 Second

7 High Discharge Temperature Above 250°C Trip 2 Second

8 Compressor Air filter clogging < 30 mbar Warning 2 Second

9 Regulation Pressure Low < 4 Bar Warning

10 Low Fuel Below 25% Corner lamp

flashing

Immediate

High Discharge Pressure protections

The system has been protected against the high discharge output pressure by the following two

different ways

1. Incorporating two safety valves, factory set at 60 psig at the output of the compressor to handle

the maximum flow (160 PPM) delivery.

2. By energizing the Quick exhaust solenoid fixed at the top of the pressure regulating pneumatic

cylinder @ 47 psig and there by letting out the excess air to the atmosphere through by-pass

muffler.




14. Special Interlocks a. Protection for Output Hose

The Engine cannot be cranked when the Output butterfly valve is kept open or the Hose selection

switch is in OPEN position. This is provided to prevent the impact of high pressure to the operators.

b. Protection for Output Hose selection ball valve

The Engine cannot be cranked if the Output hose selection ball valve is kept in OPEN position. This

protection interlock is provided for operator safety.

c. Protection for the Pressure selection modes

The Engine cannot be crank if any one of the pressure modes (AST / ACP) has been selected. This is

provided to prevent the impact of high pressure to the operators.

d. Protection for Output Hose adaptor

After mode selecting ACP/AST, first turn the ball valve open and then remove the hose adaptor from

the hose stowage and insert in the aircraft and then select the Hose 1 switch, if the above sequence

changes the output hose will not be selected.

e. Protection for Engine Cranking while Engine is running

The Engine cannot be cranked when it is running because the supply to the Starter Motor will be

disconnected. This is provided in order to protect the starter motor/flywheel teeth from damage.

Auto Inhibition of LLOP & LCOP

The Engine can be cranked by neglecting the E.LLOP & COMP.LLOP faults, since there will not be

any pressure when the engine as well as the compressor are in “ OFF ” state. This protection circuit

will take its part only after a preset time delay incorporated in the control panel. During starting. LLOP

and C.LLOP will be inhibited for 10 and 30 sec respectively to take care of low ambient conditions.




15. ELECTRICAL WIRING DIAGRAMS


CHAPTER I / II

PAGE 40


CONTROL PANEL WIRING MODULE I


CHAPTER I / II

PAGE 41


CONTROL PANEL WIRING MODULE II


CHAPTER I / II

PAGE 42


EMR WIRING DIAGRAM




16. PCB SCHEMATIC DIAGRAM

1

1

2

2

3

3

4

4

D D

C C

B B

A A

Title

Number RevisionSize

A4

Date: 20-Aug-07 Sheet of File: E:\Documents and Settings\..\Sheet1.sch Drawn By:

LCD

LCD

_RS

LC

D_E

N1

LC

D_E

N2

LC

DD

4L

CD

D5

LC

DD

6L

CD

D7

KEY

0

KEY

4K

EY5

KEY

6K

EY7

KEYS

LLOP_OHCT_O

H3AS_O

H1AS_OCHRGFAIL_OLOWCLNT_O

LCOP_O

FAULTS1

CAN

TX0R

TSTX

1RTS

TX2R

TSR

X0B

FR

X1B

F

RL

CF

1R

LFL

ASH

RLER

RLQ

XR

LST

RLE

F

RELAYS

AIN1AIN2

M_RX2M_TX2

RPMS

MO

SIM

ISO

SC

K

SPIE/P_CSCLK_O

VDD +5V

RSTVSTBY

XTALEXTAL

TEST

M_RX1M_TX1 O

NC

E-D

E_B

ON

CE-

TRST

_BO

NC

E-TM

SO

NC

E-TD

0O

NC

E-TD

1O

NC

E-T

CL

K

ONCE-PORT

RL

CF

2

CS

KB

_LED

H2AS_O

RL

FLT

RLACT1RLACT2RLACT3RLCOLD

AUX_RLY

CMPAFC_OE_AFC_OSV1CLOSESV2CLOSESV3CLOSEHOSE1_OHOSE2_OHOSE3_O

FAULTS2

CA

N_I

NT

RT

C_I

RQ

CS_

O

AST

_OA

CP_

O

INT

KEY

3

KEY

1K

EY2

PQB1

EN_ICOC

EN_INT

F_LED

F_L

ED

3F_

LE

D2

F_L

ED

1

1K

R89

1K

R90

1K

R91

VDD

F_LED

F_LED1

F_LED2

F_LED3

1K

R94

1K

R88

VDD

ICO

C20

ICO

C21

ICO

C22

INT5

INT6

INT7

15pFC19

15pFC20

1MR10

XTAL

EXTAL

VDD

VSTBY

0.1uF

C51

CHANNEL1CHANNEL2

BAT_I/P

FLA_CSTEMP_CSRTC_CSCAN_CSDAC1_CSDAC2_CSLED

LED1LED2

LED

LED1

LED2

BV1_SENBV2_SEN

BV3_SEN

IDLERUNRPLOW_OSV1OPENSV2OPENSV3OPEN

FAULTS3

EMRRPM_O

LCDBACKLITFLT_CLR_O

EMRRPM_O

ICO

C11

RST_O

RST_OCLK_O

TP

RSTTP7

TP

CLKTP8

PQB2PQB3

ADD1ADD0

MCORE CIRCUIT

SYSTEM STATUS LED

FAULT LED'S

13

2

DIO914

D4

13

2

DIO914

D5

SYS

GREEN

SYS

GREEN

FT1

RED

FT2

RED

FT3

RED

ECS-CSM-7-DN

XTAL1

8MHz-SMD

BR-2/3AE2SPBT1

MCOREASU-PRODUCTION

PCBNO:472A

CA1 11

VERSION1.1

ICO

C13

56

XTAL124

EXTAL125

RX

D2

68TX

D2

66

INT

379

INT

275

INT

172

INT

071

SCK

93M

ISO

91M

OS

I90

TXD

169

RX

D1

70

D24/PA010

D25/PA17

D26/PA25

D28/PA43 D27/PA34

D29/PA52

D30/PA61

D16/PB025

D17/PB122

D18/PB221

D19/PB320

D20/PB417

D21/PB516

D22/PB615

D23/PB712

ICO

C20

55

ICO

C21

54

ICO

C22

53

A11 / PG3 6A10 / PG2 11A9 / PG1 13A8 / PG0 14

A7 / PH7 23A6 / PH6 24A5 / PH5 26A4 / PH4 28A3 / PH3 29

A1 / PH1 49

A2 / PH2 47

A0 / PH0 50

A12 / PG4 139

A13 / PG5 137

A14 / PG6 136

A15 / PG7 134

A16

/ PF

013

2A

17 /

PF1

131

A18

/ PF

212

2A

19 /

PF3

121

A20

/ PF

411

9A

21 /

PF5

117

A22

/ PF

611

6

VD

D14

1V

DD

129

VD

D77

VD

D45

VD

D33

VD

D19

VD

D9

VD

D65

VD

DSY

N12

3

VD

DA

115

VD

DH

103

VD

DF

74

PQA0111

PQA1110

PQA3109

PQA4108

PQB0107

PQB1106

D31/PA7144

D8/

PC0

38

D9/

PC1

37

D10

/PC

236

D11

/PC

335

D12

/PC

434

D13

/PC

531

D14

/PC

630

D15

/PC

727

ICO

C12

57IC

OC

1158

ICO

C10

61

ICO

C23

52

INT

482

INT

584

INT

688

INT

789

R/W

/ P

F7

59

TEST 63VSTBY 92

TR

ST14

2

TC

LK

130

DE

143

CL

KO

UT

128

TMS

138

VPP

87

SS94

OE

95

VR

H11

3

VR

L11

2

PQB2105

PQB3104

MMC2107

RESET118

RSTOUT120

TC

0/PE

080

TC

1/PE

178

TC

2/PE

267

CSE

0/PE

362

CSE

1/PE

460

SHS/

PE7

97

TEA

/PE5

102

TA/P

E699

VSS

140

VSS

127

VSS

76V

SS64

VSS

44V

SS32

VSS

18V

SS8

VSS

SYN

126

VSS

A11

4V

SSF

73

CS1/PI1 85

CS2/PI2 83

CS3/PI3 81

CS0/PI0 86

EB0/PI4 101

EB1/PI5 100

EB2/PI6 98

EB3/PI7 96

TD

013

5T

D1

133

D0/

PD0

51

D1/

PD1

48

D2/

PD2

46

D3/

PD3

43

D4/

PD4

42

D5/

PD5

41

D6/

PD6

40

D7/

PD7

39

MMC2107CFCAG33

U8

DesignatorSheet2.sch










1

1

2

2

3

3

4

4

D D

C C

B B

A A

Title

Number RevisionSize

A4


HOLD1

VCC2

DU3

DU4

DU5

DU6

S7

Q8 W 9VSS 10DU 11DU 12DU 13DU 14D 15C 16

M25P32-VMF6G SO16 WIDE

U38

MISO

MOSISCK

W

HOLD0.1uF

C56

VDD

FLA_CS

4MB FLASH CIRCUIT

NF1

NF2

NF3

NC4

NC5

NC6

NC7

SQW8

WDI9

RSTIN110

RSTIN211

PFO12

NC13

VSS14 VBAT 15ECON 16SDO 17SDI 18RST 19EF 2032KHz 21SCL 22PFI 23VSS 24VOUT 25IRQ/FT/OUT 26E 27VCC 28

M41ST95

M41ST95W SO-28

U33

RSTIN1_PULLRST MOSI

MISO

SCK

RTC_PULL

RTC_CS

0.1uF

C49

RTC_IRQ

VDD

REALTIME CLOCK CIRCUIT

VSTBY

0.1uF

C53

VCC3

GND1 RST 2

MAX809STR

U32

VDD

0.1uF

C50

100E

R84RST

RST_PULL

RESET CIRCUIT

VDD1

CE2

SCK3

GND4 MISO 5MOSI 6

VDDA 8

MODE 7

DS1722S SO-8

U34

MOSIMISO

SCKTEMP_CS MODE

0.1uF

C54

0.1uF

C52

VDDVDD

TEMPERATURE CIRCUITVDD

CAN_CSE/P_CS

FLA_CS

TEMP_CS

RTC_IRQ

RSTIN1_PULLRTC_PULLRTC_CS

VDD

VDD

MODESCKMISOMOSI

SPI PULLUPS

1234 5

678

10K

SIP12

1234 5

678

10K

SIP11

1234 5

678

10K

SIP4

LLOP

LCOP

H2AS

HCT

H3AS

HOSE1E_AFC

SVO1

SVO3

SVO2

HOSE2

HOSE3

FAULT CONNECTOR

SVC1

SVC2

SVC3

RPLOW

CHRGFAIL

H1AS

LOWCLNT

CMPAFCP/I_IN1

P/I_IN2

R_GND

RPM

E/P_OUT

SADJ2

SADJ1

I/P'S & O/P'S

RP_ANA

FUELI/P

EOIL_P

ECLNT_TCMPOIL_P

CMPOIL_T

HDT_ANA

EOIL_T

CANH

CANL

IDLERUN_O

EMR_RPM

EMR_GND

VIN

CANH

CANL

120ER95

VIN

RTC PULLUPS

1

13

2

14

3

19

4

20

5

21

10

22

11

23

12

156

24

167

25

178

26

189

MTG1

MTG2

SAMTEC-RSP-122057-03-MALE

J5

1

13

2

14

3

19

4

20

5

21

10

22

11

23

12

156

24

167

25

178

26

189

MTG1

MTG2

SAMTEC-RSP-122057-04-FEMALE

J7

MCOREASU PERIPHERALS & INPUTS

PCBNO:472A

2 11CA

VERSION1.1

RST_PULL

0.1uFC55

SNAP ACTION RST SWITCH

21

43

OMRON-B3S-1002

SW1

MOSIMISOSCK

SPI

MOSIMISOSCK

BIVALVE3

BIVALVE2

BIVALVE1

1

1

2

2

3

3

4

4

D D

C C

B B

A A

Title

Number RevisionSize

A4


1

23

45

67

8

10

9

11

1213

1415

16

PCT4116/E

U11

LLOP

LCOP

HCT

VIN

LLOP_O

LCOP_O

HCT_O

1

23

45

67

8

10

9

11

1213

1415

16

PCT4116/E

U43

H3AS

H3AS_O

1

23

45

67

8

10

9

11

1213

1415

16

PCT4116/E

U44

E_AFC_O

HOSE1_O

HOSE2_O

HOSE3_O

OPTOQUAD

OPTOQUAD

OPTOQUAD

1

23

45

67

8

10

9

11

1213

1415

16

PCT4116/E

U39

OPTOQUAD

SV1CLOSE

SV2CLOSE

SV3CLOSE

SV1OPEN

SV2OPEN

SV3OPEN

RPLOW_O

CHRGFAIL_O

1

23

45

67

8

10

9

11

1213

1415

16

PCT4116/E

U7

OPTOQUAD

H1AS_O

LOWCLNT_O

CMPAFC_O

OPTOQUAD

1

23

45

67

8

10

9

11

1213

1415

16

PCT4116/E

U9

H2AS_O

IDLERUN

ACP ACP_O

CS

AST_OAST

CS_O

OPTOQUAD

1

23

45

67

8

10

9

11

1213

1415

16

PCT4116/E

U108K2R19

8K2R18

8K2R17

8K2R16

HOSE1

HOSE2

HOSE3IDLERUN_O

VIN

8K2R103

8K2R102

8K2R101

8K2R100

H2AS

SVO1

SVO3

SVO2

VIN

8K2R99

8K2R98

8K2R97

8K2R96

CHRGFAIL

VIN

8K2R6

8K2R7

8K2R8

E_AFC

H1AS

LOWCLNT

CMPAFC

VIN

8K2R2

8K2R3

8K2R4

8K2R5

8K2R15

8K2R14

8K2R13

VIN

8K2R86

8K2R87

8K2R92

8K2R93

SVC1

SVC2

SVC3

RPLOW

VDD

LLOP_OLCOP_OHCT_O

H2AS_O

ACP_OAST_O

VDD

CS_O

VDD

VDD

SV1CLOSESV2CLOSESV3CLOSERPLOW_O

H1AS_OLOWCLNT_OCMPAFC_O

VDD

H3AS_O

SV1OPENSV2OPENSV3OPEN

HOSE1_OHOSE2_OHOSE3_O

VDD

CHRGFAIL_O

VDD

E_AFC_O

FLT CLR_O

FLT CLR_O

VDD

1KR85FLT_CLR

8K2R12

8K2

R9

FAULTS CIRCUIT

1234 5

678

1K

SIP91234 5

678

10K

SIP8

1234 5

678

10K

SIP191234 5

678

10K

SIP7

1234 5

678

10K

SIP151234 5

678

1K

SIP6

1234 5

678

10K

SIP20

IDLERUN_O

CA3 11

PCBNO:472A

MCOREASU-SENSING INPUTS

VERSION1.1CAN_INTRTC_IRQ

CS_OAST_OACP_O

INT

CS_O

AST_OACP_O

RTC_IRQCAN_INT

BV3_SEN

BV1_SEN

BV1_SENBV2_SEN

BV3_SEN

BV2_SEN

BIVALVE3

BIVALVE2

BIVALVE1

1

1

2

2

3

3

4

4

D D

C C

B B

A A

Title

Number RevisionSize

A4


DUAL RELAY

+CTRL1

-CTRL2

+CTRL3

-CTRL4 LD 5LD 6

LD 8

LD 7

PVT322S

U37

RLER_O

RLQX_ORLER

RLQX

+CTRL1

-CTRL2

+CTRL3

-CTRL4 LD 5LD 6

LD 8

LD 7

PVT322S

U35

DUAL RELAY

RLACT3_ORLACT3

+CTRL1

-CTRL2

+CTRL3

-CTRL4 LD 5LD 6

LD 8

LD 7

PVT322S

U5

DUAL RELAY

RLFLTRLFLT_O

RLCOLD_O

RLFLASH_O

RLCOLD

RLFLASH

RLERPUL

RLQXPUL

RLACT3PUL

RLCOLDPUL

RLFLASHPUL

RLFLTPUL

+CTRL1

-CTRL2

+CTRL3

-CTRL4 LD 5LD 6

LD 8

LD 7

PVT322S

U4

DUAL RELAY

RLACT1_O

RLACT2_ORLACT2

RLACT1RLACT1PUL

RLACT2PUL

RLACT1PULRLACT2PUL

RLSTPULRLEFPUL

RLERPULRLQXPUL

RLCF1PULRLCF2PUL

RLACT3PULRLCOLDPUL

RLFLASHPULRLFLTPUL

VDD

VDD

VDD

RELAY PULLUPS RELAY CONNECTOR

VRLY

RLER_O

RLQX_O

RLST_O

RLEF_O

RLCF1_O

RLCF2_O

RLFLT_O

RLFLASH_O

RLACT1_O

RLACT2_O

RLACT3_O

RLCOLD_O

RLCF1RLFLASH

RLERRLQXRLSTRLEF

RELAYS

RLCF2

RLFLT

RLCF2RLCF1

RLFLASHRLFLTRLERRLQXRLSTRLEF


AUX_RLY


8K2

R70RLER_O

8K2

R69

8K2

R82

8K2

R81

8K2

R80

8K2

R74

8K2

R79

8K2

R78

8K2

R77

8K2

R76

8K2

R75

8K2

R73

RLST_O

RLEF_O

RLQX_O

RLCF1_O

VRLY VRLY

RLFLT_O

RLFLASH_O

RLACT1_O

RLACT2_O

RLACT3_O

RLCOLD_ORLCF2_O

RLST

RLEF

+CTRL1

-CTRL2

+CTRL3

-CTRL4 LD 5LD 6

LD 8

LD 7

PVT322S

U6

DUAL RELAY

RLST_O

RLEF_O

RLSTPUL

RLEFPUL

+CTRL1

-CTRL2

+CTRL3

-CTRL4 LD 5LD 6

LD 8

LD 7

PVT322S

U36

DUAL RELAY

RLCF1

RLCF2

RLCF1_O

RLCF2_O

RLCF1PUL

RLCF2PUL

RELAY CIRCUITS

RERYELLOW

RLQYELLOW

LSTYELLOW

REFYELLOW

CF1YELLOW

CF2YELLOW

FLHYELLOW

FLTYELLOW

AT1YELLOW

AT2YELLOW

AT3YELLOW

CLDYELLOW

1

9

2

10

3

11

4

12

5

13

6

14

7

15

8

MTG1

MTG2

SAMTEC-RSP-122057-02-FEMALE

J3

1234 5

678

1K

SIP1

1234 5

678

1K

SIP3

1234 5

678

1K

SIP2

MCOREASU-RELAY OUTPUTS

PCBNO:472A

CA4 11

VERSION1.1

1

1

2

2

3

3

4

4

D D

C C

B B

A A

Title

Number RevisionSize

A4


INH

IB1

Vin

2

Vin

3

Vin

4

GN

D5

GN

D6

GN

D7

GN

D8

Vou

t9

Vou

t10

Vou

t11

VO

adj

12

PT6303N VERTICAL

U2

1K/2WR1

0.1µFC47

1K

R68

+

470µF/16V RADIALC6

+3.3V POWERSUPPLY

VDD

VC

+

2200uF/50V RADIALC3 10K

R83

VIN

1A -3.3V 3PIN VERTICAL

+

100uFC5

1K

R72

+100uFC4

0.1uFC48

TP

-3.3

TP5

+5V

-3.3V POWERSUPPLY

TP

VIN

TP6

I/P POWER CONNECTOR

ACPAST

CS

FLT_CLR

VC

+

1uF

C12

+

1uF

C16

+

1uF

C14

+

1uF

C7

+

1uF

C11

+

1uF

C8

+

1uF

C15

+

1uF

C10

+

1uF

C9

+

1uF

C21 +

1uF

C22 +

1uF

C23

+

1uF

C17

VDD VDD

+

1uF

C18

VDD

0.1uF

C64

0.1uF

C650.1uF

C57

0.1uF

C62

0.1uF

C61

0.1uF

C600.1uF

C59

0.1uF

C58

0.1uF

C69

0.1uF

C66

VDD VDD

0.1uF

C67

0.1uF

C68

0.1uF

C71

0.1uF

C70

VDD

+5V

+

1uF

C13

0.1uF

C63

CONTROLLER CAPACITORS

1A 5V 3 PIN VERTICAL

+

100uFC1

2K

R67

+

100uFC2

0.1uFC46

+5V TP

+5V

TP3

VIN

5V POWERSUPPLY

Vin1

GN

D2

Vout 3

PT5021N

U3

-3.3V

Vin1

GN

D2

Vout 3

PT5101N

U1

VIN VRLY

TP

VC

TP1

10K

R71

TP

VRL

TP4

TP +3.3

TP2

D-PACK

D-PACK

VIN

RED

VRL

YELLOW

+3.3RED

+5VRED -3.3

RED

12

3MURD320

D2

12

3MURD320

D3

TVS1

123456

WAGO-231-136

J1

VERSION1.1

CA5 11

MCOREASU-POWERSUPPLY

PCBNO:472A

1

1

2

2

3

3

4

4

D D

C C

B B

A A

Title

Number RevisionSize

A4


ONCE-DE_B

ONCE-TD1

ONCE-TRST_B

ONCE-TD0

ONCE-TMS

1 23 45 67 89 1011 1213 14

7X2 BERGSTIC

J6

ONCE-TCLK

RST

PROGRAMMING CONNECTORENHANCEMENT CONNECTOR

CONFIGURATION

VDD

VDD

RST_PULLONCE-TCLK

TEST

CLK_O

VDD

ONCE-TCLK

ONCE-TD0

ONCE-TMSONCE-TD1

ONCE-TRST_BONCE-DE_B

VDD

VDD

CAN_INT

PROGRAMMING

KEY PULLUPS

KEYS

KEYBOARD & LCD CONNECTOR

1 23 45 67 89 1011 1213 1415 1617 1819 2021 2223 2425 26

FTSH-113-01-L-DV-EJ-K

J2

KEY7KEY5KEY1

+5V

LCDD4

LCDD6LCDD5

LCDD7 LCD_RSLCD_EN2LCD_EN1

LCDD4LCDD5LCDD6LCD_RSLCD_EN2

LCDD7LCD_EN1

KEY0 KEY1

KEY2KEY3

KEY4 KEY5KEY6 KEY7KB_LED

VDD

KEY0KEY4KEY6

KB_LEDKEY2KEY3

KEY0KEY1KEY2KEY3

KEY4KEY5KEY6KEY7

ICOC20ICOC21 ICOC22ICOC11

INT5 INT6INT7

EN_ICOC

INT5INT7

INT6VDD

DAC1_CSDAC2_CS

VDD

WHOLD

LLOP_OHCT_O

H3AS_O


LCOP_O

FAULTS1

H2AS_O

LLOP_OHCT_OLCOP_OH3AS_OH2AS_OH1AS_O

CHRGFAIL_OLOWCLNT_O

LLOP_OLCOP_OH3AS_OH1AS_O

LCD

LCD_RSLCD_EN1LCD_EN2

LCDD4LCDD5LCDD6LCDD7

KB_LED KB_LEDLCD_EN2LCD_EN1LCD_RSLCDD4LCDD5LCDD6LCDD7

KEY0

KEY4KEY5KEY6KEY7

KEYS

KEY3

KEY1KEY2

KEY0KEY1KEY2KEY3KEY4KEY5KEY6KEY7

LCDBACKLIT

PQB1

VDD VDD

RPMS

PQB2 PQB3

ONCE-DE_BONCE-TRST_BONCE-TMSONCE-TD0ONCE-TD1ONCE-TCLK

ONCE-PORTONCE-TCLKONCE-TD1ONCE-TD0ONCE-TMS

ONCE-TRST_BONCE-DE_B

CS

FLA_CSTEMP_CSRTC_CSCAN_CSDAC1_CSDAC2_CS

FLA_CSTEMP_CSRTC_CSCAN_CSDAC1_CSDAC2_CS

LLOP_OHCT_O

H3AS_O


LCOP_O

FAULTS1

H2AS_O

LLOP_OHCT_OLCOP_OH3AS_OH2AS_OH1AS_O

CHRGFAIL_OLOWCLNT_O


FAULTS2

CF1SW_OCOLDPUSH_O

COLDST_O

IDLERUNRPLOW_OSV1OPENSV2OPENSV3OPEN

FAULTS3

BV1_SENBV2_SEN

IDLERUNBV3_SEN

RPLOW_OSV1OPENSV2OPENSV3OPEN


1234 5

678

10K

SIP16

1234 5

678

10K

SIP14

1234 5

678

10K

SIP18

1234 5

678

10K

SIP17

1234 5

678

10K

SIP5

1234 5

678

10K

SIP10

1234 5

678

10K

SIP13

1 23 45 67 89 1011 1213 1415 16

NU

J4

VERSION1.1

MCOREASU-CONNECTORS & PULLUPS

PCBNO:472A

6 11CA

EN_INT

INT5INT6INT7

INT5INT6INT7

BV2_SENBV3_SEN

BV1_SEN

1

1

2

2

3

3

4

4

D D

C C

B B

A A

Title

Number RevisionSize

A4


CLK1

DIN2

CS/LD3

DOUT4 GND 5REF 6

VCC 8

VOUT 7

LTC1453 SO-8

U15

MOSIE/P_CS

10KP16

SCK

0.1uF

C87

VDD

VDD

NUR31

NUC31

D/A CIRCUIT

10KR32

10KR121

0.1uF

C83+5V

NU

R119 NU

R120

E/P_OUT

+

4.7/

25V

TA

NTA

LUM

TH

RU

HO

LE

C32

TP

E/P

TP11

CLK1

DIN2

CS/LD3

DOUT4 GND 5REF 6

VCC 8

VOUT 7

LTC1453 SO-8

U17

MOSIDAC1_CS

SCK

0.1uF

C88

VDD

DAC1 CIRCUIT

10KR41

10KR42

SADJ1

+

4.7/

25V

TA

NTA

LUM

TH

RU

HO

LEC33

CLK1

DIN2

CS/LD3

DOUT4 GND 5REF 6

VCC 8

VOUT 7

LTC1453 SO-8

U31

MOSIDAC2_CS

SCK

0.1uF

C120

VDD

DAC2 CIRCUIT

10K

R152

10KR44

SADJ2

+

4.7/

25V

TA

NTA

LUM

TH

RU

HO

LEC41

10KR35

NUC82

8K2

R134

R_GND

RPM

RPMS

1

2

3

4

8VCC

7

6

5

VO1

VO2

GNDHCPL-073A SO-8

U18 0.1uF

C89

VDD

10KR34

NUC79

8K2

R127EMR_RPM

EMR_GND

EMRRPM_O

RPMS

EMRRPM_O

NUC35

NUC90

2

3

114

1

TLC2274ID

U16A

5

67

TLC2274ID

U16B

10

98

TLC2274ID

U16C

1214

13

TLC2274ID

U16D

10KP17 5K1

R43

NUC91

5

67

TLC2272ID

U30B

REFRENCE

3

21

84

TLC2272ID

U30A

0.1uF

C119+5V

REFRENCE

REFRENCE

0.1uFC108

0.1uFC36

TP SAJ

TP10

10KP15 5K1

R40

10KP18 5K1

R172

13

2

NUD6

13

2

DIO914D1

12

3

NU ZD1

10KR175

VDD

NUR176

NUR177

NUR178

VERSION1.1

MCOREASU-RPM & DAC CKT

PCBNO:472A

7 11CA

RPM CIRCUIT

1

1

2

2

3

3

4

4

D D

C C

B B

A A

Title

Number RevisionSize

A4


150E

R116

2

31

114

TLC2274ID

U14A10KR114

10KR113

P/I_IN1

10K

R115

0.1uF

C85

0.1uF

C81

-3.3V

VDD

5

67

TLC2274ID

U14B10KR112

10KR26

10K

R128 10KP2

AIN1

150E

R39

10

98

TLC2274ID

U14C10KR141

10KR138P/I_IN2

10K

R140

12

1314

TLC2274ID

U14D10KR124

10KR139

10K

R131 10KP1

AIN2

P TO I I/P

10K

R125

NU

R2810KP3

10KR27

10KR132

VDD -3.3V

10K

R126

NU

R2910KP4

10KR30

10KR133

VDD -3.3V

12K

R25

0.01uFC30

12K

R123

0.01uFC86

+

1uF

C34

+ 1uFC28

150E

R111

2

31

114

TLC2274ID

U13A10KR24

10KR110

10K

R23

0.1uF

C84

0.1uF

C80

-3.3V

VDD

5

67

TLC2274ID

U13B10KR109

10KR108

10K

R135 10KP5

RP_ANA_O

REGULATION PRESSURE I/P

10K

R37

NU

R13710KP6

10KR36

10KR136

0ER38

VDD -3.3V

12K

R107

0.01uFC29

+

1uF

C27

RP_ANA

TP

P/I

TP9

P TO I I/P

0ER117

0ER118

200KR33

10KR122

10KR130

BAT_I/P810

9

TLC2274ID

U13C

12K

R22

0.01uFC78

BATTERY SENSING CIRCUITVC

10K

R21

10KR129

VERSION1.1

MCOREASU-P TO I CKT

PCBNO:472A

CA8 11

1

1

2

2

3

3

4

4

D D

C C

B B

A A

Title

Number RevisionSize

A4


RG1

3

-VS4 REF 5

OUT 6

+VS 7

RG 8

2

AD620AR

U29470K

R62

NU

R168

560ER61

+5V

-3.3V

0.1uF

C93

VDD

EOIL_P

CMPOIL_T_O

EOIL_T_O

ECLNT_T_O

CMPOIL_P_O

0.1uF

C106

RG1

3

-VS4 REF 5

OUT 6

+VS 7

RG 8

2

NU

U281.8K

R60

NU

R166

3.3KR59

+5V

-3.3V

0.1uF

C115

VDD

0.1uF

C105

RG1

3

-VS4 REF 5

OUT 6

+VS 7

RG 8

2

AD620AR

U27130K

R58

NU

R164

3.3KR57

+5V

-3.3V

0.1uF

C114

VDD

0.1uF

C104

EOIL_T

ECLNT_T

CMPOIL_T

CMPOIL_P

2

3

114

1

TLC2274IDU20A10KR169

10KR149 NU

R170

0.01uFC38

EOIL_P_O

0.1uF

C116

VDD

10KP14

5

67

TLC2274IDU20B

10KR167

10KR147 NU

R161

0.01uFC37

10KP12

10

98

TLC2274IDU20C

10KR165

10KR14612K

R173

0.01uFC45

10KP11

RG1

3

-VS4 REF 5

OUT 6

+VS 7

RG 8

2

AD620AR

U26470K

R56

NU

R162

560ER55

+5V

-3.3V

0.1uF

C113

VDD

0.1uF

C103

1214

13

TLC2274IDU20D

10KR163

10KR14812K

R174

0.01uFC42

10KP13

RG1

3

-VS4 REF 5

OUT 6

+VS 7

RG 8

2

AD620AR

U25130K

R53

NU

R159

3.3KR52

+5V

-3.3V

0.1uF

C112

VDD

0.1uF

C101 2

3

114

1

TLC2274IDU19A10KR160

10KR145 12K

R54

0.01uFC95

0.1uF

C92

VDD

10KP10

-3.3V

-3.3V

ANALOG CIRCUITS

VERSION1.1

MCOREASU-INSTRUMENTATION AMP(ENGINE INPUTS)

PCBNO:472A

9 11CA

AD620AR

1

1

2

2

3

3

4

4

D D

C C

B B

A A

Title

Number RevisionSize

A4


RG1

3

-VS4 REF 5

OUT 6

+VS 7

RG 8

2

AD620AR

U2427K

R51

1.8K

R157

1.5KR50

+5V

-3.3V

0.1uF

C111

VDD

0.1uF

C100

5

67

TLC2274ID

U19B10KR158

10KR14412K

R64

0.01uFC102

10KP9

RG1

3

-VS4 REF 5

OUT 6

+VS 7

RG 8

2

AD620AR

U2347K

R49

100K

R155

10KR48

+5V

-3.3V

0.1uF

C110

VDD

0.1uF

C99

10

98

TLC2274ID

U19C10KR156

10KR14312K

R45

0.01uFC94

10KP8

RG1

3

-VS4 REF 5

OUT 6

+VS 7

RG 8

2

NU

U22470K

R47

NU

R153

560ER46

+5V

-3.3V

0.1uF

C109

VDD

0.1uF

C98

1214

13

TLC2274IDU19D

10KR154

10KR142 NU

R63

0.01uFC97

10KP7

HDT_ANA_O

FUELI/P_O

RP_ANA_O

RP_ANA

HDT_ANA

FUELI/P

ANALOG CIRCUITS

Y01

Y22 Y 3

Y34

Y15

INH

6

VEE

7

GN

D8

B9 A10

X311

X012

X 13X114

X215 VC

C16

CD74HC4052M

U450.1uF

C74

VDD

HDT_ANA_OFUELI/P_O

EOIL_P_O

CMPOIL_T_O

EOIL_T_OECLNT_T_OCMPOIL_P_O

RP_ANA_O

MUX/DMUX CIRCUITS

ADD0ADD1

CHANNEL1

CHANNEL2

MCOREASU- INSTRUMENTATION AMP

PCBNO:472A

CA10 11

VERSION1.1

AD620AR

1

1

2

2

3

3

4

4

D D

C C

B B

A A

Title

Number RevisionSize

A4


1

MH1

1

MH3

1

MH7

1

MH6

1

MH2

1

MH5

1

MH4

9WAY FOR 485 COMMUNICATION

RX1

RE2

DE3

TX4 GND 5A 6

VDD 8

B 7

NU

U21

485 COMMUNICATION

VDD

2N2222AQ1

10KR171

0.1uFC26

470ER151

NUC77

VDD

0.1uF

C73

0.1uF

C72

0.1uFC118

0.1uF

C1170.1uF

C107

BA

B

A

M_RX2M_TX2

CANRX_ISO

B

VDD

A

10KR150

10KR65

360ER106

VDD

VDD

120ER66

360ER20

A

B

CANTX_ISO

360ER105

360ER104

162738495

MTG1

MTG2

J9

CANTX_ISO

NC1

2

3

NC4 GND 5

VO 6

VE 7

VCC 8

HCPL-0600 SO-8

U42

CAN_TX

VDD

VDD

CAN_RX

NC1

2

3

NC4 GND 5

VO 6

VE 7

VCC 8

HCPL-0600 SO-8

U41

CANRX_ISO

TXCAN1

RXCAN2

CLKOUT3

TX0RTS4

TX1RTS5

TX2RTS6

XTAL7

EXTAL8

GND9 RX1BF 10RX0BF 11INT 12SCK 13SI 14SO 15CS 16RST 17VDD 18

MCP2510-I/SO SO-18

U12

1KR11

CAN COMMUNICATION

8MHzXTAL2

CAN TRANSCEIVER

33PF

C2533PF

C24

CANLCANH

CAN_RX

0.1uF

C75VDD

0.1uF

C76

VDD

CAN_TX

CAN CONTROLLER

RX0BF

TX0RTS

RX1BF

TX1RTS

RST

TX2RTSCAN_INT

MOSI

CAN_CSMISO

SCKTXD1

VSS

2V

DD

3

RXD4

NC 5

CANL 6CANH 7

NC 8

SN65HVD232D SO-8

U40CANRX_ISO

CANTX_ISO

R1 IN13

R2 IN8

T1 IN11

T2 IN10

GN

D15

V+

2

V-

6

VC

C16

R1 OUT 12

R2 OUT 9

T1 OUT 14

T2 OUT 7

C1+1

C1 -3 C2+ 4

C2 - 5

MAX3232IDR SO-16

U46

0.1uF

C96

VDD

+

1uF

C43

+

1uFC39

+

1uF

C40

+

1uFC44

M_TXD1

M_RXD1

9WAY FOR SYSTEM INTERFACE232 COMMUNICATION

162738495

MTG1

MTG2

DB9/D-SUB9 FEMALE

J8

M_TX1

M_RXD1 M_RX1

M_TXD1

VDD

VDD

VERSION1.1

MCOREASU-COMMUNICATION

PCBNO:472A

11 11CA

SN65HVD08D SO-8

DB9/D-SUB9 FEMALE

CAN

TX0RTSTX1RTSTX2RTSRX0BFRX1BF

TX0RTSTX1RTSTX2RTSRX0BFRX1BF




17. ASU Remote Monitoring System Mak ASU Remote Monitoring system is Modular Hardware integrated with ASU control panel to

monitor ASU operation /control & whereabouts from remote place through Web Enabled application.

