Asu 160 PPM

OPERATION / MAINTENANCE MANUAL
ASU 160 PPM
Air+Mak
Industries, 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: sales@airmak.com
www.airmak.com
CLIENT: AIR ASIA BHD, MALAYSIA
THIS MANUAL SHOULD BE REFERRED FOR THE ASU SL.No. 2165

ASU 160 PPM
Air+Mak
Industries, Inc.
TABLE OF CONTENTS
SUBJECT
CHAPTER / SECTION
PAGE
GENERAL SAFETY INSTRUCTIONS

DEFINITIONS OF TERMS.
NOTES
I/I
DESCRIPTION AND OPERATION

1. Introduction
..........................................................
2. Special features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. Detailed Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. G.A Drawing
.........................................................
5. Controls, Monitoring and Protection

6. Specification & capabilities
.......................................
17
.............................................
20
ELECTRONICS AND ELECTRICAL MODULE

1. Pre-commissioning check
2. DOs & Donts
I / II
...............................................
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .
3. Operating Instructions
4. General description
.................................................
....................................................
5. Pneumatic block diagram
...............................................
6. Compressor lubrication circuit diagram
....................................
12
.................................................
13
......................................................
13
7. ASU Panel Description

I. Control panel
11
8. Electro Pneumatic Panel
...............................................
9. Electronic Pressure Control System

10. Pressure Regulating System
20
.......................................
23
............................................
24
11. Control System Display Parameters
......................................
26
12. Warning Indications in Control Panel Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36
13. ASU Protection Systems and set limits
....................................
37
.....................................................
38
14. Special Interlocks

ASU 160 PPM
15. Electrical Wiring Diagram
Air+Mak
Industries, Inc.
..............................................
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
....................................................
2. Compressor maintenance
................................................
TROUBLE SHOOTING
1
3
II / II
1. Trouble Shooting Procedures & Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. Engine Trouble Shooting Symptoms
......................................
3. Compressor Trouble Shooting Symptoms
...................................
4. ASU Trouble Shooting Procedures & Techniques
OVERHAUL AND MAJOR REPAIR III
ILLUSTRATED PARTS CATALOGUE - IV
RECOMMENDED SPARES V
MANUFACTURER APPENDIX VI
1. Compressor Manual
2. Engine Manual
............................
2
3

ASU 160 PPM
Air+Mak
Industries, Inc.
GENERAL SAFETY INSTRUCTIONS

S WARNING S
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 operators compartment. When the unit is left
unserviceable
If the equipment has been operating and is hot, allow cooling before starting any maintenance
work.

ASU 160 PPM
Air+Mak
Industries, Inc.
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.

ASU 160 PPM
Air+Mak
Industries, Inc.
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
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

ASU 160 PPM
Air+Mak
Industries, Inc.
NOTES

ASU 160 PPM

CHAPTER I
SECTION I
Air+Mak
Industries, Inc.

ASU 160 PPM
Air+Mak
Industries, Inc.
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 LCDs.
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
CHAPTER I / I
PAGE 1

ASU 160 PPM
Air+Mak
Industries, Inc.
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
CHAPTER I / I
PAGE 2

ASU 160 PPM
Air+Mak
Industries, Inc.
MAJOR COMPONENT LOCATIONS (REAR VIEW)
TURBO
CHARGER
FLY WHEEL
SAE
HOUSING
CHAPTER I / I
PAGE 3

ASU 160 PPM
Air+Mak
Industries, Inc.
AIR INLET SYSTEM (TOP VIEW)
EXHAUST
TURBO
CHARGER
CHAPTER I / I
PAGE 4

ASU 160 PPM
Air+Mak
Industries, Inc.
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
SUCTION
POINT
DELIVERY
POINT
CHAPTER I / I
PAGE 5

ASU 160 PPM
Air+Mak
Industries, Inc.
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 6

ASU 160 PPM
Air+Mak
Industries, Inc.
4. G.A Drawing
CHAPTER I / I
PAGE 7

ASU 160 PPM
Air+Mak
Industries, Inc.
INTERNAL LAYOUT - MAJOR COMPONENTS

LEFT SIDE VIEW
3
27
11
FRONT VIEW
7
9
30
29
28
20
CHAPTER I / I
PAGE 8

ASU 160 PPM
Air+Mak
Industries, Inc.
RIGHT SIDE VIEW
16
18
14
ENGINE
OUTPUT S ELECTION
HOSE 1
HOS E 2
S TOP
C HECK
SYSTEM OK
HOS E 3
F USE
HOOTER
OPEN
OPEN
OP EN
OP TIONAL
DIAGNOSIS
HOOTER
OP EN
CONTROL
LAMP S WITCHES
ON
11
20
C AB IN
ON
OBS TR UCTION
ON
PANEL
ON
19
10
32
REAR SIDE VIEW
15
17
18
13
12
23
19
22
24
25
26
26
CHAPTER I / I
PAGE 9

ASU 160 PPM
Air+Mak
Industries, Inc.
30
31
21
21
TOP VIEW
CHAPTER I / I
PAGE 10

ASU 160 PPM
Air+Mak
Industries, Inc.
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.
CHAPTER I / I
PAGE 11

ASU 160 PPM
Air+Mak
Industries, Inc.
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.
CHAPTER I / I
PAGE 12

ASU 160 PPM
Air+Mak
Industries, Inc.
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.
CHAPTER I / I
PAGE 13

ASU 160 PPM
RADIATOR AND
ENGINE SIDE DOOR
Air+Mak
Industries, Inc.
CONTROL PANEL AND
PNEUMATIC PANEL
DOOR
RADIATOR CUTOUT
TOP DOOR
ENGINE AIR FILTER

CUTOUT TOP DOOR
CHAPTER I / I
PAGE 14

ASU 160 PPM
Air+Mak
Industries, Inc.
SILENCER SIDE
FRONT DOOR
OIL COOLER SIDE

DOOR
CHAPTER I / I
PAGE 15

ASU 160 PPM
Air+Mak
Industries, Inc.
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
CHAPTER I / I
PAGE 16

ASU 160 PPM
Air+Mak
Industries, Inc.
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
Engine RPM
FUNCTION
Engine Speed
NORMAL VALUES
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
Hose 1 selection
INDICATION
When Air output hose 1 on / off
ball valve selected
COLOUR
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
CHAPTER I / I
PAGE 17

ASU 160 PPM
Air+Mak
Industries, Inc.
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
If EMR Communication Failure
If unit does not cranks
RPM Lost
EMR Connection Failed
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
CHAPTER I / I
PAGE 18

ASU 160 PPM
Air+Mak
Industries, Inc.
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.
CHAPTER I / I
PAGE 19

ASU 160 PPM
Air+Mak
Industries, Inc.
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.)
Make
Deutz
Model
BF 6M 1015 C
Gross power kW / BHP @ rpm
286kW @ 2100 RPM (INT DUTY)
No of cylinders
Aspiration
Turbocharged & After cooled
After cooling system
1 - Pump 2 - Loop
Displacement
14.0 ltr ( 855 cu.in )
Bore
132 mm ( 5.2 in )
PRIMEMOVER DIESEL ENGINE
CHAPTER I / I
PAGE 20

ASU 160 PPM
Air+Mak
Industries, Inc.
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
CHAPTER I / I
PAGE 21

ASU 160 PPM
Air+Mak
Industries, Inc.
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
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
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
COMPRESSOR LUBRICATING SYSTEM
SAFETY RELIEF VALVE
CHAPTER I / I
PAGE 22

ASU 160 PPM
Air+Mak
Industries, Inc.
ENGINE SILENCER
Make
MAK
Type
Residential
Quantity
1 No.
Make
MAK
Type
Residential
Quantity
1 No.
Temperature
200C ( 392 F)
Pressure
40 PSIg
Make
MAK
Control Range
90 - 400 PPM
Valve Type
Slotted pipe
Quantity
1 No
Weight/unit
61 kgs
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
BYPASS SILENCER
BY PASS VALVE
ACTUATOR
CHAPTER I / I
PAGE 23

ASU 160 PPM
Air+Mak
Industries, Inc.
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
CHAPTER I / I
PAGE 24

ASU 160 PPM
Air+Mak
Industries, Inc.
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
Make
BELLOFRAM
Model
964-501-001
Quantity
1 Nos
Make
WIKA
Model
0-4 Bar
Quantity
1 Nos
P-I TRANSDUCER
COMPRESSOR OILPRESSURE GAUGE
CHAPTER I / I
PAGE 25

ASU 160 PPM
Air+Mak
Industries, Inc.
PNEUMATIC TANK PRESSURE GAUGE

Make
WIKA
Model
0-10 Bar
Quantity
1 Nos
Make
TIGER
Model
ACC-BAT- IGN-ST
Part No.
429 2483
Quantity
1 Nos
Make
IDEC
Model
Normally Closed
Part No.
AVW402ERP
Quantity
1 Nos
Make
FINDER
Model
4 Changeover
Ratings
24V DC 7A
Part no.
55.34.9.024.0074
Quantity
6 Nos
CONTROL PANEL COMPONENTS:

STARTING KEY
EMERGENCY STOP
RELAYS
CHAPTER I / I
PAGE 26

ASU 160 PPM
Air+Mak
Industries, Inc.
TIMER RELAY
Make
FINDER
Model
4 Change over
Ratings
24V DC
Part no
85.04.0.024.0.000
Quantity
1 Nos
Make
O/E/N
Model
Single change over
Ratings
24 VDC / 30A
Part No.
531-1A-24-T-1
Quantity
2 Nos.
Make
TYCO ELECTRONICS
Model
W58-XB1A4A-5, 15 & 30
Ratings
5, 15 & 30Amps
Quantity
Each 2 Nos & 1 Nos
Make
OTTO
Model
T7-231B5 / ON-ON
Quantity
3 Nos
Make
OTTO
Model
T7-231F5 / ON-OFF-ON
Quantity
1 Nos
STARTING & COOLER FAN RELAYS
RESETTABLE FUSE
HOSE SELECTION SWITCHES
MODE SELECTOR SWITCH
CHAPTER I / I
PAGE 27

ASU 160 PPM
Air+Mak
Industries, Inc.
LAMP SWITCHES
Make
OTTO
Model
T7-231A5 / ON-OFF
Quantity
3 Nos
Make
OTTO
Model
T7-231A5 / ON-OFF
Quantity
Each 1 Nos
Make
OTTO
Model
T7-231E5 / Spring Return
Quantity
Each 1 Nos
ALARM & OPTIONAL SWITCH
DIAGONSIS & BYPASS SWITCH
HOSE INDICATION LAMP

Make
IDEC
Model
Green colour / 24 VDC
Part No.
AL6M-P4G
Quantity
3 Nos
Make
IDEC
Model
Red colour / 24 VDC
Part No.
AL6M-P4R
Quantity
1 Nos
ENGINE STOP LAMP
CHAPTER I / I
PAGE 28

ASU 160 PPM
Air+Mak
Industries, Inc.
ENGINE CHECK LAMP

Make
IDEC
Model
Yellow colour / 24 VDC
Part No.
AL6M-P4Y
Quantity
1 Nos
Make
IDEC
Model
Green colour / 24 VDC
Part No.
AL6M-P4G
Quantity
each 1 Nos
SYSTEM OK & AIR ON LAMP
10 PIN ALLIED CONNECTOR

Make
: ALLIED ELECTRONICS CORPORATION
Model / Type
Female Connector / Special - Lock Type
Part No.
MG 00F 18-1S
Quantity
1 Nos
Make
ALLIED ELECTRONICS CORPORATION
Model / Type
Female Connector / Special - Lock Type
Part No.
MG 00F28-15S
Quantity
1 Nos
Make
DHARSAN
Model
DMCL-4-F
Quantity
2 Nos
35 PIN ALLIED CONNECTOR
PANEL LOCK
CHAPTER I / I
PAGE 29

ASU 160 PPM
Air+Mak
Industries, Inc.
SENSORS
CHARGING AMMETER
Make
MURPHY
Model
-60-0+60 AMPS
Part No.
EGS21
Quantity
1 Nos
Make
MURPHY
Model
ES2F
Part No.
05-70-5668
Quantity
1 Nos
Make
MURPHY
Model
ESP-100
Quantity
1 Nos
FUEL FLOAT
COMPRESSOR OIL PRESSURE SENSOR
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
CHAPTER I / I
PAGE 30

ASU 160 PPM
Air+Mak
Industries, Inc.
COMPRESSOR AIR FILTER CLOG INDICATOR

Make
MANN
Model / Part no.
50 mBar / 3900062959
Quantity
1 Nos
Make
OMRON
Model
Proximity Switch
Part No.
E2A-M18KN16-M1-C1
Quantity
1 Nos
Make
FESTO
Model / Part no.
CRVZ-20
Quantity
1 Nos
Make
SMC
Model / Part no.
I-AF40-04
Quantity
1 Nos
Make
SMC
Model / Part no.
AFM40-04
Quantity
1 Nos
HOSE COUPLING ADAPTOR SENSOR
PNEUMATIC TANK COMPONENTS

PNEUMATIC TANK
AIR FILTER
MIST SEPEARTOR
CHAPTER I / I
PAGE 31

ASU 160 PPM
Air+Mak
Industries, Inc.
AUTODRAIN VALVE
Make
SMC
Model / Part no.
1-AD402-04
Quantity
1 Nos
Make
TVS
Model
M1K26/1
Quantity
1 Nos
Make
BENDIX
Model / Part no.
VAR VALVE_SAFTEY / 284142N
Quantity
1 Nos
Make
CURTIS
Model
ED-125
Quantity
1 Nos
Make
SMC
Model / Part no.
1-VND202D-15A-B
Quantity
1 Nos
AIR DRYER INSULATION KIT
RELIEF VALVE
SAFTEY COMPONENTS
BATTERY ISOLATOR
PILOT PROCESS VALVE
CHAPTER I / I
PAGE 32

ASU 160 PPM
Air+Mak
Industries, Inc.
LAMPS
CORNER LAMP
Make
VITRONICS
Model
Amber Colour -24 V
Quantity
6 Nos
Make
VITRONICS
Model
White Colour -24 V
Type
Rectangle
Quantity
4 Nos
Make
ALTOS
Model
Orange Colour -24 V
Quantity
1 Nos
CABIN & PANEL LAMP
OBSTRUCTION LAMP
CHAPTER I / I
PAGE 33

ASU 160 PPM
Air+Mak
Industries, Inc.
CHAPTER I
SECTION II
ELECTRONICS AND ELECTRICAL MODULE
CHAPTER I / II

ASU 160 PPM
Air+Mak
Industries, Inc.
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.
1 INSPECTION
Visually inspect if any components have been damaged during transit.
S 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.
U 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.
CHAPTER I / II
PAGE 1

ASU 160 PPM
Air+Mak
Industries, Inc.
2. Dos & Dont s

Dos
) 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.
Donts:
) 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.
CHAPTER I / II
PAGE 2

ASU 160 PPM
Air+Mak
Industries, Inc.
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.
1 INSPECTION
Visually inspect whether all the parameters are within limit and all the gauges are
functioning.
S WARNING
Do not open the Output valve unless all the parameters are under control.
U 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.
CHAPTER I / II
PAGE 3

ASU 160 PPM
Air+Mak
Industries, Inc.
B. Jet Start Operation (AST mode)

4 Uncoil the output hose (s) as required, connect to the Aircraft coupling & check for proper
connection.
4 Check for any twist in the Hose(s), if so rectify the same.
4 Ensure that the Hose selection switches (Hose1, Hose2 & Hose3) is in OFF position.
4 Change the mode selector switch from IDLE mode to AST mode.
4 Check whether all output parameters are within acceptable limits.
4 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.
4 Change the selected hose switches (Hose1, Hose2 & Hose3) to ON position.
4 Await further instructions from the crew.
C. Air Conditioning Operation (ACP mode)

4 Uncoil the output hose (s) as required, connect to the Aircraft coupling & check for proper
connection.
4 Check for any twist in the Hoses, if so rectifies the same.
4 Ensure that the Hose selection switches (Hose1, Hose2 & Hose3) are in OFF position.
4 Change the mode selector switch from IDLE mode to ACP mode.
4 Check whether all output parameters are within acceptable limits.
4 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.
4 Change the selected hose switches (Hose1, Hose2 & Hose3) to ON position.
4 Await further instructions from the crew.
CHAPTER I / II
PAGE 4

ASU 160 PPM
Air+Mak
Industries, Inc.
1 INSPECTION
Visually inspect whether the AIR ON lamp glows when the output valve is
opened for Air bleeding.
S 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.
U CAUTION
Note: No Protections will trip the Engine in Air start mode. This Interlock is
provided to avoid Hot Start of the Aircraft Engine. Operators attention is
required during this situation to save the system getting damaged.
CHAPTER I / II
PAGE 5

ASU 160 PPM
Air+Mak
Industries, Inc.
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)
1 INSPECTION
Visually inspect all the assemblies are in good condition.
S 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
CHAPTER I / II
PAGE 6

ASU 160 PPM
Air+Mak
Industries, Inc.
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 Compressors 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
CHAPTER I / II
PAGE 7

ASU 160 PPM
Air+Mak
Industries, Inc.
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.
CHAPTER I / II
PAGE 8

ASU 160 PPM
Air+Mak
Industries, Inc.
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.
CHAPTER I / II
PAGE 9

ASU 160 PPM
Air+Mak
Industries, Inc.
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.
CHAPTER I / II
PAGE 10

ASU 160 PPM
Air+Mak
Industries, Inc.
5. Pneumatic Block Diagram
CHAPTER I / II
PAGE 11

ASU 160 PPM
Air+Mak
Industries, Inc.
6. Compressor Lubrication circuit diagram

2
3
4
1.COMPRESSOR
2.OIL COOLER
3.PRESSURE GAUGE
4.COMPRESSOR OIL TEMPERATURE SENSOR
CHAPTER I / II
PAGE 12

ASU 160 PPM
Air+Mak
Industries, Inc.
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.
CHAPTER I / II
PAGE 13

ASU 160 PPM
Air+Mak
Industries, Inc.
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.
CHAPTER I / II
PAGE 14

ASU 160 PPM
Air+Mak
Industries, Inc.
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.
CHAPTER I / II
PAGE 15

ASU 160 PPM
Air+Mak
Industries, Inc.
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.
CHAPTER I / II
PAGE 16

ASU 160 PPM
Air+Mak
Industries, Inc.
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.
CHAPTER I / II
PAGE 17

ASU 160 PPM
Air+Mak
Industries, Inc.
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.
CHAPTER I / II
PAGE 18

ASU 160 PPM
Air+Mak
Industries, Inc.
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 & ElectroPneumatic controls for Protection and Pressure Regulation.
CONTROL PANEL
CHAPTER I / II
PAGE 19

ASU 160 PPM
Air+Mak
Industries, Inc.
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 compressors 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
CHAPTER I / II
PAGE 20

ASU 160 PPM
Air+Mak
Industries, Inc.
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.
CHAPTER I / II
PAGE 21

ASU 160 PPM
Air+Mak
Industries, Inc.
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
CHAPTER I / II
PAGE 22

ASU 160 PPM
Air+Mak
Industries, Inc.
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.
CHAPTER I / II
PAGE 23

ASU 160 PPM
Air+Mak
Industries, Inc.
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.
CHAPTER I / II
PAGE 24

ASU 160 PPM
Air+Mak
Industries, Inc.
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 theyre by avoiding any physical damage.
CHAPTER I / II
PAGE 25

ASU 160 PPM
Air+Mak
Industries, Inc.
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,
Thanks for
Choosing
MAK
Air Start Unit
On healthy condition (No fault status) this message is followed by the READY TO START display,
EOP: 0.0 Bar
ECT: 000 C
System OK
Ready to START
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,
EOP: 0.0 Bar
ECT: 000 C
Turn Hose Switch

1
To Close
CHAPTER I / II
PAGE 26

ASU 160 PPM
Air+Mak
Industries, Inc.
b) If one of the output Butterfly valves (Hose1) is kept in open position,

EOP: 0.0 Bar
ECT: 000 C
Close O/P Valve
1
Then Crank
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,
COP: 0.0 Bar
COT: 000 C
Close Ball valve

1
Then crank
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,
FL: 80 %
BV: 26 V
FL: 80 %
BV: 26 V
Selected AST
Change to IDLE
Selected ACP
Change to IDLE
CHAPTER I / II
PAGE 27

ASU 160 PPM
Air+Mak
Industries, Inc.
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,
Date: 06/12/2007
Time: 10:10:09PM
Start Progress
Please Wait
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.
Panel Temp :30C
H:00016:30
5.0PSIG
IDLE
168C
RPM:1300
Under any circumstances, if the Engine does not gets started then the following message will be
displayed as,
Date: 06/12/2007
Time: 10:10:09AM
Crank Failed
Reset & Try
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,
EOP: 0.0 bar
ECT: 000 C
5.0PSIG
IDLE
198C
RPM LOST
CHAPTER I / II
PAGE 28

ASU 160 PPM
Air+Mak
Industries, Inc.
In case of any loose connections/malfunction of the P-I transducer and its wiring, the following
warning message is displayed as,
EOP: 0.0 bar

ECT: 000 C
Pressure signal
Lost, check P-I
Real time Clock Display:
Date: 06/12/2007
Time: 10:10:09AM
5.0PSIG
IDLE
168C
RPM:1300
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.
SYSTEM FAULT
HIGH DT
1/1
Clear faults &

TRY again
Where as it will continue to run on AST mode irrespective of the fault occurred.
SYSTEM FAULT
HIGH DT
1/1
40.0PSIG
AST
198C
RPM:1300
CHAPTER I / II
PAGE 29

ASU 160 PPM
Air+Mak
Industries, Inc.
If more than one fault occurs at a time the Faults will be toggled and listed as,
SYSTEM FAULT
HIGH DT
1/1
Clear faults &

TRY again
SYSTEM FAULT
HI.COOL.TEMP 2/2
Clear faults &

TRY again
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,
Place Aircraft
Coupling 1
In Adaptor & Try
5.0PSIG
IDLE
168C
RPM:1300
5.0PSIG
IDLE
168C
RPM:1300
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,
SYSTEM FAULT
REG LOW PRE. 1/1
5.0PSIG
IDLE
168C
RPM:1300
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,
CHAPTER I / II
PAGE 30

ASU 160 PPM
Air+Mak
Industries, Inc.
SYSTEM FAULT
REG LOW PRE. 1/1
Reg pressure low
Change to IDLE
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,
Turn Hose Switch
1
To Close
Remove Coupling
From Adaptor& Try
5.0PSIG
IDLE
168C
RPM:1300
5.0PSIG
IDLE
168C
RPM:1300
In Bypass Mode Display:

EOP: 0.0 bar
ECT: 000 C
5.0PSI BYP IDLE
198C
RPM:1300
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,
EMR Comm. Fail
Check EMR to CPU
EMR Comm. Fail

Connector
5.0PSIG
IDLE
168C
RPM LOST
5.0PSIG
IDLE
168C
RPM LOST
CHAPTER I / II
PAGE 31

ASU 160 PPM
Air+Mak
Industries, Inc.
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,
ASU maintenance
Information
Fuel Filter Rep.
Due in 0250 Hrs
Warning! Replace
Fuel Filter
ASU maintenance
Information
Due in 050 Hrs/

0010 Days
Fuel Filter Rep.

Due in 0160 Days
ASU maintenance
Information
E.Oil&Filter Rep.
Due in 0250 Hrs
Warning! Replace
E.Oil&Filter
ASU maintenance
Information
Due in 050 Hrs/

0010 Days
E.Oil&Filter Rep.
Due in 0160 Days
CHAPTER I / II
PAGE 32

ASU 160 PPM
Air+Mak
Industries, Inc.
ASU maintenance
Information
E.Air Filter Rep.
Due in 1000 Hrs
Warning! Replace
E.Air Filter
ASU maintenance
Informatio
Due in 050 Hrs/

0010 Days
E.Air Filter Rep.

Due in 0365 Days
ASU maintenance
Information
C.Oil&Filter Rep.
Due in 0250 Hrs
Warning! Replace
C.Oil&Filter
ASU maintenance
Information
Due in 050 Hrs/

0010 Days
C.Oil&Filter Rep.
Due in 0160 Days
CHAPTER I / II
PAGE 33

ASU 160 PPM
Air+Mak
Industries, Inc.
ASU maintenance
Information
C.Air Filter Rep.
Due in 1000 Hrs
Warning! Replace
C.Air Filter
ASU maintenance
Information
Due in 050 Hrs/

0010 Days
C.Air Filter Rep.

Due in 0365 Days
ASU maintenance
Information
Check battery
Weekly Once
Use page up key to view next pages, if eleven pages completed then it returns to main page. If any key
isnt pressed for 5 sec LCD message returns to main page.
CHAPTER I / II
PAGE 34

ASU 160 PPM
Air+Mak
Industries, Inc.
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
Fuel Filter
Warning! Replace
E.Oil&Filter
Due in 050 Hrs/

0010 Days
Due in 050 Hrs/

0010 Days
Warning! Replace
E.Air Filter
Warning! Replace
C.Oil&Filter
Due in 050 Hrs/

0010 Days
Due in 050 Hrs/

0010 Days
Warning! Replace
C.Air Filter
Due in 050 Hrs/
0010 Days
CHAPTER I / II
PAGE 35

ASU 160 PPM
Air+Mak
Industries, Inc.
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
Reg pressure low
applied
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
Cannot be cranked.
the unit)
CHAPTER I / II
PAGE 36

ASU 160 PPM
Air+Mak
Industries, Inc.
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
Engine Low Lube Oil Pressure
< 2.5 bar
Trip
2 Second
Engine High Coolant Temp.
> 105 C
Trip
2 Second
Under Speed
< 800 rpm
Trip
30Second
Engine Air filter clogging
< 30 mbar
Warning
2 Second
Low Compressor Oil Pressure
< 1.0 bar
Trip
2 Second
High Compressor Oil Temp.
Above 80 C
Trip
2 Second
High Discharge Temperature
Above 250C
Trip
2 Second
Compressor Air filter clogging
< 30 mbar
Warning
2 Second
Regulation Pressure Low
< 4 Bar
Warning
10
Low Fuel
Below 25%
Remarks
Corner lamp Immediate

flashing
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.
CHAPTER I / II
PAGE 37

ASU 160 PPM
Air+Mak
Industries, Inc.
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.
CHAPTER I / II
PAGE 38

ASU 160 PPM
Air+Mak
Industries, Inc.
15. ELECTRICAL WIRING DIAGRAMS
CHAPTER I / II
PAGE 39

ASU 160 PPM
Air+Mak
Industries, Inc.
CONTROL PANEL WIRING MODULE I
CHAPTER I / II
PAGE 40