It is an integration of GPS and GSM/GPRS based Communication module.

Features

- Event Based fault reporting via designated Email and Website

- Maintenance Due Notification via designated Email and Website

- On demand current status Request via SMS

- Start /Stop disable control from remote place via SMS

- Programmable broadcast data interval via SMS

- Communication ON/OFF via SMS

- Execute commands from both Web site and Mobile

- Accurate Whereabouts

- GPRS based data communication Benefits

- Fault Monitoring/diagnosis from remote place

- Helps to carry out maintenance at right time to enhance performance

- Protects unauthorized use

- Gives control over ASU

- Web enabled application gives control over ASU around the globe. For more details please refer “ASU REMOTE MONITORING USER MANUAL”.




Maintenance Warning Message Reset Procedure :

If the Programmed Days or Hours reached 50 Hours or 10 Days, Warning message will be displayed at start up The Following Due message will be displayed, if Fuel Filter has to be replaced with in specified Hours or in Days. The screen displays each message 10 secs when more than one filter attains due. If the programmed Hours or Days reaches zero the Past Due message will be displayed as below. Press FAULT CLEAR key while warning displayed to skip the warning and Crank the ASU for operation. Press FAULT CLEAR key continuously for 3 Sec’s after replacing the filters to reload the maintenance schedule for the corresponding filter warnings.

Warning! ReplaceFuel Filter

Due in 049Hrs OR 028 Days


Past Due 49Hrs/ 28 Days


CHAPTER II / I


MAINTENANCE

CHAPTER II

SECTION I


CHAPTER II / I PAGE 1


CHAPTER - II SECTION - I

MAINTENANCE 1) ENGINE MAINTENANCE

This chapter consists of regular maintenance of the Engine for which the schedules and procedures are

laid down by the Vendors / OEM’s. For easy understanding, the original manual of the Engine is

attached to this manual for reference.

Selective maintenance at the intervals indicated below will ensure faultless operation and a long

service life. Skilled and trained personnel conversant with all applicable safety requirements shall

carry out the maintenance work.

WARNING

SHUT DOWN THE EQUIPMENT FOR ANY MAINTENANCE WORK

Note: Kindly Refer Application and Installation Manual of DEUTZ 6M1015C Model Engine Manual for details.




A) Engine Maintenance Guidelines Refer Engine Manual

i) General Information Refer Engine Manual

ii) Tools Requirement Refer Engine Manual

iii) Maintenance Schedule Refer Engine Manual

iv) Maintenance Instructions Refer Engine Manual

v) Maintenance Record Form Refer Engine Manual

B) Engine Maintenance Procedures Refer Engine Manual

i) At Daily Intervals Refer Engine Manual

ii) At Weekly Intervals Refer Engine Manual

iii) At 250 Hours or 6 Months Refer Engine Manual

iv) Every 1500 Hours or 1 year Refer Engine Manual

v) Every 6000 Hours or 2 years Refer Engine Manual

C) Adjustment, Repair and Replacement Refer Engine Manual

i) Starting Motors Refer Engine Manual

ii) Battery Cables & Connections Refer Engine Manual

iii) Belt, Cooling, Fan Drive Refer Engine Manual

iv) Water pump Drive Belt Refer Engine Manual

iv) Alternator Drive Belt Refer Engine Manual

iv) Turbocharger Refer Engine Manual iv) Engine storage – Long term Refer Engine Manual




2. COMPRESSOR MAINTENANCE Selective maintenance at the intervals indicated below will ensure faultless operation and a long service life. Skilled and trained personnel conversant with all applicable safety requirements shall carry out all maintenance work.

WARNING

SHUT DOWN THE EQUIPMENT FOR ANY MAINTENANCE WORK A) Compressor Maintenance i) At Daily Intervals - Check

Compressor lube oil Level Compressor lube oil Pressure Compressor lube oil Temperature Compressor Discharge air Pressure Compressor Discharge air Temperature Soiling of Air filter assembly / oil coolers Any leaks

ii) At Weekly Intervals - Check

Compressor lube oil Level Compressor Air filter clogging status Compressor lube oil pipe lines tightness

iii) At Every 6 months Intervals

Analysis of Compressor lube Oil Replacement of Compressor Air filter assembly

iv) At Every 12 months Intervals

Replacement of Compressor lube Oil Replacement of Compressor lube Oil filter Replacement of Compressor Air filter assembly




B) Oil Cooler Maintenance

In Normal operation, the cooler is maintenance free.

In dusty environments, dirt may accumulate on the air fins. This can be removed by lightly brushing

the surface, or with compressed air blow off. The cooler cannot be cleaned internally.

Note: Oil recommendation Recommended lubricants with ingredients prevent oxidation, corrosion and foaming

GHH RAND recommends ULTRA LUBE synthetic lubricant.


CHAPTER II / II


TROUBLE SHOOTING

CHAPTER II

SECTION II


CHAPTER II / II PAGE 1


TROUBLE SHOOTING

1. Trouble Shooting Procedures & Techniques

It is strongly recommended to go thoroughly all the chapters and sections of Operation & maintenance

of Engine, & Illustrated Parts catalogue manuals before attending to trouble shoot and rectify any

problems.

This chapter describes some typical operating problems, their causes, and some acceptable corrections.

Unless noted otherwise, the problems listed are those which an operator can diagnosis and repair. It is

assumed that the trouble shooting person is a qualified Engineer.

CAUTION

Performing trouble-shooting procedures not outlined in this section can result in equipment

damage or personal injury. Consult MAK Authorized Repair location for diagnosis and repair

beyond that which is outlined and for symptoms not listed in this section.

Before beginning any troubleshooting, please refer to General Safety Instructions provided in

this manual.

Follow the suggestions given below for troubleshooting:

1. Study the complaint thoroughly before acting

2. Refer to the System diagrams

3. Find and correct the cause of the complaint

4. Do the easiest and most logical things first




2. ENGINE TROUBLE SHOOTING SYMPTOMS

This chapter describes some typical engine operating problems, their causes, and some acceptable

corrections to those problems. Refer to the Charts to aid in diagnosing specific engine symptoms

provided in the original Engine Manual.

CAUTION

Performing trouble-shooting procedures not outlined in this section can result in equipment


beyond that which is outlined and for symptoms not listed in this section.

Before beginning any troubleshooting, please refer to General Safety Instructions provided in

this manual.

Engine Troubleshooting Symptoms Refer Engine Manual

i) Trouble shooting symptoms Sec - TS Refer Engine Manual

3. COMPRESSOR TROUBLE SHOOTING SYMPTOMS

This chapter describes some typical compressor operating problems, their causes, and some acceptable

corrections to those problems. Refer to the Charts.

CAUTION Performing trouble-shooting procedures not outlined in this section can result in equipment


beyond that which is outlined and for symptoms not listed in this section. Before beginning any troubleshooting, please refer to General Safety Instructions provided in this manual.




4. ASU Trouble Shooting Procedures & Techniques

This chapter describes some typical electrical and mechanical operating problems, their causes, and

some acceptable corrections to those problems. Refer to the Charts to aid in diagnosing specific

engine symptoms provided in Manual.

4.1.Engine cannot be Cranked:

CAUSE CORRECTIONS Output butterfly valve may be in open position. Check and Close the valve and try Hose selection switch may be in Open position. Close all the hose selection switches and try Hose selection ball valves may be in Open position

Check and close all the hose selection ball valves and then try

Pressure mode selection switch is in AST or ACP mode.

Bring back the switch to No load position – Idle mode and then try.

Battery Voltage may be low. If charge is less than 18V recharge or Replace the Battery.

Control Panel Fuse (F3) may be Blown. Rating - 15 A

Check F3 (refer control panel 1 wiring diagram) and if it is popped out reset the same by pressing it inside and check the display.

EMR power supply fuse (F1) may be blown out. Rating - 5 A.

Check F1 (refer EMR wiring diagram) and if it is popped out reset the same by pressing it inside and try.

Relays RLST, RLEF & RLS may be loose / faulty.

Check (refer control panel 1 wiring diagram) and if damaged replace with exact rating.

Starter motor wire connector may be loose. Check and Tighten the same.

Battery negative (main ground) connection may be loose.

Check and Tighten the same.

Starter motor may be faulty. Check and replace it.

Faults other than E.LLOP & COMP. LCOP may be present.

Check and clear the faults.




4.2. Engine cranks but stops when start key is released

CAUSE CORRECTIONS

Air lock in the fuel line. Check for any loose connections in the engine

suction line and tighten it. If hose found

damaged Replace them. Use priming feed

pump.

4.3. No Display in Control panel Annunciation display

CAUSE CORRECTIONS

Control Panel Fuse (F3) may be Blown. Rating

- 15 A

Check F3 (refer control 1 panel wiring

diagram) and if it is popped out reset the same

by pressing it inside and check the display.

10 PIN Allied connectors used in the ASU

control panel may be loose/removed.

Check (refer control panel 1 wiring diagram)

Tighten the same.

6 way wago connector J1 may loose/Removed Check (refer control panel 1 wiring diagram)

Tighten the same.

26 way LCD interface connector J1 from the

CPU card to LCD card may be

loose/removed/damaged


Properly fix the same. If the cable found

damaged replace the same with exact one.

LCD connector in the display card may be

loose.

Check, Tighten the same.

Contrast volt is not adequate Adjust the trim pot in the LCD / PCB No.475

in the clockwise few turns and check.

4.4. Compressor Oil Foaming

CAUSE CORRECTIONS

Incorrect oil brand; Mixture of different

brands, water present in oil.

Drain and fill with new oil according to oil

specifications.




4.5.No RPM Display in LCD

CAUSE CORRECTIONS

Can interface connector may be loose/left

open.


Fix the same. If found open connect it and

check.

4.6.Fault remains in LCD always

CAUSE CORRECTIONS

Fault sensor wires may be grounded. Check (refer control panel 1 & 2 wiring

diagram) connections and rectify.

Fault may exist. Carefully Check and rectify (by referring

Trouble shooting symptoms of Engine,

Compressor).

Key board 10 way FRC connector may be

loose/removed


for proper tightness & Switch may be faulty.

4.7.Speed does not Pick up in AST / ACP mode

CAUSE CORRECTIONS

RPM speed control connection in PCB may be

loose.

Check (refer control 1 panel wiring diagram)

and tighten the same.

Control circuiting in the PCB may be faulty. Check the PCB and replace it.

Variable speed input to the EMR wire may be

loose in the EMR 25 pin connector

Check, if found loose tighten the same




4.8.Pressure shows “00” or “Prsr.Signal Lost”

CAUSE CORRECTIONS

P- I transducer wire may be loose. Check (refer control panel 1 wiring diagram)


P-I transducer may be defective. Replace with a new one of exact rating.

Control piping may be open. Check and refit the same.

4.9.Output Pressure not maintained in ACP / AST mode

CAUSE CORRECTIONS

Leakage in sensing line, Control lines. Check for any loose connections / leakage in

the output sensing line and tighten it. If the

gasket found defective remove and replace it.

Transducers P – I & E – P may be defective. Check (refer control panel 1 wiring diagram) if

damaged replace with exact rating.

Speed Control input circuit may be defective Check and replace the CPU card.

Pressure control circuit may be defective Check and replace the CPU card.

Relief valve may be open Check and correct it.

Regulating pressure may be low Check the tank pressure level. If it is less than 4

bar, Change to IDLE mode and run the Engine

for 3 minutes and observe the pressure building

up. If not check for any leakage in the

pipelines.




Mode selection switch may be faulty Check for the functionality of the switch by

looking for the mode selection display in the

LCD / Air on indication lamp. If the switch

found faulty replace the same with exact rating

4.10.Battery not getting charged

CAUSE CORRECTIONS

Loose connection in the charging alternator Check (refer control panel 1 wiring diagram)


Charging Alternator may be faulty. Check the Alternator and replace it.

Charging minimum load may be left open /

short circuit

Check and fix a minimum load to the D+

supply of the charging alternator

4.11.Safety Valve(s) Open

CAUSE CORRECTIONS

Dis charge pressure excessive Check, for defective P – I & E – P transducer

(refer control panel 1 wiring diagram) if

damaged replace.

Safety valve(s) settings may be incorrect. Check the valve(s) and recalibrate it.

Quick Exhaust solenoid may be faulty Check (refer control panel 2 wiring diagram) if

found defective replace it with exact rating

4.12.AIR ON Indication Lamp not glowing

CAUSE CORRECTIONS

AST / ACP mode selection switch contact may

be defective


Replace if defective.

Lamp may have blown. Check (refer control panel 1 wiring diagram),

Replace if defective.




4.13.Display remains in IDLE mode even after selecting AST mode

CAUSE CORRECTIONS

Mode selection switch may be faulty Check for the functionality of the switch by

looking for the mode selection display in the

LCD / Air on indication lamp. If the switch

found faulty replace the same with exact rating

4.14.Oil Coolers fans are not running

CAUSE CORRECTIONS

Fan relay may be faulty. Check (refer control panel 2 wiring diagram) if


Wires may be loose Check ((refer control panel 2 wiring diagram)

Tighten the same.

Oil cooler Fan DC motor may be defective Check (refer control panel 2 wiring diagram) if

defective replace with exact ratings

4.15.Unit trips with High Compressor Oil Temperature

CAUSE CORRECTIONS

Oil cooler fans not working. Refer to Fault # 14

Oil level in the tank might be low. Fill the tank with required quantity of oil.

Oil cooler fins might have choked. Clean with forced Air.

HCOT switch (Sensor) may be faulty. Check, if damaged replace with exact rating.

Loose connections in wiring. Check (refer control panel 1 wiring diagram)





4.16.Unit trips with Compressor Low Lube Oil Pressure

CAUSE CORRECTIONS

LCOP switch may be faulty. Check (refer control panel 1 wiring diagram) if


Loose connections in wiring. Check (refer control 1 panel wiring diagram)


Oil level in the tank might be low. Fill the tank with required quantity of oil.

Pressure setting of the relief valve (Non Return

Valve) must be disturbed.

Check up and correct the pressure setting if

needed.

Leakage in pipeline joints. Check and tighten the same.

Suction filter may be clogged. Clean and refit the same.

4.17.Unit trips with Engine High Coolant Temperature

CAUSE CORRECTIONS

Engine coolant temperature sensor may be

faulty.

Check (refer control panel 1 wiring diagram) if


Loose connections in wiring. Check (refer control panel 1 wiring diagram)


Coolant level in the radiator might be low. Fill with required quantity of coolant.

Any leakage of coolant from the radiator Check and rectify the defect




4.18.Unit trips with Engine Low Lube Oil Pressure

CAUSE CORRECTIONS

Oil level in the oil tank might be low. Fill the oil tank with required quantity of oil.

Leakage in pipeline joints. Check and tighten the same.

Suction filter may be clogged. Clean and refit the same.

4.19. Hose cannot be selected

CAUSE CORRECTIONS

Hose adaptor sensor may be faulty Check and replace it.

Loose connections in Hose adaptor sensor Check and tighten the same

Loose connections in wiring. Check (refer control 1 panel wiring diagram)


Hose selection switch may be faulty Check and replace it.


CHAPTER III


OVERHAUL AND MAJOR REPAIR

CHAPTER III

To perform Overhaul and Major Repair Consult MAK Authorized Repair location for diagnosis and repair.

AIR + MAK INDUSTRIES INC.

11154,WILDWOOD DRIVE, OLIVE BRANCH, MS 38654

PHONE: (662) 893 3444

FAX: (662) 893 3476

E-MAIL: [email protected]

WEBSITE: www.airmak.com


CHAPTER IV


ILLUSTRATED PARTS CATALOGUE

CHAPTER IV


CHAPTER V


CHAPTER V

RECOMMENDED SPARES


CHAPTER V


RECOMMENDED SPARES:

A. 4 CHANGE OVER RELAY (FINDER RELAY) - 1 No

B. 4 CHANGE OVER RELAY BASE (FINDER RELAY) - 1 No

C. TIMER RELAY (4 CHANGE OVER) - 1 No

D. RELAY SNUBBER - 2 Nos

E. SYSTEM OK LAMP (GREEN COLOUR) - 1 No

F. ENGINE STOP LAMP (RED COLOUR) - 1 No

G. SINGLE CHANGE OVER RELAY (O/E/N RELAY) - 1 No

H. CONTROL FUSE

(15AMPS RESETTABLE FUSE) - 1 No

I. EMR FUSE

(5AMPS RESETTABLE FUSE) - 1 No

J. ENGINE AIR FILTER ELEMENT - 1 No

K. ENGINE OIL FILTER - 1 No

L. ENGINE FUEL FILTER - 1 No

M. ENGINE CHARGING ALTERNATOR FAN BELT - 1 No

N. ENGINE FUEL WATER SEPARATOR ELEMENT - 1 No

O. COMPRESSOR OIL FILTER - 1 No

P. COMPRESSOR AIR FILTER - 1 No

Q. CONTROL AIR FILTER ELEMENTS - 1 SET

R. QUICK EXHAUST SOLENOID - 1 No

S. OUTPUT BALL VALVE - 1 No

T. FUEL HOSE - 1 SET


CHAPTER VI


CHAPTER VI

MANUFACTURER APPENDIX


CHAPTER VI


1. COMPRESSOR MANUAL


CHAPTER VI PAGE 1


SCREW COMPRESSOR

Principle of Operation

Screw-type compressors operate on the positive displacement principle in the same way as

reciprocating compressors. Unlike the latter, they do not need any inlet or outlet valves (wearing

components) that provide a virtually continuous medium flow. Further, they do not have any parts or

masses, which would be in alternating motion (low-vibration running), and there is no contact inside

the compression chamber (and consequently no wear).

Inside the screw compressor casing there are two rotors, which rotate in opposite directions. The rotors

have specially shaped profile lobes, which are helically listed in axial direction, comparable to a

helically toothed pair of gear wheels. The number of lobes in a single-stage CD screw compressor is 3

for the male rotor (MR) and 4 for the female rotor (FR), with an asymmetric profile.

The profile is of such a configuration that a small, precisely defined gap (clearance) is maintained over

the full meshing line between the male and female rotor lobes even in heated condition inside the

permissible limits of application. A pair of timing gears arranged outside the compression chamber

excludes any contact between the rotors.

The radial and axial clearances between the rotors and the casing are also very low. Therefore, for

increased safety, small projections have been provided on the profile o.d. and on the discharge-side

face ends of the rotors to ensure perfect running. Should there be any fouling, these projections will

during continued operation.

The operating principle of a screw compressor is illustrated in Figs.1 and 2 for a particular interlobal

space (flute) between the male and female rotors. The view in Fig.1 is towards the compressor suction

side and shows the intake or suction progress. The radial and axial intake opening has been specially

marked, being connected to the suction nozzle by an appropriate configuration of the casing.

As the rotors are rotating, the volume of the interlobal space is continuously increased from 0 (not

shown) via the intermediate positions in Fig. 1a, 1b and 1c to its maximum value (Fig. 1d). This


CHAPTER VI PAGE 2


increase in volume causes air to be sucked in until the “trailing” male and female rotor lobes at the end

of the flute pass over the inlet control ledges limiting the intake opening. When this happens, there is

no longer any connection between the flute and the intake opening, and the suction process is thus

completed (Fig.1 a-d).

Fig.1: Intake process (facing the suction side)

a) - c) Interlobal space (flute) being increased

d) Completion of suction process/start of compression phase.

1. Male rotor

2. Female rotor

3. Intake opening

4. Inlet control ledges

5. Outlet opening (concealed)

As rotation of the rotors is continued, the volume of our flute is reduced again, as has been shown in

Fig.2 where the view is at the discharge side of the compression chamber. The radial and axial area

marked to identify the outlet opening is connected to the discharge nozzle by an appropriate

configuration of the casing.

Since the decreasing flute initially remains closed off by the casing wall, the air in it is compressed

(Fig.2a). This process is continued until the flute reaches the control ledges of the outlet opening with

its “leading” male and female rotor lobes (Fig.2b). With continued rotor rotation, connection is

established between the flute being considered by us and the compressor discharge nozzle via the


CHAPTER VI PAGE 3


marked Outlet opening (Fig.2c). As the flute volume is continuously being reduced to 0 (not shown)

via the intermediate position in Fig.2d, the compressed air in it is completely discharged.

Fig.2: Compression and discharge (facing the discharge side)

a) - b) Compression phase with decreasing flute volume

c) - d) Discharge as flute volume is being further reduced.

3. Inlet opening (partly concealed)

4. Outlet opening

5. Outlet control ledges.

As the number of lobes on the male rotor is 3, the complete operation of suction - compression -

discharge is repeated thrice per each male rotor rotation. Since several flutes at a time are in

connection with the inlet and outlet openings, there is a virtually uninterrupted medium flow through

the compressor.

The shape of the inlet and outlet control ledges is matched with the configuration of the lobe tips

(radially) and flanks (axially) in Figs.1d and 2b. Whereas the inlet control ledges are in a fixed position

in order to create the largest possible flute volume as a function of the profile shape, helix angle, and

application of each compressor. Their location defines the internal pressure ratio, which is the relation

between the pressure in the flute when reaching the outlet ledges (Fig. 2b) and the flute pressure upon

completion of the suction phase. (Fig. 1d).

The outlet control ledges are so arranged that the internal discharge pressure (i.e. flute pressure when

reaching the outlet ledges) is the same as the external discharge pressure (i.e. pressure in discharge

piping). Considering, however, that the compressors as a rule are working at different discharge


CHAPTER VI PAGE 4


pressure levels, there will be expansion of the flute volume to the pressure in the discharge nozzle if

this is less than the internal discharge pressure.

On the other hand, if the external discharge pressure is higher than the inner pressure, the air in the

flute is compressed to the backpressure level on reaching the outlet control ledges, and is then

discharged. The greater the difference between the internal discharge pressure and the back pressure,

the larger the pulsation in the compressed air, which has a frequency of three times the male rotor

speed.

The rotors are arranged one above the other with the male rotor at top. The rotor bearings are anti-

friction type. Radial forces are absorbed by cylindrical roller bearings, and axial loads by 4-point

bearings (ball races) on the discharge side.

The shaft sealing elements fitted between the compression chamber and the suction/discharge-side

bearings are used for minimizing air leakage from the compression chamber by means of tyred carbon

rings, while the fitted oil sealing rings prevent any bearing lube oil from penetrating into the

compression chamber. Pressure balancing pockets with discharge to the atmosphere are provided

between the carbon and oil sealing rings.

The suction nozzle of the air-cooled compressor casing points upwards, while the discharge nozzle is

arranged laterally. The complete compressor stage is fixed to the gear unit and centred by the flange of

the suction-side male rotor-bearing chamber.

GEAR UNIT

The driving gear and pinion have helical teething, with the helix angle so directed that the male rotor

axial bearing is relieved. The pinion is overhung on the tapered suction-side male rotor journal. The

driving shaft rests in anti-friction bearings on both sides of the shrink-fitted gear wheel. The oil pump

is driven direct by the driving shaft. On type CD26S, where the oil pump is flanged to the outside of

the gear casing on the compressor side, shaft sealing on the driving journal is by a labyrinth ring


CHAPTER VI


2. ENGINE MANUAL

Operation Manual

1015

26 3

88/1

Please read and observe the informationgiven in this Operation Manual. This willenable you to avoid accidents, preserve themanufacturer’s warranty and maintain theengine in peak operating condition.

This engine has been built exclusively forthe application specified in the scope ofsupply, as described by the equipment manu-facturer and is to be used only for theintended purpose. Any use exceeding thatscope is considered to be contrary to theintended purpose. The manufacturer willnot assume responsibility for any damageresulting therefrom. The risks involved areto 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 foroperation, maintenance and servicing. Theengine should only be operated by person-nel trained in its use and the hazards in-volved.

The relevant accident prevention guidelinesand other generally accepted safety andindustrial hygiene regulations must be ob-served.

When the engine is running, there is a risk ofinjury 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 regulatingsystem may also influence the performanceof the engine, and its emissions. Adherenceto legislation on pollution cannot be guaran-teed under such conditions.

Do not change, convert or adjust the coolingair intake area to the blower.The manufacturer shall not be held respon-sible for any damage which results fromsuch work.

When carrying out maintenance/repair op-erations on the engine, the use of DEUTZoriginal parts is prescribed. These are spe-cially designed for your engine and guaran-tee perfect operation.Non-compliance results in the expiry of thewarranty!

Maintenance and cleaning of the engineshould only be carried out when the engineis switched off and has cooled down.You must ensure that the electrical systemshave been switched off and the ignition keyhas been removed.Accident prevention guidelines concerningelectrical systems (e.g. VDE-0100/-0101/-0104/-0105 Electrical protective measuresagainst dangerous touch voltage) are to beobserved.When cleaning with fluids, all electrical com-ponents are to be covered impermeably.

Safety guidelines / Accident prevention

0297 9684 en

Please enter here the engine serial number. By quotingthis number you will help to facilitate dealing withquestions concerning Customer Service, Repairs andSpare Parts (see Section 2.1).

EngineSerial Number:

In view of continuous design improvements or changes,the technical specifications and the illustrations shownin this Operation Manual are subject to alteration.Reprinting and reproduction, in part or in whole, aresubject to our written approval.

Operation Manual

1015

Foreword

Dear Customer,

Liquid-cooled DEUTZ engines are designedfor a broad spectrum ofapplications.Consequently, a wide range ofvariants are offered to meet the specificrequirements of each individual case.

Your engine is appropriately equipped forthe installation concerned, which meansthat not all the components described in thisOperation Manual are necessarily mountedto your engine.

We have endeavoured to highlight anydifferences so that you will be able to locatethe operating and maintenance instructionsrelevant to your engine quickly and easily.

Please read this Manual before starting yourengine, and always observe the operatingand maintenance instructions.

Should you have any inquiries we shall bepleased to provide advice.

Sincerely,

DEUTZ AG

1. General

2. Description of Engine2.1 Model Designation2.1.1 Rating Plate2.1.2 Location of Rating Plate2.1.3 Engine Serial Number2.1.4 Numbering of Cylinders2.2 Engine Illustrations2.2.1 Cyl. Bank A BF6 M 10152.2.2 Cyl. Bank B BF6 M 10152.2.3 Cyl. Bank A BF8 M 10152.2.4 Cyl. Bank B BF8 M 10152.3 Lube Oil Circuit2.3.1 Lube Oil Circuit Schematic 1015

3. Operation3.1 Commissioning3.1.1 Filling in Engine Oil3.1.2 Filling Oil Bath Air Cleaner with

Engine Oil3.1.3 Filling the Fuel Tank3.1.4 Filling/Bleeding the Cooling System

10153.1.5 Other Preparations3.2 Starting3.2.1 Electric Starting3.3 Monitoring Systems3.3.1 Engine Oil Pressure3.3.2 Coolant Temperature3.3.3 Coolant Level3.3.4 Lube Oil Level3.4 Stopping3.4.1 Mechanical Shutdown3.4.2 Electric Shutdown

3.5 Operating Conditions3.5.1 Winter Operation3.5.2 High Ambient Temperature, High

Altitude

4. Operating Media4.1 Lube Oil4.1.1 Quality Grade4.1.2 Viscosity4.2 Fuel4.2.1 Quality Grade4.2.2 Winter Grade Fuel4.3 Coolant4.3.1 Water Quality for Coolant

Preparation4.3.2 Coolant Preparation4.3.3 Cooling System Protective Agents

5. Routine Maintenance5.1 Maintenance Schedule5.2 Maintenance Chart5.3 Completed Maintenance Jobs

6. Service and Maintenance6.1 Lubrication System6.1.1 Oil Change Intervals6.1.2 Changing Engine Oil, Checking Oil

Level6.1.3 Renewing Oil Filter6.2 Fuel System6.2.1 Renewing Fuel Filter6.2.2 Change Fuel Leakage Line6.2.3 Fuel Pre-filter Element

Clean/Replace if necessary

Table of Contents

6.3 Cooling System6.3.1 Cleaning Intervals6.3.2 Draining Cooling System6.3.3 Filling/Bleeding Cooling System6.3.4 Cleaning engine6.4 Combustion Air Cleaner6.4.1 Cleaning Intervals6.4.2 Dry-Type Air Cleaner6.4.3 Removing Cyclone-Type

Precleaner6.4.4 Cleaning Oil Bath Air Cleaner6.5 Belt Drives6.5.1 Checking Alternator V-Belt6.5.2 Retensioning/Renewing Alternator

V-Belt6.6 Adjustments6.6.1 Checking/Adjusting Valve

Clearances6.6.1.1 Valve Clearance

Adjustment Schematic6.7 Accessories6.7.1 Battery6.7.2 Three-Phase Alternator6.7.3 Lifting Tackle

7. Troubleshooting7.1 Diagnosis Chart

8. Engine Preservation8.1 Preservation

9. Specification Data9.1 Engine Specifications and Settings9.2 Torque Wrench Settings9.3 Tools

10. Service

26 3

88/1

1DEUTZ Diesel Engines

are the product of many years of research anddevelopment. The resulting know-how, coupledwith stringent quality standards, guarantee theirlong service life, high reliability and low fuelconsumption.It goes without saying that DEUTZ Diesel Enginesmeet the highest standards for environmentalprotection.