ASU 160 PPM
Air+Mak
Industries, Inc.
CONTROL PANEL WIRING MODULE II
CHAPTER I / II
PAGE 41

ASU 160 PPM
Air+Mak
Industries, Inc.
EMR WIRING DIAGRAM
CHAPTER I / II
PAGE 42

ASU 160 PPM
Air+Mak
Industries, Inc.
16. PCB SCHEMATIC DIAGRAM
CHAPTER I / II
PAGE 43
MCORE CIRCUIT
90 MOSI
91 MISO
93 SCK
94
128
95
CS_O
ACP_O
AST_O
RTC_IRQ
CAN_INT
INT5
INT6
INT7
SPI
E/P_CS
CLK_O
VDD
TP8
CLK
RST_O
CLK_O
EN_INT
71
72
75
79
82
84
88
89
61
58 ICOC11
57
56
55
ICOC20
54
ICOC21
53
ICOC22
52
69
70
66
68
EMRRPM_O
M_RX2
M_TX2
M_RX1
M_TX1
ONCE-PORT
INT
+5V
130 ONCE-TCLK
133 ONCE-TD1
135 ONCE-TD0
138 ONCE-TMS
142 ONCE-TRST_B
143 ONCE-DE_B
EMRRPM_O
RPMS
9
19
33
45
65
77
129
141
123
74
103
113
115
87
EN_ICOC
A
TP7
RST
TP
TP
SYSTEM STATUS LED

LED
SYS
TCLK
TD1
TD0
TMS
TRST
DE
VDD
VDD
VDD
VDD
VDD
VDD
VDD
VDD
VDDSYN
VDDF
VDDH
VRH
VDDA
VPP
MOSI
MISO
SCK
SS
CLKOUT
OE
INT0
INT1
INT2
INT3
INT4
INT5
INT6
INT7
ICOC10
ICOC11
ICOC12
ICOC13
ICOC20
ICOC21
ICOC22
ICOC23
TXD1
RXD1
TXD2
RXD2
KEYS
R/W / PF7
A22 / PF6
A21 / PF5
A20 / PF4
A19 / PF3
A18 / PF2
A17 / PF1
A16 / PF0
RLCF2
59
RLCF1 116
RLFLASH117
RLFLT 119
RLER
121
RLQX
122
RLST
131
RLEF
132
VSS
VSS
VSS
VSS
VSS
VSS
VSS
VSS
VSSF
VSSA
VSSSYN
VRL
8
18
32
44
64
76
127
140
73
114
126
112
TC0/PE0
TC1/PE1
TC2/PE2
CSE0/PE3
CSE1/PE4
TEA/PE5
TA/PE6
SHS/PE7
RESET
RSTOUT
XTAL
EXTAL
TX0RTS
80
TX1RTS
78
TX2RTS
67
RX0BF
62
RX1BF
60
F_LED1102
F_LED2 99
F_LED3 97
118
RST 120
RST_O 124
XTAL
EXTAL 125
A0 / PH0
A1 / PH1
A2 / PH2
A3 / PH3
A4 / PH4
A5 / PH5
A6 / PH6
A7 / PH7
D16/PB0
D17/PB1
D18/PB2
D19/PB3
D20/PB4
D21/PB5
D22/PB6
D23/PB7
D0/PD0
D1/PD1
D2/PD2
D3/PD3
D4/PD4
D5/PD5
D6/PD6
D7/PD7
25
22
21
20
17
16
15
12
51
48
46
43
42
41
40
39
LLOP_O
HCT_O
LCOP_O
H3AS_O
H2AS_O
H1AS_O
CHRGFAIL_O
LOWCLNT_O
CS0/PI0
CS1/PI1
CS2/PI2
CS3/PI3
EB0/PI4
EB1/PI5
EB2/PI6
EB3/PI7
MMC2107
KEY0
KEY1
KEY2
KEY3
KEY4
KEY5
KEY6
KEY7
FAULTS1
D24/PA0
D25/PA1
D26/PA2
D27/PA3
D28/PA4
D29/PA5
D30/PA6
D31/PA7
D8/PC0
D9/PC1
D10/PC2
D11/PC3
D12/PC4
D13/PC5
D14/PC6
D15/PC7
LED
FLA_CS
10
TEMP_CS
7
RTC_CS
5
CAN_CS
4
DAC1_CS
3
DAC2_CS
2
LED1
1
LED2 144
38
37
36
35
34
31
30
27
PQA0
PQA1
PQA3
PQA4
PQB0
PQB1
PQB2
PQB3
1K
GREEN
KB_LED
LCD_EN2
LCD_EN1
LCD_RS
LCDD4
LCDD5
LCDD6
LCDD7
CS
111
110
109
108
107
106
105
104
R94
LED1
U8
CHANNEL1
CHANNEL2
AIN1
AIN2
BAT_I/P
PQB1
PQB2
PQB3
VDD
GREEN
A8 / PG0
A9 / PG1
A10 / PG2
A11 / PG3
A12 / PG4
A13 / PG5
A14 / PG6
A15 / PG7
VSTBY
TEST
86 BV3_SEN
85 BV1_SEN
83 BV2_SEN
81 IDLERUN
101 RPLOW_O
100 SV1OPEN
98 SV2OPEN
96 SV3OPEN
50
49
47
29
28
26
24
23
92
63
CAN
1K
VDD
D4
1
3
VSTBY
2
DIO914
D5
FAULTS2
B
1
3
2
DIO914
BT1
BR-2/3AE2SP
C51
0.1uF
AUX_RLY
XTAL
C19
15pF
FLT_CLR_O
LCDBACKLIT
ADD0
ADD1
XTAL1
R10
1M
8MHz-SMD
ECS-CSM-7-DN
C20
15pF
VSTBY
TEST
C
EXTAL
VDD
MMC2107CFCAG33
RED
R89
F_LED1
FT1
RED
FT2
RELAYS
1K
R90
F_LED2
FAULT LED'S
F_LED
LCD
SYS
CMPAFC_O
E_AFC_O
SV1CLOSE
SV2CLOSE
SV3CLOSE
HOSE1_O
HOSE2_O
HOSE3_O
14 RLACT1
13 RLACT2
11 RLACT3
6 RLCOLD
139
137
136
134
R88
LED2
FAULTS3
RED
1K
R91
F_LED3
FT3
1K
F_LED
Title
MCOREASU-PRODUCTION
Designator Designator Designator Designator Designator Designator Designator
Sheet2.sch Sheet3.sch Sheet4.sch Sheet5.sch Sheet6.sch Sheet7.sch Sheet8.sch
Designator
Sheet9.sch
Designator
Sheet10.sch
Designator
Sheet11.sch
Size
A4
Date:
File:
Number
Revision
PCBNO:472A
20-Aug-07
E:\Documents and Settings\..\Sheet1.sch
VERSION1.1
Sheet 1 of 11
Drawn By: CA
4
VDD
REALTIME CLOCK CIRCUIT
FAULT CONNECTOR
C49
I/P'S & O/P'S
J7
0.1uF
VDD
RSTIN1_PULL
RST
1
2
3
4
5
6
7
8
9
10
11
12
13
14
28
27
26
25
24
23
22
21
20
19
18
17
16
15
NF
VCC
NF
E
NF
IRQ/FT/OUT
NC
VOUT
NC
VSS
NC M41ST95
PFI
NC
SCL
SQW
32KHz
WDI
EF
RSTIN1
RST
RSTIN2
SDI
PFO
SDO
NC
ECON
VSS
VBAT
M41ST95W SO-28
C56
RTC_CS
RTC_IRQ
MTG1
4MB FLASH CIRCUIT
U33
U38
HOLD
0.1uF
SCK
FLA_CS
MISO
RTC_PULL
MOSI
MISO
1
2
3
4
5
6
7
8
HOLD
VCC
DU
DU
DU
DU
S
Q
16
15
14
13
12
11
10
9
C
D
DU
DU
DU
DU
VSS
W
EOIL_P
R_GND
CMPAFC
SCK
MOSI
FUELI/P
CMPOIL_P
ECLNT_T
CMPOIL_T
EOIL_T
E_AFC
RPLOW
H1AS
LLOP
HDT_ANA
CHRGFAIL
LCOP
RP_ANA
LOWCLNT
HCT
M25P32-VMF6G SO16 WIDE
VSTBY
C53
0.1uF
RTC PULLUPS
TEMPERATURE CIRCUIT
VDD
C52
0.1uF
TEMP_CS
SCK
U34
1
2
3
4
VDD
CE
SCK
GND
1
2
3
4
FLA_CS
CAN_CS
E/P_CS
TEMP_CS
8
7
6
5
8
7
6
5
RPM
H2AS
VIN
1
10
19
2
11
20
3
12
21
4
13
22
5
14
23
6
15
24
7
16
25
8
17
26
9
18
MTG1
1
10
19
2
11
20
3
12
21
4
13
22
5
14
23
6
15
24
7
16
25
8
17
26
9
18
SADJ2
SVC1
P/I_IN1
CANH
SVC2
CANL
SVC3
P/I_IN2
IDLERUN_O
HOSE1
EMR_RPM
HOSE2
E/P_OUT
EMR_GND
HOSE3
SVO1
BIVALVE1
SADJ1
SVO2
BIVALVE2
SVO3
MTG2
MTG2
10K
0.1uF
VDDA
MODE
MOSI
MISO
BIVALVE3
H3AS
VIN
SIP4
VDD
C54
VDD
J5
VDD
MODE
MOSI
MISO
SAMTEC-RSP-122057-04-FEMALE
SIP11
RTC_IRQ
RTC_CS
RTC_PULL
RSTIN1_PULL
DS1722S SO-8
1
2
3
4
SAMTEC-RSP-122057-03-MALE
C
8
7
6
5
SPI
10K
MOSI
MISO
SCK
RESET CIRCUIT
CANH
MOSI
MISO
SCK
R95
120E
CANL
VDD
RST
GND
R84
100E
RST
RST_PULL
SPI PULLUPS
SW1
VDD
SIP12
RST_PULL
2
MAX809STR
0.1uF
VCC
U32
3
C50
SNAP ACTION RST SWITCH

OMRON-B3S-1002
MODE
SCK
MISO
MOSI
1
2
3
4
8
7
6
5
Title
C55
0.1uF
Size
A4
Date:
File:
MCOREASU PERIPHERALS & INPUTS
10K
Number
Revision
PCBNO:472A
20-Aug-07
VERSION1.1
Sheet 2 of 11
Drawn By: CA
4
FAULTS CIRCUIT
VIN
VIN
U11
A
LLOP
LCOP
R19 8K2
R18 8K2
R17 8K2
HCT
H3AS
R16 8K2
16
2
3
15
14
4
5
13
12
6
7
11
10
LLOP_O
U44
LCOP_O
HOSE1
HCT_O
HOSE2
R103 8K2
R102 8K2
R101 8K2
H3AS_O
HOSE3
VDD
PCT4116/E
OPTOQUAD
IDLERUN
R100 8K2
16
2
3
15
14
4
5
13
12
6
7
11
10
R15 8K2
HOSE1_O
AST
HOSE2_O
ACP
HOSE3_O
IDLERUN_O
CS
U10
1
16
R14 8K2
2
3
15
14
R13 8K2
4
5
13
12
R12 8K2
6
7
11
10
CHRGFAIL
PCT4116/E
OPTOQUAD
VIN
A
AST_O
ACP_O
CS_O
CHRGFAIL_O
PCT4116/E
OPTOQUAD
VIN
U43
1
H2AS
R99 8K2
R98
8K2
SVO1
SVO2
SVO3
R97
8K2
R96 8K2
U9
16
2
3
15
14
4
5
13
12
6
7
11
10
H2AS_O
BIVALVE1
R6
8K2
SV1OPEN
R7
8K2
BIVALVE2
SV2OPEN
R8 8K2
BIVALVE3
FLT_CLR
R9
SV3OPEN
R85 1K
16
2
3
15
14
4
5
13
12
6
7
11
10
8K2
PCT4116/E
OPTOQUAD
VIN
SVC1
R86 8K2
R87 8K2
SVC2
SVC3
RPLOW
R92 8K2
R93 8K2
BV3_SEN
LLOP_O
LCOP_O
HCT_O
H3AS_O
1
2
3
4
16
2
3
15
14
4
5
13
12
6
7
11
10
SV1CLOSE
H1AS
R2
8K2
R3
8K2
R4
8K2
SV2CLOSE
LOWCLNT
SV3CLOSE
CMPAFC
RPLOW_O
E_AFC
PCT4116/E
OPTOQUAD
R5
8K2
VDD
1
2
3
4
SIP7
8
7
6
5
1
2
3
4
BV1_SEN
BV2_SEN
BV3_SEN
FLT CLR_O
10K
16
2
3
15
14
4
5
13
12
6
7
11
10
10K
SIP19
H2AS_O
SV1OPEN
SV2OPEN
SV3OPEN
10K
VDD
SIP15
CMPAFC_O
8
7
6
5
VDD
H1AS_O
LOWCLNT_O
8
7
6
5
VDD
U7
1
2
3
4
AST_O
ACP_O
CS_O
CHRGFAIL_O
1K
SV1CLOSE
SV2CLOSE
SV3CLOSE
RPLOW_O
1
2
3
4
SIP8
8
7
6
5
FLT CLR_O
OPTOQUAD
U39
C
VDD
SIP9
BV2_SEN
PCT4116/E
VIN
VDD
BV1_SEN
SIP6
8
7
6
5
1
2
3
4
H1AS_O
LOWCLNT_O
CMPAFC_O
E_AFC_O
10K
8
7
6
5
1K
VDD
E_AFC_O
SIP20
HOSE1_O
HOSE2_O
HOSE3_O
IDLERUN_O
PCT4116/E
OPTOQUAD
1
2
3
4
8
7
6
5
10K
INT
D
CS_O
ACP_O
AST_O
RTC_IRQ
CAN_INT
Title
MCOREASU-SENSING INPUTS
CS_O
AST_O
ACP_O
RTC_IRQ
CAN_INT
Size
A4
Date:
File:
1
Number
Revision
PCBNO:472A
20-Aug-07
VERSION1.1
Sheet 3 of 11
Drawn By:
CA
4
RELAY CIRCUITS
RELAY PULLUPS
RELAY CONNECTOR
VDD
U6
A
RLSTPUL
RLST
RLEFPUL
RLEF
1
2
3
4
+CTRL
-CTRL
+CTRL
-CTRL
J3
LD
LD
LD
LD
8
7
6
5
SIP1
RLST_O
RLEF_O
PVT322S
DUAL RELAY
1
2
3
4
RLSTPUL
RLEFPUL
RLCF1PUL
RLCF2PUL
MTG1
8
7
6
5
1K
VDD
U37
RLERPUL
RLER
RLQXPUL
RLQX
1
2
3
4
+CTRL
-CTRL
+CTRL
-CTRL
LD
LD
LD
LD
8
7
6
5
SIP3
RLER_O
RLQX_O
DUAL RELAY
PVT322S
1
2
3
4
RLERPUL
RLQXPUL
RLFLASHPUL
RLFLTPUL
VRLY
8
7
6
5
1
2
3
4
+CTRL
-CTRL
+CTRL
-CTRL
1K
RLCF1_O
RLACT2_O
VDD
LD
LD
LD
LD
8
7
6
5
SIP2
RLFLASH_O
RLFLT_O
DUAL RELAY
PVT322S
RLER_O
RLCF2_O
RLACT3_O
RLQX_O
RLFLASH_O
RLCOLD_O
RLST_O
RLFLT_O
RLEF_O
RLACT1_O
U5
RLFLASHPUL
RLFLASH
RLFLTPUL
RLFLT
1
6
11
2
7
12
3
8
13
4
9
14
5
10
15
1
2
3
4
RLACT1PUL
RLACT2PUL
RLACT3PUL
RLCOLDPUL
8
7
6
5
MTG2
SAMTEC-RSP-122057-02-FEMALE
1K
U36
RLCF1PUL
RLCF1
RLCF2PUL
RLCF2
1
2
3
4
+CTRL
-CTRL
+CTRL
-CTRL
LD
LD
LD
LD
8
7
6
5
RLCF1_O
VRLY
RLCF2_O
DUAL RELAY
PVT322S
U4
RLACT1PUL
RLACT1
RLACT2PUL
RLACT2
1
2
3
4
+CTRL
-CTRL
+CTRL
-CTRL
LD
LD
LD
LD
8
7
6
5
RLACT2_O
+CTRL
-CTRL
+CTRL
-CTRL
RLQX_O
YELLOW
RLST_O
YELLOW
RLEF_O
U35
1
2
3
4
YELLOW
LD
LD
LD
LD
8
7
6
5
REF
RLCF2_O
YELLOW
RLFLT_O
8K2
8K2
RLACT2_O YELLOW
8K2
R80
CF1
RLACT3_O YELLOW
8K2
R79
CF2
R78
FLH
RLCOLD_O YELLOW
8K2
8K2
R77
YELLOW
RLACT1_O YELLOW
R81
YELLOW
RLCF1_O
RLFLASH_O YELLOW
R82
LST
YELLOW
8K2
R69
RLQ
RLACT3_O
RLCOLD_O
R70
RER
RLACT1_O
DUAL RELAY
PVT322S
RLACT3PUL
RLACT3
RLCOLDPUL
RLCOLD
RLER_O
VRLY
FLT
8K2
R76
AT1
8K2
R75
AT2
8K2
R74
AT3
8K2
R73
CLD
8K2
DUAL RELAY
PVT322S
RELAYS
RLCF2
RLCF1
RLFLASH
RLFLT
RLER
RLQX
RLST
RLEF
RLCF2
RLCF1
RLFLASH
RLFLT
RLER
RLQX
RLST
RLEF
AUX_RLY
Title
RLACT1
RLACT2
RLACT3
RLCOLD
Size
A4
Date:
File:
MCOREASU-RELAY OUTPUTS
RLACT1
RLACT2
RLACT3
RLCOLD
Number
Revision
PCBNO:472A
20-Aug-07
VERSION1.1
Sheet 4 of 11
Drawn By: CA
4
+3.3V POWERSUPPLY
A
INHIB
Vin
Vin
Vin
GND
GND
GND
GND
Vout
Vout
Vout
VOadj
TP1
VIN
D2
R68
2
3
VC
+3.3
WAGO-231-136
1K
MURD320
D-PACK
+
C3
2200uF/50V RADIAL
R83
10K
TVS1
+
C6
470F/16V RADIAL
C47
0.1F
R1
1K/2W
CONTROLLER CAPACITORS
RED
+3.3
VDD
VIN
VDD
VDD
B
C12
C7
TP
VC
1
2
3
4
5
6
FLT_CLR
AST
ACP
CS
TP2
VDD
TP
VIN
J1
VC
PT6303N VERTICAL
1
2
3
4
5
6
7
8
9
10
11
12
TP
TP6
I/P POWER CONNECTOR
U2
C15 C17
+
+
1uF
+
1uF
1uF
C16 C11
RED
C10 C18
YELLOW
1uF
C14 C8
C13
1uF
C9
R71
1uF
1uF
C21 C22
10K
TP
VRL
1uF
1uF
C63
C23
MURD320
D-PACK
D3
1uF
VRLY
1
VIN
+5V
+
1uF
1uF
1uF
TP4
1uF
1uF
0.1uF
VRL
5V POWERSUPPLY
-3.3V POWERSUPPLY
+5V
1A 5V 3 PIN VERTICAL
2K
+
C2
100uF
C46
0.1uF
RED
+5V
C5
100uF
Vin
GND
R67
PT5021N
2
GND
PT5101N
2
Vout
VDD
VDD
C64
C62
C59
C57
C66
0.1uF
C65
0.1uF
C61
0.1uF
C58
0.1uF
C60
0.1uF
C67
0.1uF
C68
0.1uF
C71
0.1uF
C70
0.1uF
C69
0.1uF
0.1uF
0.1uF
0.1uF
0.1uF
-3.3
1A -3.3V 3PIN VERTICAL
U3
Vout
C4
100uF
R72
1K
C1
100uF
Vin
-3.3V
+5V
U1
1
VDD
TP5
+5V
TP
VIN
TP
TP3
RED
-3.3
C48
0.1uF
Title
MCOREASU-POWERSUPPLY
Size
A4
Date:
File:
1
Number
Revision
PCBNO:472A
20-Aug-07
VERSION1.1
Sheet 5 of 11
Drawn By:
CA
4
ENHANCEMENT CONNECTOR
PROGRAMMING
PROGRAMMING CONNECTOR
FLA_CS
TEMP_CS
RTC_CS
CAN_CS
DAC1_CS
DAC2_CS
SIP16
EN_ICOC
J6
J4
ICOC11
ICOC21
INT5 INT5
INT7
INT7
PQB2
VDD
1
3
5
7
9
11
13
15
2
4
6
8
10
12
14
16
ICOC20
ICOC22
INT6
ONCE-TD1
ONCE-TD0
ONCE-TCLK
INT6
PQB1
PQB3
VDD
1
3
5
7
9
11
13
RST
VDD
1
2
3
4
ONCE-TD0
ONCE-TD1
ONCE-TMS
ONCE-TCLK
2
4
6
8
10
12
14
8
7
6
5
VDD
SIP18
1
2
3
4
CAN_INT
ONCE-DE_B
ONCE-TRST_B
RPMS
CONFIGURATION
8
7
6
5
SIP14
B
1
2
3
4
LLOP_O
LCOP_O
H3AS_O
H1AS_O
KEYBOARD & LCD CONNECTOR

+5V
LCDD7
LCD_EN1
KEY0
KEY4
KEY6
KB_LED
KEY2
KEY3
VDD
C
1
3
5
7
9
11
13
15
17
19
21
23
25
2
4
6
8
10
12
14
16
18
20
22
24
26
LCDD4
LCDD5
LCDD6
LCD_RS
LCD_EN2
KEY1
KEY5
KEY7
LCDBACKLIT
SIP17
1
2
3
4
CLK_O
RST_PULL
ONCE-TCLK
TEST
8
7
6
5
VDD
1
2
3
4
FAULTS3
COLDST_O
CF1SW_O
COLDPUSH_O
10K
8
7
6
5
KEY PULLUPS
VDD
10K
KEYS
FTSH-113-01-L-DV-EJ-K
SIP10
KEY0
KEY1
KEY2
KEY3
1
2
3
4
8
7
6
5
10K
FAULTS1
LLOP_O
LLOP_O
HCT_O
HCT_O
LCOP_O
LCOP_O
H3AS_O
H3AS_O
H2AS_O
H2AS_O
H1AS_O
H1AS_O
CHRGFAIL_O
CHRGFAIL_O
LOWCLNT_O
LOWCLNT_O
KB_LED
LCD_EN2
LCD_EN1
LCD_RS
LCDD4
LCDD5
LCDD6
LCDD7
KEYS
KEY0
KEY1
KEY2
KEY3
KEY4
KEY5
KEY6
KEY7
KEY0
KEY1
KEY2
KEY3
KEY4
KEY5
KEY6
KEY7
KEY4
KEY5
KEY6
KEY7
CMPAFC_O
E_AFC_O
SV1CLOSE
SV2CLOSE
SV3CLOSE
HOSE1_O
HOSE2_O
HOSE3_O
FAULTS2
FAULTS1
1
2
3
4
8
7
6
5
LLOP_O
HCT_O
LCOP_O
H3AS_O
H2AS_O
H1AS_O
CHRGFAIL_O
LOWCLNT_O
Title
MCOREASU-CONNECTORS & PULLUPS
INT5
INT6
INT7
Size
A4
Date:
File:
1
CMPAFC_O
E_AFC_O
SV1CLOSE
SV2CLOSE
SV3CLOSE
HOSE1_O
HOSE2_O
HOSE3_O
LLOP_O
HCT_O
LCOP_O
H3AS_O
H2AS_O
H1AS_O
CHRGFAIL_O
LOWCLNT_O
10K
EN_INT
INT5
INT6
INT7
BV1_SEN
BV2_SEN
BV3_SEN
IDLERUN
RPLOW_O
SV1OPEN
SV2OPEN
SV3OPEN
BV1_SEN
BV2_SEN
BV3_SEN
IDLERUN
RPLOW_O
SV1OPEN
SV2OPEN
SV3OPEN
VDD
SIP13
LCD
KB_LED
LCD_EN2
LCD_EN1
LCD_RS
LCDD4
LCDD5
LCDD6
LCDD7
ONCE-TCLK
ONCE-TD1
ONCE-TD0
ONCE-TMS
ONCE-TRST_B
ONCE-DE_B
B
SIP5
DAC1_CS
DAC2_CS
W
HOLD
ONCE-TCLK
ONCE-TD1
ONCE-TD0
ONCE-TMS
ONCE-TRST_B
ONCE-DE_B
VDD
10K
LCDD4
LCDD5
LCDD6
LCD_RS
LCD_EN2
KEY1
KEY5
KEY7
ONCE-PORT
10K
8
7
6
5
J2
A
FLA_CS
TEMP_CS
RTC_CS
CAN_CS
DAC1_CS
DAC2_CS
10K
ONCE-TMS
ONCE-DE_B
ONCE-TRST_B
7X2 BERGSTIC
NU
LCDD7
LCD_EN1
KEY0
KEY4
KEY6
KB_LED
KEY2
KEY3
CS
VDD
Number
Revision
PCBNO:472A
20-Aug-07
VERSION1.1
Sheet 6 of 11
Drawn By: CA
4
VDD
RPM CIRCUIT
R134
C88
TP10
0.1uF
U17
D6
NU
C82
NU
R35
10K
0.1uF
U18
SCK
MOSI
DAC1_CS
VCC
1
VO1
VDD
C79
NU
D1
DIO914
EMRRPM_O
GND
HCPL-073A SO-8
R34
10K
SADJ1
9
+
TLC2274ID
C33
EMRRPM_O
U16D
12
REFRENCE
5K1
P1510K
R177
NU
14
13
B
3
EMR_RPM
C36
0.1uF
TLC2274ID
R127
8K2
VDD
VDD
+5V
C83
CLK
DIN
CS/LD
DOUT
VCC
VOUT
REF
GND
4
R121 10K
U16A
1
E/P
E/P_OUT
TLC2274ID
+
11
LTC1453 SO-8
VDD
R43
R176
NU
R120
R119 NU
C31
NU
5K1
P17 10K
U16B
7
REFRENCE
NU
TLC2274ID
P16
10K
C32
SCK
MOSI
DAC2_CS
1
2
3
4
0.1uF
CLK
DIN
CS/LD
DOUT
8
7
6
5
VCC
VOUT
REF
GND
R44 10K
U30A
R152
TLC2272ID
10K
LTC1453 SO-8
SADJ2
2
+
C41
R178
NU
REFRENCE
U30B
R172
7
6
C108
0.1uF
TLC2272ID
P18 10K
5K1
C91
NU
Title
ZD1
Size
A4
Date:
File:
1
Number
Revision
PCBNO:472A
20-Aug-07
MCOREASU-RPM & DAC CKT
NU
U31
2
R32 10K
R31
NU
0.1uF
TP11
TP
SCK
MOSI
E/P_CS
8
7
6
5
4.7/25V TANTALUM THRU HOLE
0.1uF
U15
1
2
3
4
+5V
C119
0.1uF
C120
DAC2 CIRCUIT
C87
D/A CIRCUIT
10
R41 10K
C90
NU
U16C
R42 10K
R40
VO2
8
7
6
5
VCC
VOUT
REF
GND
LTC1453 SO-8
C35
NU
R175
10K
EMR_GND
CLK
DIN
CS/LD
DOUT
RPMS
RPMS
R_GND
1
2
3
4
SAJ
C89
TP
8K2
DAC1 CIRCUIT
VDD
3
RPM
VERSION1.1
Sheet 7 of 11
Drawn By:
CA
4
P TO I I/P
R125
VDD
A
C81
VDD
REGULATION PRESSURE I/P
P3 10K
R28
10K
-3.3V
C80
0.1uF
R114 10K
R128
R112 10K
10K
R36
10K
RP_ANA
R25
7
TLC2274ID
R113 10K
11
AIN1
12K
TLC2274ID
R26 10K
10K
150E
U14B
R136
10K
+
P2
10K
C85
0.1uF
R38
0E
R135
4
U14A
-3.3V
R23
R111
10K
150E
R137
NU
1uF
R115
R116
P/I_IN1
C27
R117
0E
VDD
P6 10K
10K
R24 10K
R110 10K
U13A
1
TLC2274ID
C30
0.01uF
C84
0.1uF
P5
10K
10K
R109 10K
R108 10K
U13B
R107
RP_ANA_O
12K
TLC2274ID
11
P/I
R27
10K
TP9
R132
10K
1uF
TP
C28
R37
VDD
NU
C29
0.01uF
B
0.1uF
-3.3V
-3.3V
P TO I I/P
R126
VDD
P4 10K
10K
R29
-3.3V
NU
VC
C34
+
R133
10K
1uF
R30
10K
R33
200K
R140
R39
10K
R131
150E
P/I_IN2
R141 10K
R138 10K
BATTERY SENSING CIRCUIT
R118
0E
P1
10K
10K
U14C
8
10
TLC2274ID
R124 10K
R139 10K
13
U14D
R123
14
12
AIN2
12K
TLC2274ID
R130 10K
10
R129 10K
R122
10K
U13C
8
R22
BAT_I/P
12K
C78
0.01uF
TLC2274ID
C86
0.01uF
R21
10K
Title
Size
MCOREASU-PTOICKT
Number
Revision
A4
PCBNO:472A
Date:
File:
20-Aug-07
VERSION1.1
Sheet 8 of 11
Drawn By:
CA
4
+5V
VDD
R62
R168
RG
RG
NU
+VS
2
C106
OUT
ANALOG CIRCUITS
-VS
REF
0.1uF
7
6
R169 10K
R149 10K
TLC2274ID
U20A
1
R170
-3.3V
VDD
C38
0.01uF
11
AD620AR
+5V
EOIL_P_O
NU
0.1uF
R56
R55
560E
-3.3V
P14 10K
R162
VDD
R60
R166
RG
NU
C105
-VS
-VS
RG
REF
0.1uF
R167 10K
R147 10K
R161
NU
R164
RG
U25
1
CMPOIL_T
R159
RG
OUT
-VS
REF
0.1uF
U20C
TLC2274ID
RG
+VS
2
C101
CMPOIL_P_O
12K
VDD
C112
C92
0.1uF
0.1uF
OUT
-VS
REF
C
8
7
6
R160 10K
R145 10K
AD620AR
0.1uF
R165 10K
10
R146 10K
R173
ECLNT_T_O
TLC2274ID
U19A
1
R54
CMPOIL_T_O
12K
C95
0.01uF
-3.3V
-3.3V
12K
C45
0.01uF
AD620AR
P10 10K
-3.3V
Title
P11 10K
Size
A4
Date:
File:
R174
130K
RG
NU
0.1uF
D
14
C42
0.01uF
R53
R52
3.3K
C114
+VS
2
C104
13
+5V
130K
NU
VDD
VDD
12
R148 10K
EOIL_T_O
C37
0.01uF
R58
ECLNT_T
R163 10K
P13 10K
P12 10K
U27
-3.3V
+5V
R57
3.3K
U20D
TLC2274ID
U20B
TLC2274ID
-3.3V
C
REF
0.1uF
AD620AR
NU
AD620AR
0.1uF
OUT
0.1uF
OUT
+VS
C115
+VS
RG
2
C103
1.8K
U28
1
EOIL_T
RG
NU
+5V
C113
470K
U26
1
CMPOIL_P
R59
3.3K
0.1uF
EOIL_P
C116
11
C93
470K
U29
R61
560E
VDD
MCOREASU-INSTRUMENTATION AMP(ENGINE INPUTS)