Service

Please contact one of our authorized servicerepresentatives in the event of breakdowns or forspare parts inquiries. Our trained specialists willcarry out repairs quickly and professionally, usingonly genuine spare parts.Original parts from DEUTZ AG are always producedin accordance with state-of-the-art technology.Please turn to the end of this manual for furtherservice information.

General

!

Care and Maintenance

Sound care and maintenance practices will ensurethat the engine continues to meet the requirementsplaced on it. Recommended service intervals mustbe observed and service and maintenance workcarried out conscientiously.Special care should be taken under abnormallydemanding operating conditions.

Asbestos

DEUTZ original parts are asbestos-free.

Safety

This symbol is used for all safetywarnings. Please follow themcarefully. The attention of operatingpersonnel should be drawn to thesesafety instructions. General safety

and accident prevention regulations laid down bylaw must also be observed.

Beware of Running Engine

Shut the engine down before carrying out mainte-nance or repair work. Ensure that the engine cannotbe accidentally started. Risk of accidents.When the work is complete, be sure to refit anypanels and guards that may have been removed.Never fill the fuel tank while the engine is running.Observe industrial safety regulations when runningthe engine in an enclosed space or underground.

CaliforniaProposition 65 Warning

Diesel engine exhaust and some of its consti-tuents are known to the State of California tocause cancer, birth defects, and other repro-ductive harm.

1

2

Description of Engine

2.1 Model Designation2.2 Engine Illustrations2.3 Lube Oil Circuit

2

26 332 0 26 389 0 26 390 0

CD

Description of Engine 2.1 Model Designation

2.1.1 Rating Plate 2.1.2 Location of Rating Plate 2.1.3 Engine Serial Number

The model designation A, the engine serialnumber B and the performance data are stampedon the rating plate.

When ordering spare parts, it is essential to quotethe model designation and the engine serialnumber.

The rating plate C is affixed to the crankcase. The engine serial number is stamped on thecrankcase iteself (arrow) and on the rating plate.

A B

2

26 391 0

2.1.4 Numbering of Cylinders

The cylinders are numbered consecutively foreither cyl. bank A or B, beginning at flywheel end.

2.1 Model Designation Description of Engine

2

26 392 0

1

2

3

4

5

6

78910

11

12

13

14

15

2.2.1 Cyl. Bank A – BF6M 1015

1 Oil filler neck 2 Cylinder head 3 Exhaust manifold 4 SAE housing 5 Crankcase 6 Starter 7 Oil pan 8 Oil filter 9 Coolant connection from heat exchanger to

engine10 Vibration damper11 V-belt pulley12 Alternator13 Coolant connection to heat exchanger14 Solenoid (shutdown solenoid)15 Flame-type heater plug (B-side)

Description of Engine 2.2 Engine Illustration

2

26 393 0

16

17

181920

21

22

23

2.2.2 Cyl. Bank B – BF6M1015

16 Charge air pipe17 Oil dipstick18 Oil drain plug19 SAE housing20 Flywheel21 Exhaust turbocharger22 Injection pump23 Flame-type heater plug (A-side)

2.2 Engine Illustration Description of Engine

2

26 412 0

2.2.3 Cyl. Bank A – BF8M 1015

1 Exhaust turbocharger 2 Exhaust manifold 3 Crankcase 4 Starter 5 Oil filler neck 6 Oil pan 7 Lube oil filter 8 V-belt pulley with vibration damper 9 Coolant connection from heat exchanger to

engine10 Oil cooler11 Fan12 Exhaust stack13 Charge air pipe to the charge air cooler14 Flame-type heater plug system (B-side)

Description of Engine 2.2 Engine Illustration

1

2

3

4

5678

9

10

11

12

13

14

2

26 413 0

2.2.4 Cyl. Bank B – BF8M 1015

14 Flame-type heater plug system (A-side)15 Oil filler neck16 Cylinder head17 Alternator18 Oil dipstick19 SAE housing20 Flywheel21 Compressor22 Fuel connecting line

2.2 Engine Illustration Description of Engine

14

15

16

17

181920

21

22

2

26 394 0

2.3.1 Lube Oil Circuit Schematic 1015Wet Sump Lubrication

1 Oil pan 2 Intake pipe 3 Oil pump 4 Overpressure relief valve 5 Oil cooler 6 Spin-on oil filter 7 Main oil bores 8 Main bearing 9 Big-end bearing10 Camshaft bearing11 Oil supply to injection pump12 Injection pump13 Return line from injection pump to

crankcase14 Line to spray nozzle15 Spray nozzle with pressure-holding valve for

piston cooling16 Tappet with control groove for pulse

lubrication of rocker arms17 Pushrod, oil supply to rocker arm lubrication18 Rocker arm19 Oil return bore in cylinder head to crankcase.20 Oil pressure sensor / oil pressure switch21 Oil line to exhaust turbocharger22 Exhaust turbocharger23 Oil line to compressor (hydr. pump)24 Compressor25 Hydraulic pump26 Pressure-holding valve (adjustable)27 Oil return line from compressor (hydr.

pump) to crankcase28 Oil return line from turbocharger to

crankcase

Description of Engine 2.3 Lube Oil Circuit

3

Engine Operation

3.1 Commissioning3.2 Starting3.3 Monitoring Systems3.4 Stopping3.5 Operating Conditions

3

26 397 0 24980 2 26 398 0

OIL FUEL

Engine Operation 3.1 Commissioning

3.1.1 Filling in Engine Oil

As a rule, the engines are delivered withoutoil filling.Fill in lube oil through the oil filler neck(arrow).For oil filling volume, see 9.1.For oil quality grade and oil viscosity, see 4.1.

Fill engine oil into bowl 1 of oil bath aircleaner (if fitted) up to the arrow mark.For oil quality grade and oil viscosity, see 4.1.

Use only commercial-grade diesel fuel. Forfuel quality grade, see 4.2.Use summer- or winter-grade fuel,depending on the ambient temperature.

3.1.3 Filling the Fuel Tank3.1.2 Filling Oil Bath Air Cleaner withEngine Oil

!Never fill oil into theprecleaner’s dust collector, ifprovided. !

Stop engine before filling thefuel tank!Observe strict cleanliness! Donot spill any fuel!

3

26 399 0

2

1

3.1 Commissioning Engine Operation

3.1.4 Filling/Bleeding CoolingSystem1015

Connect coolant inlet 1 and coolant outlet 2 toexternal coolant tank.

Fill in coolant into cooling system.

Start engine and run up to normal operatingtemperature until thermostat opens (line 2warms up).

Check coolant level in external cooling system,top up coolant if necessary.

3.1.5 Other Preparations

Check battery and battery cable connections,see 6.7.1.

Trial run– Upon completing the preparations run the

engine for a short trial run of about 10minutes under low load.

During and after trial run– Check the engine for leaks.

After the engine has been stopped– Check oil level and top up if necessary, see

6.1.2– Retension V-belts, see 6.5.

Breaking-inDuring the breaking-in phase, it isrecommended to check the oil level twice a day.After the breaking-in phase, checking once aday will be sufficient.

3

26 400 0 26 411 0

2

1

P

1

2

0+–1

2

3

3.2.1 Electric Starting

Before starting, make surethat nobody is standing in theimmediate vicinity of theengine or driven machine.After repair work :

Check whether all removed guards are putback in place and all tools are removed fromthe engine.When starting with flame-type heater plugs,do not use any other additional starting aids(e.g. injection with start pilot). Accidenthazard!Important: Never start the engine withspeed governor removed.Disconnect battery!

Disengage the clutch to separate the enginefrom the driven equipment.

Move speed control lever 1 in direction ofarrow at least to middle speed position.

Move shutdown lever 2 to „Run” position(opposite direction of arrow, item.1).

Insert key.– Position 0 = no operating voltage.

Turn key clockwise.– Position 1 = operating voltage,– Pilot lamps light up.

Turn key further clockwise against springaction.– Position 2 = starting.

Release key as soon as the engine starts firing.– Pilot lamps go out.

without Cold-Starting Aid

Do not actuate the starter for more than 20seconds at a time. If the engine does notstart, wait one minute before repeating theattempt.If the engine does not start after twoattempts, trace the cause with the aid of theDiagnosis Chart (see 7.1).

!

Engine Operation 3.2 Starting

3

P

1

2

0+–1

2

3

26 411 0

with Cold-Starting AidFlame-Type Heater Plug System

Important: The starting processmust be carried out within the30 seconds, otherwise repeatstarting attempt.

!

Insert key.– Position 0 = no operating voltage.

Turn key clockwise.– Position 1 = operating voltage,– Pilot lamps 1+2+3 light up.– Preheat until heater plug indicator 3 blinks,

max. 30 seconds.– Engine is ready for operation.

3.2 Starting Engine Operation

Turn key further clockwise against springaction to– Position 2 = starting

Release key as soon as the engine starts firing.– Pilot lamps go out.

3

25752 1 25754 0 26246 0

3.3.1 Engine Oil Pressure

Oil Pressure Pilot Lamp Oil Pressure Gauge

3.3.2 Coolant Temperature

The oil pressure pilot lamp lights up withoperating voltage applied and engine shut off.

The oil pressure pilot lamp must go out whenthe engine is running.

The pointer of the oil pressure gauge mustindicate the minimum oil pressure (see 9.1).

The pointer of the temperature indicator shouldremain in the green sector and enter the yellow-greeen sector only in exceptional cases. If thepointer enters the orange sector, the engine isoverheating. Turn it off and establish the causefrom the Diagnosis Chart (see 7.1).

Engine Operation 3.3 Monitoring Systems

3

26 291 1 26 278 1minmin min

3.3.3 Coolant Level 3.3.4 Lube Oil Level

Lamp of coolant level indicator lights up(contact via float switch/level sensor when min.coolant level has been reached):Turn engine off and establish cause from theDiagnosis Chart (see 7.1)

Functional check of coolant level:Insert key in position 1 or 2(Float switch or level sensor)Pilot lamp lights up for about 2 seconds– Coolant level o.k.: lamp goes out– Coolant level not o.k.: lamp does not go out.

Lamp of lube oil level indicator lights up(contact via float switch/level sensor when min.lube oil level has been reached):Turn engine off and establish cause from theDiagnosis Chart (see 7.1)

Functional check of lube oil level:Insert key in position 1 or 2(Float switch or level sensor)Pilot lamp lights up for about 2 seconds– Lube oil level o.k.: lamp goes out– Lube oil level not o.k.: lamp does not go out.

3.3 Monitoring Systems Engine Operation

3

26 401 0 26 411 0

1

2P

1

2

0+–1

2

3

3.4.1 Mechanical Shutdown 3.4.2 Electric Shutdown

Set speed control lever 1 to low speed position.

Actuate shutdown lever 2 until engine comes tostandstill. Charging-current and oil pressurepilot lamps light up when engine has come tostandstill.

Turn key counter-clockwise (to position 0) andpull off. Pilot lamps go out.

Engine Operation 3.4 Starting

3

26248 0

3.5.1 Winter Operation

Lube Oil Viscosity– Select the oil viscosity (SAE grade)

according to the ambient temperatureprevailing at the time when the engine isstarted 4.1.2.

– Keep shorter periods between oil changeswhen operating at temperatures below –10°C (+14 °F), see 6.1.1.

Diesel Fuel– Use winter-grade diesel fuel for operation

below 0 °C (+32 °F), see 4.2.2.

Coolant– Set the water / antifreeze mix to suit the

lowest temperature likely to occur (max. –35°C /–31 °F), see 4.3.1.

Additional Maintenance Jobs– Drain the sludge from the fuel tank once a

week (by undoing the sludge drain plug).– Adjust the oil filling in the oil bath air cleaner

(if fitted) to the prevailing ambienttemperature as in the case of engine oil.

– At temperatures below –20 °C (–4 °F)lubricate the flywheel ring gear with low-temperature grease, e.g. Bosch FT 1 V31,

from time to time through the pinion hole (ifnecessary remove starter).

Cold-Starting Aids– At temperatures near or below freezing point

start with flame-type heater plug, see 3.2.1.This not only lowers the starting limittemperature, but proves also useful at tem-peratures normally not requiring a startingaid.

Battery– Cold starting requires a good state of charge

of the battery, see 6.7.1.– The starting limit temperature can be

lowered by 4-5 °C by heating the battery upto +20 °C (+65 °F). To do so, remove thebattery and store in a warm place.

3.5 Operating Conditions Engine Operation

3

25901 1

3.5.2 High Ambient Temperature,High Altitude

With increasing altitude and rising ambienttemperatures the density of the air. tends todecrease, which affects the maximum poweroutput, the exhaust gas quality, thetemperature level and in extreme cases, thestarting behaviour. Under transient runningconditions, operation is permissible at altitudesup to 1000 meters at ambient temperatures upto 30 °C (86 °F)If an engine is operated under more severeconditions (at higher altitudes or ambient tem-peratures) it will be necessary to reduce theinjected fuel quantity and thus engine power.

In case of doubt concerning such engineapplications, ask your engine or equipmentsupplier whether, in the interest of operationalreliabillty, service life and exhaust gas quality(smoke!), an engine derating had beenconsidered necessary, or simply contact yourservice representative.

Engine Operation 3.5 Operating Conditions

4

4.1 Lube Oil4.2 Fuel4.3 Coolant

Operating Media

4 4.1.1 Quality Grade

The lube oil quality grade is defined byspecifications. The following lube oilspecifications are approved:

lube oil quality class:

classification/specification

DEUTZ- DQC I DQC II DQC III

ACEA- E2-96 E3-96/E5-02 E4-99

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

Worldwide - DHD-1 -

If in doubt, contact your service representative

4.1.2 Viscosity

Generally, multi-grade oils shall be used. Inclosed heated rooms at temperatures >5°C,also single-grade oils can be used. Theindicated lube oil grades must, of course, alsobe observed for single-grade oils.As the viscosity of lube oil is dependent ontemperature, the choice of SAE gradeshould be governed by the ambienttemperature prevailing at the engineoperating site.Optimum operating behaviour will beattained if you take the accompanying oilviscosity diagram as a guide.Should the temperature fall temporarilybelow the limits of the SAE grade selected,cold starting may be affected but the enginewill not be damaged.In order to keep wear to a minimum, do notexceed application limits for extendedperiods of time.Oil changes dictated by the seasons can beavoided by using multi-grade lube oils. Mul-ti-grade oils - particularly low-friction oils -also reduce fuel consumption.

Operating Media 4.1 Lube Oil

only with engineoil preheating

© 30 298 1

4

4.1 Lube Oil Operating Media

4.1.2.1 Specific lube oildefinitions

Turbocharged engines with uprated powerand engines with high loading

The oils listed in enclosure 1 are to be usedfor the following engines and applications: 1015 CP all engines in CHP plants all engines in gensets operating in parallel

with the mains/with each other engines in combines with:These are high-grade oils according to ACEA or API.In addition most of these oils are partly synthetic,some even fully synthetic (5W-40) and thus achievethe thermal stability required for the relevantapplication and are distinguished by a low tendencyto cause deposits in the turbocharger and in thecharge air pipes with closed-circuit crankcasebreather

Exhaust emission-optimized engines forcommercial vehicles as from EURO II andmobile machinery as from level 2. For exhaustemission-optimized engines of all DEUTZseries which meet the following exhaustemission requirements:a) as from EURO II the requirements of 88/

77/EEC and 91/542/EECfor commercialvehicles in Europe,

b) as from level 2 the requirements of 97/68/EC, for mobile machinery in Europe

c) as from level 2 the requirements for USnonroad engines the following oil gradeswill be permissible:- ACEA E3-96 and E4-98 for requirements a) and b)- API CG-4 and CH-4 for application c)

Producer Type of lube oil SAE class AvailabilityDEUTZ Deutz Öl TLX 10W-40FE EuropaGIP Agip Sigma Ultra TFE 10W-40 worldwideAGIP Autol Valve Ultra FE 10W-40 GermanyARAL GmbH Aral MegaTurboral 10W-40 worldwideARAL GmbH Aral SuperTurboral 5W-30 worldwideBAYWA BayWa Super Truck 1040 MC 10W-40 South GemanyBAYWA BayWa Turbo 4000 10W-40 South GemanyCastrol GmbH Castrol SYNTRUCK 5W-40 Europe, North America, Brazil

Argentina, Australia, South AfricaCastrol GmbH Castrol DYNAMAX 7,5W-40 Europe, North America, Brazil

Argentina, Australia, South AfricaCHEVRON Chevron Delo 400 Synthtic 5W-40 North AmericaESSO Essolube XTS 501 10W-40 EuropeFINA FINA KAPPA FIRST 5W-30 EuropeFINA FINA KAPPA ULTRA 10W-40 EuropeFUCHS DEA DEA Cronos Synth 5W-40 Germany, EuropeFUCHS DEA DEA Cronos Premium LD 10W-40 Germany, EuropeFUCHS DEA Fuchs Titan Cargo MC 10W-40 worldwideFUCHS DEA Deutz Oel TLL 10W-40 MB 10W-40 GermanyFUCHS DEA DEA Cronos Premium FX 10W-40 EuropeFUCHS DEA Fuchs Titan Unic Plus MC 10W-40 worldwideMOBIL OIL Mobil Delvac 1 SHC 5W-40 Europe, SE Asia, AfricaMOBIL OIL Mobil Delvac 1 5W-40 worldwideMOBIL OIL Mobil Delvac XHP Extra 10W-40 Europe, SE AsiaBP OIL International BP Vanellus HT Extra 10W-40 EuropeShell International Shell Myrina TX / 5W-30 Europe, different

Shell Rimula Ultra description in some countryShell International Shell Myrina TX / 10W-40 Europe, different

Shell Rimula Ultra description in some countryTOTAL TOTAL RUBIA TIR 86000 10W-40 worldwideSchmierölraffinerie Wintershall TFG 10W-40 EuropeSalzbergen GmbHThe table will be extended as and when required.

Lube oils forengines with uprated power andengines with high

loading

4

Operating Media 4.2 Fuel

4.2.1 Quality Grade

Use commercial brands of diesel fuel with asulfur content of less than 0.5%. If the sulfurcontent is higher than 0.5%, oil changeintervals should be reduced, see 6.1.1.

The following specifications / standards areapproved:

CEN EN 590 or DIN/EN 590

DIN 51 601 (Feb.1986)

BS 2869 (1988): A1 and A2

ASTM D975-88: 1-D and 2-D

NATO Code F-54 and F-75

The exhaust emission levels determinedduring certification always refer to thereference fuel specified by the supervisingauthorities for such certification.

4.2.2 Winter-Grade Fuel

At low temperatures, waxing may occur andclog the fuel system, causing operationaltrouble. In case of sub-zero (+32 °F)ambient temperatures it is recommended touse winter-grade diesel fuel (down to –15 °C= +5 °F). Normally, such fuel is offered at thefilling stations in good time before the coldseason starts. Diesel fuel containing additi-ves („Super Diesel”) is frequently also onsale for use at temperatures down to –20 °C(–4 °F).

At temperatures below –15 °C (+5 °F) or –20 °C (–4 °F), kerosene should be addedto the diesel fuel. The relevantpercentages are given in the diagram atthe right.

If summer-grade diesel fuel has to be usedat temperatures below zero (+32 °F), up to60% kerosene may be added (see diagramat the right).

In most cases, adequate resistance to coldis also attained by adding a flow improver(fuel additive). Ask your servicerepresentative for this.

0 10 20 30 40 50 60 %

0

- 5

- 10

- 15

- 20

- 25

- 30

+32

+23

+14

+ 5

- 4

- 13

- 22

BA°F °C

' 26441 1

I

II

Mix in tank only! Fill in theappropriate amount of kerosenefirst, then add the diesel fuel.

I Summer diesel fuel

II Winter diesel fuelA Ambient temperature

B Percentage of kerosene added

Illustration legend:

Diesel fuels must never be mixedwith petrol (normal and supergrade petrol)!

4

In the case of liquid-cooled engines, specialattention must be paid to the treatment andcontrol of the coolant, as the engine mayotherwise become damaged as a result ofcorrosion, cavitation and freezing.The treatment of the coolant is carried out by adding acooling system protectant to the cooling water.The cooling system must be continuously monitored,see 5.1. In addition to checking the coolant level, thisalso involves checking the concentration of the coolingsystem protectant.The cooling system protectant concentration can bechecked with commercially available testers (example:gefo glycomat®).

4.3.2 Coolant treatment 4.3.3 Cooling system protectants4.3.1 Quality of water for coolantin the recirculating watersystem

The values listed below must not be exceeded.In order to examine the quality of your water, a test casecan be ordered from DEUTZ under Order No. 12130382.

Water quality min max

ph value at 20 °C /68° F 6.5 8.5

Chloride ion content [mg/dm3] - 100

Sulphate ion content [mg/dm3] - 100

Total hardness [°dGH] 3 20

Cooling system protectant Water

max. 45 Vol.% 55%min. 35 Vol.% 65%

If nitrite-based cooling systemprotectants are mixed withamine-based agents, danger-ous nitrosamines are formed.

Cooling system protectants mustbe disposed of in an environmen-tally-friendly manner.

DEUTZ cooling system protectants must be purchasedin drums under Order No. 01011490 (5 litres) or 12211500 (210 litres). These are nitrite, amine and phos-phate-free, and provide effective protection againstcorrosion, cavitation and freezing.If the above mentioned cooling system protectant isunavailable, the following products may be used inexceptional cases.

Manufacturer Product designationAVIA AVIA Antifreeze ExtraARAL Antifreeze ExtraBASF Glysantin G 48DEA DEA kylarfrostsskydd

SHELL SHELLGlycoShell

The cooling system protectant in the coolant should notfall below or exceed the following concentration:

Filling volume, see Chapter 9.1.The use of other cooling system protectants, e.g. chemi-cal anti-corrosion agents, is possible in exceptionalcases. Consult DEUTZ Service.The use of anti-corrosion oils is not permitted.

4.3 Coolant Operating Media

4

18 20 22 25 27 30 32 35

35 –22 6,3 7,0 7,7 8,75 9,5 10,5 11,2 12,3

40 –28 7,2 8,0 8,8 10 10,8 12 12,8 14

45 –35 8,1 9,0 9,9 11,3 12,2 13,5 14,4 15,8

50 –45 9,0 10 11 12,5 13,5 15 16 17,5

Protective agent[Liters]

Cooling system capacity *)[Liters]

Cooling System Protection

*) For coolant capacity of your engine, see Section 9.1.Note: Consult head-office regarding figures in the grey field.

Protectiveagent

[% by vol.]

Protectionagainst freezing to

[°C]

Operating Media 4.3 Coolant

5

5.1 Maintenance Schedule5.2 Maintenance Chart5.3 Completed Maintenance Jobs

Routine Maintenance

46 en

5

© 2

000Routine maintenance 5.1 Maintenance schedule

check 2x daily before or during 1st trial run, during running- In period or when commissioning new or overhauled enginesevery 10 OH or daily

in operating hours (OH) every:E10 E20 E30 E30 E40 E60 E70

check = adjust = clean = replace = 25

0

500

1000

6000

1200

0

1 2

Lube oil level, top up if necessary 6.1.2/3.3.4Lube oil (oil change int. depending on engine app.), see TR 0199-99-3002 6.1.1/6.1.2Oil filter cartridge 6.1.3Fuel filter cartridge 6.2.1Fuel leakage lines (should be replaced in there entirety) 6.2.2Injection valve #Fuel pre-cleaner 4.2Coolant (additive concentration) 4.3.1/2/3Coolant pump –Coolant level –Intake air cleaner (if available, maintain according to maintenance indicator) 6.4.3/6.4.4Intercooler (drain lube oil/condensation) –Battery and cable connectors 6.7.1Engine monotoring system, Warning system 3.3 #Valve clearance (adjust if necessary) 6.6.1V-belts (retension if necessary, replaced if damaged) 6.5.1Crankcase pressure-relief valve/injection valve #Crankcase pressure vent valve #Check engine for leaks (visual inspection) –Draining bores between cylinder banks, engine cleaning 6.3.1/6.3.4Engine mount (replaced if damaged) 9.2Fasteners, hose connections/clips –General overhaul #

Years

Operation Section

Industriel enginesThe specified engine maintenance values arepermissible recommended maximums. Dependingon usage, reduced maintenance intervals may benecessary; comply with the unit manufacturer’soperating instructions. # Maintenance must only becarried out by authorised service personnel.

9684en_k05.p65 12.01.2005, 14:5746

47 Gerade en

5

© 2

000

5.1 Maintenance schedule Routine maintenance

check 2x daily before or during 1st trial run, during running- In period or when commissioning new or overhauled enginesevery 10 OH or daily

in operating hours (OH) every:

Additions andmodifications for engines

with EPA approvalThe specified engine maintenance values arepermissible recommended maximums. Dependingon usage, reduced maintenance intervals may benecessary; comply with the unit manufacturer’soperating instructions. # Maintenance must only becarried out by authorised service personnel.

check = adjust = clean = replace =

250

500

1000

4000

6000

1200

0

1 2Lube oil (oil change int. depending on engine app.), see TR 0199-99-3002 6.1.1/6.1.2Injection valve #Intercooler (drain lube oil/condensation) #Intercooler inlet, clean as necessary –Crankcase pressure vent valve #Exhaust Turbo-Charger outlet, clean as necessary –

Years

Operation Section

E10 E20 E30 E40 E70

9684en_k05.p65 12.01.2005, 14:5747

48 en

5

© 2


check 2x daily before or during 1st trial run, during running- In period or when commissioning new or overhauled enginesevery 200 km or daily

Kilometrage (km) every:Service group I

Vehicle enginesThe specified engine maintenance values arepermissible recommended maximums. Dependingon usage, reduced maintenance intervals may benecessary; comply with the unit manufacturer’soperating instructions. # Maintenance must only becarried out by authorised service personnel.


00

10 00

0

20 00

0

120 0

00

240 0

00

1 2

Lube oil level, top up if necessary 6.1.2/3.3.4Lube oil (oil change int. depending on engine app.), see TR 0199-99-3002 6.1.1/6.1.2Oil filter cartridge 6.1.3Fuel filter cartridge 6.2.1Fuel leakage lines (should be replaced in there entirety) 6.2.2Injection valve #Fuel pre-cleaner 4.2Coolant (additive concentration) 4.3.1/2/3Coolant pump –Coolant level 4.3.2/4.3.3Intake air cleaner (if available, maintain according to maintenance indicator) 6.4.3/6.4.4Intercooler (drain lube oil/condensation) #Battery and cable connectors 6.7.1Engine monotoring system 3.3Valve clearance (adjust if necessary) 6.6.1V-belts (retension if necessary, replaced if damaged) 6.5.1Crankcase pressure-relief valve/injection valve #Crankcase pressure vent valve #Check engine for leaks (visual inspection) –Draining bores between cylinder banks, engine cleaning 6.3.1/6.3.4Engine mount (replaced if damaged) 9.2Fasteners, hose connections/clips –General overhaul #

Years

Operation Section

Service groupe Annual kilometrage average speed approx.(km) approx. km/h

I < 30 000 20II > 30 bis 100 000 40III > 100 000 60

E10 E20 E30 E30 E40 E60 E70

9684en_k05.p65 12.01.2005, 14:5748

49 Gerade en

5

© 2

000

5.1 Maintenance schedule Routine maintenance


Kilometrage (km) every:Service group II


check = adjust = clean = replace =

10 00

0

20 00

0

40 00

0

240 0

00

480 0

00

1 2

Lube oil level, top up if necessary 6.1.2/3.3.4Lube oil (oil change int. depending on engine app.), see TR 0199-99-3002 6.1.1/6.1.2Oil filter cartridge 6.1.3Fuel filter cartridge 6.2.1Fuel leakage lines (should be replaced in there entirety) 6.2.2Injection valve #Fuel pre-cleaner 4.2Coolant (additive concentration) 4.3.1/2/3Coolant pump –Coolant level –Intake air cleaner (if available, maintain according to maintenance indicator) 6.4.3/6.4.4Intercooler (drain lube oil/condensation) #Battery and cable connectors 6.7.1Engine monotoring system # 3.3Valve clearance (adjust if necessary) 6.6.1V-belts (retension if necessary, replaced if damaged) 6.5.1Crankcase pressure-relief valve/injection valve #Crankcase pressure vent valve #Check engine for leaks (visual inspection) –Draining bores between cylinder banks, engine cleaning 6.3.1/6.3.4Engine mount (replaced if damaged) 9.2Fasteners, hose connections/clips –General overhaul #

Years

Operation Section


I < 30 000 20II > 30 bis 100 000 40III > 100 000 60

E10 E20 E30 E30 E40 E60 E70

9684en_k05.p65 12.01.2005, 14:5749

50 en

5

© 2



Kilometrage (km) every:Service group III



. 000

60. 00

0

120. 0

00

360. 0

00

1.000

.000

1 2

Lube oil level, top up if necessary 6.1.2/3.3.4Lube oil (oil change int. depending on engine app.), see TR 0199-99-3002 6.1.1/6.1.2Oil filter cartridge 6.1.3Fuel filter cartridge 6.2.1Fuel leakage lines (should be replaced in there entirety) 6.2.2Injection valve #Fuel pre-cleaner 4.2Coolant (additive concentration) 4.3.1/2/3Coolant pump –Coolant level –Intake air cleaner (if available, maintain according to maintenance indicator) 6.4.3/6.4.4Intercooler (drain lube oil/condensation) #Battery and cable connectors 6.7.1Engine monotoring system 3.3Valve clearance (adjust if necessary) 6.6.1V-belts (retension if necessary, replaced if damaged) 6.5.1Crankcase pressure-relief valve/injection valve #Crankcase pressure vent valve #Check engine for leaks (visual inspection) –Draining bores between cylinder banks, engine cleaning 6.3.1/6.3.4Engine mount (replaced if damaged) 9.2Fasteners, hose connections/clips –General overhaul #

Years

Operation Section


I < 30 000 20II > 30 bis 100 000 40III > 100 000 60

E10 E20 E30 E30 E40 E60 E70

9684en_k05.p65 12.01.2005, 14:5750

5The maintenance chart shown here is supplied asself-adhesive label with each engine. It should beaffixed where it can be clearly seen on the engineor driven equipment.

Check that this is the case!

If necessary, ask your engine or equipmentsupplier for a fresh supply of labels!

Routine maintenance work should be carried outaccording to the schedule in 5.1.

Stop the engine before carryingout any maintenance work.!

5.2 Maintenance Chart Routine Maintenance

0297 4963 1

10151000in.

a

ex.

0,25 mm0.009 in.in.=0,30 mm0.012 in.ex.=

10

OILmax.

500 500

OIL

500

OIL

API = CD/CECCMC = D4 o. D5

D5 = SHPD

1000

1000 FUEL

125-2000

10

AIRh

Std.

5 –

250

500

750

1000

1250

1500

1750

2000

2250

2500

2750

50-150*

125

375

625

875

1125

1375

1625

1875

2115

2375

2625

Running hours DateDate Signature / Stamp Signature / StampRunning hours

* after commissioning of new and overhauled enginesDuly completed maintenance jobs can be recorded and signed off in the above table.

Routine Maintenance 5.3 Completed Maintenance Jobs

52875

3125

3375

3625

3875

4125

4375

4625

4875

5125

5375

5625

3000

3250

3500

3750

4000

4250

4500

4750

5000

5250

5500

5750

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

5.3 Completed Maintenance Jobs Routine Maintenance


55875

6125

6375

6625

6875

7125

7375

7625

7825

8125

8375

8625

6000

6250

6500

6750

7000

7250

7500

7750

8000

8250

8500

8750




58875

8125

8375

8625

8875

9125

9375

9625

9825

10125

10375

10625

9000

8250

8500

8750

9000

9250

9500

9750

10000

10250

10500

10750




510875

11125

11375

11625

11875

12125

12375

12625

12825

13125

13375

13625

11000

11250

11500

11750

12000

12250

12500

12750

13000

13250

13500

13750




513875

14125

14375

14625

14875

15125

15375

15625

15825

16125

16375

16625

14000

14250

14500

14750

15000

15250

15500

15750

16000

16250

16500

16750




5

6

6.1 Lubrication System6.2 Fuel System6.3 Cooling System6.4 Combustion Air Cleaner6.5 Belt Drives6.6 Adjustments6.7 Accessories

Service and Maintenance

6

Service and Maintenance 6.1 Lubrication System

¸ The first oil change after commissioning orrecommissioning following repair work iscarried out after 50 running hours.

¸ The oil change intervals are dependent on :– Lube oil quality– Sulfur content in the fuel– Engine application

¸ Should, within a year, the engine run less thanthe hours stated in the table, the oil must bechanged at least once a year.