Number
Revision
PCBNO:472A
20-Aug-07
VERSION1.1
Sheet 9 of 11
Drawn By:
CA
4
ANALOG CIRCUITS
+5V
VDD
R51
A
R50
1.5K
U24
1
FUELI/P
R157
RG
RG
1.8K
+VS
C100
C111
27K
OUT
-VS
REF
0.1uF
7
6
R158 10K
R144 10K
U19B
7
R64
FUELI/P_O
MUX/DMUX CIRCUITS
12K
AD620AR
C102
0.01uF
TLC2274ID
0.1uF
VDD
-3.3V
C74
+5V
10K
16
P9
VDD
U23
1
HDT_ANA
R155
RG
RG
100K
+VS
C99
C110
47K
OUT
-VS
REF
0.1uF
7
6
R156 10K
10
R143 10K
U19C
8
R45
HDT_ANA_O
12
14
15
11
X0
X1
X2
X3
CMPOIL_T_O
FUELI/P_O
HDT_ANA_O
RP_ANA_O
1
5
2
4
Y0
Y1
Y2
Y3
10
9
A
B
12K
AD620AR
C94
0.01uF
TLC2274ID
0.1uF
EOIL_P_O
EOIL_T_O
ECLNT_T_O
CMPOIL_P_O
ADD0
ADD1
13
CHANNEL1
CHANNEL2
CD74HC4052M
6
7
8
-3.3V
VCC
R48
10K
0.1uF
U45
R49
INH
VEE
GND
P8
+5V
C
10K
C
VDD
R47
R46
560E
U22
1
RP_ANA
R153
RG
NU
RG
+VS
2
C98
C109
470K
OUT
-VS
REF
0.1uF
U19D
TLC2274ID
R154 10K
12
R142 10K
13
14
NU
RP_ANA_O
C97
0.01uF
NU
AD620AR
0.1uF
R63
-3.3V
D
P7
Title
10K
Size
A4
Date:
File:
1
MCOREASU- INSTRUMENTATION AMP
Number
Revision
PCBNO:472A
20-Aug-07
VERSION1.1
Sheet 10of 11
Drawn By:
CA
4
232 COMMUNICATION
9WAY FOR SYSTEM INTERFACE
485 COMMUNICATION
9WAY FOR 485 COMMUNICATION
VDD
VDD
C43
MTG1
J8
VDD
MTG1
2
6
16
0.1uF
M_TXD1
U46
V+
VVCC
R1 OUT
R2 OUT
T1 OUT
T2 OUT
C2+
C2 -
12
9
14
7
4
5
M_RX1
M_RXD1
M_TXD1
+
C44
1uF
MAX3232IDR SO-16
0.1uF
U21
M_TX2
M_RX2
R151
470E
Q1
2N2222A
1
2
3
4
C117
8
7
6
5
RX VDD
RE
B
DE
A
TX GND
A
B
A
B
R66
120E
0.1uF
B
NU
SN65HVD08D SO-8
0.1uF
C118
1
6
2
7
3
8
4
9
5
R65
10K
R150
10K
MTG2
MTG2
DB9/D-SUB9 FEMALE
15
C39
1uF
GND
M_TX1
R1 IN
R2 IN
T1 IN
T2 IN
C1+
C1 -
R171
10K
1
6
2
7
3
8
4
9
5
+
1uF
13
8
11
10
1
3
C107
C96
1uF
C40
M_RXD1
J9
VDD
DB9/D-SUB9 FEMALE
B
B
VDD
VDD
C72
R104
360E
CAN COMMUNICATION
NC
VCC
VE
VDD
VDD
C76
CAN CONTROLLER
CAN_TX
CAN TRANSCEIVER C75
4
U12
C24
R11
1K
XTAL2
8MHz
VO
NC
GND
0.1uF
R20
360E
7
6
CANTX_ISO
CANTX_ISO
C77
NU
HCPL-0600 SO-8
3
0.1uF
RST
CAN_CS
MISO
MOSI
SCK
CAN_INT
RX0BF
RX1BF
U40
1
CANTX_ISO
CAN_RX
MCP2510-I/SO SO-18
TXD
RXD
NC
CANH
CANL
NC
8
VDD
7
6
VDD
C73
CANH
CANL
R105
360E
VDD
U42
1
SN65HVD232D SO-8
NC
VCC
33PF
C25
TXCAN
VDD
RXCAN
RST
CLKOUT
CS
TX0RTS
SO
TX1RTS
SI
TX2RTS
SCK
XTAL
INT
EXTAL RX0BF
GND
RX1BF
0.1uF
VDD
TX0RTS
TX1RTS
TX2RTS
18
17
16
15
14
13
12
11
10
VSS
CAN_TX
CANRX_ISO
1
2
3
4
5
6
7
8
9
VDD
U41
VE
33PF
3
CAN_RX
VO
NC
GND
0.1uF
R106
360E
7
6
CANRX_ISO
CANRX_ISO
C26
0.1uF
HCPL-0600 SO-8
MH1
MH3
MH7
MH6
MH2
MH5
MH4
CAN
TX0RTS
TX1RTS
TX2RTS
RX0BF
RX1BF
Title
TX0RTS
TX1RTS
TX2RTS
RX0BF
RX1BF
Size
A4
Date:
File:
3
MCOREASU-COMMUNICATION
Number
Revision
PCBNO:472A
20-Aug-07
VERSION1.1
Sheet 11of 11
Drawn By:
CA
4

ASU 160 PPM
Air+Mak
Industries, Inc.
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.
CHAPTER I / II
PAGE 55

ASU 160 PPM
Air+Mak
Industries, Inc.
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.
Warning! Replace
Fuel Filter
Due in 049Hrs
OR 028 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.
Warning! Replace
Fuel Filter
Past Due 49Hrs/
28 Days
Press FAULT CLEAR key while warning displayed to skip the warning and Crank the ASU for
operation.
Press FAULT CLEAR key continuously for 3 Secs after replacing the filters to reload the
maintenance schedule for the corresponding filter warnings.
CHAPTER I / II
PAGE 56

ASU 160 PPM
Air+Mak
Industries, Inc.
MAINTENANCE
CHAPTER II
SECTION I
CHAPTER II / I

ASU 160 PPM
Air+Mak
Industries, Inc.
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 / OEMs. 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.
S WARNING
SHUT DOWN THE EQUIPMENT FOR ANY MAINTENANCE WORK
Note: Kindly Refer Application and Installation Manual of DEUTZ 6M1015C

Model Engine Manual for details.
CHAPTER II / I
PAGE 1

ASU 160 PPM
Air+Mak
Industries, Inc.
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
iv) Engine storage Long term
Refer Engine Manual

Refer Engine Manual
CHAPTER II / I
PAGE 2

ASU 160 PPM
Air+Mak
Industries, Inc.
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.
S 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
CHAPTER II / I
PAGE 3

ASU 160 PPM
Air+Mak
Industries, Inc.
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 / I
PAGE 4

ASU 160 PPM
Air+Mak
Industries, Inc.
TROUBLE SHOOTING
CHAPTER II
SECTION II
CHAPTER II / II

ASU 160 PPM
Air+Mak
Industries, Inc.
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.
U 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
CHAPTER II / II
PAGE 1

ASU 160 PPM
Air+Mak
Industries, Inc.
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.
U CAUTION
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.
U CAUTION
this manual.
CHAPTER II / II
PAGE 2

ASU 160 PPM
Air+Mak
Industries, Inc.
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
Output butterfly valve may be in open position.
CORRECTIONS
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.
CHAPTER II / II
PAGE 3

ASU 160 PPM
Air+Mak
Industries, Inc.
4.2. Engine cranks but stops when start key is released

CAUSE
Air lock in the fuel line.
CORRECTIONS
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
Check F3 (refer control 1 panel wiring
- 15 A
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.
Tighten the same.
6 way wago connector J1 may loose/Removed

Tighten the same.
26 way LCD interface connector J1 from the
CPU card to LCD card may be
Properly fix the same. If the cable found
loose/removed/damaged
damaged replace the same with exact one.
LCD connector in the display card may be
Check, Tighten the same.
loose.
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
Drain and fill with new oil according to oil
brands, water present in oil.
specifications.
CHAPTER II / II
PAGE 4

ASU 160 PPM
Air+Mak
Industries, Inc.
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
Fault sensor wires may be grounded.
CORRECTIONS
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
Check (refer control 1 panel wiring diagram)
loose.
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
Check, if found loose tighten the same
loose in the EMR 25 pin connector
CHAPTER II / II
PAGE 5

ASU 160 PPM
Air+Mak
Industries, Inc.
4.8.Pressure shows 00 or Prsr.Signal Lost

CAUSE
P- I transducer wire may be loose.
CORRECTIONS
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
Leakage in sensing line, Control lines.
CORRECTIONS
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.
CHAPTER II / II
PAGE 6

ASU 160 PPM
Mode selection switch may be faulty
Air+Mak
Industries, Inc.
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
Loose connection in the charging alternator
CORRECTIONS
Charging Alternator may be faulty.
Check the Alternator and replace it.
Charging minimum load may be left open /
Check and fix a minimum load to the D+
short circuit
supply of the charging alternator
4.11.Safety Valve(s) Open

CAUSE
Dis charge pressure excessive
CORRECTIONS
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

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.
CHAPTER II / II
PAGE 7

ASU 160 PPM
Air+Mak
Industries, Inc.
4.13.Display remains in IDLE mode even after selecting AST mode

CAUSE
Mode selection switch may be faulty
CORRECTIONS
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
Fan relay may be faulty.
CORRECTIONS
Wires may be loose
Check ((refer control panel 2 wiring diagram)

Tighten the same.
Oil cooler Fan DC motor may be defective

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.

CHAPTER II / II
PAGE 8

ASU 160 PPM
Air+Mak
Industries, Inc.
4.16.Unit trips with Compressor Low Lube Oil Pressure

CAUSE
LCOP switch may be faulty.
CORRECTIONS

Oil level in the tank might be low.
Fill the tank with required quantity of oil.
Pressure setting of the relief valve (Non Return
Check up and correct the pressure setting if
Valve) must be disturbed.
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.

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
CHAPTER II / II
PAGE 9

ASU 160 PPM
Air+Mak
Industries, Inc.
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
Loose connections in Hose adaptor sensor
Check and tighten the same

Hose selection switch may be faulty
CHAPTER II / II
PAGE 10

ASU 160 PPM
Air+Mak
Industries, Inc.
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: sales@airmak.com
WEBSITE: www.airmak.com
CHAPTER III

ASU 160 PPM
Air+Mak
Industries, Inc.
ILLUSTRATED PARTS CATALOGUE

CHAPTER IV
CHAPTER IV

ASU 160 PPM
Air+Mak
Industries, Inc.
CHAPTER V
RECOMMENDED SPARES
CHAPTER V

ASU 160 PPM
Air+Mak
Industries, Inc.
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 V

ASU 160 PPM
Air+Mak
Industries, Inc.
CHAPTER VI
MANUFACTURER APPENDIX
CHAPTER VI

ASU 160 PPM
Air+Mak
Industries, Inc.
1. COMPRESSOR MANUAL
CHAPTER VI

ASU 160 PPM
Air+Mak
Industries, Inc.
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 1

ASU 160 PPM
Air+Mak
Industries, Inc.
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 2

ASU 160 PPM
Air+Mak
Industries, Inc.
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 3

ASU 160 PPM
Air+Mak
Industries, Inc.
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 antifriction 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
PAGE 4

ASU 160 PPM
Air+Mak
Industries, Inc.
2. ENGINE MANUAL
CHAPTER VI
Operation Manual
26 388/
1015
Safety guidelines / Accident prevention

Please read and observe the information
given in this Operation Manual. This will
enable you to avoid accidents, preserve the
manufacturers warranty and maintain the
engine in peak operating condition.
This engine has been built exclusively for
the application specified in the scope of
supply, as described by the equipment manufacturer and is to be used only for the
intended purpose. Any use exceeding that
scope is considered to be contrary to the
intended purpose. The manufacturer will
not assume responsibility for any damage
resulting therefrom. The risks involved are
to be borne solely by the user.
Use in accordance with the intended purpose also implies compliance with the conditions laid down by the manufacturer for
operation, maintenance and servicing. The
engine should only be operated by personnel trained in its use and the hazards involved.
The relevant accident prevention guidelines
and other generally accepted safety and
industrial hygiene regulations must be observed.
When the engine is running, there is a risk of
injury through:
- turning/hot components
- engines with positive ignition
- ignition systems (high electrical voltage)
You must avoid contact at all times!
Unauthorized engine modifications will invalidate any liability claims against the manufacturer for resultant damage.
Manipulations of the injection and regulating
system may also influence the performance
of the engine, and its emissions. Adherence
to legislation on pollution cannot be guaranteed under such conditions.
Do not change, convert or adjust the cooling
air intake area to the blower.
The manufacturer shall not be held responsible for any damage which results from
such work.
When carrying out maintenance/repair operations on the engine, the use of DEUTZ
original parts is prescribed. These are specially designed for your engine and guarantee perfect operation.
Non-compliance results in the expiry of the
warranty!
Maintenance and cleaning of the engine
should only be carried out when the engine
is switched off and has cooled down.
You must ensure that the electrical systems
have been switched off and the ignition key
has been removed.
Accident prevention guidelines concerning
electrical systems (e.g. VDE-0100/-0101/0104/-0105 Electrical protective measures
against dangerous touch voltage) are to be
observed.
When cleaning with fluids, all electrical components are to be covered impermeably.
Operation Manual
1015
0297 9684 en
Engine
Serial Number:
Please enter here the engine serial number. By quoting
this number you will help to facilitate dealing with
questions concerning Customer Service, Repairs and
Spare Parts (see Section 2.1).
In view of continuous design improvements or changes,

the technical specifications and the illustrations shown
in this Operation Manual are subject to alteration.
Reprinting and reproduction, in part or in whole, are
subject to our written approval.
Foreword
Dear Customer,
Liquid-cooled DEUTZ engines are designed
for
a
broad
spectrum
of
applications.Consequently, a wide range of
variants are offered to meet the specific
requirements of each individual case.
Your engine is appropriately equipped for
the installation concerned, which means
that not all the components described in this
Operation Manual are necessarily mounted
to your engine.
We have endeavoured to highlight any
differences so that you will be able to locate
the operating and maintenance instructions
relevant to your engine quickly and easily.
Please read this Manual before starting your
engine, and always observe the operating
and maintenance instructions.
Should you have any inquiries we shall be
pleased to provide advice.
Sincerely,
DEUTZ AG
Table of Contents
1.
General
2.
2.1
2.1.1
2.1.2
2.1.3
2.1.4
2.2
2.2.1
2.2.2
2.2.3
2.2.4
2.3
2.3.1
Description of Engine
Model Designation
Rating Plate
Location of Rating Plate
Engine Serial Number
Numbering of Cylinders
Engine Illustrations
Cyl. Bank A BF6 M 1015
Cyl. Bank B BF6 M 1015
Cyl. Bank A BF8 M 1015
Cyl. Bank B BF8 M 1015
Lube Oil Circuit
Lube Oil Circuit Schematic 1015
3.
Operation
3.1 Commissioning
3.1.1 Filling in Engine Oil
3.1.2 Filling Oil Bath Air Cleaner with
Engine Oil
3.1.3 Filling the Fuel Tank
3.1.4 Filling/Bleeding the Cooling System
1015
3.1.5 Other Preparations
3.2 Starting
3.2.1 Electric Starting
3.3 Monitoring Systems
3.3.1 Engine Oil Pressure
3.3.2 Coolant Temperature
3.3.3 Coolant Level
3.3.4 Lube Oil Level
3.4 Stopping
3.4.1 Mechanical Shutdown
3.4.2 Electric Shutdown
3.5 Operating Conditions

3.5.1 Winter Operation
3.5.2 High Ambient Temperature, High
Altitude
4.
4.1
4.1.1
4.1.2
4.2
4.2.1
4.2.2
4.3
4.3.1
Operating Media
Lube Oil
Quality Grade
Viscosity
Fuel
Quality Grade
Winter Grade Fuel
Coolant
Water Quality for Coolant
Preparation
4.3.2 Coolant Preparation
4.3.3 Cooling System Protective Agents
5.
5.1
5.2
5.3
Routine Maintenance
Maintenance Schedule
Maintenance Chart
Completed Maintenance Jobs
6.
Service and Maintenance
6.1 Lubrication System
6.1.1 Oil Change Intervals
6.1.2 Changing Engine Oil, Checking Oil
Level
6.1.3 Renewing Oil Filter
6.2 Fuel System
6.2.1 Renewing Fuel Filter
6.2.2 Change Fuel Leakage Line
6.2.3 Fuel Pre-filter Element
Clean/Replace if necessary
6.3 Cooling System

6.3.1 Cleaning Intervals
6.3.2 Draining Cooling System
6.3.3 Filling/Bleeding Cooling System
6.3.4 Cleaning engine
6.4 Combustion Air Cleaner
6.4.2 Dry-Type Air Cleaner
6.4.3 Removing Cyclone-Type
Precleaner
6.4.4 Cleaning Oil Bath Air Cleaner
6.5 Belt Drives
6.5.1 Checking Alternator V-Belt
6.5.2 Retensioning/Renewing Alternator
V-Belt
6.6 Adjustments
6.6.1 Checking/Adjusting Valve
Clearances
6.6.1.1
Valve Clearance
Adjustment Schematic
6.7 Accessories
6.7.1 Battery
6.7.2 Three-Phase Alternator
6.7.3 Lifting Tackle
7.
7.1
Troubleshooting
Diagnosis Chart
8.
8.1
Engine Preservation
Preservation
9.
9.1
9.2
9.3
Specification Data
Engine Specifications and Settings
Torque Wrench Settings
Tools
10.
Service
26 388/1
General
DEUTZ Diesel Engines
Care and Maintenance
Service
are the product of many years of research and

development. The resulting know-how, coupled
with stringent quality standards, guarantee their
long service life, high reliability and low fuel
consumption.
It goes without saying that DEUTZ Diesel Engines
meet the highest standards for environmental
protection.
Sound care and maintenance practices will ensure

that the engine continues to meet the requirements
placed on it. Recommended service intervals must
be observed and service and maintenance work
carried out conscientiously.
Special care should be taken under abnormally
demanding operating conditions.
Please contact one of our authorized service

representatives in the event of breakdowns or for
spare parts inquiries. Our trained specialists will
carry out repairs quickly and professionally, using
only genuine spare parts.
Original parts from DEUTZ AG are always produced
in accordance with state-of-the-art technology.
Please turn to the end of this manual for further
service information.
Beware of Running Engine
Safety
California
Proposition 65 Warning
Shut the engine down before carrying out maintenance or repair work. Ensure that the engine cannot
be accidentally started. Risk of accidents.
When the work is complete, be sure to refit any
panels and guards that may have been removed.
Never fill the fuel tank while the engine is running.
Observe industrial safety regulations when running
the engine in an enclosed space or underground.
This symbol is used for all safety

warnings. Please follow them
carefully. The attention of operating
personnel should be drawn to these
safety instructions. General safety
and accident prevention regulations laid down by
law must also be observed.
Asbestos
DEUTZ original parts are asbestosfree.
Diesel engine exhaust and some of its constituents are known to the State of California to
cause cancer, birth defects, and other reproductive harm.
2
2.1 Model Designation
2.2 Engine Illustrations
2.3 Lube Oil Circuit
2
2.1.1 Rating Plate

2.1.2 Location of Rating Plate
2.1.3 Engine Serial Number
26 332 0
The model designation A, the engine serial

number B and the performance data are stamped
on the rating plate.
When ordering spare parts, it is essential to quote
the model designation and the engine serial
number.
26 389 0
The rating plate C is affixed to the crankcase.
26 390 0
The engine serial number is stamped on the

crankcase iteself (arrow) and on the rating plate.
2
2.1.4 Numbering of Cylinders
26 391 0
The cylinders are numbered consecutively for

either cyl. bank A or B, beginning at flywheel end.
2
2.2 Engine Illustration
2.2.1 Cyl. Bank A BF6M 1015
15
14
2
13
3
12
4
5
11
10
7
26 392 0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Oil filler neck

Cylinder head
Exhaust manifold
SAE housing
Crankcase
Starter
Oil pan
Oil filter
Coolant connection from heat exchanger to
engine
Vibration damper
V-belt pulley
Alternator
Coolant connection to heat exchanger
Solenoid (shutdown solenoid)
Flame-type heater plug (B-side)
2.2.2 Cyl. Bank B BF6M1015
23
16
22
17
21
20
19
18
26 393 0
16
17
18
19
20
21
22
23
Charge air pipe

Oil dipstick
Oil drain plug
SAE housing
Flywheel
Exhaust turbocharger
Injection pump
Flame-type heater plug (A-side)
2
2.2.3 Cyl. Bank A BF8M 1015
14
13
12
2
11
3
10
4
8
5
26 412 0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Exhaust manifold
Crankcase
Starter
Oil filler neck
Oil pan
Lube oil filter
V-belt pulley with vibration damper
Coolant connection from heat exchanger to
engine
Oil cooler
Fan
Exhaust stack
Charge air pipe to the charge air cooler
Flame-type heater plug system (B-side)
2.2.4 Cyl. Bank B BF8M 1015
22
14
15
16
21
17
20
19
18
26 413 0
14
15
16
17
18
19
20
21
22
Flame-type heater plug system (A-side)

Oil filler neck
Cylinder head
Alternator
Oil dipstick
SAE housing
Flywheel
Compressor
Fuel connecting line
2
2.3 Lube Oil Circuit
2.3.1 Lube Oil Circuit Schematic 1015