¸ The table refers to the following conditions:– For diesel fuel max. sulfur content > 0.5 %

by wt.– Continuous ambient temperature down to

–10 °C (+14 °F)

¸ If the sulfur content is > 0.5 to > 1 % or thecontinuous ambient temperature below –10 °C(+14 °F), the intervals between the oil changesshould be halved.

¸ In the case of fuels containing sulfur > 1 % ,ask your service representative.

6.1.1 Oil Change Intervals

Change the oil with the engine off but still warm(lube oil temperature approx. 80 °C / 176 °F).

¸ If, for vehicle engines, lube oil changeintervals are determined by operating hours,the lube oil change intervals indicated intable 6.1.1.1. for “Oil use under normal duty”will apply.

6Lube oil grade

Deutz lube oil quality class DQC I DQC II DQC III

ACEA-specfication E2-96 E3-96/E5-02 E4-99

API-specfication CF/CF-4 CG-4/CH-4 -

Worldwide specfication - DHD-1 -

special DEUTZ release list - - siehe Kap.4.1.2.1

Standard lube oil code for building EO.. . EO...C -

equipment and nonraod vehicles EO...A, EO...B

Engine Engine version Lube oil change intervals in op. hoursseries Oil use Oil use Oil use

normal high normal high normal high

1015 All engines except for: 250 125 500 250 500 250

1015C from Nonroad Stufe II - - 500 250 500 250

1015CP - - - - 500 250

BF6M1015MC P ≤ 300 kW - - 500 250 500 250

BF8M1015MC P ≤ 400 kW - - 500 250 500 250

BF6M1015MC P > 300 kW - - - - 500 250

BF8M1015MC P > 400 kW - - - - 500 250

* Gensets as referred to here are units operating in parallel with the mains / with each other. Emergency power units are dealt with in TC 0199-99-1126.

6.1.1.1 Lube oil change intervals for industrial and marine engines

6.1 Lubrication System Service and Maintenance

6Av

erag

e sp

eed

in k

m/h

app

rox.

]


Lubeoil-qualityDeutz lube oil quality class DQC I DQC II DQC IIIACEA-specification E2-96 E3-96/E5-02 E4-99API-specification CF/CF-4 CG-4/CH-4 -worldwide specification - DHD-1 -special DEUTZ release - - Enclosure 4.1.2.1

Application Engine version Lube oil change intervals in kmSite vehicles/ 25 1015 Euro I, except for - 15 000 20 000city busses 1015CP Euro II - - 20 000Local traffic 40 1015 Euro I, except for - 20 000 30 000

1015CP Euro II - - 30 000Long distance 60 1015 Euro I, except for - 50 000 40 000traffic 1015CP Euro II - - 60 000

If, for vehicle engines, lube oil change intervals are determined by operating hours, the lube oil change intervals indicated in table 4.1. for “Oil useunder normal duty” will apply.

6.1.1.2Oil change intervals for vehicle engines

6

26 023 0 26 022 0 25 729 0

Be careful when draining hot oil – dangerof scalds! Do not let used oil run into thesoil but catch it in a container ready for

6.1 Lubrication System Service and Maintenance

6.1.2 Checking Oil Level /Changing Engine Oil

6.1.2.1 Checking Oil Level 6.1.2.2 Engine Oil Change

Ensure that the engine or vehicle is on a levelsurface.

Allow the engine to warm up– Lube oil temperature approx. 80°C.

Switch off the engine.

Place oil tray under the engine. Unscrew drain plug. Drain oil. Fit oil drain plug, with the new gasket and tighten

firmly (for torque, see 9.2). Fill with lube oil.

– For grade / viscosity, see 4.1– For quantity, see 9.1

Check oil level, see 6.1.2.1

Ensure that the engine or vehicle is on a levelsurface.

Immediately before the oil level is measured, theengine should should be driven at low idlingspeed for approx. 2 minutes.

Switch off the engine. Pull out the oil dipstick. Wipe off with a non-fibrous, clean cloth. Insert up to the stop and pull out again. Check the oil level and if necessary fill up to the

“MAX” level.– If the oil level is just above the “MIN” marking,

extra oil must be added.

!The oil level must not fall below the “MIN” marking.

6

25881 0 25882 025880 0

6.1.3 Renewing Oil Filter

With fitted torsion lock:Loosen screws and slide clamps downwards.

Undo the oil filter cartridge with commercialtool and spin off.

Catch any escaping oil.

Clean sealing surface of the filter carrier ifnecessary.

Lightly oil the rubber gasket of the new oil filtercartridge.

Screw in the new cartridge finger tight againstthe gasket.

Tighten oil filter cartridge tightly by giving a fi-nal half turn.

If a torsion lock is fitted, slide clamps up intoposition and tighten screws.

Check oil level, see 6.1.2.

Check oil pressure, see 3.3.1.

Check sealing of oil filter cartridge for leaks.

Beware of hot oil:Danger of scalding!!


6

25880 0 25881 0 25882 0

Close fuel stopcock.

Undo fuel filter cartridge with commercial tooland spin off.

Catch any escaping fuel.

Clean sealing surface of filter carrier ifnecessary.

Apply light film of oil or diesel fuel to rubbergasket of new fuel filter cartridge.

Screw in the cartridge finger tight against thegasket.

Tighten fuel filter cartridge firmly.

Open fuel stopcock.

Check for leaks.

!When working on the fuel system,keep open flames away!Do not smoke!

6.2.1 Renewing Fuel Filter

6.2 Fuel System Service and Maintenance

Bleeding of the fuel system is not necessary.

6

Service and Maintenance 6.2 Fuel System

© 31 891 0

1

57

3

2

3

46

6.2.2 Replace fuel oil leak line

Close the fuel shut-off valve. Remove valve cover. Loosen and remove banjo bolts 7. Remove rubber hoses 1, 3, 4, unions 2 and O-

rings 6 and dispose of in accordance with envi-ronmental regulations; banjo union 5 and banjobolt 7 can be re-used.

Connect new oil leak line (complete) with banjounion 5 to rubber hoses.Fasten oil leak line using existing banjo bolt 7 andtwo new O-rings 6.

Re-fit valve cover. Open fuel shut-off valve. Check for leaks after start-up.

6.2.3 Fuel Pre-filter ElementClean/Replace if necessary

Clean (purge) - remove water: Turn off engine or, in the case of a change-

over filter, switch over to the other filter. Close the fuel stopcock or supply. (if

available) Open the bleed screw 1 on the cover 2 Place the fuel collector underneath the fuel

pre-filter. Empty water and dirt from the bowl 6 by

opening (press in and turn slightly withoutusing force) the drain cock 8 and close thedrain cock 8 again

Close the bleed screw 1 on the cover 2 again Bleed the fuel pipe according to instructions,

see 6.2.5 opposite

Changing the filter element 5:Change at least once a year or as required(drop in performance also after purging) Turn off the engine or switch to other filter in

case of changeover filter Close the fuel stopcock or supply (if available) Loosen the cover screws 3 diagonally Remove the cover 2 Remove the spring cassette 4 Remove the filter element 5 from the bracket Insert new filter element 5 Place spring cassette 4 on the element Check that the cover seal is fit properly in the

cover 2 and check for damage (change ifnecessary)

Tighten the cover 2 with the screws 3diagonally (torque 6 Nm)

Check the cover 2 for proper fit and leaks Bleed the fuel system, see 6.2.3.

Naked flames are prohibitedwhen working on the fuelsystem! Do not smoke!Dispose of old fuel in an environ-mentally friendly way!

The connection of a warning system(lamp/horn) via contacts 7 is specified.

Immediate maintenance is necessary whenthe warning system is triggered.

© 31 811 2

6

33 545 0

6.3.3 Filling / Bleeding CoolingSystem

6.3.2 Draining Cooling System6.3.1 Cleaning Intervals

The degree of soiling of the cooler units isdependent on the type of engine application.

The danger of soiling is increased due toresidues of oil and fuel on the engine. Checkextra carefully, therefore, for leakages whenapplications involve high dust fallout.

More severe soiling can occur, e.g. in the caseof:– Construction site application due to heavily

dust-laden air.

In view of the varying conditions of application,the cleaning intervals must be determined fromcase to case. The cleaning intervals stated inthe table can be taken as guide values.

Place tray under drain plug 1. Remove drain plug 1 and sealing ring below

coolant inlet. Drain coolant. Filling / bleeding as under 6.3.3 Screw on drain plug 1 with new sealing ring

and tighten (see 9.2). Check for leaks.

Fill with coolant and bleed cooling systemaccording to manufacturer’s instructions.

Checking / Cleaning IntervalsEngine Application

2000 Ships, gensets in enclosedspaces, pumps

1000 Vehicles on paved roads

500 Mobile gensets

250 Vehicles on construction sites andunpaved roads, Constructionequipment, compressors, under-ground mining equipment

125 Farm equipment

Guide Values(RH)

6.3 Cooling System Service and Maintenance

Be careful when draining hotcoolant. Danger of scalding!Catch drained coolant and disposeof in accordance with anti-pollution regulations!

!

6

Clean only with engine stationary

12

34

12

34A

B

1

43

21

43

21B

A

1

6.3.4 Cleaning engine- with compressed air

Blow compressed air onto engineWash out loosened dirt particles from V-spacewith water jet.

Make sure that drain holes 1 of V-space are free.

26 454 1 26 455 0

Let engine run up to operating temperatureafter each wet-cleaning procedure allowingany remaining water to evaporate, thusavoiding corrosion.

- with cold cleaning agent

Spray engine with commercial cold cleansingagent and let stand for about 10 min.

Then spray clean with strong water jet (do notspray water directly onto sensitive componentssuch as alternator, starter, wiring, electroniccomponents).

Make sure that drain holes 1 of V-space are free.

!

6.3 Cooling System Service and Maintenance

6

25885 1

6.4.1 Cleaning Intervals

The degree of soiling of the combustion aircleaner depends on the amount of dustcontained in the air and the size of the filterused. If very dusty air is to be expected, acyclone-type precleaner can be fitted to the aircleaner.

Consequently, the cleaning intervals cannot befixed generally, but have to be determined fromcase to case.

When a dry-type air cleaner is used, when indi-cated by the service indicator or switch.

Air cleaner servicing is needed when :– Service Indicator

the red sector 1 is fully visible when theengine is off.

– Service Switchthe yellow pilot light comes on when theengine is running.

After having carried out service work, reset thesignal by pressing the button of the serviceindicator. The service indicator is ready toresume its function.

Service and Maintenance 6.4 Combustion Air Cleaner

6

25888 1 25889 0

6.4.2 Dry-Type Air Cleaner

Dust Discharge Valve Filter Cartridge

Empty dust discharge valve 1 by pressing apartlips of discharge slot as indicated by thearrows.

Clean discharge slot from time to time.

Remove any caked dirt by pressing togetherthe upper section of the valve.

Release fastening clamps 1.

Take off hood 2 and remove cartridge 3.

Clean cartridge, replace at least once a year.

Clean cartridge 3:– blow through with dry compressed air (max.

5 bar) from inside to outside, or– in difficult cases, tap out, taking care not to

damage the cartridge, or– wash out according to manufacturer’s

instructions.

Check cartridge for damage to filter paper (byshining the paper through with a light), andinspect sealing element. Renew if necessaray.

After having serviced the filter cartridge fivetimes, or after two years at the latest, renewsafety cartridge 4 (never clean!).To do this, proceed as follows:– Undo hex. nut 5 and remove cartridge 4.– Insert new cartridge, insert and tighten hex.

nut.

Install cartridge 3, place hood 2 back inposition and secure fastening clamps 1.

!Never clean filter cartridge withpetrol (gasoline) or hot liquids!

6.4 Combustion Air Cleaner Service and Maintenance

6

25887 025886 0

!

6.4.3 Emptying Cyclone-TypePrecleaner

Undo wing nut 1 and remove cover 2.

Remove collector bowl 3 from lower section 4and empty. Remove leaves, straw and otherforeign matter from lower section ofprecleaner.

Reposition collector bowl 3 onto lower section4, fasten cover 2 in place by tightening wingnut 1.

Turn engine off and wait about 10 minutes forthe oil to drain from filter housing 1.

Release snap clips 2 and remove oil cup 3together with filter element 4. If necessary,press element out with a screwdriver, takingcare not to damage rubber gasket 5.

Remove dirty oil and sludge. Clean oil cup.

Clean filter element 4 in diesel fuel and allow todrip-dry.

Clean filter housing 1 if very dirty.

Inspect and replace rubber gaskets 5 and 6 ifnecessary.

Never clean air cleaner with petrol(gasoline)!Dispose of old oil in accorrdancewith anti-pollution regulations!

6.4.4 Cleaning Oil Bath Air Cleaner

Service and Maintenance 6.4 Combustion Air Cleaner

Fill oil cup with engine oil up to the mark(arrow) (for viscosity, see 4.1.2).

Refit oil cup and element to filter housing andsecure with snap clips.

6

26 261 126 403 0 25 997 0

!

6.5.1 Checking Alternator V-Belt

Checking

Inspect entire V-belt for damage

Renew damaged V-belts.

After installing new belts, run engine for 15minutes, then check belt tension.

Use a belt tension gauge (see 9.3) to check belttension.– Place indicator arm 1 into gauge.– Position gauge on V-belt 2, midway between

the pulleys, with flange 3 on bottom ofgauge against the edge of belt.

– Press slowly on the black pad 4 at rightangles to belt 2 until the spring is heard orfelt to trigger.

– Carefully remove the gauge without alteringthe position of the indicator arm 1.

– Read off the value: Turn the gauge sidewaysto see the exact spot where the top of theblack indicator arm 1 intersects scale 5(arrow). For settings, see 9.1.

– If necessary, retension belt and measureagain.

Check / retension and renew V-belts only with the engine off. Refitbelt guard, if provided.

6.5.2 Retensioning / RenewingAlternator V-Belt

Retensioning

Slacken hex. bolts 1, 2 and 3.

Turn lock nut 2 in direction A until correct V-belt tension is attained.

Tighten bolts 1, 2 and 3.

6.5 Belt Drives Service and Maintenance

6

25 998 0

Renewing

Slacken hex. bolts 1, 2 and 3.

Turn lock nut 2 in direction B as far as it will go.Now the new V-belt can be easily placed inposition.

Tighten bolts 1, 2 and 3 until correct V-belttension is attained (see Section 6.5.1).

Service and Maintenance 6.5 Belt Drives

6

12

326 406 0 26 404 0

EX IN2

1

2

1

33

6.6.1 Checking / Adjusting ValveClearances

Before adjusting valve clearance, allow engineto cool down for at least 30 minutes. The oiltemperature should be below 80 °C (176 °F).

Position crankshaft as per schematic, see6.6.1.1.

Slacken bolts 1.

Remove rocker cover 2 together with gasket 3.

Check valve clearance 1 between rocker arm/tappet contact face 2 and valve stem 3 withfeeler gauge (there should only be a slightresistance when feeler blade is inserted).For permissible valve clearance, see 9.1.

6.6 Adjustments Service and Maintenance

6

26 405 0

EX

IN

EX

IN7

6

54

If necessary, adjust valve clearance as follows:– Loosen lock nut 4 using wrench 7.– Adjust set screw 5 by means of screwdriver

6 in such a manner that with lock nut 4tightened (wrench), the correct valveclearance 1 is attained.

Check the valve clearances at each of theremaining cylinders and adjust if necessary.

Refit rocker cover (together with new gasket ifnecessary).

Service and Maintenance 6.6 Adjustments

6

Firing Order BF6M 1015: Firing Order BF8M 1015:A1 – B3 – A3 – B2 – A2 – B1 A1 – B4 – A4 – B1 – B3 – A3 – B2 – A2

6.6.1.1 Valve Clearance Adjustment Schematic

Sequence 1 2 3 4 5 6 1 2 3 4 5 6 7 8

Valve overlap A1 B3 A3 B2 A2 B1 A1 B4 A4 B1 B3 A3 B2 A2

Adjusting B2 A2 B1 A1 B3 A3 B3 A3 B2 A2 A1 B4 A4 B1

6.6 Adjustments Service and Maintenance

6

26 407 0

A1 A2 A3

B1 B2 B3

A1 A2 A3

B1 B2 B3

A1 A2 A3

B1 B2 B3

A4

B4

A1 A2 A3

B1 B2 B3

A4

B4

AdjustmentTurn crankshaft according to sequence shownin the diagram (starting with cyl. 1).The valves of the relevant cylinder overlap,marked in white, (exhaust valves about toclose, inlet valves about to open). Adjustclearance of valves, marked in black,according to schematic. Mark the respectiverocker arm with chalk to show that theadjustment has been done.

Service and Maintenance 6.6 Adjustments

6

25895 0 24232 3 25896 0

6.7.1 Battery6.7.1.1 Checking Battery and Cable

Connections6.7.1.2 Checking Electrolyte Level 6.7.1.3 Checking Specific Gravity of

Electrolyte

Keep battery clean and dry.

Undo soiled terminals.

Clean battery plus and minus poles andterminals and apply a film of acid-free and acid-resistant grease.

When reconnecting, ensure good contact ofterminals. Fasten clamping bolts finger tight.

Remove cell caps 1.

If electrolyte test elements 2 are fitted:The level should be high enough to wet thebottom of these.

If no such elements are provided :Check to make sure that the level is 10-15 mmabove the top edge of the plates.

Top up with distilled water if necessary.

Fit cell caps back in position.

Measure the specific gravity of the individualcells with a commercial hydrometer.The measured values (see adjacent table)indicate the state of charge of the battery.During the measurement, the temperature ofthe electrolyte should preferably read 20 °C.

6.7 Accessories Service and Maintenance

6

Specific Gravity

in [kg/l] in [°Bé (degrees Baumé) *] State of Charge

Normal Tropics Normal Tropics

1.28 1.23 32 27 Fully charged

1.20 1.12 24 16 Half charged, recharge

1.12 1.08 16 11 Discharged, charge up immediately

* Measurement of the specific gravity in °Bé (de-grees Baumé) is obsolete and rarely used today.

The gases emitted by the batteryare explosive! Avoid formation ofsparks in the vicinity of battery,keep away any open flames!Do not allow acid to come intocontact with skin or clothing!

Wear protective goggles!Do not place tools on battery!

!

Service and Maintenance 6.7 Accessories

6

Notes on the three-phase system:

When the engine is running, never disconnectthe cables between battery, alternator andregulator.

Where it is, however, necessary, to start andoperate the engine without battery, disconnectthe regulator from the alternator beforestarting.

Be sure not to confuse the battery terminals.

Renew a defective charging pilot light bulbimmediately.

Engine cleaning: Do not spray with water/steam jet directly against alternator!Warm up engine to allow water residues toevaporate.

Do no loosen connecting cable between batteryand alternator during engine operation.

The habit of touching a lead against frame tocheck whether it is live must under nocircumstances be applied with a three-phaseelectric system.

In case of electric welding, connect the earthterminal of the welding unit direct to the part tobe welded.

26 409 0 26 410 0

For transporting the engine, always use theproper lifting tackle.

Remove lifting tackle.– Do not start engine with lifting tackle fitted.

Always use the proper liftingtackle!!

6.7.2 Three-Phase Alternator 6.7.3 Lifting Tackle

6.7 Accessories Service and Maintenance

1

2

6

7

Troubleshooting

7.1 Diagnosis Chart

7

Troubleshooting 7.1 Diagnosis Chart

If engine problems occur, they frequently havetheir cause in improper operation ormaintenance of the engine.

So, in case of trouble, always check firstwhether the operating and maintenanceinstructions have been observed.

A helpful Diagnosis Chart is to be found on theopposite page.

If you cannot identify the cause of the troubleor are unable to rectify it yourself, contact yourservice representative.

Before starting, make sure thatnobody is standing in theimmediate vicinity of the engine ordriven machine.After repairs :

Important: Never start engine with the speedgovernor removed.Disconnect battery terminals!

!

7

PPPPSP / EP / EP / WPPP / WP / RP / RP / RPP

Causes SectionNot declutched (declutch where possible) OperationBelow start limit temperatureEngine shutdown lever still in stop position (shutdown solenoid defective)Oil level too highOil level too lowExcessive inclination of engineSpeed control lever set to middle positionDirty air cleaner / defective turbocharger Combustion AirAir cleaner service switch/indicator defectiveLDA* defective (leaking line)Charge air pipe leakingCoolant pump defective Cooling SystemCharge air cooler dirtyCoolant heat exchanger dirtyCoolant thermostat does not openBattery defective or discharged Electrics

* LDA = manifold pressure compensator Table 1 of 2

Troubles Remedial MeasureEngine fails (or difficult) to start Check P

Engine starts, but runs unevenly or stalls Adjust EEngine becomes too hot, temperature monitor gives warning (coolant) Renew W

Engine gives poor performance Clean REngine not working on all cylinders Top up A

Engine has little or no oil pressure Lower level SEngine oil consumption excessive Bleed L

Engine smokes – blue– white– black

7.1 Diagnosis Chart Troubleshooting

7

Troubleshooting 7.1 Diagnosis Chart

PPEPP / RPP / WP / LP/R/WWP / WP / A

Causes SectionCable connection to starter loose or oxidized ElectricsStarter defective or pinion does not engageIncorrect valve clearance EngineLeaking injection lineVent pipe clogged (coolant heat exchanger)Flame-type heater plug system defectiveInjector defectiveAir in fuel system (lack of fuel)Fuel filter / prefilter contaminateIncorrect lube oil SAE class or quality grade Operating MediaFuel quality grade not corresponding to specification under 4.2.1Lack of coolant

Troubles Remedial MeasureEngine fails (or difficult) to start Check P

Engine starts, but runs unevenly or stalls Adjust EEngine becomes too hot, temperature monitor gives warning Renew W

Engine gives poor performance Clean REngine not working on all cylinders Top up A

Engine has little or no oil pressure Lower Level SEngine oil consumption excessive Bleed L

Engine smokes – blue– white– black

8

Engine Preservation

8.1 Preservation

8

Engine Preservation 8.1 Preservation

26 408 012

3

4

If the engine is to be shut down for an extendedperiod, it is necessary to take preservationmeasures to prevent rust formation. Thepreservation measures described here will protectthe engine for a period of up to about 6 months.Before reusing the engine, the preservatives mustbe removed,.

Anti-corrosion oils to Specification:– MIL-L 21260B– TL 9150-037/2– Nato Code C 640 / 642

Recommended cleansing agent for removingpreservatives:– Petroleum benzine (hazardous materials

class A3)

Preserving the Engine: Clean engine (in case of need with cold

cleansing agent).Clean cooling system according tomanufacturer’s instructions.

Run engine until warm and stop. Drain engine oil, see 6.1.2, and fill in anti-

corrosion oil. Drain coolant, see 6.3.3. Fill in anti-corrosion agent, see 4.3.3. Clean oil bath air cleaner, if provided, see 6.4.3,

and fill in anti-corrosion oil. Drain fuel from tank. Prepare a mixture of 90% diesel fuel and 10%

anti-corrosion oil and fill up tank.

Run engine for about 10 minutes.

Stop engine.

Turn engine several times by hand.When turning engine with starter, moveshutdown lever to stop position.

Remove V-belt 2 and store in wrappedcondition.

Spray grooves of V-belt pulleys with anti-corrosion agent.

Close coolant inlet and outlet openings 3 andair intake opening 4.

Close exhaust discharge opening.

8.1 Preservation

Drain off anti-corrosion agent, see 6.3.3.

Removing Engine Preservatives:

Remove anti-corrosion agent from the groovesof the V-belt pulleys.

Fit V-belt 2. Retension, if necessary, after shortperiod of operation, see 6.5.

Remove plugs 1, 3 and 4 and plug fromexhaust discharge opening.

Fill in coolant according to instructions ofradiator manufacturer.

Start up engine.

9

Specification Data

9.1 Engine Specifications and Settings9.2 Torque Wrench Settings9.3 Tools

9

Number of cylinders 6 8 6 8Cylinder arrangement 90° Vee-angleBore [mm] 132Stroke [mm] 145Total displacement [cm3] 11906 15874 11906 15874Compression ratio [ε] 17Working cycle / combustion system 4-stroke TC engine/direct injectionDirection of rotation counter-clockwise

Weight incl. cooling system [approx. kg] Consult headquartersWeight w/o cooling system acc. to DIN 70020-A [approx. kg] 830 1060 830 1060Engine power [kW] 190-240 1) 250-320 1) 228-300 1) 304-400 1)

Speed [rpm] 1)Valve clearance, engine cold 5) [mm] inlet 0.25 + 0,1 / exhaust 0.3 + 0,1

Injector opening pressure [bar] 290 barCommencement of delivery [°CA BTDC] 1)Firing order 1-6-3-5-2-4 1-8-4-5-7-3-6-2 1-6-3-5-2-4 1-8-4-5-7-3-6-2

A1-B3-A3-B2-A2-B1 A1-B4-A4-B1-B3-A3-B2-A2 A1-B3-A3-B2-A2-B1 A1-B4-A4-B1-B3-A3-B2-A2

V-belt tension: tension / retension 2)Alternator 55 amperes [N] 450 / 200-350 ± 50

Alternator 120 amperes [N] 550 / 300-450 ± 50

Specification Data 9.1 Engine Specifications and Settings

1) Engine power, speed, commencement of delivery, etc. are stamped on the rating plate, see 2.1.2) Retension after running for 15 minutes under load.

Model 1015 BF6M 1015 BF8M 1015 BF6M 1015 C/ CP BF8M 1015 C / CP

9

Cooling system liquid-cooled / cooling system protectionCoolant quantity [approx. lit.] 17 + MFK* 21 + MFK* 17 + MFK* 21 + MFK*

Perm. cont. coolant temperature engine outlet [°C] max.103Temperature difference betweencoolant inlet / outlet [°C] max.5Thermostat starts opening at [°C] 87 ±2

Thermostat fully open from [°C] 102

Coolant pumpDelivery pressure in [bar] 4)Delivery rate in [m3/h] 22,5 4) 30 4) 22,5 4) 30 4)

Lubrication forced-feed lubricationSAE oil (see 4.1) 15 W 40Min. oil pressure with engine warm (120 °C)at low idle / rated speed [bar] 1,0Oil capacity (initial filling) without filter [approx. lit.] 34 3) 45 3) 34 3) 45 3)

Oil capacity (initial filling) engine-mounted filter [approx. lit.] 36* 3) 47* 3) 36* 3) 47* 3)

Oil capacity (initial filling), separate filter [approx. lit.] 38 3) 50 3) 38 3) 50 3)

9.1 Engine Specifications and Settings Specification Data

Model 1015 BF6M 1015 BF8M 1015 BF6M 1015 C/ CP# BF8M 1015 C// CP#

3) Approximate figures can vary depending on the design. Decisive is always the upper dipstick mark.4) 3 bar at engine speed n = 2100 rpm -15) see 6.1.1 (# only synthetic lube oil, see.4.1.2.1)* MFK Engine radiator

9

Rocker cover

Inspection Cover

Rocker arm setscrew

rigid mounting

flexible mounting

Air intake manifold

Exhaust manifold

Oil drain plug

Injector mounting

Injection line mounting

Oil pan

Oil filter cartridge

Coolant drain plug

Pin-type heater plugs / pipe union

Mount

Preloading [Nm] Tightening [° deg.]

1st 2nd 3rd 1st 2nd 3rd 4thStage Stage Stage Stage Stage Stage Stage

LocationTotal[Nm] Notes

22

22

20

106

21

61

100

60

25

24

27

38

4

30 45

Specification Data 9.2 Torque Wrench Settings

engine mountedor separate

9

26002 0

V-belt Tension Gauge

The V-belt tension gauge can be obtained underorder number 8115 + 8120 from:

Fa. WILBÄRPostfach 14 05 80D-42826 Remscheid

9.3 Tools Specification Data

Notes

en Warnings to Place on Equipment

CALIFORNIA

Proposition 65 Warning

Diesel engine exhaust and some of itsconstituents are known to the State ofCalifornia to cause cancer, birthdefects, and other reproductive harm.

Warning in the Manual

CALIFORNIA


Diesel engine exhaust and some of itsconstituents are known to the State ofCalifornia to cause cancer, birthdefects, and other reproductive harm.

or

CALIFORNIA


Diesel engine exhaust and some of its constituents are knownto the State of California to cause cancer, birth defects, andother reproductive harm.

Notes

enCALIFORNIA PROPOSITION 65 INFORMATION

TO CALIFORNIA CUSTOMERS ANDTO CUSTOMERS SELLING DIESEL ENGINE EQUIPMENT INTO OR

FOR USE IN CALIFORNIA.

Proposition 65, a California law, requires warnings on products which expose individuals in California to chemicals listed under that law,including certain chemicals in diesel engine exhaust.

Obligations of Manufactures of Diesel-Powered Off-Road Equipment. The California Superior Court has approved either of the followingtwo methods of compliance with Proposition 65 requirements by manufactures of off-road equipment containing diesel engines. (The courtorder containing these provisions is attached.)

1. On-Equipment Warning. Place the warning pictured in attachment 1 on all equipment shipped by you into or for sale in California afterJanuary 1, 1996. The warning must be in a location where it is easily visible to the operator of the equipment when (s)he is operating theequipment. The warning must be secured to the equipment. If warnings or operating instructions are provided through a digital display,you may usee that method of providing warning.

2. Operator Manual Warning. When the operator manual is next revised or by December 31, 1995 whichever is earlier, place the warningin attachment 2 in the operator manual. The warning may be either printed in the manual or on a sticker.

The warning must appear in one of the following locations: Inside The front cover Inside the back cover Outside the front cover Outside the back cover As the first page of text

Under either alternative, the warning must appear in the same size, print and format as the attachment selected or be of an equally conspicuoussize and format. If the warning is provided in an on-screen display, the warning must contain the language in the attachment and must beprovided at the time of or in connection with ignition in the same manner as other safety warnings electronically communicated on screen.

Obligation of Resellers of Diesel Engines. This letter must accompany any loose diesel engine sold in California.Should you have any questions, please call Deutz Corporation Product Support Department.

9

Notes

10

Service

Knowing it’s DEUTZ

DEUTZ has always stood for excellence in motorconstruction, pioneering many developments inthe industry. As an independent motor manu-facturer, we offer — worldwide — a com-prehensive range of diesel and gas motorsspanning from 4kW to 7,400kW. Our products areperfectly tailored to meet our customers’ individualrequirements.

Over 1.4 million DEUTZ motors do their jobreliably all over the world. We are determined topreserve the high standard of performance anddependability of our motors, thus keeping ourcustomers satisfied at all times. Therefore we arerepresented worldwide through a network of highlycompetent service partners who will meet theneeds of our customers, wherever they are.

This is why DEUTZ is not only the name for motorswhich pack a lot of inventive genius. DEUTZ alsomeans reliable service and comprehensive supportto enhance your motor’s performance.

This index Sales & Service offers you an overviewof the DEUTZ partners in your vicinity, including theproducts for which they are responsible and therange of services provided. But even when no directproduct responsibility is mentioned, your DEUTZpartner will be happy to help you with expert advice.

The Index is constantly updated. Please ask yourDEUTZ service partner for the latest edition.

DEUTZ AG — at your service.

Order-No.: 0312 0806

Order-No.: 0312 0807 (CD-ROM)

DEUTZ AGDeutz-Mülheimer Str. 147-149D-51057 Köln

Phone: 0049-221-822-0Telefax: 0049-221-822-5304Telex: 8812-0 khd dhttp://www.deutz.de

Obtainable from the local service Partner reponsiblefor you or from:

en

Ersatzteilliste

Spare Parts Catalogue

Catalogue de Pièces de Rechange

Lista de Piezas de Repuesto

1015

Rechts 1

© 20041

deenfresptitnlsvdafnnoeltrruarpl

ErsatzteillisteSpare Parts CatalogueCatalogue de Pièces de RechangeLista de Piezas de RepuestoLista de peças sobresselentesListino parti di ricambioOnderdelenlijstReservdelslistaReservedelslisteVaraosaluetteloReservedelsliste

ETL 11.08.2004.p65 22.09.04, 13:531

0312 1887

1015

© 2004 2

ServiceSehr geehrter Kunde Motornummer

Bitte tragen Sie hier die Motornummer ein. Sieerleichtern hierdurch die Abwicklung bei Kun-dendienst-, Reparatur- und Ersatzteilfragen.

Gegenüber Darstellungen und Angaben dieserErsatzteilliste sind technische Änderungen, diezur Verbesserung der Motoren notwendig wer-den, vorbehalten. Nachdruck und Vervielfälti-gung jeglicher Art, auch auszugsweise, bedarfunserer schriftlichen Genehmigung.

de

Vorwort

die Motoren der Marke DEUTZ sind für ein breitesAnwendungsspektrum entwickelt. Dabei wirddurch ein umfangreiches Angebot von Variantensichergestellt, daß die jeweiligen speziellen An-forderungen erfüllt werden.

Ihr Motor ist dem Einbaufall entsprechend ausge-rüstet, das heißt nicht alle in dieser Ersatzteillistedargestellten Bauteile und Komponenten sind anIhrem Motor dargestellt.

Obwohl die Grafiken weitgehend nicht mit allenDetails dargestellt sind, können die einzelnenVarianten deutlich unterschieden werden, sodaß das für Ihren Motor relevante Ersatzteil leichtherauszufinden ist. Über Positions-, Baugrup-pen- und Motornummer wird in jedem Fall dasrichtige Ersatzteil ermittelt.

Bitte beachten Sie bei dieser Ersatzteilbestellungunsere Bestellhinweise (siehe nachfolgendeBeispielgrafiken), damit wir Ihnen schnell undzuverlässig die benötigten Ersatzteile in der je-weils dem letzten Änderungsstand entspre-chenden Ausführung liefern können.

Für Ihre Rückfragen stehen wir Ihnen gerneberatend zur Verfügung.

IhreDEUTZ AG

Seit jeher steht DEUTZ für bahnbrechende Ent-wicklungen im Motorenbau. Als unabhängigerMotorenhersteller bieten wir weltweit eine kom-plette Palette von Diesel- und Gasmotoren imLeistungsbereich von 4 bis 7.400 kW an. UnsereProdukte sind auf die Anforderungen unsererKunden perfekt zugeschnitten.

Weltweit verrichten mehr als 1,4 Millionen DEUTZMotoren zuverlässig ihren Dienst. Die Einsatz-bereitschaft unserer Motoren und damit dieZufriedenheit unserer Kunden wollen wir erhal-ten. Daher sind wir weltweit mit einem Netz vonkompetenten Partnern vertreten, dessen Dichteder regionalen Verteilung unserer Motoren ent-spricht.

So ist DEUTZ nicht nur der Name für Motoren mitErfindungsgeist. Sondern auch für ein komplet-tes Leistungspaket rund um den Motor und einenService, auf den Sie sich verlassen können.

Einen Überblick über die DEUTZ Partner in ihrerNähe, über deren Produkt-Zuständigkeiten undService-Leistungen. Aber auch wenn keine di-rekte Produkt-Zuständigkeit vermerkt ist, hilft Ih-nen der DEUTZ Partner mit kompetenter Beratungweiter.Ihre DEUTZ AG

Deutz-Mülheimer Str. 147-149D-51057 KölnTelefon: 0049-221-822-0Telefax: 0049-221-822-5304Telex: 8812-0 khd dhttp://www.deutz.de

Händlerstempel


© 20043

DEUTZ Dieselmotoren

SERVICE

Wenden Sie sich bei Betriebsstörungen undErsatz-teilfragen an eine unserer zuständigenService-Vertretungen. Unser geschultes Fach-personal sorgt im Schadensfall für eine schnelleund fach-gerechte Instandsetzung unter Ver-wendung von Original DEUTZ Teilen.

Original DEUTZ Teile DEUTZ Austauschkomponenten

sind das Produkt jahrelanger Forschung undEntwicklung. Das dadurch gewonnene fundier-te know how in Verbindung mit hohen Qualitäts-anforderungen ist die Garantie für die Herstel-lung von Motoren mit langer Lebensdauer, hoherZuverlässigkeit und geringem Kraftstoffver-brauch. Es ist selbstverständlich, daß auch diehohen Anforderungen zum Schutz der Umwelterfüllt werden.

DEUTZ Austauschkomponentensind eine preiswerte Alternative.Selbst-verständlich gelten auch hierwie für Neuteile höchste Qualitäts-maß-stäbe. In Funktion und Zuver-

lässigkeit sind DEUTZ Austauschkomponentenden Original DEUTZ Teilen gleichwertig.

Asbest

Bei diesem Motor verwendeteDichtungen sind asbestfrei. Bitteverwenden Sie bei Wartungs-und Reparaturarbeiten entspre-chende Ersatzteile.

Vorwort

unterliegen den gleichen strengen Qualitätsan-forderungen wie die DEUTZ Motoren. Weiter-entwicklungen, zur Verbesserung der Motorenwerden selbstverständlich auch bei den Origi-nal DEUTZ Teilen eingeführt. Nur die Verwen-dung von nach neuesten Erkenntnissen gefer-tigten Original DEUTZ Teilen bietet die Gewähreinwandfreier Funktion und hoher Zuverlässig-keit.

Vorsicht bei laufendem Motor

Wartungsarbeiten oder Reparaturen nur bei ab-gestelltem Motor durchführen. Evtl. entfernteSchutzvorrichtungen nach Abschluß der Arbei-ten wieder montieren. Bei Arbeiten am laufen-den Motor soll die Arbeitskleidung fest anliegen.Nur bei abgestelltem Motor tanken. Motor nie ingeschlossenen Räümen laufen lassen– Vergiftungsgefahr.

de


© 2004 4

Engine Serial No.

Please enter your engine serial no. here. This willfacilitate dealing with your questions concerningafter-sales service, repair and spare parts.

This Spare Parts Catalogue is subject to enginee-ring changes necessary for engine advance-ment. All rights reserved. No part of this publica-tion may be reprinted or reproduced in any form,without our prior permission in writing.

Dear Customer

Preface

en

Service

DEUTZ has always stood for excellence inengine construction, pioneering many develop-ments in the industry. As an independentenginemanufacturer, we offer - worldwide -acomprehensive range of diesel and gasengines spanning from 4kW to 7,400kW. Ourproducts are perfectly tailored to meet ourcustomers’ individual requirements.

Over 1.4 million DEUTZ engines do their job reliablydependability of our engines, thus keeping ourengines which pack a lot of inventive geniusengine's performance. Therefore we arerepresented worldwide through a network ofhighly competent service partners who will meetthe needs of our customers, wherever they are.This is why DEUTZ is not only the name for motorswhich pack a lot of inventive genius. DEUTZ alsomeans reliable service and comprehensivesupport to enhance your motor’s performance.An overview of the DEUTZ partners in yourarea,their product responsibilities and range ofservices provided. But even when no directproduct responsibility is mentioned, your DEUTZpartner will be happy to help you with expertadvice.

DEUTZ AG — at your service.Deutz-Mülheimer Str. 147-149D-51057 KölnPhone: 0049-221-822-0Telefax: 0049-221-822-5304Telex: 8812-0 khd dhttp://www.deutz.de

DEUTZ engines are developed to meet therequirements of a wide range of applications. Anextensive program of variant options gives themtheir high flexibility.

Your engine is custom-made, i.e. specificallyequipped for your requirement, which meansthat not all of the components and assembliescontained in this catalogue are fitted to yourengine.

The greater part of the illustrations does not depictall details, and yet you will find it easy todifferentiate between versions and thus toidentify the parts pertaining to your engine model.Fig. Item No., Assembly Group No., Engine SerialNo. are the codes that infallibly lead to selectionordering hints (see graphic examples below).This allows speedy and reliable

When placing your order, please observe ourordering hints. This allow speedy and reliabledelivery of the required parts that are based onlatest engineering standards.

If there are any questions, please do not hesitateto contact us.

Sincerely,DEUTZ AG Dealer’s stamp


© 20045

DEUTZ Diesel Engines

SERVICE

In case of operational trouble with your equip-ment or queries about spare parts please contactyour nearest service dealership. Our skilledstaff of service exoerts will trace and remedyany defect quickly, using genuine DEUTZ parts.

Genuine DEUTZ Parts DEUTZ Exchange Components

are products based on long-standing researchand development. The profound know-howacquiredin conjunction with high quality requi-rements guarantee that engines leaving ourworks achieve a long life, high reliability andexcellent fuel economy. Naturally, they also attainbest ratings as regards environmentalprotection.

are a low-cost alternative. Ofcourse, they are subject to the samehigh quality requirements as newparts. And as regards functions and

reliability, DEUTZ exchange components equalgenuine DEUTZ parts.

Preface

are subject to equally stringent quality require-ments as the engines themselves. Impro-vements in engine design are guaranteed to fit thegenuine DEUTZ parts. To ensure that your enginewill retain its functions and high reliability, youshould use genuine DEUTZ parts only.

Beware of the Running Engine

Be sure to shut down the engine beforeperforming maintenance or repair work. Afterrepair, put back in place any removed panels andguards. When doing work on the running engine,working clothes should fit tightly so that looseends cannot get caught. Do not run the engine inenclosed rooms.- Danger of intoxication

en

Asbestos

Gaskets used for this engine do notcontain asbestos. Please use suit-able spare parts when carrying outmaintenance and repairs.


© 2004 6

Numéro du moteur

Veuillez incrire ici le numéro du moteur. Vousfacilitez ainsi le règlement des questions duService après-vente ainsi que tous les problè-mes de réparation et de pièces de rechange.

Nous nous réservons le droit de procéder danscette liste de pièces détachées à toutesmodifications techniques utiles visant à améliorerla qualité des moteurs. Toute réimpression oureproduction du présent document, faite même àtitre exceptionnel, exige notre autorisation écrite.

Cher client,

Avant-propos

Service

f r

les moteurs de la marque DEUTZ ont étédéveloppés pour une gamme étendue d'appli-cations. Il existe un grand choix de variantesrépondant aux exigences spéciales demandéesdans chaque cas.

Votre moteur est équipé pour le cas d’applicationenvisagé, ce qui signifie que toutes les pièces etcomposants représentés dans ce catalogue depièces de rechange ne sont pas montés sur votremoteur.

Bien que les graphiques ne représentent pastous les détails, les variantes se distinguentnettement les unes des autres, si bien que voustrouverez sans problème la pièce de rechangecorrespondant à votre moteur. Les numéros deréférence, de l’organe et du moteur permettenten tous les cas de retrouver la pièce de rechangeque vous cherchez.

Lors de votre commande de pièces de rechangeveuillez respecter nos indications de com-mande, (cf. les tableaux graphiques suivants)afin que nous puissons vous fournir rapidementet sûrement les pièces de rechange demandéesdans la version correspondante réactualisée.

Nous restons à votre entière disposition pourtoute question complémentaire.

DEUTZ AG

DEUTZ est depuis toujours synonyme d’innovationdans le domaine de la construction de moteurs. Ennotre qualité de fabricant indépendant, nousoffrons une gamme complète de moteurs diesel età gaz d’une puissance de 4 à 7 400 kW dans lemonde entier. Nos produits son parfaitementadaptés aux exigences de nos clients.

Aujourd’hui, plus de 1,4 million de moteurs DEUTZtournent dans le monde entier. Notre doubleobjectif est d’assurer la fiabilité de nos moteurs etde garantir la satisfaction de nos clients. C’estpourquoi nous sommes repré-sentés aux quatrecoins de la planète par un réseau de partenairescompétents qui correspond à la répartitionrégionale de nos moteurs.

DEUTZ, ce n’est donc pas seulement une marqueinnovatrice de moteurs. C’est aussi une gammecomplète de services autour du moteur, c’est aussiun nom sur lequel vous pouvez toujours compter.

Voici un aperçu des concessionnaires DEUTZ lesplus proches et de leurs compétences techniqueset des services qu’ils vous offrent. Et même s’il n’estpas directement spécialisé dans le produit qui vousintéresse, votre partenaire DEUTZ pourra vousconseiller avec compétence.

Votre DEUTZ AG

Deutz-Mülheimer Str. 147-149D-51057 KölnTéléphone: 0049-221-822-0Téléfax: 0049-221-822-5304Téléx: 8812-0 khd dhttp://www.deutz.de

Cachet du concessionnaire


© 20047

Les moteurs Diesel DEUTZ

SERVICE

En cas de panne d’exploitation et pour toutequestion relative à des pièces de rechangeveuillez vous adresser à notre point de serviceresponsable pour votre secteur. Notre per-sonnel qualifié assure une remise en état rapideet appropriée de votre moteur en n’utilisant quedes pièces d’origine DEUTZ.

Pièces de rechange DEUTZ Composants de rechange DEUTZ

sont le fruit de longues recherches et d’undéveloppment continu. Le solide savoir-faireainsi acquis conjugué à des exigences élevéesen matière de qualité est la garantie de fabricationde moteurs à longue durée de vie, haute fiabilitéet faible consommation en carburant. Il va de soique les moteurs doivent aussi respecter desexigences élevées en matière de protection del’environnement.

Les composants de rechangeDEUTZ sont une alternative. Làaussi, de même que pour lespièces neuves, on applique desnormes de qualité élevées. Du

point de vue fonctionnement et fiabilité lescomposants de rechange DEUTZ sont équi-valents aux pièces de rechange DEUTZ.

Amiante

Les joints utilisées pour cesmoteurs sont exempts d’amiante.Veuillez employer, lors des tra-vaux d'entretien et de réparation,les pièces de rechange corres-pondantes.

Avant-propos

Elles sonts soumises aux même niveaud’exigence de qualité que les moteurs DEUTZ.Toute progrès visant à améliorer les moteurs estnaturellement immédiatement adpoté pour lespièces d’orgine DEUTZ. Seule l’utilisation depièces d’origine DEUTZ d’origine fabriquéesselon des méthodes ultramodernes garantit unfonctionnement irréprochable et une hautefiabilité.

Précaution à prendre quandle moteur marche

N’effectuer les travaux d’entretien ou les répara-tions que lorsque le moteur est arrêté. A la fin destravaux, remonter les dispositifs de protectionayant été déposés. Lors de travaux à faire surle moteur en marche, les vêtements de travaildoivent bien coller au corps. Ne faire le plein quelorsque le moteur est arrêté. Ne jamais fairefonctionner les moteurs dans des locaux fermés.Danger d’asphyxie !

fr


© 2004 8 es

No. de motor

Registre registrar en estas casillas el No. demotor. Así facilita la tramitación de cuestiones deservicio postventa, reparaciones y repuestos.

Nos reservamos el derecho de efectuar, frentea las representaciones e indicaciones de estaLista de repuestos, las modificaciones técnicasnecesarias para perfeccionar los motores. Parala reimpresión y reproducción en cualquier for-ma, también en la de extractos, se requierenuestra autorización por escrito.

Estimado cliente:

Prefacio

DEUTZ AGDeutz-Mülheimer Str. 147-149D-51057 KölnTéléfono: 0049-221-822-0Telefax: 0049-221-822-5304Telex: 8812-0 khd dhttp://www.deutz.de

La confianza de saber que es DEUTZ

DEUTZ siempre ha estado a la vanguardia de laindustria de fabricación de motores. Como marcaindependiente, ofrecemos, a escala mundial,una gama muy completa de motores diesel y degas, con potencias comprendidas entre 4kW y7400kW. Nuestros productos están estudiadospara satisfacer plenamente las exigencias denuestros clientes.Más de 1.400.000 motores DEUTZ funcionan contoda fiabilidad en distintas partes del mundo.Estamos dispuestos a mantener la disponibilidadoperacional de nuestros motores y de este modola satisfacción de nuestros clientes. Por ello, esta-mos representados mundialmente por una red desocios competentes cuya proximidad y distribu-ción regional corresponde a nuestros motores.Así pues, DEUTZ no es tan sólo el nombre de unmotor fruto del genio creador. Sino también un pa-quete de servicios completo para el motor y unaasistencia técnica en la que puede Ud. confiar.Un resumen de los centros de DEUTZ máscercanos, los productos de los que se ocupa cadacentro y la gama de servicios disponibles. Peroincluso cuando no se mencione un productodeterminado, puede Ud. estar seguro que sucentro de asistencia DEUTZ tendrá mucho gustoen asesorarle y ayudarle en todo lo que pueda.

El registro se actualiza periódicamente. No dudeen solicitar la última edición a su centro deasistencia DEUTZ.

DEUTZ AGA su servicio.

Los motores de la marca DEUTZ se handesarrollado han desarrollado para una ampliagama de aplicaciones. Una extensa oferta devariantes garantiza que se cumplan lasexigencias especiales de cada caso.

Su motor se ha equipado de acuerdo con el casode montaje. Esto significa que en su motor noestán montados todos los componentesdescritos en esta lista de repuestos

Pese a que la mayoría de los gráficos no contienetodos los detalles, se pueden distinguir bien lasdiferentes variantes de modo que resulta fácilidentificar el repuesto corres-pondiente a sumotor. El repuesto correcto para cada caso sedetermina a través de los números de posición,de grupo constructivo y de motor.

Le rogamos que tenga en cuenta nuestrasindicaciones al confeccionar su pedido derepuestos para que le podamos suministrarrápida y eficazmente los repuestos requeridosen el modelo correspondiente al último estado demodificación.

En caso de dudas, estamos a su disposición paraasesorarle.

DEUTZ AGSello del distribuidor


© 20049 es

Motores diesel DEUTZ

SERVICE

En caso de anomalías en el funcionamiento ycuestiones sobre repuestos, diríjase a uno denuestros centros responsables del serviciotécnico a uno de nuestros Servicíos Oficioles.Nuestro personal especializado y cualificado seocupará de arreglar efecientemente y con rapi-dez cualquier desperfecto, utilizando repuestosoriginales DEUTZ.

Piezas originales de DEUTZ Componentes de recambio deDEUTZ

son el producto de trabajos de investigación ydesarrollo de muchos años. Los conocimientosfundamentados que se han ganado con ello juntocon las altas exigencias de calidad es la garantíade la fabricación de motores con una largadurabilidad, una alta eficacia y un bajo consumode combustible. Se sobreentiende que secumplen también las elevadas exigencias para laprotección del medioambiente.

Los componentes de recambiode DEUTZ constituyen unaalternativa económica frente apiezas originales de DEUTZ.Naturalmente rigen también aquí,

igual que para piezas nuevas, elevadísimas ex-igencias de calidad. Los componentes derecambio DEUTZ equivalen a las piezas origina-les de DEUTZ en cuanto a funcionamiento yfiabilidad.

Amianto

Las juntas utilizadas en estemotor están exentas de amianto(asbesto). Para trabajos de man-tenimiento y reparacion utilizar losrepuestos correspondientes.

Prefacio

están sometidas a las mismas exigencias decalidad rigurosas que los motores DEUTZ. Losavances para mejorar los motores se aplican deigual forma a las piezas originales de DEUTZ. Sóloel empleo de piezas originales de DEUTZ origina-les farbricados según los conocimientos másrecientes garantiza un funcionamiento correctoy alta fiabilidad.

Precaución con el motor en marcha

Realizar trabajos de mantenimiento o reparaciónúnicamente con el motor parado. Volver a montaruna vez terminados los trabajos los dispositivosde protección quitados eventualmente. En casode que se tengan que efectuar trabajos con elmotor en marcha, debe ajustarse bien la ropa detrabajo debe tocar al cuerpo para evitar acci-dentes. Suministrar combustible únicamente conel motor parado. No hacer funcionar nunca elmotor en locales cerrados – peligro de intoxica-ción.


© 2004 10 pt

Número do motor

Indique aqui, por favor, o número do motor.Facilitará, com isso, o processamento com a as-sistência técnica, as reparações e as questõesde peças sobresselentes.

Reservamonos o direito proceder a alteraçõesde ordem técnica na representação e nos dadosdesta lista de peças sobresselentes que setornem neces-sárias para o aperfeiçoamentodos motores. Toda e qualquer reimpressão ereprodução, mesmo só em parte, requere anossa autorização por escrito.

Prezado cliente:

Prefácio

Serviços

Os motores da marca DEUTZ foram desenvol-vidos para um espectro de aplicação vasto.Assegura-se ao mesmo tempo cumprimento dasexigências particulares correspondentes atravésda ampla oferta de variantes.

O seu motor encontra-se equipado de acordocom o tipo de montagem, isto é, não estãoembutidas no mesmo todas as peças e partescomponentes representadas na sua lista depeças sobresselentes.

Embora os gráficos não se encontremamplamente representados com todos ospormenores, é possível distinguir claramentecada uma das variantes, de forma a en-contrar-se facilmente a peça sobresselentede importância para o seu motor. É possível,em todo o caso, verificar a devida peçasobresselente correcta.

Quanto ao pedido de peças sobresselentesqueira, por favor, observar as nossasinstruções para encomendas (veja os gráficosde exemplo que seguem), a fim de podermosfornecer-lhe rápida e seguramente as peçassobresselentes requeridas de acordo com acorrespondente versão à da última alteraçãoactualizada.

Estamos à sua inteira disposição para umaconselhamento no caso de quaisquer pedidode informação que nos dirigir.

A suaDEUTZAG

Desde sempre que a DEUTZ é responsável porprogressos revolucionários na construção demotores. Como fabricante independente demotores oferecemos em todo o mundo uma gamacompleta de motores a Diesel e a gás numa gamade potência de 4 a 7.400 kW. Os nossos produtossão desenvolvidos à medida das exigências dosnossos clientes.

Em todo o mundo mais de 1,4 milhões de motoresDEUTZ executam o seu serviço com eficácia.Queremos conservar a confiabilidade opera-cional dos nossos motores e, com ela asatisfação dos nossos clientes. É por este factoque estamos representados em todo o mundocom uma rede de competentes parceiros cujarepresentação corresponde à distribuição regio-nal dos nossos motores.Deste modo, a DEUTZ é não só o nome demotores com espírito inovativo, como também deum completo conjunto de serviços relacionadoso motor e de uma assistência técnica de perfeitaconfiança.Consulte a informação fornecida pelos parceirosDEUTZ da sua área, as suas competências deprodutos e prestações de serviços. E, mesmo naausência de um registo de competência deprodutos directo, qualquer parceiro DEUTZestaria disponível para dar o seu conselhocompetente.

A suaDeutz AG

Deutz-Mülheimer Str. 147-149D-51057 KölnTelefone: 0049-221-822-0Fax: 0049-221-822-5304Telex: 8812-0 khd dhttp://www.deutz.de

Carimbo do vendedor


© 200411 pt

Os motores diesel DEUTZ

SERVIÇOS

No caso de avarias operacionais e de possíveisconsultas relacionadas com peças e partessobressalentes, queira dirigir-se a uma dasnossas representações autorizadas de serviço.O nosso pessoal técnico especializado procu-rará, em caso de uma avaria, proceder a umareparação rápida e tecnicamente competente,com a aplicação de peças originais DEUTZ.

Peças originais DEUTZ Componentes de substituição DEUTZ

são produto de longos anos de pesquisa edesenvolvimento. O „know how“ consolidadoassim adquirido constitui, aliado às grandesexigências de qualidade, a garantia para ofabrico de motores com uma vida útil longaelevada fiabilidade de serviço e um consumoreduzido de combustível.É evidente de igual modo, são respeitados oselevados requisitos de preservação do meioambiente.

Os Componentes de substituiçãoDEUTZ são uma alternativa econó-mica para as peças sobresselentesoriginais DEUTZ.Naturalmente que vigoram aqui, tal,

como para as peças novas, os padrões maiselevados de qualidade.Os Componentes de substituição DEUTZ sãoequivalentes na sua função e confiabilidade àspeças sobresselentes DEUTZ.

Amianto

As vedações utilizadas nestemotor são isentas de amianto.Utilizar, por favor, as correspen-dentes peças sobresselentesnos trabalhos de manutenção ereparação.

Prefácio

estão sujeitas às mesmas exigências severasde qualidade para os motores DEUTZ. Natural-mente que se introduzem aperfeiçoamentostambém nas peças originais DEUTZ para omelhoramento dos motores. Somente o empre-go de peças e partes originais fabricadas deacordo com os conhecimentos mais modernospoderá garantir um funcionamento perfeito e umelevado grau de fiabilidade.

Precaução com o motor emfuncionamento

Proceder aos trabalhos de manutenção e àsreparações apenas com o motor desligado.Depois de ter terminado os trabalhos é precisouma nova montagem de dispositivos protec-tores, eventualmente removidos. No caso deefectuar trabalhos com o motor em funciona-mento, o vestuário de trabalho deverá estar justoao corpo. Enchimento de combustível apenascom o motor desligado. Nunca se deve deixar omotor a trabalhar num recinto fechado, porqueexiste o perigo de intoxicação.


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Numero del motore

Voglia annotare qui il numero del motore. Inquesto modo faciliterà il disbrigo in caso diquestioni relative all’assistenza tecnica, allariparazione ed ai pezzi di ricambio.

Rispetto all’illustrazione ed alle indicazioni diquesta lista dei pezzi di ricambio, ci si riservaquelle modifiche tecniche che sono necessarieper migliorare i motori. Per la ristampa e lariproduzione di qualsiasi tipo è necessaria lanostra autorizzazione scritta.

Egregio cliente,

Prefazione

DEUTZ: un nome che vuol direeccellenza!

DEUTZ, da sempre sinonimo di innovazione nelsettore della fabbricazione dei motori, è unfabbricante indipendente che offre sul mercatomondiale una gamma completa di motori dieseled a gas di potenza compresa fra 4 e 7400 kW.Noi forniamo prodotti perfettamente adatti allespecifiche esigenze dei nostri clienti.

Oggi, più di 1,4 milioni di motori DEUTZ sono inattività in tutto il mondo. Noi perseguiamo unduplice obiettivo: garantire la massima affidabilitàdei nostri prodotti e garantire un elevato livello disoddisfazione ai nostri clienti. Ecco perchéabbiamo istituito una rete mondiale di partner, la cuidensità è funzione diretta del numero di motoriin attività in ciascuna regione.

DEUTZ non è solamente un marchio innovatoredi motori, ma anche una gamma completa diservizi in grado di accentuare le lorocaratteristiche di affidabilità ed un nome su cuipotrete sempre contare.

Segue una panoramica dei partner DEUTZ vicinia voi, inclusa la gamma di servizi offerti e le famigliedi prodotti per cui essi possono assicurarvi unamanutenzione specializzata. Qualora nonpotessero fornirvi un aiuto diretto, potranno inogni caso consigliarvi con competenza.

Il Vostro DEUTZ AGDeutz-Mülheimer Str. 147-149D-51057 Köln

Telefono: 0049-221-822-0Telefax: 0049-221-822-5304Telex: 8812-0 khd dhttp://www.deutz.de

i motori DEUTZ raffreddati ad agua sono stati svi-luppati per un ampio spettro d’uso. Grazie ad unavasta offerta di varianti viene garantito che verràfatto fronte alle rispettive esigenze particolari.

Il Suo motore è allestito secondo lo specifico casodi montaggio, vale a dire che non tutti gli elementied i componenti illustrati nel Suo listino dei pezzidi ricambio sono integrati nel Suo motore.

Nonostante i grafici non siano illustrati con tutti idettagli, si possono distinguere chiaramente lesingole varianti, così che è facile trovare confacilità il pezzo di ricambio importante per il Suomotore. In ogni caso verrà rilevato il pezzo diricambio giusto tramite numero di posizione, digruppo di assemblaggio e di motore.

Per l’ordinazione di pezzi di ricambio vogliaosservare le nostre indicazioni per l’ordina-zioneal fine di permetterci di fornirle in modo celere esicuro i pezzi di ricambio necessari nella relativaversione, conforme all’ultima modifica.

Siamo a Vs. completa disposizione per eventualichiarimenti.

SuaDEUTZ AG

Timbro del concessionario


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I motori Diesel DEUTZ

SERVICE

In caso di avarie o richieste di ricambi, rivolgersiimmediatamente ai nostri Centri di Assistenzaautorizzati. Il nostro personale appositamenteaddestrato è a disposizione in caso di guasto perun intervento rapido, garantendo l'uso di ricambioriginali DEUTZ.

I pezzi di ricambio DEUTZ Componenti intercambiali DEUTZ

sono il prodotto di numerosi anni di ricerca esviluppo. Il solido know how così ottenuto incombinazione con elevate esigenze qualitative èla garanzia per la fabbricazione di motori aventilunga durata, elevata affidabilità ed un bassoconsumo di combustibile. E’naturale che si facciafronte anche alle elevate esigenze a favore dellaprotezione ambientale.

I componenti intercambiabili DEUTZsono un’alternativa economica aipezzi di ricambio originali.Naturalmente anche qui, come per ipezzi nuovi, valgono massimi criteri

qualitativi. I componenti intercambiablili DEUTZsono equivalenti ai pezzi di ricambio per ciò checoncerne il loro funzionamento ed affidabilità.

Prefazione

sono soggetti alle stesse severe esigenze quali-tative poste ai motori DEUTZ. I perfezionamentiatti a migliorare i motori vengono naturalmenteintrodotti anche per i pezzi di ricambio originali.Soltanto l’uso di pezzi di ricambio originali, fab-bricati secondo le più attuali conoscenze, offrela garanzia di un perfetto funzionamento e dielevata affidabilità.

Prudenza con il motore acceso

Eseguire i lavori di manutenzione o di riparazionesolo con motore spento. Al termine dei lavori ri-montare i dispositivi di sicurezza eventualmenteasportati. Per lavori da eseguire con il motore ac-ceso, l’abbigliamento da lavoro deve aderirebene al corpo. Fare rifornimento di combustibilesolo con motore spento. Non lasciare il motoreacceso in locali chiusi – pericolo di avvelena-mento.

Ambianto

Le guarnizioni utilizzate per questomotore sono esenti da amianto.Per i lavori di manutenzione edi riparazione fate uso degliappositi ricambi.


© 2004 14

Motornummer:

Noteer hier het motornummer. Op die maniervereenvoudigt u de afhandeling van even-tuele klantenservice-, reparatie- en onder-delenkwesties.

Technische wijzigingen ten opzichte van detekeningen en gegevens in deze onder-delenlijst, die noodzakelijk zijn ter verbeteringvan de motoren, blijven voorbehouden. Hetnadrukken of kopiëren van deze gebruiks-aanwijzing of gedeelten ervan, in welke vormdan ook, is niet toegestaan zonder onzevoorafgaande schriftelijke toestemming.

Geachte klant,

Voorwoord

Service

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De motoren van het merk DEUTZ werdenontwikkeld voor een breed toepassings-spectrum. Door middel van een uitgebreidaanbod van varianten wordt er steeds weervoor gezorgd dat er aan de betreffendespecifieke eisen wordt voldaan.

Uw motor werd uitgerust in overeenstemmingmet de specifieke inbouwsituatie. Dat wil zeggendat uw motor niet al de onderdelen die in deze lijstwerden opgenomen bevat.

Hoewel de tekeningen in de meeste gevallen nietalle details bevatten, kunnen de verschillendeuitvoeringen duidelijk onderscheiden worden,zodat u het voor uw motor relevante onderdeelgemakkelijk kunt vinden. Met behulp van hetpositie-, het constructie- en het motornummerkunt u het juiste onderdeel in ieder geval bepalen.

Gelieve bij het bestellen van onderdelen rekeningte houden met onze bestelaanwijzingen (zieonderstaande voorbeeldtekeningen), zodat wiju de benodigde onderdelen snel en in hun juisteuitvoering kunnen leveren.

Voor nadere inlichtingen staan wij geheel te uwerbeschikking.

DEUTZ AG

Van oudsher staat de naam DEUTZ voorbaanbrekende ontwikkelingen op het gebied vande constructie van motoren. Als onafhankelijkemotorenfabrikant bieden wij wereldwijd eencompleet assortiment diesel- en gasmotoren meteen vermogen van 4 tot 7.400 kW. Onzeproducten zijn perfect afgestemd op de eisenvan onze klanten.

Wereldwijd vervullen ruim 1,4 miljoen DEUTZ-motoren hun taak op betrouwbare wijze. Wijwillen de bedrijfszekerheid van onze motoren, enop die manier ook de tevredenheid van onzeklanten, consolideren. Daarom zijn wij wereld-wijd vertegenwoordigd via een netwerk vancompetente dealers, waarvan de dichtheidovereenstemt met de regionale verspreiding vanonze motoren.

Zo staat DEUTZ niet alleen voor innovatievemotoren maar ook voor een compleetdienstenpakket rondom de motor en voor eenservice waar u steeds op kunt rekenen.

Er bestaat een overzicht van de DEUTZ-dealersin uw omgeving, van hun productverant-woordelijkheid en hun onderhoudsdiensten.Maar ook wanneer een bepaalde DEUTZ-dealeru niet rechtstreeks aan een bepaald product kanhelpen, zal hij u in ieder geval deskundig kunnenadviseren.

Uwe DEUTZ AG

Deutz-Mülheimer Str. 147-149D-51057 Köln

Tel.: 0049-221-822-0Fax: 0049-221-822-5304Telex: 8812-0 khd dhttp://www.deutz.de

Stempel handelaar


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DEUTZ-dieselmotoren

SERVICE

In geval van storingen en met vragen omtrentreserveonderdelen kunt u terecht bij een vanonze service-vertegenwoordigingen. Ons ge-schoolde vakpersoneel zorgt in geval van scha-de of storingen voor een snelle en vakkundigereparatie met originele DEUTZ-onderdelen.