Wet Sump Lubrication
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
26 394 0
28
Oil pan
Intake pipe
Oil pump
Overpressure relief valve
Oil cooler
Spin-on oil filter
Main oil bores
Main bearing
Big-end bearing
Camshaft bearing
Oil supply to injection pump
Injection pump
Return line from injection pump to
crankcase
Line to spray nozzle
Spray nozzle with pressure-holding valve for
piston cooling
Tappet with control groove for pulse
lubrication of rocker arms
Pushrod, oil supply to rocker arm lubrication
Rocker arm
Oil return bore in cylinder head to crankcase.
Oil pressure sensor / oil pressure switch
Oil line to exhaust turbocharger
Oil line to compressor (hydr. pump)
Compressor
Hydraulic pump
Pressure-holding valve (adjustable)
Oil return line from compressor (hydr.
pump) to crankcase
Oil return line from turbocharger to
crankcase
Engine Operation
3
3.1
3.2
3.3
3.4
3.5
Commissioning
Starting
Monitoring Systems
Stopping
Operating Conditions
Engine Operation
3
3.1 Commissioning
3.1.1 Filling in Engine Oil
3.1.2 Filling Oil Bath Air Cleaner with

Engine Oil
3.1.3 Filling the Fuel Tank
OIL
FUEL
26 397 0
As a rule, the engines are delivered without

oil 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.
26 398 0
24980 2
Fill engine oil into bowl 1 of oil bath air

cleaner (if fitted) up to the arrow mark.
For oil quality grade and oil viscosity, see 4.1.
Use only commercial-grade diesel fuel. For

fuel quality grade, see 4.2.
Use
summeror
winter-grade
fuel,
depending on the ambient temperature.
Never fill oil into the

precleaners dust collector, if
provided.
Stop engine before filling the

fuel tank!
Observe strict cleanliness! Do
not spill any fuel!
Engine Operation
3.1 Commissioning
3.1.4 Filling/Bleeding Cooling
System
1015
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 10
minutes under low load.
During and after trial run

Check the engine for leaks.
26 399 0
Connect coolant inlet 1 and coolant outlet 2 to

external coolant tank.
Fill in coolant into cooling system.
Start engine and run up to normal operating
temperature until thermostat opens (line 2
warms up).
Check coolant level in external cooling system,
top up coolant if necessary.
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-in
During the breaking-in phase, it is
recommended to check the oil level twice a day.
After the breaking-in phase, checking once a
day will be sufficient.
Engine Operation
3
3.2 Starting
3.2.1 Electric Starting

without Cold-Starting Aid
Before starting, make sure
that nobody is standing in the
immediate
vicinity
of
the
engine or driven machine.
After repair work :
Check whether all removed guards are put
back in place and all tools are removed from
the engine.
When starting with flame-type heater plugs,
do not use any other additional starting aids
(e.g. injection with start pilot). Accident
hazard!
Important: Never start the engine with
speed governor removed.
Disconnect battery!
0
1
1
2
3
26 411 0
26 400 0
Disengage the clutch to separate the engine

from the driven equipment.
Insert key.
Position 0 = no operating voltage.
Move speed control lever 1 in direction of

arrow at least to middle speed position.
Turn key clockwise.

Position 1 = operating voltage,
Pilot lamps light up.
Move shutdown lever 2 to Run position

(opposite direction of arrow, item.1).
Do not actuate the starter for more than 20
seconds at a time. If the engine does not
start, wait one minute before repeating the
attempt.
If the engine does not start after two
attempts, trace the cause with the aid of the
Diagnosis Chart (see 7.1).
Turn key further clockwise against spring

action.
Position 2 = starting.
Release key as soon as the engine starts firing.
Pilot lamps go out.
Engine Operation
3.2 Starting
with Cold-Starting Aid

Flame-Type Heater Plug System
0
1
1
2
3
26 411 0
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.
Important: The starting process

must be carried out within the
30 seconds, otherwise repeat
starting attempt.
Turn key further clockwise against spring

action to
Position 2 = starting
Release key as soon as the engine starts firing.
Pilot lamps go out.
Engine Operation
3
3.3.1 Engine Oil Pressure
3.3.2 Coolant Temperature
Oil Pressure Pilot Lamp
Oil Pressure Gauge
25752 1
The oil pressure pilot lamp lights up with

operating voltage applied and engine shut off.
The oil pressure pilot lamp must go out when
the engine is running.
25754 0
The pointer of the oil pressure gauge must

indicate the minimum oil pressure (see 9.1).
26246 0
The pointer of the temperature indicator should

remain in the green sector and enter the yellowgreeen sector only in exceptional cases. If the
pointer enters the orange sector, the engine is
overheating. Turn it off and establish the cause
from the Diagnosis Chart (see 7.1).
Engine Operation

3.3.3 Coolant Level
min
3.3.4 Lube Oil Level
26 291 1
min
26 278 1
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 the
Diagnosis Chart (see 7.1)
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 the
Diagnosis 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.
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.
Engine Operation
3
3.4 Starting
3.4.1 Mechanical Shutdown
3.4.2 Electric Shutdown
0
1
1
2
1
26 401 0
Set speed control lever 1 to low speed position.

Actuate shutdown lever 2 until engine comes to
standstill. Charging-current and oil pressure
pilot lamps light up when engine has come to
standstill.
3
26 411 0
Turn key counter-clockwise (to position 0) and

pull off. Pilot lamps go out.
Engine Operation
3.5.1 Winter Operation
Lube Oil Viscosity

Select the oil viscosity (SAE grade)
according to the ambient temperature
prevailing at the time when the engine is
started 4.1.2.
Keep shorter periods between oil changes
when 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 ambient
temperature as in the case of engine oil.
At temperatures below 20 C (4 F)
lubricate the flywheel ring gear with lowtemperature grease, e.g. Bosch FT 1 V31,
from time to time through the pinion hole (if

necessary 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 limit
temperature, but proves also useful at temperatures normally not requiring a starting
aid.
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 up
to +20 C (+65 F). To do so, remove the
battery and store in a warm place.
26248 0
Engine Operation
3
3.5.2 High Ambient Temperature,

High Altitude
With increasing altitude and rising ambient
temperatures the density of the air. tends to
decrease, which affects the maximum power
output, the exhaust gas quality, the
temperature level and in extreme cases, the
starting behaviour. Under transient running
conditions, operation is permissible at altitudes
up to 1000 meters at ambient temperatures up
to 30 C (86 F)
If an engine is operated under more severe
conditions (at higher altitudes or ambient temperatures) it will be necessary to reduce the
injected fuel quantity and thus engine power.
In case of doubt concerning such engine
applications, ask your engine or equipment
supplier whether, in the interest of operational
reliabillty, service life and exhaust gas quality
(smoke!), an engine derating had been
considered necessary, or simply contact your
service representative.
25901 1
Operating Media
4
4.1 Lube Oil
4.2 Fuel
4.3 Coolant
Operating Media
4
4.1 Lube Oil
4.1.1 Quality Grade
4.1.2 Viscosity
The lube oil quality grade is defined by

specifications. The following lube oil
specifications are approved:
Generally, multi-grade oils shall be used. In

closed heated rooms at temperatures >5C,
also single-grade oils can be used. The
indicated lube oil grades must, of course, also
be observed for single-grade oils.
As the viscosity of lube oil is dependent on
temperature, the choice of SAE grade
should be governed by the ambient
temperature prevailing at the engine
operating site.
Optimum operating behaviour will be
attained if you take the accompanying oil
viscosity diagram as a guide.
Should the temperature fall temporarily
below the limits of the SAE grade selected,
cold starting may be affected but the engine
will not be damaged.
In order to keep wear to a minimum, do not
exceed application limits for extended
periods of time.
Oil changes dictated by the seasons can be
avoided by using multi-grade lube oils. Multi-grade oils - particularly low-friction oils also reduce fuel consumption.
lube oil quality class:

classification/specification
DEUTZ-
DQC I
DQC II
DQC III
ACEA-
E2-96
E3-96/E5-02
E4-99
CF/CF-4
CG-4/CH-4
DHD-1
APIWorldwide
If in doubt, contact your service representative
only with engine

oil preheating
30 298 1
Operating Media
4.1 Lube Oil
4.1.2.1
Specific lube oil

definitions
Lube oils for

engines with uprated power andengines with high
loading
Turbocharged engines with uprated power

and engines with high loading
Producer
DEUTZ
Type of lube oil

Deutz l TLX
The oils listed in enclosure 1 are to be used

for the following engines and applications:
l 1015 CP
l all engines in CHP plants
l all engines in gensets operating in parallel
with the mains/with each other
l engines in combines with:
GIP
AGIP
ARAL GmbH
ARAL GmbH
BAYWA
BAYWA
Castrol GmbH
Agip Sigma Ultra TFE

Autol Valve Ultra FE
Aral MegaTurboral
Aral SuperTurboral
BayWa Super Truck 1040 MC
BayWa Turbo 4000
Castrol SYNTRUCK
10W-40
10W-40
10W-40
5W-30
10W-40
10W-40
5W-40
Castrol GmbH
Castrol DYNAMAX
7,5W-40
CHEVRON
ESSO
FINA
FINA
FUCHS DEA
FUCHS DEA
FUCHS DEA
FUCHS DEA
FUCHS DEA
FUCHS DEA
MOBIL OIL
MOBIL OIL
MOBIL OIL
BP OIL International
Shell International
Chevron Delo 400 Synthtic

Essolube XTS 501
FINA KAPPA FIRST
FINA KAPPA ULTRA
DEA Cronos Synth
DEA Cronos Premium LD
Fuchs Titan Cargo MC
Deutz Oel TLL 10W-40 MB
DEA Cronos Premium FX
Fuchs Titan Unic Plus MC
Mobil Delvac 1 SHC
Mobil Delvac 1
Mobil Delvac XHP Extra
BP Vanellus HT Extra
Shell Myrina TX /
Shell Rimula Ultra
Shell Myrina TX /
Shell Rimula Ultra
TOTAL RUBIA TIR 86000
Wintershall TFG
5W-40
10W-40
5W-30
10W-40
5W-40
10W-40
10W-40
10W-40
10W-40
10W-40
5W-40
5W-40
10W-40
10W-40
5W-30
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 achieve
the thermal stability required for the relevant
application and are distinguished by a low tendency
to cause deposits in the turbocharger and in the
charge air pipes with closed-circuit crankcase
breather
Exhaust emission-optimized engines for

commercial vehicles as from EURO II and
mobile machinery as from level 2. For exhaust
emission-optimized engines of all DEUTZ
series which meet the following exhaust
emission requirements:
a) as from EURO II the requirements of 88/
77/EEC and 91/542/EECfor commercial
vehicles 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 US
nonroad engines the following oil grades
will be permissible:
- ACEA E3-96 and E4-98 for requirements
a) and b)
- API CG-4 and CH-4 for application c)
Shell International
SAE class
10W-40FE
10W-40
TOTAL
10W-40
Schmierlraffinerie
10W-40
Salzbergen GmbH
The table will be extended as and when required.
Availability
Europa
worldwide
Germany
worldwide
worldwide
South Gemany
South Gemany
Europe, North America, Brazil
Argentina, Australia, South Africa
Europe, North America, Brazil
Argentina, Australia, South Africa
North America
Europe
Europe
Europe
Germany, Europe
Germany, Europe
worldwide
Germany
Europe
worldwide
Europe, SE Asia, Africa
worldwide
Europe, SE Asia
Europe
Europe, different
description in some country
Europe, different
description in some country
worldwide
Europe
Operating Media
4
4.2 Fuel
4.2.1 Quality Grade
4.2.2 Winter-Grade Fuel
Use commercial brands of diesel fuel with a

sulfur content of less than 0.5%. If the sulfur
content is higher than 0.5%, oil change
intervals should be reduced, see 6.1.1.
At low temperatures, waxing may occur and

clog the fuel system, causing operational
trouble. In case of sub-zero (+32 F)
ambient temperatures it is recommended to
use winter-grade diesel fuel (down to 15 C
= +5 F). Normally, such fuel is offered at the
filling stations in good time before the cold
season starts. Diesel fuel containing additives (Super Diesel) is frequently also on
sale for use at temperatures down to 20 C
(4 F).
The following specifications / standards are

approved:
l CEN EN 590 or DIN/EN 590
l DIN 51 601 (Feb.1986)
l BS 2869 (1988): A1 and A2
l NATO Code F-54 and F-75
l At temperatures below 15 C (+5 F) or

20 C (4 F), kerosene should be added
to the diesel fuel. The relevant
percentages are given in the diagram at
the right.
The exhaust emission levels determined

during certification always refer to the
reference fuel specified by the supervising
authorities for such certification.
If summer-grade diesel fuel has to be used

at temperatures below zero (+32 F), up to
60% kerosene may be added (see diagram
at the right).
l ASTM D975-88: 1-D and 2-D
In most cases, adequate resistance to cold

is also attained by adding a flow improver
(fuel
additive).
Ask
your
service
representative for this.
Diesel fuels must never be mixed

with petrol (normal and super
grade petrol)!
+32
+23
-5
+14
- 10
+ 5
- 15
- 4 - 20
- 13 - 25
II
- 22 - 30
F
10
20
30
40
50
B
60 %
' 26441 1
Illustration legend:
I
Summer diesel fuel
II
A
Winter diesel fuel

Ambient temperature
Percentage of kerosene added
Mix in tank only! Fill in the

appropriate amount of kerosene
first, then add the diesel fuel.
Operating Media
4.3 Coolant
4.3.1 Quality of water for coolant
in the recirculating water
system
4.3.2 Coolant treatment
4.3.3 Cooling system protectants
The values listed below must not be exceeded.