Originele DEUTZ-onderdelen Tweedehands DEUTZ-onderdelen

zijn het resultaat van vele jaren van onderzoek enontwikkeling. De daardoor verworven know-how staat samen met onze hoge kwaliteitseisengarant voor motoren met een lange levensduur,een hoge betrouwbaarheid en een laagbrandstofverbruik. En het spreekt vanzelf datonze dieselmotoren ook voldoen aan de hogeeisen inzake milieubescherming.

Tweedehands DEUTZ-onderdelenvormen een voordelig alternatiefvoor nieuwe originele onderdelen.Natuurlijk gelden ook hier zeer hoge

kwaliteitsnormen, net als bij nieuwe onderdelen.Inzake werking en betrouwbaarheid zijn tweede-hands DEUTZ-onderdelen gelijkwaardig aannieuwe onderdelen.

Asbest

De in deze motor gebruiktepakkingen zijn vrij van asbest.Gebruikt u bij onderhouds- enreparatiewerkzaamhedena.u.b. onderdelen van dezelfdekwaliteit.

Voorwoord

zijn onderworpen aan dezelfde strengekwaliteitseisen als de DEUTZ-motoren. Nieuweontwikkelingen ter verbetering van de motorenworden natuurlijk ook doorgevoerd op deoriginele DEUTZ-reserveonderdelen. Alleen hetgebruik van originele DEUTZ-onderdelen, die opbasis van de nieuwste inzichten worden ont-wikkeld, garandeert een onberispelijke werkingen een hoge betrouwbaarheid.

Voorzichtig bij draaiende motor

Onderhoudswerkzaamheden en reparatiesmogen alleen bij uitgeschakelde motor wordendoorgevoerd. Eventueel verwijderde bescherm-platen enz. moeten na de werkzaamhedenopnieuw worden gemonteerd. Bij werkzaam-heden aan draaiende motoren dient men nauwaansluitende werkkleding te dragen. Tank alleenbij uitgeschakelde motor. Laat de motor nooit ineen gesloten ruimte draaien wegens vergifti-gingsgevaar.

nl


© 2004 16 sv

Motornumret:

Ange motornumret här. Därmed underlättar duhanteringen vid frågor som rör kundtjänst,reparationer eller reservdelar.

Vi förbehåller oss att göra tekniska ändringar,nödvändiga för att förbättra motorerna ytterligare,gentemot de bilder och uppgifter som finns i denhär reservdelslistan. Varje typ av kopiering ochmångfaldigande, även delar av den, kräver vårtskriftliga tillstånd.

Bäste kund,

Förord

Service

Deutz motorer har utvecklats för att täcka ett brettanvändningsområde. Tack vare ett omfattandeutbud av varianter säkerställs att alla speciellakrav uppfylls.

Din motor är alltid rätt utrustad inför monteringen,vilket i praktiken innebär att vissa av de delar ochkomponenter som finns i den här reservdelslistaninte finns i din motor.

Trots att inte alla detaljer visas på ritningarna, ärdet enkelt att skilja på de olika varianterna. Därmedär det lätt att hitta den reservdel som passar till justdin motor. Den korrekta reservdelen fastställs viapositionsnummer, modulnummer och motor-nummer.

Beakta våra beställningsanvisningar vid beställningav reservdelar (se nedanstående exempel), såatt vi snabbt och tillförlitligt kan leverera denödvändiga reservdelarna i det utförande sommotsvarar den senaste ändringsstatusen.

Vi hjälper gärna till om du har några frågor.

Din

DEUTZ AG

Sedan lång tid tillbaka står DEUTZ förbanbrytande utveckling inom motorbyggnad.Som oberoende motortillverkare erbjuder vi ettkomplett sortiment av diesel- och gasmotorer ieffektområdet 4 kW till 7 400 kW över hela världen.Våra produkter är perfekt utformade för att klarade krav som våra kunder ställer.

I hela världen arbetar mer än 1,4 miljoner DEUTZ-motorer på ett tillförlitligt sätt. Vi vill behålla våramotorers funktionssäkerhet och därmed vårakunders belåtenhet. Därför representeras viglobalt av kompetenta partner, vars koncen-tration motsvarar den regionala fördelningen.

Därmed står namnet DEUTZ inte bara förinnovativa motorer utan även för ett kompletttjänstepaket som rör motorerna och en servicesom du kan lita på.

Här får du en överblick över DEUTZ partner i dinnärhet och om deras produktansvar och service.Även om det inte finns något direkt produkt-ansvar, så hjälper DEUTZ partner ändå till medkompetent rådgivning.

DinDEUTZ AGDeutz-Mülheimer Str. 147-149D-51057 Köln

Telefon: 0049-221-822-0Telefax: 0049-221-822-5304Telex: 8812-0 khd dhttp://www.deutz.de

Återförsäljarens stämpel


© 200417 sv © 2000

DEUTZ-dieselmotorer

SERVICE

Vänd dig till någon av våra servicerepresen-tanter vid driftstörningar och frågor som rörreservdelar. Våra utbildade fackmän reparerarmotorn snabbt och korrekt med hjälp av DEUTZoriginaldelar.

DEUTZ originaldelar DEUTZ Utbyteskomponenter

Detta är en produkt som krävt många årsforskning och utveckling. Den därigenom upp-byggda kunskapen utgör, i förbindelse med högakvalitetskrav, en garanti för tillverkning av motorermed lång livslängd, hög tillförlitlighet och lågbränsleförbrukning. Det är självklart att även dehöga kraven beträffande miljöskydd uppfylls.

DEUTZ Utbyteskomponenter utgörett prisvärt alternativ. Naturligtvisgäller även här högsta kvalitetskrav,precis som på nya delar. När detgäller funktion och tillförlitlighet är

DEUTZ utbyteskomponenter likvärdiga medDEUTZ originaldelar.

Förord

Dessa underkastas samma hårda kvalitetskravsom DEUTZ-motorerna. Vidareutvecklingar föratt förbättra motorerna införs naturligtvis ävenbeträffande DEUTZ originaldelar. Endast vid an-vändning av DEUTZ originaldelar, som tillverkatsenligt den senaste kunskapen, går det att garan-tera felfri funktion och hög tillförlitlighet.

Var försiktig när motorn går

Utför underhållsarbeten och reparationer endastnär motorn är avstängd. Sätt tillbaka eventuelltborttagna skyddsanordningar efter att arbetethar avslutats. Om arbete måste utföras medanmotorn går, så ska arbetskläderna sitta tätt motkroppen. Låt aldrig en motor gå i ett slutet rum - detfinns då risk för förgiftning.

Asbest

De tätningar som används i denhär motorn är asbestfria. Användendast sådana reservdelar vidunderhållsarbeten och reparatio-ner.


© 2004 18 da

Motornummer

Notér motornummeret her. Derved lettes afvik-lingen i forbindelse med service-værksted, repara-tion og bestilling af reservedele.

Ret til tekniske ændringer, som bliver nødvendigetil forbedring af motorerne, forbeholdes.Eftertryk og mangfoldiggørelse af enhver art,også i uddrag, kun tilladt med vores skriftligesamtykke.

Kære kunde!

Forord

Service

Fra tidernes morgen har DEUTZ væretensbetydende med banebrydende udviklingerinden for fremstillingen af motorer. Som uaf-hængig motorfabrikant tilbyder vi over heleverden et komplet spektrum af diesel- og gas-motorer med en effekt på 4 til 7.400 kW. Voreprodukter er perfekt skræddersyet efter vorekunders behov.

Over hele verden udretter mere end 1,4 millionerDEUTZ-motorer deres arbejde til alles tilfreds-0hed. Vi ønsker at bevare vore motorersanvendelsesberedskab og dermed også vorekunders tilfredshed. Derfor er vi over hele verdenrepræsenteret af et helt net af kompetentepartnere, hvis tæthed svarer til vore motorersregionale fordeling.

Således er DEUTZ ikke kun navnet på motorer tilstadig nye opgaver, men også på en kompletservicepakke med hensyn til alt, hvad der har medmotorer at gøre, og med en service, De kan stolepå.

Over disses produkt-kompetancer og service-ydelser. Men selvom der ikke direkte er angivetnogen produkt-kompetance, hjælper DEUTZ-partneren Dem videre med en kompetentrådgivning.

Deres DEUTZ AGDeutz-Mülheimer Str. 147-149D-51057 KölnTelefon: 0049-221-822-0Telefax: 0049-221-822-5304Telex: 8812-0 khd dhttp://www.deutz.de

De væskekølede motorer fra firmaet DEUTZ erudvik-let til et bredt anvendelsesspektrum.Derved sikres det på grund af det omfattendeudbud af varianter, at de individuelle speciellekrav kan opfyldes.

Deres motor er udstyret, så den svarer tilbrugstilfældet; d.v.s. at ikke alle elementer ogkomponenter, som er afbildet i denne reserve-delsliste, er monteret på Deres motor.

Selv om de grafiske afbildninger ikke kan visesmed alle detaljer, kan man tydeligt se forskel på deenkelte varianter, så De let kan finde dereservedele, som er relevante til Deres motor.Ved hjælp of positions-, type- og motor-nummeret kan man altid finde frem til den rigtigereservedel.

Første gang De bestiller reservedele, bedes Debemærke vore bestillingshenvisninger, så vihurtigt og korrekt kan finde frem til de nødvendigereservedele i den udførelse, som svarer til dennyeste ændringstilstand.

Vi står gerne til rådighed, hvis De har spørgsmål.

DeresDEUTZ AG Forhandlerens stempel


© 200419 da

DEUTZ-dieselmotorer

SERVICE

I tilfælde af driftsforstyrrelser og ved reserve-delsspørgsmål kan De henvende Dem til en afvores ansvarlige service-repræsentationer.Vores skolede fag-personale sørger i tilfælde afskader for en hurtig og faglig korrekt istand-sættelse under anvendelse af originale dele.

Original dele DEUTZ udskiftningskomponenter

er produktet af mange års forskning og udvikling.Det velunderbyggede knowhow, vi dermed harvun-det, i forbindelse med høje kvalitetskrav erDeres garanti for en produktion af motorer medlang leve-tid, høj pålidelighed og lavt brændstof-forbrug. Det er en selvfølge, at de høje krav mht.beskyttelsen af miljøet også opfyldes.

DEUTZ-udskiftningskomponen-ter er et prisbilligt alternativ til origi-nale dele. Selvfølgelig gælderogså her de højeste kvali-tetskrav – som ved de nye dele. DEUTZ-

udskiftnings-komponenter fungerer lige så godtog er lige så pålidelige som originale dele.

Forord

underligger de samme strenge kvalitetskrav somDEUTZ-motorerne. Videreudviklinger til forbed-ring af motorerne bliver naturligvis også anvendtved original dele. Kun hvis man anvender- origi-nale dele, som er udfærdiget efter de nyesteerkendelser, har man sikkerhed for en upå-klagelig funktion og høj pålidelighed.

Forsigtig, når motoren løber

Vedligeholdelsesarbejder og reparationer måkun gennemføres, når motoren er slået fra. Evt.fjernede beskyttelsesanordninger skal attermonteres på, når arbejderne er afsluttet. Vedarbejder med løbende motor må man ikke bæreløsthængende tøj. Der må kun fyldes brændstofpå med motoren slået fra. Lad aldrig motoren løbei lukkede rum – fare for forgiftning.

Asbest

Pakningerne, som er anvendt tildenne motor, er asbestfrie. An-vend venligst ved vedligeholdelses-og reparationsarbejde tilsvarendereservedele.


© 2004 20

Mottorinumero:

Merkitkää tähän moottorinumero. Sen ilmoit-taminen helpottaa asioiden käsittelyä huolto-,korjaus- ja varaosakysymyksien yhteydessä.

Tämän varaosaluettelon kuvauksien ja tietojensuhteen pidätämme oikeuden muutoksiin, jotkaovat tarpeellisia moottorin teknisen kehityksenkannalta. Kaikenlaiseen jälkipainosten ja kopioi-den tekoon, myös osittain, tarvitaan kirjallinenlupamme.

Hyvä asiakas

Esipuhe

fn

Hyvä tietää, se on DEUTZ.

DEUTZ-moottorit on kehitetty laajaa käyttäjä-kuntaa silmälläpitäen. Niinpä tarjolla on laajavalikoima moottorivaihtoehtoja, jotka täyttävätasiakkaiden vaihtelevat moottoritarpeet.

Moottorinne on toimitettu tietyin varustein, eivätkäkaikki tässä varaosaluettelossa esiintyvät osatvälttämättä kuulu moottorinne varusteisiin.

Vaikka kaaviokuvat eivät sisällä kaikkia yksityis-kohtia, eri vaihtoehdot on kuitenkin helppo erottaatoisistaan moottorillenne tärkeiden varaosientunnistamiseksi. Position, rakenneryhmä- jamoottorinumeron avulla pystytään joka tapauk-sessa toimittamaan oikea varaosa.

Varaosia tilattessa on noudatettava annettujatilausohjeita, jotta pystymme nopeasti ja varmastitoimittamaan tarvittavat, kyseisen mallin viimei-sintä teknistä kehitystä vastaavat varaosat.

Annamme mielellään lisätietoja ja vastaammekysymyksiinne.

DEUTZ AG

DEUTZ on edustanut jo alunalkaen uraauurtaaviauudistuksia moottorinrakennusalalla. Riippu-mattomana moottorinvalmistajana tarjo-ammeympäri maailmaa täydellisen valikoiman diesel- jakaasumoottoreita, joiden suorituskyky vaihteleevälillä 4 - 7400 kW. Tuotteemme on sovitettutäydellisesti asiakkaittemme vaatimusten mukaan.

Yli 1,4 miljoonaa DEUTZ-moottoria täyttääympäri maailmaa luotettavasti tehtävänsä.Tarkoituksenamme on säilyttää moottoreidemmekäyttövalmius ja täten asiakkaittemme tyyty-väisyys. Tästä syystä olemme edustettuinaympäri asiantuntevan edustajaverkoston kautta,jonka tiheys vastaa moottoreidemme alueellistalevinneisyyttä.

DEUTZ-nimi ei merkitse näin vain keksijähenkisiämoottoreita. , vaan myös moottoreihin liittyvääkokonaispakettia ja palvelua, johon voitte luottaa.

Yleiskatsaus DEUTZ-edustajista, heidän edusta-mistaan tuotteista ja palveluista antavat teillekokonaiskuvan verkostostamme. Ja vaikka yksilöl-listä tuote-edustusta ei olisikaan mainittu, DEUTZ-edustaja auttaa sinua eteenpäin asiantuntevallaneuvonnalla.

DEUTZ AGDeutz-Mülheimer Str. 147-149D-51057 KölnPuh.: 0049-221-822-0Telefax: 0049-221-822-5304Telex: 8812-0 khd dhttp://www.deutz.de

Liikkeen leima


© 200421

DEUTZ dieselmoottorit

SERVICE

Käyntihäiriöissä ja varaosakysymyksissä kään-tykää DEUTZ-edustajanne puoleen. Vauriota-pauksessa koulutettu henkilökunta huolehtiinopeasta ja asianmukaisesta korjauksestakäyttämällä alkuperäisiä DEUTZ-osia.

Alkuperäiset DEUTZ varaosat DEUTZ vaihto-osat

ovat monien vuosien tutkimuksen ja kehittelyn tu-los. Näin saavutettu know-how yhdistettynä kor-keisiin laatuvaatimuksiin on tae pitkäikäisten, luo-tettavien ja vähän polttoainetta kuluttavienmoottreiden valmistukselle. On itsestään selvää,että myös tarkat ympäristön suojelua koskevatmääräykset on otettu huomioon.

DEUTZ-vaihto-osat ovat edullinenvaihtoehto alkuperäisille DEUTZvaraosille.On myös itsestään selvää, ettänäille osille asetetaan samat kor-

keat laatuvaatimukset kuin uusillekin osille. Toi-minnaltaan ja luotettavuudeltaan DEUTZ vaihto-osat ovat samanarvoisia alkuperäisten DEUTZvaraosien kanssa.

Asbesti

Tässä moottorissa käytetyissätiivisteissä ei ole asbestia.Huolto- ja korjaustöissä pyy-dämme käyttämään vastaaviavaraosia.

Esipuhe

täyttävät samat, tiukat laatuvaatimukset kuinDEUTZ-moottoritkin. Moottorien parantamiseenkäytettyä kehitystä sovelletaan myös DEUTZvaraosiin. Moitteeton toiminta ja luotettavuus ontaattu käyttämällä ainoastaan viimeisimmäntekniikan mukaan valmistettuja alkuperäisiäDEUTZ varaosia.

Varo moottorin käydessä

Huolto- tai korjaustyöt saa suorittaa ainoastaanmoottorin ollessa pysäytettynä. Mahdollisesti ir-rotetut suojalaitteet on asennettava töiden pää-tyttyä jälleen paikoilleen. Huollettaessa käyväämoottoria työvaatetus ei saa olla liian väljä.Moottori on pysäytettävä tankkauksen ajaksi.Moottoria ei saa koskaan käyttää suljetuissatiloissa – myrkytysvaara.

fn


© 2004 22

Motornummer:

Vennligst noter motornummeret her. Dette gjørbehandlingen av spørsmål angående service,reparasjoner og reservedeler enklere.

Vi forbeholder oss tekniske foranderinger i vårebeskrivelser og opplysninger i denne instruk-sjonsboken som er nødvendig for forbedringav motorene. Ettertrykk og kopiering på enhvermåte, også delvis, må ikke gjøres uten vårskriftlige tillatelse.

Kjære kunde,

Allment

no

Service

Deutz har alltid stått for en banebrytende utviklingav motorer. Som uavhengig motorprodusenttilbyr vi verden over et komplett utvalg av diesel-og gassmotorer med en effekt på 4 til 7.400 kW.Våre produkter er perfekt tilpasset våre kunderskrav.

Verden over arbeider mer enn 1,4 millionerDEUTZ motorer pålitelig. Vi vil sørge for åopprettholde motorenes driftsklarhet og dermedvåre kunders tilfredshet. Derfor er vi verden overrepresentert med et nett av kompetente partneresom er tilpasset den regionale fordelingen avvåre motorer.

DEUTZ er dermed ikke bare et navn for innovativemotorer, men også for en komplett pakke medytelser for alt som har med motorer å gjøre og foren service du kan stole på.

En oversikt over DEUTZ-partnere nær deg, hvilkeprodukter de har ansvar for og hvilke service-tjenester de tilbyr. Og selv om en DEUTZ-partnerikke er merket av med produktansvar for dinmotor, kan han gi deg kompetent hjelp.Vennlig hilsen DEUTZAG


Telefon: 0049-221-822-0Telefax: 0049-221-822-5304Telex: 8812-0 khd dhttp://www.deutz.de

Væskekjølte motorer av merket DEUTZ er utvikletmed tanke på mange forskjellige bruksområder.Et bredt spekter av varianter sikrer at mangeforskjellige spesielle krav kan oppfylles.

Din motor er utstyrt for det aktuelle bruksområde.Derfor vil ikke alle deler og komponenter som eroppført på denne reservedelslisten, være mon-tert på din motor.

Selv om bildene ikke alltid viser alle detaljer, kande enkelte variantene tydelig skilles frahverandre slik at det er lett å finne frem til derelevante reservedelene til din motor. Ved hjelp avposisjonsnummer, komponentgruppenummer ogmotornummer kan du i hvert enkelt tilfelle finnefrem til riktig reservedel.

Vi ber deg vennligst følge våre anvisninger vedbestilling av reservedeler (se bildeeksempelnedenfor) slik at vi kan levere de reservedelenedu har bruk for, raskt og sikkert og ifølge deseneste endringer.

Vi står gjerne til din disposisjon hvis du harytterligere spørsmål.

Vennlig hilsenDEUTZ AG

Forhandlerstempel


© 200423

DEUTZ-dieselmotorer

SERVICE

Ta kontakt med en av våre ansvarlige service-representanter ved driftsforstyrrelser og spør-smål angående reservedeler. Vårt utdannetefagpersonal sørger for rask og fagmessigreparasjon med DEUTZ originaldeler.

Originaldeler DEUTZ byttekomponenter

er resultatet av mangeårig forskning og utvikling.En omfattende know-how i forbindelse medhøye kvalitetskrav er garantien for fremstillingenav motorer med lang levetid, stor pålitelighet oglavt drivstofforbruk Det er en selvfølge at destrenge miljøkravene blir oppfylt.

DEUTZ byttekomponenter er etbillig alternativ til originaldeler.Selvfølgelig gjelder også her dehøyeste kvalitetskrav på sammemåte som for nye deler. Når det

gjelder funksjon og pålitelighet, er DEUTZ bytte-komponenter likeverdige med originaldeler.

Asbest

Pakningene som benyttes i dennemotoren, er asbestfrie.Bruk reservedeler uten asbestved vedlikeholds- og reparasjons-arbeid.

Allment

er underkastet strenge kvalitetskrav på linje medDEUTZ motorer. Videreutvikling for å forbedrevåre motorer blir selvfølgelig fulgt opp med for-bedringer på originaldeler. Bruk derfor bare ori-ginaldeler som er fremstilt etter de nyesteerfaringer for å være sikker på feilfri funksjon oghøy pålitelighet.

Vær forsiktig med motor i drift!

Vedlikeholdsarbeid og reparasjoner skal bareutføres med avslått motor. Monter alle beskyt-telsesanordninger igjen etter avsluttet arbeid.Bruk tettsittende arbeidstøy ved arbeid på enmotor som går. Tank bare med avslått motor.La aldri motoren gå i lukkete rom - fare forforgiftning!

no


© 2004 24


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Service

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© 200435

Service

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© 2004 36

Indicaciones para el pedido:

Al solicitar piezas originales de DEUTZ seránecesario indicar los siguientes datos:

- Nº de Motor:

- Nº de identificatión

- Cantidad de piezas

Estructuración de la documentación

- Las tablas con las ilustraciones de dichaspiezas de repuesto están clasificadas deacuerdo con el grupo constructivo de losmotores.

- Los grupos constructivos se indican en elresumen correspondiente del motor.

- El Nº de identificación 06/59 consta del grupo(v.g. 06) y de la posición (v.g. 59).

Leyenda

número del grupo constructivo (p.ej. 06)

índice de modificación (p.ej. 000)

número de página (p.ej. 96)

referencia recíproca a la página decontinuación (p.ej. 94)

símbolo de enlace- aparece siempre, por lo menos, como

pareja (p.ej. A-A, B-B, C-C, etc.)

Indications de commande

Lors d’une commande de pièces détachéesoriginales de DEUTZ, il est nécessaire de fournirles indications suivantes:

- n° de moteur

- n° d’identification

- nombre

Structure de la documentation

- Les tableaux illustrés de cette liste de piècesdétachées sont classés par groupe demoteur.

- Les groupes constitutifs figurent dans lerécapitulatif moteur.

- Le n° d’identification 06/59 est constituédu n° de groupe (p.ex. 06) et du n° de position(p.ex. 59).

Explication des symboles

Numéro de groupe constitutif (p. ex. 06)

Indice de modification (p. ex. 000)

Numéro de page (p. ex. 96)

Renvoi à la page de suite (p. ex. 94)

Symbole d’assemblage- se présente toujours par paire

(p. ex. A-A, B-B, C-C)

Order information

Please specify the following information whenordering original DEUTZ parts:

- Engine no.

- Ident no.

- Quantity

Document structure

- The picture diagrams in this spare list aresorted according to engine assembly groups.

- The assemblies are listed in the engineoverview.

- The ident no. 06/59 is made up of theassembly group (e.g. 06) and item number(e.g. 59).

Explanation of symbols

assembly No. (e.g. 06)

revision level (e.g. 000)

page number (e.g. 96)

cross reference on continuation page(e.g. 94)

A connection symbol- always occurs at least in pairs

(e.g. A-A, B-B, C-C etc.)

Servicedeenfresptitnlsvdafnnoeltrruarpl

-06-

000

A

96

94

-06-

000

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96

94

-06-

000

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96

94

© 200437

Dati di ordinazionePer l’ordinazione di pezzi di ricambio originaliDEUTZ, indicare sempre i seguenti dati:

- No. del motore

- Codice d’identificazione

- Quantità pezzi

Struttura della docomentazione- Le tavole di questa lista dei pezzi di ricambio

sono suddivise secondo i gruppi costruttividei motori in base alle unità dei motori

- Gli elementi costruttivi sono specificati nellavista panoramica del motore

- Il codice d’identificazione 06/59 è costituitodall'unità costruttivo (per es. 06) e dallaposizione(per es. 59)

LegendaNumero dell'unità dell’elementocostruttivo (ad esempio 06)

Numero variabile (ad esempio 000)

Numero della pagina (ad esempio. 96)

Riferimento incrociato alla pagina dicontinuazione (ad esempio 94)

Simbolo di collegamento- compare sempre almeno a coppie

(ad esempio A-A, B-B, C-C, ecc.)

-06-

000

A

96

94

Dados necessários para aencomenda:

Para encomendar as peças originais DEUTZ énecessário indicar os seguintes dados:

- Nº do motor

- Nº de identificação

- Quantidade

Esquema da documentação

- As figuras representativas das peçassobres-salentes estão agrupadas pelosmódulos do motor.

- Os elementos módulos são apresentados navista geral do motor.

- O Nº de identificação 06/59 consiste a partirdo número do módulo (por ex. 06) e da posição(por ex. 59)

Explicação dos símbolos

Número dos módulos (p.ex. 06)

Algarismo variável (p.ex. 000)

Número de página (p.ex. 96)

Referência transversal à página decontinuação (p.ex. 94)

Símbolo de conexão- introduzir sempre, no mínímo, em

pares (p.ex. A-A, B-B, C-C etc.)

Service

Bestelgegevens

Bij bestelling van originele DEUTZ onderdelendienen de volgende gegevens verstrekt te worden:

- motornummer

- identificatienummer

- aantal

Gebruiksaanwijzing voor documen-tatie

- De afbeeldingen in deze onderdelenlijst zijngeordend naar deelsamenstelling.

- De constructiegroepen zijn in het overzichtvan de motoren vermeld.

- Het identificatienummer (bijv. 06/59) isopgebouwd uit de deelsamenstelling (bijv.06), gevolgd door de positie (bijv. 59).

Verklaring van de symbolen

Nummer van de constructiegroep (b.v. 06)

Modificatie cijfer (b.v. 000)

Paginanummer (b.v. 96)

Kruisverwijzing naar de volgende pagina(b.v. 94)

Het aansluitsymbool- verschijnt altijd minstens paarsgewijs (bijv. A-A, B-B, C-C, enz.)


-06-

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© 2004 38

Tilaustiedot

Alkuperäisten DEUTZ-varaosien tilauksenyhteydessä on ilmoitettava seuraavat tiedot:

- moottori nro

- tunnusnro

- kappalemäärä

Dokumentaation rakenne

- Tämän varaosaluettelon kuvat on ryhmiteltymoottorin rakenneryhmien mukaan.

- Rakenneryhmät käyvät selville moottorinlistasta.

- Tunnusnumero 06/59koostuu rakenneryhmästä (esim. 06) jaosanumerosta (esim. 59).

Symbolien selitykset

Rakenneryhmänumero (esim. 06)

Muutosnumero (esim. 000)

Sivunumero (esim. 96)

Ristiviittaus jatkosivulla(esim. 94)

Liitäntäsymbooli- ilmenee aina vähintään parittain

(esim. A-A, B-B, C-C, j.n.e.)

-06-

000

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94

Service

Beställningsuppgifter

För beställning av DEUTZ original reservdelarkrävs följande uppgifter:

- Motornr.

- ID-nr.

- Antal

Dokumentationens uppbyggnad

- Illustrationerna i denna reservdelslista ärsorterade enligt motorns moduler.

- Modulerna framgår i översikten över motorn.

- ID-numret 06/59 består av modul (t.ex. 06) ochposition (t.ex.59).

Symbolförklaring

Modulnummer (t.ex. 06)

Förändringsnummer (t.ex. 000)

Sidnummer (t.ex. 96)

Korsreferens till nästa sida(t.ex. 94)

Anslutningssymbol- visas alltid minst parvis

(t.ex. A-A, B-B, C-C, osv)

-06-

000

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96

94

Bestillingsangivelser

Ved bestillingen af originale DEUTZ-dele er detnødvendigt med følgende angivelser:

- motor-nr.

- ident.-nr

- antal

Dokumentationens opbygning

- Billederne i denne reservedelsliste er sorteretefter motor-komponenter.

- Delmontagerne findes i motoroversigten.

- Ident-nr. 06/59 er opbygget af komponent(f.eks. 06) og position (f.eks. 59).

Symbolforklaring

delmontagenummer (f.eks. 06)

ændringsciffer (f.eks. 000)

sidenummer (f.eks. 96)

krydshenvisning til næste side(f.eks. 94)

tilslutningssymbol- optræder altid mindst parvis

(f.eks. A-A, B-B, C-C osv.)

-06-

000

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94


© 200439

Service

Bestillingsangivelser

Ved bestilling av originale DEUTZ deler erfølgende opplysninger nødvendige:

- Motor-nr.

- Ident-nr.

- Antall

Dokumentasjonsoversikt

- Illustrasjonene i denne reservedelslisten ersortert etter komponentgruppe.

- Komponentgruppen vises på motortegningen.

- Ident-nr. 06/59 består av konstruksjons-gruppe (f.eks 06) og posisjon (f.eks 59)

Symbolforklaring

Delenummer (f.eks. 06)

Endringsnummer (f.eks. 000)

Sidenummer (f.eks. 96)

Kryssreferanse på fortsettelsessiden.(f.eks. 94)

Koblingssymbol- Føres alltid opp parvis

(f.eks. A-A, B-B, C-C osv.)

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the engine company

DEUTZ AG

Service-Technik

Instandhaltungstechnik Motoren

Deutz-Mülheimer Str. 147-149

D-51057 Köln

Tel.: ++49 (0)2 21-8 22-0

Fax: ++49 (0)2 21-8 22-53 58

Internet: www.deutz.de

Printed in Germany

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1st Edition, © 12/04

Order No.: 0312 1887

System DescriptionElectronic Engine Governor EMR 2

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EMR 2Chapter Overview

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Chapter

Introduction

Important Notes

System Description

System Functions

Interfaces

Configuration and Parameter Setting

Diagnostic Button and Fault Indicator Lamp

Replacement of System Components

Technical Data

Index of Specialist Terms

Index

Connection Diagams

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EMR 2Chapter Overview

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EMR 2Table of Contents

Contents Page

1 Introduction 65

2 Important Notes 672.1 Operating instructions 672.2 Installation guidelines 672.3 Damage 672.4 Customer side wiring, plug connection 682.5 Remove plug 682.6 Electrical welding 68

3 System Description 693.1 Utilization of the EMR 2 693.2 System overview 693.3 Description of functions 703.4 Basic equipment 70

4 System Functions 714.1 Overview features 724.2 Function extensions 734.3 Speed control 744.4 Set point settings 764.5 Fuel quantity limitation (performance curve) 774.6 Droop control 784.7 Engine start/stop 784.8 Displays / Outputs (monitoring function) 794.9 LDA function 814.10 Temperature-dependent start control 814.11 Speed throttling (input F 7) 814.12 Engine protection functions 814.13 Altitude correction 824.14 Fuel volume control 824.15 Emergency running (limp home) 824.16 Cold start installation 82

5 Interfaces 835.1 Diagnostic interface (basic function) 835.2 CAN-Bus interface 83

6 Configuration and Parameter Setting 856.1 Function overview, pin assignment and configuration example 86

7 Diagnostic Button and Fault Indicator Lamp 877.1 Self-diagnostic (without operating the diagnostic button) 877.2 Diagnostic with Button and Error Code 907.3 Diagnostic possibilities with the SERDIA software 98

8 Replacement of system components 998.1 Replacement EMR ↔↔↔↔ EMR 2 998.2 Features of the Replacement of the Control Unit 998.3 Features of the Replacement of the Actuator 1008.4 Combination EMR, EMR 2, Control Unit and Actuator 100

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EMR 2Table of Contents

9 Technical Data 1019.1 General Data 1019.2 Signal Specification 1029.3 Plug assignments 1039.4 Sensor Data 105

10 Index of Specialist Terms 107

11 Index 109

12 Connection diagrams 113

Appendix 11512.1 Connection diagram - Vehicle side / Unit side 11512.2 Connection diagram Engine side (sheet 1) 11612.3 Connection diagram Engine side (sheet 2) 11712.4 Connection diagram for CAN-Bus and Diagnostic Line 118

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EMR 2Introduction

1 Introduction

This system description provides an overview of the design and operation of the electronic engine governor(EMR 2) as a control unit when used in engines of the model series 1012/1013/2012/2013/10151).

In addition, an explanation is given of the functions of the EMR 2 and how problems with the EMR 2 can berecognized and overcome.

The EMR 2 is a further development of the previously utilized EMR.

Basically, it has the same functionality as the EMR, but is equipped with additional functions and extensi-ons that are summarized in Chapter 4.2.

Reference is made to Chapter 8 for information regarding replacements,

1) Same system with Bosch EDC-actuator (1015).

General notesIt is our aim to permanently improve and extend the contents of this brochure. For this purpose, the experi-ences of the circle of users can be particularly helpful.

Should you desire changes, extensions, improvements, etc., we would welcome your input (Engine mainte-nance technology department, VS-TI). Please make as much use of this as you wish. In this way, you areassisting in making the next version more up-to-date. We pay close attention to every message and willprepare a new issue of the brochure at the appropriate time. We thank you in advance for your cooperation.

Your

DEUTZ AG

Maintenance technology engines

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EMR 2Introduction

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EMR 2Important Notes

2 Important Notes

2.1 Operating instructions

IMPORTANT!The purpose of this document is the explanation and clarification of the design and functionsof engines, engine components and systems.The information contained herein always corresponds to the technical conditions valid at thetime of going into print and are not subject to any immediate alteration service.

IMPORTANT!Applicable for the operation, maintenance and start-up are exclusively the information of thepublished and currently valid technical documentation, corresponding to the scope of deli-very and function (such as operating instructions, switching diagrams, workshop manual,repair and adjustment instructions, technical circulars, service information, etc.).

2.2 Installation guidelines

IMPORTANT!For the mechanical installation of the apparatus, reference should be made to the applicableissue of the “Installation Guidelines for electronic systems of DEUTZ diesel engines”. Moreinformation can be obtained from the DEUTZ AG, dept. technical operation support.

H REMARKS!Sufficient ventilation of control unit and actuator must be ensured in order to prevent limitati-ons of function and damage.

2.3 Damage

H REMARKS!Sensors and actuators may not be fitted individually to, or between, power sources for eitherinspection or testing purposes but only in connection with the EMR 2, as there is a danger ofdestruction!

H REMARKS!Despite polarity reversal protection in the control apparatus, it is necessary to prevent incor-rect polarity. Incorrect polarity can damage control units!

H REMARKS!The plug connections of the control units are only dust and watertight when plugged intomating connection! Until the mating connector has been plugged in, the control units must beprotected against spray water!

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EMR 2Important Notes

2.4 Customer side wiring, plug connection

IMPORTANT!In order to attain the required protection class (IP 66) at the control unit, the individual wireseals, plugs and sealing rings provided must be used.

IMPORTANT!The connection between pins and individual wires must only be carried out with the properpinching tools.

H REMARKS!The voltage supply for inputs and outputs for the users must be able to be switched in a de-energized manner via the key switch (terminal 15) - not via continuous positive.

2.5 Remove plug

H REMARKS!Removing the 25-pole equipment plug and engine plug when the control unit is on, i.e. whenthe voltage supply is on (terminal 15 on) is not permitted.

1. Voltage supply off- only then -

2. pull out equipment plug and engine plug

2.6 Electrical welding

H REMARKS!In order to prevent damage when carrying out ELECTRIC welding of the installation, the plugconnections at the control unit must first be pulled out.

H REMARKS!The ignition (terminal 15) must be switched off when working at the EMR 2.

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EMR 2System Description

3 System Description

3.1 Utilization of the EMR 2

The purpose of the electronic engine governor (EMR 2) is the regulation of the speed of revolution of DEUTZDiesel engines of the model series 1012/1013/2012/2013/1015 for applications in agricultural and con-struction machinery as well as in generating sets. It is designed for heavy duty also under difficult environ-mental conditions and possesses the corresponding protection classes.

The governor fulfils all the functions of the mechanical governor (variable speed governing, torque limitati-ons, LDA function) and makes further functions available.

3.2 System overview

Basically, the EMR 2 consists of the sensors, the control unit and the actuator. Engine-side as well as vehicle-side or plant-side installation are connected by means of separate cable har-nesses to the EMR control unit. The cabling on the plant side is carried out by the vehicle or plant manufac-turer.

For arrangement on the engine and plant/vehicle side, see the following figure.

Charge-air pressure

sensor (optional) Power supply

Set and vehicle-side equipmentEngine-side equipment

Multi function displays

Outputs (modifiable)

Accelerator pedel

Hand operated throttle(optional)

Start/StopKey-operated switch

Functions changeoverswitch

Diagnostic button

Fault indicatorlamp

Diagnosis interface/CAN-Bus

Inputs (modifiable)(PWM/digital/analog)

2nd Speed sensor(optional)

Cold start aid(optional)

Fuel temperature(optional)

Charge air temperature(optional)Lifting solenoid

(optional)Oil pressure sensor

(optional)

Coolant temperaturesensor

Camshaft speedsensor

Control rod position sensor/

actuator -Control unit

Üs_en © 06/02*with atmospheric pressure sensor (otional)

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EMR 2System Description

3.3 Description of functions

The sensors attached to the engine provide the electronics in the control unit with all the relevant physicalparameters.

In accordance with the information of the current condition of the engine and the preconditions (acceleratorpedal etc.), the EMR 2 controls an actuator that operates the control rod of the injection pump and thusdoses the fuel quantity in accordance with the performance requirements.

The exact position of the regulating rod is reported back and, if necessary, is corrected, by means of thecontrol rod travel sensor, situated together with the rotation magnets in a housing of the “actuator”.

The EMR 2 is equipped with safety devices and measures in the hardware and software in order to ensureemergency running (Limp home) functions (see Chapter 7.1).

In order to switch the engine off, the EMR 2 is switched in a de-energized fashion over the ignition switch. Astrong spring in the actuator presses the control rod in the de-energized condition into the zero position. Asa redundancy measure, an additional solenoid serves for switching off and this, independently of the actua-tor, also moves the control rod in the de-energized condition into the zero position.

After the programming, that is carried out over the ISO 9141 interface, the EMR 2 is possesses a motor-specific data set and this is then fixedly assigned to the engine. Included in this are the various applicationcases as well as the customer’s wishes regarding a particular scope of function. The result of this is that anylater alteration must be reported back to the DEUTZ AG so that, in case of replacement anywhere in theworld, the new control unit can be programmed with the current data set.

3.4 Basic equipment

Besides the control unit, the following components are required as minimum equipment for the operationof the engine:

Vehicle side:

! Energy supply (battery)

! Diagnostic interface (ISO 9141)

! Fault lamp/diagnostic lamp

! Diagnostic button

! Set point selection

! Key operated switch

! Function change-over switch

! Cable harness

Engine side:

! Actuator (contains control rod travel sensor and positioning magnet)

! Speed sensor (camshaft)

! Coolant temperature sensor (NTC)

! Cable harness

Further components and installation are possible depending on the application case or the desiredfunctions (see chapters 4 and 6). The combination can be selected from the DEUTZ pocket handbook.

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EMR 2System Functions

4 System Functions

The EMR 2 makes a broad range of functions available and these can be activated by the application-dependent configuration and the allocation of the inputs and outputs. It makes possible signal exchangebetween the engine (via the engine plug) and the EMR 2, as well as between the vehicle (via the vehicleplug) and the EMR 2. The signals can be transmitted as analog, digital, impulse modulated (PWM signals)and as CAN-Bus messages.Which functions are used, depends on the application conditions of the engine. Correspondingly, there aredifferent variations of the functions and the pin assignments of the plugs.

The functions of the EMR 2 refer to the speed control, quantity limitations (fuel injection), monitoring,vehicle and apparatus functions and communication and diagnostic interfaces.

The EMR 2 offer a basic equipment on which all the optional variations can be structured.

Because of the numerous possibilities of combinations, DEUTZ has defined function ranges. These can becrossed off in the DEUTZ pocket handbook. The switching diagram for each function range should also benoted especially for the wiring required on the customers side.

Sensor inputs:

! Control rod travel! Speed! Coolant temperature! (Charge air pressure)! (Oil pressure)! (2nd speed)! (Coolant level)! (Charge air temperature)! (Fuel temperature)! (Tacho signal)

Actuator functions

! Actuator! (Switch-off magnet)

Display functions /outputs

! Fault lamp! (Warning signals)! (Multi-function dis-

plays)

Interfaces

! ISO 9141! CAN-Bus, SAE J1939

Microprocessor

Memory for

! Parameters! Char. curve ! Char. diagram! Faults

Set point input

! Key-operated switch! (Pedal sensor)! (Throttle lever)! (Via CAN-Bus)! (Voltage 0 - 5 V)! (PWM signal)

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EMR 2(Atm pressure sensor)

Transfer switch forfunctions

The functions shown in brackets are optional.

Memory foroperatingsoftware

Energy supply

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4.1 Overview features

Feature Chapter Description

Speed control 4.3

As variable speed, idling/end or fixed speed governor; choice of switchable governor features during operation, freezing the current speed, fixed speed governor for network synchronization or load distribution, overdrive speed

Set point input 4.4

By means of! Pedal sensor and/or hand throttle! External voltage signal (0 - 5 V)! CAN Bus (remote electronics)! Fixed speed signal (genset operation)! Pulse width modulation (PWM)! Touch control operation Up/Down (digital)Optimal adaptation to different applications

Torque limitation 4.5 Up to three performance curves can be set independently of each other within the framework of the engine limits

Governor behaviour (speed droop)

4.6 Constant, variable or switchable speed droop from 0 - 80 % for adaptation to the application

Engine Start/Stop 4.7 Engine switch-off by means of EMR actuator (additional safety using switch-off solenoid possible)

Monitoring and signaloutput functions

4.8

Coolant temperature and level, oil pressure, charge air temperature, fuel temperature → fault display and/or performance reduction or engine switch-off for engine protection

LDA function 4.9Smoke limitation through charge air pressure and/or temperature-dependent limitation of the adjustment speed of the injection

Temperature-dependent start control

4.10 Improving the starting ability, gentle cold start without smoke ejection

Altitude correction 4.13 Engine protection because of reduced air pressure

Fuel volume correction 4.14 Compensation for loss of performance due to fuel heating

Emergency running 4.15Emergency running after failure of set point signal (e.g. using accelerator pedal), the charge air sensor or the vehicle speed signal

Selection of coldstart help installations

4.16 Failure of auxiliary control units, EMR 2 controls a selection of heating flange, glow plugs or flame starting apparatus

Data communication 5 Interfaces, diagnostics and programming

Output of fault fault blink codes

7.2 Simplified fault diagnosis

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4.2 Function extensions

The EMR 2 has the same functions as the EMR but possesses extended and new functions.

The new functions in detail are:

! Improved speed control

! Third performance curve

! Smoke limitation = function of the charge air temperature

! Monitoring the charge air temperature, coolant level

! Altitude-referenced fuel quantity

! Control of an engine brake

! Special set point parameter for genset applications

! Special vehicle speed evaluation to DIN 11786

! New functions via the diagnostic button:- fault blink codes- clearing the fault memory 1

! 2 Independent fault memories (mirroring the first fault memory)

! Acquisition of a load collective

! Baud rate alteration for ISO communication possible

! Possibility of a software update for the operating software via the ISO interface

! Newly introduced or changed commands in ISO communication

! CAN Bus protocol to SAE J1939 has been greatly extended, but is upwards compatible to the present EMR applications.

Caution!

EMR and EMR 2 are separate systems. An exchange of control units and actuators is not possible (seeChapter 8).

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4.3 Speed control

Provision is made for various variations of speed control that must be programmed in advance (at the endof the programming) depending on the application case (power generation, building or agricultural machi-nes) and usage conditions. The variations depend on the type of programmed and the selected functions.

The following types of speed regulation (switches) are optional and are programmed at the works depen-ding on the variant (pin assignment see Chapter 6.1):

Function Variant Description RemarksVariable speedcontrol

Variable speed

governor1)

1) Types of speed controlVariable speed control

For this type of control the speed of the engine is governed or kept constant with reference to the desired speed of revolution.For changes of load, the new required amount of fuel is set in accordance with a PID control. The desired value can bedetermined through various variants.

Min/Max controlFor this type of control, the fuel injection quantity is determined on the basis of the desired value. the result of this is that, forthis type of control, a speed of revolution depending on the load situation is set. The idling (= Minimum) and the endrevolutions (= Maximum) are controlled taking into account the control parameter speed droop 1 and speed droop 2. Thebasis for this type of control is the drive characteristic field.

Pure variable speed governor without addi-tion and switch-over functions

Only one vari-ant can be selectedFixed speed governor Variable speed governor with fixed, pre-defi-

ned speed for gensets (1,500 or 1,800 rpm), desired speed of rotation is defined in the scope of customer supply (KLU).

Change-over switching speed 1 /

22)

2) Change-over switching see point 4.3.1.

Variable speed governor with change-over switching possibility between two speeds.

Change-over swit-ching speed fixed/

variable2)

Variable speed governor with change-over switching possibility between a fixed pro-grammed and a variable speed of revolution.

Speed variable /

freeze2)Variable speed governor with change-over switching possibility between:freezing a current desired speed as set point independent of the pedal setting, and a varia-ble revolution.

Speed memoryfunction

Customer-specific solution for storing and calling up two speeds of revolution.

Gensetapplications

Power generationgovernor with adju-stable speed range

As for change-over switching fixed/variable speed. Without Load the speed can be adju-sted in the speed range.

See also system des-cription EMR Genset, TN 0297 9939

Power generation for network synchronisa-tion or Load distribu-tion

As for change-over switching fixed/variable speed. The variable revolutions can be adju-sted in the revolution range for network syn-chronization or load distribution.

Power generationgovernor with adju-stable speed and switchable overdrive speed

As for change-over switching fixed/variable speed the power generator, in fixed speed mode, can be used as the overdrive speed without loading, in variable mode or forparallel switching.

Variable speed-, Min/Max-control

Variable speed,

Min/Max governor2)Switching over between variable speed and Min/Max control.

Min/Max-control Min/Max governor1) Idling and end revolutions for vehicle applications.

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4.3.1 Switchable speed functions

The conditions for the switchable variants are selected by means of a switch (Input pin 18, GND pin 17V plug). The switch closes a contact to -UBatt.

The following is applicable for the switchable speed functions:

The switching condition can be displayed with the aid of the SERDIA diagnostic software (see Chapter 7.3)

4.3.2 Second speed input (optional)

This input can be used as a redundant speed input. If a second speed sensor has been installed, then theengine will not be switched off on failure of the first speed sensor but will switch over to the second one.The failure of a speed sensor is indicated by the continuous burning of the fault lamp. The operation of theengine can be limited by defining a lower desired speed (see also Chapter 7.1).

4.3.3 Excess speed protection

when the speed limit is exceeded, the EMR 2 moves the control rod into the Stop position. The output,engine switch off (Digital 3, M 2) is activated (if it is programmed) and a fault message is generated.

With applications in mobile machines the thrust mode is programmed as a safety measure. Exceeding of the revolution limit can occur in thrust mode. In this case the control rod is moved to the zeroposition and the fault lamp lights up. The engine is protected against excess revolutions also in this type ofoperation.After falling below the programmed recovery limit, the governing is again taken up and the fault lamp isextinguished. The parameters “Above speed limit” and “Recovery limit” are adjustable.

Switchable speed functions(for a selectable)

Switch open1)

(1/HIGH)

1) With an open switch, the underlined conditions above are activated as preset values (default values).

Switch closed(0/LOW)

Speed 1/ speed 2 Speed 1 Speed 2

Fixed / variable speed Variable Fixed

Speed variable / freeze Variable Freeze

Variable speed governor / Min/Max governor

Variable speed governor Min/Max regulator

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4.4 Set point settings

The following variants for the set point settings of the governor can be configured:

Function Variant Description Remarks

Set point setting Accelerator value sensor(SWG 1)

Setting with potentiometer (5 V reference

voltage, max. 30 mA1), typ. 1 kΩ linear, pin 25,

input pin 24, GND pin 23, V-plug2))

1) PIN 25: Imax=30 mA (Pedal value sensor and hand throttle combined).2) V*plug = Vehicle plug / GND = Ground.

Voltage Setting by means of external voltage (0.5 -4.5 V, input pin 24, GND pin 23, V-plug)

Replacement for pedal value sensor

Hand throttle(SWG 2)

Setting with hand throttle. The set point in the EMR 2 is determined by means of a maximum

function (5 V reference voltage, max. 30 mA1), typ. 1 kΩ linear, pin 25, input pin 20, GND pin 23 V-plug)

Memoryfunction

Freezing the current engine speed Only possible in con-nection with the pedal value sensor (SWG 1)

CAN Setting via the CAN interface (see Chapter 6.1)

CAN = Controller Area Network

Internal (fixed speed)

Setting via internal parameters. The parameter is determined in the customer scope of supply (KLU).

For gensets

PWM signal 1 PWM signal 2

The desired value is set by means of an exter-nal PWM signal (frequecyz=100 Hz) with a modulation of 5 % to 95 % (see Chapter. 9.2) Input pin 18 or 20, GND pin 17 V-plug

Auxiliary for pedal value sensor

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4.5 Fuel quantity limitation (performance curve)

In order to set the engine performance and the desired torque course, the maximum injection quantity/thrust must be limited in accordance with the settings.

Provision is made in the EMR 2 for three performance curves. The performance curve is created as a cha-racteristic curve with 13 freely selectable speed support points. The sampling points must be supportpoints, whereby the sample of the engine is carried out with performance curve 1. The performance curve 2is correspondingly corrected with the correction data of performance curve 1.


Perfor-mance curve

Performance curve 1

Quantity limitation with a performance curve (perfor-mance curve 1)

Only 1 variant can be selected

Performance curves 1/2

Switching between two performance curves

Performance curves 1/2/3

Change-over switching only via CAN

Performance curve change-over switching (Input)

pin 19, GND pin17 V-plug

Switch open(1/HIGH)1)

1) With open switches, the underlined conditions above are activated as default values.


Performance curve 1/ performance curve 2 Performance curve 1 Performance curve 2

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4.6 Droop control

One of the features of the electronic governing is that, in contrast to mechanical governors, the P-Gradientcan be set to 0 % and switched over between two defined P-gradients. The maximum value lies at 80 %.

For limiting the P-gradient relationship of the mechanical governor, provision is made for a speed-depen-dent P-gradient function by means of a characteristic curve with eight speed support points.

4.7 Engine start/stop

As soon as the control apparatus recognizes the start-speed, the control rod is freed for the start.For switching the engine off, the EMR 2 must be switched via the key-operated switch in a de-energizedmanner. With this setting, the controlling rod is moved to the stop position by the spring action of the actua-tor and/or the redundancy solenoid.The switching off of the engine can also be triggered by a fault in the EMR 2 (see Chapter 7.1, Self-Diagno-stic).


P-gradient Constant P-gradient P-gradient is constant within the whole speed range. Only one variant canbe selectedVariable P-gradient Speed-dependent P-gradient

P-gradients 1/2 Switching between two fixed P-gradients

Constant/variable Switching between constant and variable P-gradients

Switchable variantpin 21, GND pin 17 V-plug

Switch open(1/HIGH)1)

1) With open switches, the underlined conditions above are activated as default values..


P-Gradient 1/ P-Gradient 2 P-gradient 1 P-gradient 2

Constant / variable P-gradient Constant Variable

Function Variant Description

Engine start/stop Switching off with the EMR 2 actuator

In a de-energized condition, the EMR 2 actuator moves the control rod into the stop position and switches the engine off

Redundant switching-off with the solenoid

(pin M 21) and M 1)

1) M 2: Engine plug, pin 2

In addition, the engine is switched off by means of a sole-noid (must be programmed in the control unit)

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4.8 Displays / Outputs (monitoring function)

By means of the digital PWM outputs and depending on the configuration, various signals can be displayedand output.

Fault lamp (Pin 4 vehicle plug)

A red fault lamp must be placed where it is easily visible at the customer apparatus side. The fault lamp ser-ves as a rough estimate of the fault that has occurred; here the following means:

! Lamp 2 s on: Self diagnosis with switched on the voltage supply. Result: There are no faults.

! Continuous light: There is a fault message; however the system is operational (possibly limited).

! Flashing: Serious malfunction - engine will be switched off or engine cannot be started.

! Blink code: Query malfunction locality by means of diagnostic button.

For detailed information see Chapter 7.1.

Output signals (maximum of 4 output signals possible)

Function Variant Description

Display functions Speed 1(pin 16, vehicle plug)

Corresponding to the (No. of teeth on gear wheel) symmetrical square signal (Voltage level from 0 V to +UBatt)

Torque(pin 5, vehicle plug)

PWM signal (100 Hz) with button relationship from 5 to 95 %. Reference value: performance curve in the working point or MdMax

Warning signal coolant temperature(pin 3, vehicle plug)

Overstepping limiting valueHigh/Low change-over switching

Warning signal oil pres-sure(pin 15, vehicle plug)

Speed-dependent oil pressure controlHigh/Low change-over switching

Warning signal charge air monitor (pin variable)

General display for overstepping or falling below the limi-ting values

Freely selectable digital output signal

By arrangement

Freely selectable measu-ring or calculation value(PWM- signal)

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Load collective

The EMR 2 measures the loading of the engine. For this purpose, the respective load and revolution regionsare allocated to the engine operating hours.

S1 to S9 are operating hours within the respective sector.

The load collective can only be displayed and printed with SERDIA.

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Speed [rpm]

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(torquemax)

Torque referred to torquemax [%]

100

50

30

S7 S8 S9

S4 S5 S6

S1 S2 S3

1000 2000 4000

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4.9 LDA function

For mobile applications, the injection quantity for acceleration and dynamic load increase is limited withreference to the charge air pressure (smoke quantity-characteristic field). Usage: protection of the exhaustturbo supercharger and prevention of smoke ejection.

4.10 Temperature-dependent start control

In order to prevent smoke ejection and for optimizing the governing relationship, the start quantity, thespeed ramp and the governor parameters are controlled with reference to the temperature (required basicfunction).

4.11 Speed throttling (input F 7)

This function is designed for a driving speed evaluation is accordance with DIN 11786.

4.12 Engine protection functions

All monitoring functions can be provided with a message lamp on the plant side (dependent on the scope ofthe function and the pins that can be assigned).

Oil pressure monitoring

The user is warned by means of the message lamp when! the oil pressure has overstepped the warning limit and/or! after a pre-warning period, the performance has been reduced by the EMR 2, or! the oil pressure falls below the switch-off limit and, after a pre-warning period,

the engine is switched off.

Coolant temperature monitoring

The user is warned by means of the message lamp when! the temperature exceeds the warning limit and/or! after a pre-warning period, the performance has been reduced by the EMR 2, or! the temperature exceeds the switch-off limit and, after a pre-warning period,

the engine is switched off

Charge air monitoring

The user is warned by means of the message lamp when! the temperature exceeds the warning limit and/or! after a pre-warning period, the performance has been reduced by the EMR 2, or! The temperature exceeds the switch-off limit and after a pre-warning period, the engine is

switched off.

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Coolant monitoring

The user is warned by means of the message lamp when! the coolant level falls below the warning limit and/or! after a pre-warning period, the performance has been reduced by the EMR 2, or! the the coolant level falls below the switch-off limit and, after a pre-warning period, the engine is

switched off.

4.13 Altitude correction

The altitude correction is carried out by means of an Atmospheric pressure sensor in the control unit. Twodifferent control unit variants are offered (with and without atmospheric pressure sensor).

4.14 Fuel volume control

Compensation for loss of performance due to fuel heating. Necessary variant with fuel temperature sensor.

4.15 Emergency running (limp home)

The EMR 2 provides comprehensive emergency running functions that are configured depending on thefield of application. These functions are necessary in order that, in an emergency, the operation can be con-tinued with auxiliary speed. In detail, this function can be activated by

a) set point defaultb) charge air pressurec) vehicle speed signal and/ord) speed acquisition

It is also possible by the failure of the set point default to switch over via CAN Bus

a) on the accelerator pedal andb) on auxiliary speed

The respective type of malfunction is defined in the fault memory.

4.16 Cold start installation

Failure of additional control units; if desired EMR 2 controls heating flange, glow plugs or flame start instal-lation.

© 06/02 Page 83

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EMR 2Interfaces

5 Interfaces

The EMR 2 is equipped with various interfaces. The wiring is carried out on the customers side and must beintegrated in the vehicle plug. For pin assignment see the application-dependent switch diagrams.

5.1 Diagnostic interface (basic function)

The end programming of the EMR 2 is carried out via the serial diagnostic interface (according toISO 9141).

With the aid of a PC connected to an interface and the SERDIA (see also Chapter 7.3) diagnostic software -measuring values, error messages and other parameters can be displayed and set - depending on accessauthorization. Furthermore, new control units can be programmed.

Communication is only possible with the electric power switched on.

5.2 CAN-Bus interface

The CAN-Bus interface (Controller Area Network) is increasingly being used in vehicles and is suitable formeasuring values and data exchange with one or more apparatus-side control units (hydraulics, drive con-trol, etc.). The SAE J1939 protocol is utilized for communication.

The following is an aid to utilization of the respective scope of functions:

! Selection according to the DEUTZ pocket handbook! Definition before supply of engine! Connection in accordance with connection diagram (see Chapter 12.1 to 12.3)

Subsequent changes to the configuration is only possible in conjunction with the DEUTZ operating partnerand the aid of SERDIA (see Chapter 6).

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Page 84 © 06/02

EMR 2Interfaces

© 06/02 Page 85

EMR 2 Configuration andParameter Setting

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6 Configuration and Parameter Setting

The EMR 2 is specially programmed and configured for each individual engine, which means that theEMR 2 contains a specially engine-specific data set. Configuration is carried out via the externally accessi-ble diagnostic interface (ISO 9141) and is strongly dependent on the customer’s wishes, from the applica-tion cases and from the behaviour of a vehicle in operation.

Access to the various parameters is protected (by password) by means of access authorizations organizedon four levels and can only be carried out by authorized personnel.

More than 1200 different parameters are available. Access to these parameters, as well as to other data,can be carried out by means of the special SERDIA diagnostic software installed on a PC (see Chapter7.3).

Important!Rebuilding, as well as alteration to the parameters can only be carried out in conjunction withthe corresponding DEUTZ operating partners. For this purpose SERDIA Level III is required. In connection with the above-mentioned possibilities, the changed data sets must be repor-ted back to DEUTZ (see Service Note No. 0199-99-9287).

Type of operatione.g. parallel opera-

tion

Scope of function Switchingdiagrams

Other type ofoperationdesired

Part data set

Performance dataset

Complete data set

see “SERDIA” handbook

Notificationto DEUTZ

see “SM 0199-99-9287”

Re-blocking

! Other set speed

! Other performance

! Other set speed and other performance

Otherperformance data

desired

© 06/02

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EMR 2Configuration and Parameter Setting

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6.1 Function overview, pin assignment and configuration example

Summarized function overview with examples of function selection

The user-referenced selection is carried out using the DEUTZ pocket handbook

Functions Plugengine/vehicle

Pin Input/OutputScope of function

(Example1))

1) Above example applicable to genset series 1012/1013, single frequency generating sets.

Scope of function 0211 2291Model No. 0029 3766No. of connection diagram engine side 0419 9752No.of connection diagram vehicle/plant side 0419 9780

Sensor inputsSpeed sensor 1 (camshaft) E 12, 13 E !

Speed sensor 2 (crankshaft) E 10, 11 E -Charge air sensor (LDA function) E 23, 24, 25 E -Oil pressure sensor E 20, 21, 22 E !

Atmospheric pressure sensor (in control unit) - - - -Coolant level sensor E 6, 8 E -Charge air temperature sensor E 4, 8 E -Fuel temperature sensor E 5, 8 E -Coolant temperature sensor E 9, 8 E -Control rod travel sensor E 16, 17, 18, 19 E !

Actuator functionsOperating solenoid E 14, 15 A -Dig. output (PWM) E 3 A -Solenoid E 2 A !

Default functions (set point defaults via)Hand throttle V 23, 20, 25 E -Voltage V 23, 24 E -Accelerator pedal (potentiometer) V 23, 24, 25 E !

CAN V 12, 13 E/A !

PWM signal 1 V 17, 18 E -PWM signal 2 V 17, 21 E -

Memory functionsFixed speed (upper limit) V 17, 18 E -Fixed speed (lower limit) V 17, 21 E -Freeze current speed V 17, 19 E -Limit fuel quantity of a performance curve !

Switch-over functionsspeed 1 / 2 V 17, 18 E -Fixed / variable speed V 17, 18 E -Freezing / variable speeds V 17, 18 E -Variable speed governor min/max regulation V 17, 18 E -Performance curve1 / 2 V 17, 19 E -Performance curve1 / 2 / 3 (via CAN) V 12, 13 E -P-gradient 1 / 2 V 17, 21 E !

P-gradient const. / variable V 17, 21 E -Key-operated Start/Stop, energy supply V 1, 14 !

Display / output functionsFault lamp V 4, (Cl. 15) A !

Warning coolant temperature V 3, (Cl. 15) A !

Warning oil pressure V 15, (Cl.15) A !

speed V 16, (Cl. 15) A -Torque (reserve) V 5, (Cl. 15) A -Warning monitoring charge air -Freely selectable digital output signal -Freely selectable measuring or calculation value -Load collective !

Diagnostic interfaceISO 9141-L V 10 E/A !

ISO 9141-K V 11 E/A !

CAN-Bus (SAE J1939 protocolCAN-H V 12 E/A !

CAN-L V 13 E/A !

© 06/02 Seite 87

EMR 2 Diagnostic Button andFault Indicator Lamp

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7 Diagnostic Button and Fault Indicator Lamp

Diagnostic button and fault indicator lamp must be placed in the vehicle or plant on the customer side.They can be used for diagnosis.

7.1 Self-diagnostic (without operating the diagnostic button)

The EMR 2 possesses numerous protection functions for the engine - depending on the available measu-ring points or sensors. Depending on the seriousness of the recognized fault, the engine may run on inreduced mode (limp home), whereby the fault indicator lamp is continuously lit, or the engine is switchedoff, whereby the fault indicator lamp flashes.

A lit fault indicator lamp indicates an error in the wiring (short circuit, cable break) or a defect in the displaysof the corresponding sensors. A further source of faults could be falling below or exceeding the measuringvalue limits (see Chapter 9.4).

Faults in the electronics are registered or stored in the control unit and shown by the fault indicator lamp.The fault indicator lamp is extinguished as soon as the fault has been removed. Only when the electronicshas been switched to emergency running (-speed), need the engine be switched off briefly with the key-operated switch in order to extinguish the fault indicator lamp.

Also corrected or non-current faults remain stored in the control unit and can be read out or deleted withthe SERDIA diagnostic software (see Chapter 7.3).

+UBatt 15

Diagnostic button switch diagram

Pin F 4Fault indicator lamp

Diagnostic button

GND-UBatt

© 06/02

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EMR 2Diagnostic Button and Fault Indicator Lamp

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On

OffTime

2 s

On

OffTime

© 06/02

Key switch (terminal 15)

On

OffTime

On

OffTime

Fault indicator lamp

Case a) Lamp extinguished after 2 s: there is no active fault

2 s 1 s1 s

Case b) Lamp flashes after 2 s: there is at least one serious fault.the engine cannot be started.

Case c) Continuous light: there is at least one fault.

On

OffTime

2 s

Case d) As case c), only with monitoring delay tv dependent on selected setting.

tv

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Function control of the configured warning lamps

With the activation of the key switch (pin 15), the warning lamp is also switched on for the duration of theself-diagnostic (2 s).

On

OffTime

2 s

On

OffTime

© 06/02


On

OffTime


2 s

e.g. warning lamp oil pressure

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7.2 Diagnostic with Button and Error Code

With the diagnostic button there is the possibility of reading out the existing faults as blink codes and todelete the fault memory 1. The Diagnostic button and the fault indicator lamp are situated in the movingpart of the vehicle.

7.2.1 Reading out a current fault memory blink codes

The fault indicator lamp shows a fault, e.g., it flashes or lights continuously. The Diagnostic button isdepressed for a time period of 1 s to 3 s. The EMR 2 recognizes the request for a read out and starts to dis-play the faults. (see blink code overview, Chapter 7.2.3). The read-out of the blink code is only possible afterextinguishing of fault indicator lamp or after the initialization phase of the operating program. This meansthat the fault indicator lamp can also show continuous lighting after switching on if a fault has been recogni-zed already after switching. The EMR 2 only shows active faults as blink codes.

In the following the steps for reading out the first blink code are shown:

a The fault indicator lamp indicates a fault, e.g. it flashes of lights continuously.

! Press diagnostics buttons 1 to 3: the flashing or continuous light of the fault indicator lamp is extinguished.

b After 2 s: recognition by the EMR 2 (2×short flashes).

! Output of the flashing sequence of the first stored fault. (example: fault number 01, “speed sensor 1“):c after 2 s: 1×longd after 2 s: 1×short

! After fault code output e 5 s pause, then display of flashing or continuous light.

© 06/02

On

OffTime

1 - 3 s

Diagnostic button


On

OffTim

2 s 2 s 2 s

0.8 s 0.8 s

0.4

s

0.4

s

5 s

“2” “1” “1”

a b c d e

© 06/02 Seite 91


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Steps for reading out the next fault:

a The fault indicator lamp indicates a fault, e.g. it flashes of lights continuously.

! Press diagnostics buttons 1 to 3:the flashing or continuous light of the fault indicator lamp is extinguished

b After 2 s: recognition by the EMR 2 (2×short flashes).

! The next blink code is output (c, d)

! After fault code output e 5 s pause, then display of flashing or continuous light.

The steps can be repeated until the last stored fault code is output. After that, the first fault code is shownagain.

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7.2.2 Deletion of the fault memory 1

The EMR 2 has two fault memories (1 and 2). Every fault is stored in both memories at the same time. Withthe aid of the diagnostic button it is possible to delete passive faults in fault memory 1. The fault memory 2can only be deleted with SERDIA.

The following shows the steps for deleting the fault memory 1:

a Press, and keep depressed, the diagnostic button.

b Switch ignition on.

c Whilst the fault indicator lamp is lit up (duration 2 s) release diagnostic button.

d All passive faults in faults in fault memory 1 are deleted.

e The deletion process is confirmed by three short flash impulses.

© 06/02

On

OffTime

Diagnostic button


On

OffTime

0.4

s

0.4

s

On

OffTime


2 s

< 2 s

a

b

c

d e

© 06/02 Seite 93


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7.2.

3F

ault

blin

k co

de

ove

rvie

w

Faul

t g

roup

Faul

t no

.(in

SE

RD

IA)

Fau

lt lo

calit

y/Fa

ult

des

crip

tio

nB

link

cod

eF

MI

SP

NC

ause

Rem

arks

Hel

p

sho

rtlo

ngsh

ort

0,4

s0,

8s

0,4

s

Zero

err

or

disp

lay

-N

o fa

ults

2-

-31

5242

87No

act

ive

faul

ts p

rese

nt

Revo

lutio

ns

/ spe

ed

acqu

isiti

on

01S

pee

d s

enso

r 1

21

18

190

Sens

or fa

ilure

. Dis

tanc

e fro

m g

ear

too

far.

Addi

tiona

l fau

lt im

puls

es.

Cabl

e jo

int i

nter

rupt

ed.

Gove

rnor

in e

mer

genc

y op

erat

ion

(if

sens

or 2

ava

ilabl

e). E

mer

genc

y sw

itch-

off (

if se

nsor

2 n

ot a

vaila

ble

or fa

iled)

. Ch

eck

dist

ance

. Che

ck c

able

co

nnec

tion.

Che

ck s

enso

r and

re

plac

e if

requ

ired.

02S

pee

d s

enso

r 2

21

28

190

Gove

rnor

in e

mer

genc

y op

erat

ion

(with

sen

sor 1

)Em

erge

ncy

switc

h-of

f (if

sens

or 1

no

t ava

ilabl

e or

faile

d).

03S

pee

d s

enso

r2

13

884

Tach

o fa

iled.

Add

ition

al fa

ult

impu

lses

. Cab

le c

onne

ctio

n in

terr

upte

d.Go

vern

or in

em

erge

ncy

oper

atio

n.

(see

Cha

pter

4.1

5).

Chec

k ca

ble

conn

ectio

n an

d Ta

cho.

Rep

lace

if re

quire

d.

04E

xces

s sp

eed

sw

itch-

off

21

40

190

Spee

d w

as/is

in e

xces

s of

lim

it.e.

Engi

ne s

top.

(s

ee C

hapt

er 4

.3.3

)Ch

eck

para

met

er(2

1). C

heck

sp

eed

setti

ngs.

Chec

k PI

D se

tting

. Che

ck ro

ds. C

heck

act

uato

r and

repl

ace

if re

quire

d. C

heck

cab

le to

act

uato

r (im

puls

e on

in

corr

ect s

peed

). Ch

eck

No. o

f tee

th. F

or v

ehic

les

chec

k fo

r pos

sibl

e th

rust

mod

e.

Sens

ors

05S

et p

oint

sen

sor

1ac

cele

rato

r p

edal

)2

21

291

Faul

t at c

orre

spon

ding

sen

sor e

ntry

(e

.g. s

hort

circ

uit o

r cab

le b

reak

).

See

Chap

ter 4

.15

influ

enci

ng fa

ult

reac

tion.

With

failu

re o

f the

sen

sor,

the

asso

ciat

ed m

onito

ring

func

tion

is

de-a

ctiv

ated

.

Chec

k se

nsor

cab

le. C

heck

se

nsor

and

repl

ace

if re

quire

d.

Chec

k fa

ult l

imits

for s

enso

r.

06S

et p

oint

sen

sor

2 (h

and

thr

ottle

)2

22

220

1

07C

harg

e ai

r p

ress

ure

22

32

102

08O

il p

ress

ure

22

42

100

09C

oola

nt t

emp

erat

ure

22

52

110

10C

harg

e ai

r te

mp

erat

ure

22

62

105

11Fu

el t

emp

erat

ure

22

72

174

Seite 94 © 06/02


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Func

tiona

l fa

ult

war

ning

30O

il p

ress

ure

war

ning

23

11

100

Oil p

ress

ure

belo

w s

peed

-de

pend

ent w

arni

ng li

ne

char

acte

ristic

Faul

t mes

sage

(dis

appe

ars

whe

n oi

l pr

essu

re is

aga

in a

bove

reco

very

lim

it).

Afte

r a d

elay

tim

e - f

ill li

mita

tion.

Chec

k en

gine

(oil

leve

l, oi

l pu

mp)

. Che

ck o

il pr

essu

re

sens

or a

nd c

able

. Che

ck o

il pr

essu

re w

arni

ng li

ne

char

acte

ristic

.

31C

oola

nt t

emp

erat

ure

war

ning

23

20

110

Cool

ant t

empe

ratu

re h

as e

xcee

ded

war

ning

leve

l.

Faul

t mes

sage

(dis

appe

ars

whe

n co

olan

t tem

pera

ture

aga

in d

rops

be

low

reco

very

leve

l). A

fter a

del

ay

time

- fill

lim

itatio

n.

Chec

k co

olan

t. Ch

eck

cool

ant

tem

pera

ture

sen

sor a

nd c

able

.

32C

harg

e ai

r te

mp

erat

ure

war

ning

23

30

105

Char

ge a

ir te

mpe

ratu

re h

as

exce

eded

war

ning

leve

l.

Faul

t mes

sage

(dis

appe

ars

whe

n ch

arge

air

tem

pera

ture

gai

n dr

ops

belo

w re

cove

ry le

vel).

Afte

r a d

elay

tim

e - f

ill li

mita

tion.

Chec

k ch

arge

air.

Che

ck c

harg

e ai

r-te

mpe

ratu

re s

enso

r and

ca

ble.

34C

oola

nt le

vel w

arni

ng2

35

111

1Sw

itch

inpu

t “Lo

w c

oola

nt le

vel”

is

activ

e.Fa

ult m

essa

ge.

Chec

k co

olan

t lev

el. C

heck

co

olan

t lev

el s

enso

r and

cab

le.

35S

pee

d w

arni

ng (w

ith

thru

st m

ode

oper

atio

n).

23

614

SID

190

revo

lutio

ns w

as/is

abo

ve (t

op)

revo

lutio

n sp

eed

limit.

“Th

rust

m

ode”

func

tion

is a

ctiv

e.Se

e Ch

apte

r 4.3

.3 E

xces

s sp

eed

prot

ectio

n.Ch

eck

para

met

ers.

Che

ck s

peed

se

tting

s(21

).

Chec

k PI

D se

tting

. Che

ck ro

ds. C

heck

act

uato

r and

repl

ace

if re

quire

d. C

heck

cab

le to

act

uato

r. Ch

eck

spee

d se

nsor

(im

puls

es o

n in

corr

ect s

peed

). Ch

eck

No. o

f tee

th. F

or v

ehic

les

chec

k fo

r pos

sibl

e th

rust

mod

e.

36Fu

el t

emp

erat

ure

war

ning

23

70

174

Fuel

-tem

pera

ture

has

exc

eede

d w

arni

ng le

vel.

Faul

t mes

sage

(dis

appe

ars

whe

n fu

el

tem

pera

ture

aga

in d

rops

bel

ow

reco

very

leve

l).

Chec

k fu

el. C

heck

fuel

te

mpe

ratu

re s

enso

r and

cab

le.

Faul

t g

roup

Faul

t no

.(in

SE

RD

IA)

Fau

lt lo

calit

y/Fa

ult

des

crip

tio

nB

link

cod

eF

MI

SP

NC

ause

Rem

arks

Hel

p

sho

rtlo

ngsh

ort

0,4

s0,

8s

0,4

s

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13

Func

tiona

l fa

ult,

switc

h-of

f

40O

il p

ress

ure

switc

h-of

f2

31

110

0Oi

l pre

ssur

e be

low

sw

itch-

off l

imit

Emer

genc

y st

op

Chec

k en

gine

(oil

leve

l, oi

l pu

mp)

. Che

ck o

il pr

essu

re

sens

or a

nd c

able

. Che

ck o

il pr

essu

re -s

witc

h-of

f lim

it.

41C

oola

nt t

emp

erat

ure

switc

h-of

f2

32

011

0Co

olan

t tem

pera

ture

has

exc

eede

d sw

itch-

off l

imit.

Chec

k co

olan

t lev

el. C

heck

co

olan

t lev

el s

enso

r and

cab

le.

Chec

k sw

itch-

off l

imit.

42C

harg

e ai

r te

mp

erat

ure

switc

h-

off

23

30

105

Char

ge a

ir te

mpe

ratu

re h

as

exce

eded

sw

itch-

off l

imit.

Chec

k ch

arge

air.

Che

ck c

harg

e ai

r-te

mpe

ratu

re s

enso

r and

ca

ble.

Che

ck s

witc

h-of

f lim

it.

44C

oola

nt le

vel s

witc

h-of

f2

35

111

1Sw

itch

inpu

t “Lo

w c

oola

nt le

vel”

is

activ

e.Em

erge

ncy

stop

. Sta

rt lo

ck.

Chec

k co

olan

t lev

el. C

heck

co

olan

t lev

el s

enso

r and

cab

le.

Actu

ator

50Fe

edb

ack

25

1

12S

ID 2

4

Actu

ator

not

con

nect

ed. F

ault

in

actu

ator

con

firm

atio

n.Em

erge

ncy

switc

h-of

f. Ac

tuat

or

cann

ot b

e op

erat

ed.

Chec

k ac

tuat

or, r

epla

ce if

re

quire

d. C

heck

cab

le, c

heck

fa

ult l

imits

for “

Conf

irmat

ion”

.

52R

efer

ence

feed

bac

k13

SID

24

Chec

k ac

tuat

or, r

epla

ce if

re

quire

d. C

heck

cab

le, c

heck

fa

ult l

imits

for “

Rife

ness

co

nfirm

atio

n”.

53C

ontr

ol t

rave

l d

iffer

ence

7S

ID 2

3In

ject

ion

pum

p/ac

tuat

or ja

mm

ed o

r no

t con

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Seite 96 © 06/02


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Hard

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e in

puts

/ou

tput

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val

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of p

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eter

s (3

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and

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). Sw

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and

on a

gain

. Che

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gain

. If

faul

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© 06/02 Seite 97


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Cont

rol u

nit

hard

war

e

80P

ower

sup

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(A

ctua

tor)

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s w

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in th

e no

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e).

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on

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n.

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k ag

ain.

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ulty

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rm

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for a

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appe

ars

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in in

the

norm

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.Sw

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nd o

n ag

ain.

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eck

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n. If

faul

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form

DE

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pher

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n pe

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sibl

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nge.

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t mes

sage

(dis

appe

ars

whe

n po

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aga

in in

nor

mal

rang

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pre

ssur

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ult o

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g se

tting

of p

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eter

/ sa

ving

or

rese

t.).

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ne c

anno

t be

star

ted.

Chec

k da

ta fo

r cor

rect

set

tings

. Sa

ve p

aram

eter

s. S

witc

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n of

f and

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n. C

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in. I

f fa

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info

rm D

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genc

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par

amet

ers

(389

7 an

d 38

98).

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nitio

n of

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in. I

f fau

lty

info

rm D

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.

94In

tern

al fa

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2S

ID 2

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0,4

s0,

8s

0,4

s

Seite 98 © 06/02


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7.3 Diagnostic possibilities with the SERDIA software

SERDIA (Service Diagnosis) is a software program with the aid of which the user can monitor the measure-ment value on a running diesel engine from a PC or Notebook computer and can thus recognize faulty ope-rating behaviour.

! With a stopped engine, it is possible to enter certain parameters in a targeted manner from the PC intothe control unit (parameter setting) in order to change the operating behaviour of the engine.

! With the aid of the SERDIA diagnostic software, the fault messages stored in the control unit can beread out and evaluated.

Information is displayed on the following:

- Fault locality (e.g. pedal sensor, coolant temperature sensor).- Fault type (e.g. lower limit exceeded, sporadic error).- Environmental data/operating data (speed and operating hours at the time of the occurrence of the last

fault).- Number of fault localities- Frequency of the fault- Fault status (active - fault persists / passive - fault eliminated).

Fault messages of non-current and eliminated faults can be deleted with SERDIA.

! Function test

In the function test, the outputs and the control rod travel can be activated with the engine stopped.

! Input/output assignment

Display of the current input/output assignment.

! Measuring value depiction

A large selection of measuring values are available and these can also be used if there is no EMR 2 error(starting behaviour, engine saws, poor performance).

For this purpose, the PC is connected by an interface cable to the diagnostic interface. Communicationwith the control unit is carried out via a special EMR 2 protocol.

Working with SERDIA is described in a separate operating instruction.

© 07/02 Page 99

EMR 2 Replacement of systemcomponents

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8 Replacement of system components

In case of malfunction, the individual system components such as sensors, control unit, actuators, can bereplaced but not repaired.

8.1 Replacement EMR ↔↔↔↔ EMR 2

The EMR 2 is a further development of the EMR. But are not compatible in the case of replacement. Onlythe part numbers (TN) that count for the respective system can be utilized.

8.2 Features of the Replacement of the Control Unit

Each control unit is fixedly assigned to the engine (engine number) in accordance with its individual applica-tion case. In case of a replacement, therefore, the control unit must be equipped

a) with its engine-specific data set and

b) with a ticket [engine number...]

Programming with an engine-specific data set is only possible with SERDIA (Levels III and IIIa) and can becarried out in two ways:

! By ordering a new control unit with information of the engine and part number (completion by DEUTZ-Parts Logistics).

! Transferring the data set 1:1 from the “old” control unit to the “new” control unit (see SERDIA manual).

Remarks:

– TN on control unit → non programmed control unit (stores unit). Engine cannot be started!Control unit must be programmed.

– TN in SERPIC → programmed and completed control unit (with engine number - ticket)

Caution!

Only setting alterations that have been notified back to DEUTZ permit proper return of a programmed andcompleted control unit with current data settings (see SM 0199-99-9287).

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EMR 2Replacement of system components

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8.3 Features of the Replacement of the Actuator

8.3.1 Model series1012/1013/2012/2013

The actuators are replaceable on a 1:1 basis without additional programming.

8.3.2 Model series 1015

Actuator (EDC-actuator) and Bosch pump belong together (one TN). In the case of a replacement, theactuator (with the pump) must be calibrated with the control unit. This calibration is necessary (with SERDIALevel IIIa), because the new characteristic curves must be stored in the control unit.

8.4 Combination EMR, EMR 2, Control Unit and Actuator

EMR control units, see also SM 0199-99-9334.

The EMR 2 control unit automatically recognizes the actuator EMR or EMR 2. In order to limit errors, there-fore, an “old” EMR actuator can be combined with the EMR 2 control unit. In reverse, a “new” EMR 2actuator is not accepted by the EMR control unit (fault message).

Control unit Actuator EMR1012/1013/2012

Actuator EMR 21012/1013/2012

EDC actuator1015

EMR Fault message

Engine cannot be started Calibration required

EMR 2

© 06/02 Page 101

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EMR 2Technical Data

9 Technical Data

9.1 General Data

Designation Technical data / Remarks

Nominal voltage 12 and 24 V DC, working range 10 ... 36 V DC, engine starting is possible from 6 V

Maximum cable length governor-engine 5 m (remote engine extension)

Current consumption (inc. actuator) ≤ 9 A, ≤ 11.5 A for 60 s, (fuse 15 A)

Permissible operating temperatures -40 ... +85 °C

Dimensions 231 × 204 × 62 mm (length × width × height)

Weight 1.6 kg

Air humidity < 98 % (at 55 °C)

Type of protection IP 66k, IP X7, IP X9k to DIN 40050

Shock permissibility < 50 g

Vibration< 1,5 mm (at 10 ... 20 Hz)< 180 mm/s (at 21 ... 63 Hz)< 7 g (at 64 ... 2.000 Hz)

Resistance Resistant to usual materials in an engine environment

Housing material Cast aluminium, unvarnished

Diagnostic interface Serial interface to ISO 9141

Data interface CAN-Bus with protocol to ISO/DIS 11989, SAE J1939

Plug connection to vehicle/plant, cable harness

Company AMP, 2 x 25-pole, coded, individual strand isolation

EMVEmitted interference to 95/54/EWGinterference immunity up to 100 V/m to ISO 11452-2, ISO 7637, TR 10605

Load dump U < 60 V(actuator not powered during the interference effects)

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EMR 2Technical Data

9.2 Signal Specification

All outputs are short circuit-protected against negative and positive polarity of the battery.

Pin1)

1) Double assignment possible.

Pin type/Signal type Technical data / Remarks

Inputs

F4, F6, F7, F18, F19, F20, F21, F24, M6, M11, M21, M24

Digital input Ulow < 2 V, Uhigh > 6,5 V, Rpull = 4.7 kΩ after +UBatt

F4 Digital inputIsink < 0.5 A, Urest < 0.5 V, Ileck < 0.1 mA (ground switching),Diagnostic button (closing) after -UBatt

F20, F24, M21, M24 Analog input

Uin = 0 ... 5 V, fg = 7 Hz, Ri = 220 kΩ,Uref = 5 V ± 25 mV, Imax = 25 mA

F18, F21 PWM inputUlow < 2 V, Uhigh > 6,5 V, Rpull = 4,7 kΩ, fin < 500 Hz (typ. 100 Hz), Tan/Tper = 5 ... 95 %

M11, M13 Frequency input Inductive sensor, Uin = 0,2 ... 30 V AC, fin = 25 ... 9.000 Hz

F7, M11 Speed input max. 255 Impulse/m

M17, M18, M19 Inductive input Control travel sensor

M4, M5, M9 Temperature input NTC resistance measurement, max. ± 4 °C (tolerance, typ. ± 2 °C)

Outputs

F4 Digital outputIsink < 0.5 A, Urest < 0.5 V, Ileck < 0.1 mA (ground switching),Diagnostic button (closing) after -UBatt

F3, F5, F15, F16,M3

Digital output(low side)

Isink < 0.5 A, Urest < 0.5 V, Ileck < 0.1 mA (ground switching)

M2 Digital power output(high side)

Isource < 4 A, Urest < 0.5 V, Ileck < 0.1 mA (positive switching)

M7 Digital power output(low side)

Isource < 4 A, Urest < 0.5 V, Ileck < 0.1 mA (ground switching)

M7 PWM power outputIsource < 4 A, Urest < 0.5 V, Ileck < 0.1 mA (positive switching),faus < 500 Hz (typ. 100 Hz), Tan/Tper = 5 % ... 95 %

M14, M15 PWM power output Actuator control (actuator), to 11.5 A

F5 PWM outputIsink < 0.5 A, Urest < 0.5 V, Ileck < 0.1 mA (ground switching),faus < 500 Hz (typ. 100 Hz), Tan/Tper = 5 % ... 95 %

F16 Frequency outputIsink < 0.5 A, Urest < 0.5 V, Ileck < 0.1 mA (ground switching),with Pull-Up resistance Uaus = 0 ... +UBatt

Interfaces

F10, F11 ISO 9141-Bus Baud rate typ. 9,600 Baud, stimulation via L-line, communication via K-line

F12, F13 CAN-Bus Extended CAN, < 250 kBaud

© 06/02 Page 103

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EMR 2Technical Data

9.3 Plug assignments

The 25-pole plugs of the EMR 2 control unit are mechanically coded (different part numbers). Because ofthe different pins, the vehicle plugs (F) or the plant plugs (F) and engine plug (M) only into the sockets provi-ded for them, so that incorrect plugging in is impossible.

9.3.1 Engine Plug (M)

Pin No. Designation Description1 Reserve Reserve

2 Output: digital 3 Digital output for solenoid1)

1) For continuous power: < 4 A

3 Output: digital 4 For heating flange (optional)/glow plug (optional)

4 Input (optional) Temp 1 Fuel temperature2)

2) Corresponds to special function”fuel temperature compensation at the EMR (0211 2571)

5 Input (optional) Temp 2 Charge air temperature

6 Input (optional) DigIn 5 Coolant level / oil level

7 Output: PWM2/digital 6

8 GND Reference potential for analog signal at pin 9

9 Input: analog 7 Analog input for Coolant temperature sensor (NTC)


11 Multi-function input: speed 2/DigIn 2

Digital input second engine speed (crankshaft) (optional) and speed signal (optional)


13 Input: speed 1 Digital input first engine speed (camshaft)

14 STG - PWM output, signal for actuator coil

15 STG + PWM output, signal for actuator coil

16 Screen Screening regulating rod travel sensor (for lines 17, 18, 19)

17 RF - General connection for reference and measuring coil

18 RF REF Analog input, reference signal of the reference coil

19 RF MESS Analog input, measuring signal of the measuring coil

20 GND Reference potential for signal at pin 21

21 Input: analog 4/digital 9 Analog input 4 (sensor signal oil pressure sensor) or digital input 9

22 +5 V REF +5 V Reference voltage for signal at pin 21 (max. 15 mA)


24 Input: analog 2/digital 7 Analog input 2 (sensor signal charge air) or digital input 7

25 +5 V LDA +5 V Reference potential for signal at pin 24 (max. 15 mA)

Pb_mst1 © 06/02

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Seite 104 © 06/02

EMR 2Technical Data

9.3.2 Vehicle Plug (F) / Plant Plug

Pin-No. Designation Description1 U Batt - Negative pole at battery (clamp 31)

2 GND Reference potential for signal

3 Output: digital 2 PWM or digital output, various functions

4 Input / output: DigInOut Fault lamp and diagnostic button

5 Output: PWM 1/Dig 1 PWM or digital output, various functions

6 Multi-function input: DigIn 3 Genset applications/gear shift/motor brake

7 Input: digital 10/velocity Speed signal (tacho input)

8 NC Not occupied

9 NC Not occupied

10 L-line Serial ISO 9141 interface

11 K-line Serial ISO 9141 interface

12 CAN high Interface for CAN-Bus

13 CAN low Interface for CAN-Bus

14 U Batt + Positive pole for battery (clamp 15)

15 Output: digital 5 Digital output, various functions

16 Output: digital 7/Frequency Frequency, PWM or digital output, various functions

17 Ground Reference potential for signal at pins 18, 19 and 21

18 Input: digital 1 / PWM 1 PWM 1 or digital input 1,various functions

19 Multi-function input: DigIn 4 Performance curve switching/genset applications

20 Multi-function input: digital 8 / analog 3

Hand hand throttle/genset applications, Digital (8) or analog input (3)

21 Input: digital 2 / PWM 2 PWM 2 or digital input 2,various functions

22 Screen Screening (e.g. for lines hand throttle or PWG)


24 Input: analog 1 / digital 6 Analog input 1 (pedal value sensor, PWG) or digital input 6

25 +5 V REF +5 V Reference voltage for signal at pin 24

Pb_fst1 © 06/02

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EMR 2Technical Data

9.4 Sensor Data

Temperature sensor (NTC), coolant

Pins: Signal pin 9, GND pin 8, engine plug

Measuring range: -40 °C to 130 °C

Temperature sensor (NTC), fuel



Temperature sensor (NTC), charge air



Oil pressure sensor

Pins: Signal pin 21, GND pin 20, reference voltage +5 V pin 22, engine plug

Measuring range: 0 to 10 bar

Output signal: 0.5 V to 4.5 V DC

Charge air pressure sensor

Pins: Signal pin 24, GND pin 23, reference voltage +5 V pin 25, engine plug

Measuring range: 0.5 to 4 bar

Output signal: 0.5 V to 4.5 V DC

Speed sensor

Measuring range: 30 to 4,500 1/min

1st speed:

Conn. locality: camshaft, wheel box


- 44 Impulse/camshafts-revolutions for model series 1012/2012

- 48 Impulse/camshafts-revolutions for model series 1013/2013

- 167 Impulse/camshafts-revolutions for model series 1015

2nd speed (optional):

Conn. locality SAE-housing, crankshaft


- 129 Impulse/crankshafts-revolutions for model series 1012/1013

- Clamp w (dynamo impulses)

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EMR 2Technical Data

Coolant level sensor


Measuring range:

Atmospheric pressure sensor

Depending on unit configuration, integrated into control unit, see Chapter 4.13

© 06/02 Page 107

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EMR 2Index of Specialist Terms

10 Index of Specialist Terms

AGR Exhaust gas return

Actuator Actuator

AMP plug Multi-pole plug of the AMP company

Baud rate Data transmission speed [Bit/s]

CAN-Bus Interface (Controler Area Network)

EDC-actuator Actuator of the Bosch company

EEPROM Memory module in the microprocessor

EER 2 Electronic engine governer

ELTAB Electronic engine pocket handbook

EMV Electromagnetic compatibility

F-plug Vehicle plug / plant-side plug at the control unit

GND Mass (Ground)

High Switch open (high)

ISO International Standard Organization

Clamp 31 Minus clamp at battery

KLU Scope of customer supply

KM-temperature Coolant temperature

LDA Charge air pressure dependent full load stop

Limp home Emergency running features

Load dump Noise limit

Low Switch closed (low)

M-plug Engine plug

Md Torque

NC Not assigned

NTC Negative temperature coefficient

P-grad Proportional gradient; P-grad = 0 (Isochronous); P-grad adjustable (Droop).

PID control Proportional, integral, differential parts of the control

Pin Plug pin

Pull-up resistance Resistance to supply voltage

PWM-signal Pulse width modulated signal

REF Reference voltage or potential

SERDIA DEUTZ service diagnosis software with interface

Setpoint Setpoint

SWG 1/2 Setpoint sensor 1/2

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EMR 2Index

11 Index

A

Actuator ..................................................................................................................................................... 100Actuator functions ....................................................................................................................................... 86Altitude correction ....................................................................................................................................... 82Atmospheric pressure sensor .............................................................................................................. 82, 106

B

basic equipment .............................................................................................................................. 70, 71, 72Blink codes .................................................................................................................................................. 90

C

CAN-Bus ...................................................................................................................................................... 86CAN-Bus interface ....................................................................................................................................... 83Charge air monitoring .................................................................................................................................. 81Charge air pressure sensor ........................................................................................................................ 105Cold start installation ................................................................................................................................... 82Configuration ............................................................................................................................................... 85Configuration example ................................................................................................................................. 86Connection diagrams ................................................................................................................................. 113Coolant level sensor .................................................................................................................................. 106Coolant monitoring ...................................................................................................................................... 82Coolant temperature monitoring .................................................................................................................. 81

D

Damages ...................................................................................................................................................... 67Default functions .......................................................................................................................................... 86Description of functions ............................................................................................................................... 70Diagnostic button ........................................................................................................................................ 87Diagnostic interface ............................................................................................................................... 83, 86Display / output functions ............................................................................................................................ 86Displays ....................................................................................................................................................... 79Droop control ............................................................................................................................................... 78

E

Electrical welding ......................................................................................................................................... 68Emergency running ...................................................................................................................................... 82Engine plug ................................................................................................................................................ 103Engine protection functions ......................................................................................................................... 81Engine-start/stop ......................................................................................................................................... 78Error code .................................................................................................................................................... 90Excess speed protection ............................................................................................................................. 75

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F

Fault blink code overview ............................................................................................................................ 93Fault group ................................................................................................................................................... 93Fault indicator lamp ..................................................................................................................................... 87Fault lamp .................................................................................................................................................... 79Fault locality/fault description ...................................................................................................................... 93Fault memory ............................................................................................................................................... 92Fault no. ....................................................................................................................................................... 93Fuel quantity limitation (performance curve) ................................................................................................ 77Fuel volume control ..................................................................................................................................... 82Function control ........................................................................................................................................... 89Function extensions ..................................................................................................................................... 73Function overview ........................................................................................................................................ 86Functions ..................................................................................................................................................... 86

I

Important notes ........................................................................................................................................... 67Installation guidelines .................................................................................................................................. 67Interfaces ............................................................................................................................................. 83, 102Introduction .................................................................................................................................................. 65

L

LDA function ................................................................................................................................................ 81Limp home ................................................................................................................................................... 82Load collective ............................................................................................................................................. 80

M

Memory functions ........................................................................................................................................ 86Min/Max control ........................................................................................................................................... 74Monitoring function ...................................................................................................................................... 79

N

Notes ........................................................................................................................................................... 65

O

Oil pressure monitoring ................................................................................................................................ 81Oil pressure sensor .................................................................................................................................... 105Operating instructions ................................................................................................................................. 67Output signals .............................................................................................................................................. 79Outputs ................................................................................................................................................ 79, 102

P

Parameter setting ......................................................................................................................................... 85Pin .............................................................................................................................................................. 102Pin assignment ............................................................................................................................................ 86Pin type ...................................................................................................................................................... 102Plant plug ................................................................................................................................................... 104Plug assignments ...................................................................................................................................... 103Plug connection ........................................................................................................................................... 68

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R

Replacement of system components .......................................................................................................... 99

S

Scope of function ........................................................................................................................................ 86Second speed input ..................................................................................................................................... 75Self-diagnostic ............................................................................................................................................. 87Sensor data ................................................................................................................................................ 105Sensor inputs ............................................................................................................................................... 86SERDIA ........................................................................................................................................................ 98Set point settings ......................................................................................................................................... 76Signal specification .................................................................................................................................... 102Signal type ................................................................................................................................................. 102Software ....................................................................................................................................................... 98Speed control .............................................................................................................................................. 74Speed sensor ............................................................................................................................................. 105Speed throttling ........................................................................................................................................... 81Switchable speed functions ......................................................................................................................... 75System description ...................................................................................................................................... 69System functions ......................................................................................................................................... 71System overview .......................................................................................................................................... 69

T

Technical data ........................................................................................................................................... 101Temperature sensor (NTC), charge air ....................................................................................................... 105Temperature sensor (NTC), coolant ........................................................................................................... 105Temperature sensor (NTC), fuel ................................................................................................................. 105Temperature-dependent start control ......................................................................................................... 81

U

Utilization of the EMR 2 ............................................................................................................................... 69

V

Variable speed regulation ............................................................................................................................ 74Vehicle plug ............................................................................................................................................... 104

W

Wiring ........................................................................................................................................................... 68

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EMR 2Connection diagrams

12 Connection diagrams

The following connection diagrams present the maximum scope of the EMR2. Customer or model-specificwishes are not taken into account.

12.1 Connection diagram vehicle / plant side

12.2 Connection diagram vehicle side (sheet 1)

12.3 Connection diagram vehicle side (sheet 2)

12.4 Connection diagram for CAN-Bus and diagnostic line

Only the switching diagram specific for the particular engine is binding. This is prepared by the DEUTZcustomer representative before supply of the first engine as the switching diagram is not part of the docu-mentation supplied with the engine.

Methods of obtaining the switching diagrams are:

! Sales or customer representative, or

! Dept. Sales Documentation (Format DIN-A2) or

! Sales drawing CD-ROM or

! Engine pocket handbook (from page 3.150, size DIN-A4) or

! ELTAB CD-ROM

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12.1 Anschlussplan Fahrzeug-/Anlagenseite Connection diagram - Vehicle side / Unit side

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12.2 Anschlussplan Motorseite (Blatt 1) Connection diagram - Engine side (sheet 1)

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12.3 Anschlussplan Motorseite (Blatt 2) Connection diagram - Engine side (sheet 2)

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12.4 Anschlussplan für CAN-Bus und Diagnoseleitung Connection Diagram for CAN-Bus and Diagnostic Line

emsemr2 © 06/02

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