In order to examine the quality of your water, a test case
can be ordered from DEUTZ under Order No. 1213
0382.
In the case of liquid-cooled engines, special

attention must be paid to the treatment and
control of the coolant, as the engine may
otherwise become damaged as a result of
corrosion, cavitation and freezing.
The treatment of the coolant is carried out by adding a
cooling system protectant to the cooling water.
The cooling system must be continuously monitored,
see 5.1. In addition to checking the coolant level, this
also involves checking the concentration of the cooling
system protectant.
The cooling system protectant concentration can be
checked with commercially available testers (example:
gefo glycomat).
DEUTZ cooling system protectants must be purchased

in drums under Order No. 01011490 (5 litres) or 1221
1500 (210 litres). These are nitrite, amine and phosphate-free, and provide effective protection against
corrosion, cavitation and freezing.
If the above mentioned cooling system protectant is
unavailable, the following products may be used in
exceptional cases.
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]
20
Manufacturer
AVIA
ARAL
BASF
DEA
SHELL
Product designation
AVIA Antifreeze Extra
Antifreeze Extra
Glysantin G 48
DEA kylarfrostsskydd
SHELLGlycoShell
The cooling system protectant in the coolant should not

fall below or exceed the following concentration:
Cooling system protectant
Water
max. 45 Vol.%
min. 35 Vol.%
55%
65%
Filling volume, see Chapter 9.1.

The use of other cooling system protectants, e.g. chemical anti-corrosion agents, is possible in exceptional
cases. Consult DEUTZ Service.
The use of anti-corrosion oils is not permitted.
If nitrite-based cooling system

protectants are mixed with
amine-based agents, dangerous nitrosamines are formed.
Cooling system protectants must

be disposed of in an environmentally-friendly manner.
Operating Media
4
4.3 Coolant
Cooling System Protection

Cooling system capacity *)
[Liters]
Protective
agent
[% by vol.]
Protection
against freezing to
[C]
35
22
6,3
7,0
7,7
8,75
40
28
7,2
8,0
8,8
45
35
8,1
9,0
50
45
9,0
10
18
20
22
25
27
30
32
35
9,5
10,5
11,2
12,3
10
10,8
12
12,8
14
9,9
11,3
12,2
13,5
14,4
15,8
11
12,5
13,5
15
16
17,5
Protective agent
[Liters]
*) For coolant capacity of your engine, see Section 9.1.

Note: Consult head-office regarding figures in the grey field.
Routine Maintenance
5
5.1 Maintenance Schedule
5.2 Maintenance Chart
5.3 Completed Maintenance Jobs
Routine maintenance
5
5.1 Maintenance schedule
check =
adjust =
clean = V
replace =
check 2x daily before or during 1st trial run, during running- In period or when commissioning new or overhauled engines

every 10 OH or daily
2000
Years
1
12000
6000
1000
500
250
in operating hours (OH) every:

E10 E20 E30 E30 E40 E60 E70
Industriel engines
The specified engine maintenance values are
permissible recommended maximums. Depending
on usage, reduced maintenance intervals may be
necessary; comply with the unit manufacturers
operating instructions. # Maintenance must only be
carried out by authorised service personnel.
Operation
Lube oil level, top up if necessary
Lube oil (oil change int. depending on engine app.), see TR 0199-99-3002
Oil filter cartridge
Fuel filter cartridge
Fuel leakage lines (should be replaced in there entirety)
Injection valve
Fuelpre-cleaner
Coolant (additive concentration)
Coolant pump
Coolant level
Intake air cleaner (if available, maintain according to maintenance indicator)
Intercooler (drain lube oil/condensation)
Battery and cable connectors
Engine monotoring system, Warning system
Valve clearance (adjust if necessary)
V-belts (retension if necessary, replaced if damaged)
Crankcase pressure-relief valve/injection valve
Crankcase pressure vent valve
Check engine for leaks (visual inspection)
Draining bores between cylinder banks, engine cleaning
Engine mount (replaced if damaged)
Fasteners, hose connections/clips
Generaloverhaul
46en
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12.01.2005, 14:57
Section
6.1.2/3.3.4
6.1.1/6.1.2
6.1.3
6.2.1
6.2.2
#
4.2
4.3.1/2/3
6.4.3/6.4.4
6.7.1
3.3 #
6.6.1
6.5.1
#
#
6.3.1/6.3.4
9.2
Routine maintenance

check = O
adjust =
clean = V
replace =

every 10 OH or daily

in operating hours (OH) every:
V
V
12000
Years

Operation
Injection valve
Intercooler inlet, clean as necessary
Exhaust Turbo-Charger outlet, clean as necessary
Section
6.1.1/6.1.2
#
#
2000
E70
6000
4000
E40
1000
500
E30
250
E10 E20
Additions and
modifications for engines
with EPA approval
47Geradeen
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12.01.2005, 14:57
Routine maintenance
5
check =
adjust =
clean = V
replace =

every 200 km or daily

Service groupe Annual kilometrage
average speed approx.
Kilometrage (km) every:
(km)
approx. km/h
Service group I
I
< 30 000
20
E10 E20 E30 E30 E40 E60 E70
II
> 30 bis 100 000
40
Years
III
> 100 000
60
Operation
Section
6.1.2/3.3.4
6.1.1/6.1.2
6.1.3
6.2.1
6.2.2
Injection valve
#
V
Fuelpre-cleaner
4.2
4.3.1/2/3
Coolant pump
Coolant level
4.3.2/4.3.3
6.4.3/6.4.4
V
#
6.7.1
Engine monotoring system
3.3
6.6.1
6.5.1
#
#
V
6.3.1/6.3.4
9.2
Generaloverhaul
#
2000
240 000
120 000
20 000
10 000
5000
Vehicle engines
48en
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12.01.2005, 14:57
Routine maintenance
check =
adjust =
clean = V
replace =


(km)
approx. km/h
Service group II
I
< 30 000
20
E10 E20 E30 E30 E40 E60 E70
II
> 30 bis 100 000
40
Years
III
> 100 000
60
Operation
Section
6.1.2/3.3.4
6.1.1/6.1.2
6.1.3
6.2.1
6.2.2
Injection valve
#
V
Fuelpre-cleaner
4.2
4.3.1/2/3
Coolant pump
Coolant level

6.4.3/6.4.4
V
#
6.7.1
# 3.3
6.6.1
6.5.1
#
#
V
6.3.1/6.3.4
9.2
Generaloverhaul
#
49Geradeen
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49
12.01.2005, 14:57
2000
480 000
240 000
40 000
20 000
10 000
Vehicle engines
Routine maintenance
5
check =
adjust =
clean = V
replace =


(km)
approx. km/h
Service group III
I
< 30 000
20
E10 E20 E30 E30 E40 E60 E70
II
> 30 bis 100 000
40
Years
III
> 100 000
60
Operation
Section
6.1.2/3.3.4
6.1.1/6.1.2
6.1.3
6.2.1
6.2.2
Injection valve
#
V
Fuelpre-cleaner
4.2
4.3.1/2/3
Coolant pump
Coolant level

6.4.3/6.4.4
V
#
6.7.1
3.3
6.6.1
6.5.1
#
#
V
6.3.1/6.3.4
9.2
Generaloverhaul
#
2000
1.000.000
360.000
120.000
60.000
30.000
Vehicle engines
50en
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12.01.2005, 14:57
Routine Maintenance
5.2 Maintenance Chart
The maintenance chart shown here is supplied as

self-adhesive label with each engine. It should be
affixed where it can be clearly seen on the engine
or driven equipment.
a
Check that this is the case!

If necessary, ask your engine or equipment
supplier for a fresh supply of labels!
Routine maintenance work should be carried out
according to the schedule in 5.1.
1015
1000
in.
h
Std.
AIR
10
ex.
in.=
ex.=
0,25 mm
0.009 in.
0,30 mm
0.012 in.
1252000
OIL
max.
1000
10
1000
500
500
500
OIL
OIL
0297 4963
Stop the engine before carrying

out any maintenance work.
API = CD/CE
CCMC = D4 o. D5
D5 = SHPD
FU
EL
Routine Maintenance
5
Running hours
Date
Signature / Stamp

Running hours
50-150*
125
250
375
500
625
750
875
1000
1125
1250
1375
1500
1625
1750
1875
2000
2115
2250
2375
2500
2625
2750
* after commissioning of new and overhauled engines

Duly completed maintenance jobs can be recorded and signed off in the above table.
Date
Signature / Stamp
Routine Maintenance

Running hours
Date
Signature / Stamp
Running hours
2875
3000
3125
3250
3375
3500
3625
3750
3875
4000
4125
4250
4375
4500
4625
4750
4875
5000
5125
5250
5375
5500
5625
5750
Date
Signature / Stamp
Routine Maintenance
5
Running hours
Date
Signature / Stamp

Running hours
5875
6000
6125
6250
6375
6500
6625
6750
6875
7000
7125
7250
7375
7500
7625
7750
7825
8000
8125
8250
8375
8500
8625
8750
Date
Signature / Stamp
Routine Maintenance

Running hours
Date
Signature / Stamp
Running hours
8875
9000
8125
8250
8375
8500
8625
8750
8875
9000
9125
9250
9375
9500
9625
9750
9825
10000
10125
10250
10375
10500
10625
10750
Date
Signature / Stamp
Routine Maintenance
5
Running hours
Date
Signature / Stamp

Running hours
10875
11000
11125
11250
11375
11500
11625
11750
11875
12000
12125
12250
12375
12500
12625
12750
12825
13000
13125
13250
13375
13500
13625
13750
Date
Signature / Stamp
Routine Maintenance

Running hours
Date
Signature / Stamp
Running hours
13875
14000
14125
14250
14375
14500
14625
14750
14875
15000
15125
15250
15375
15500
15625
15750
15825
16000
16125
16250
16375
16500
16625
16750
Date
Signature / Stamp

6
6.1
6.2
6.3
6.4
6.5
6.6
6.7
Lubrication System
Fuel System
Cooling System
Combustion Air Cleaner
Belt Drives
Adjustments
Accessories

6
6.1.1 Oil Change Intervals
z The first oil change after commissioning or

recommissioning following repair work is
carried out after 50 running hours.
z The oil change intervals are dependent on :
Lube oil quality
Sulfur content in the fuel
Engine application
z Should, within a year, the engine run less than
the hours stated in the table, the oil must be
changed at least once a year.
z 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)
z If the sulfur content is > 0.5 to > 1 % or the
continuous ambient temperature below 10 C
(+14 F), the intervals between the oil changes
should be halved.
z In the case of fuels containing sulfur > 1 % ,
ask your service representative.
Change the oil with the engine off but still warm
(lube oil temperature approx. 80 C / 176 F).
z If, for vehicle engines, lube oil change

intervals are determined by operating hours,
the lube oil change intervals indicated in
table 6.1.1.1. for Oil use under normal duty
will apply.
6.1.1.1 Lube oil change intervals for industrial and marine engines
Lube oil grade
Deutz lube oil quality class
DQC I
DQC II
DQC III
ACEA-specfication
E2-96
E3-96/E5-02
E4-99
CF/CF-4
CG-4/CH-4
Worldwide specfication
DHD-1
special DEUTZ release list
API-specfication
Standard lube oil code for building

equipment and nonraod vehicles
Engine
EO..
EO...C
EO...A, EO...B
Engine version
Lube oil change intervals in op. hours
series
1015
siehe Kap.4.1.2.1
Oil use
Oil use
Oil use
normal
high
normal
high
normal
high
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
All engines except for:
* 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.

6.1.1.2Oil change intervals for vehicle engines
Deutz lube oil quality class
ACEA-specification
API-specification
worldwide specification
special DEUTZ release
Application
Site vehicles/
city busses
Local traffic
Long distance
traffic
Engine version
Average speed
in km/h approx. ]
25 1015
1015CP
40 1015
1015CP
60 1015
1015CP
DQC I
E2-96
CF/CF-4
-
Lubeoil-quality
DQC II
DQC III
E3-96/E5-02
E4-99
CG-4/CH-4
DHD-1
Enclosure 4.1.2.1
Lube oil change intervals in km

Euro I, except for
Euro II
Euro I, except for
Euro II
Euro I, except for
Euro II
15 000
20 000
50 000
-
20 000
20 000
30 000
30 000
40 000
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 use
under normal duty will apply.

6.1.2
6.1.2.1
Checking Oil Level /

Changing Engine Oil
Checking Oil Level
6.1.2.2
25 729 0
Ensure that the engine or vehicle is on a level

surface.
Immediately before the oil level is measured, the
engine should should be driven at low idling
speed 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.
Engine Oil Change
26 022 0
Ensure that the engine or vehicle is on a level

surface.
Allow the engine to warm up
Lube oil temperature approx. 80C.
Switch off the engine.
26 023 0
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
Be careful when draining hot oil danger

of scalds! Do not let used oil run into the
soil but catch it in a container ready for

6
6.1.3 Renewing Oil Filter
25880 0
25882 0
25881 0
With fitted torsion lock:

Loosen screws and slide clamps downwards.
Clean sealing surface of the filter carrier if

necessary.
Tighten oil filter cartridge tightly by giving a final half turn.
Undo the oil filter cartridge with commercial

tool and spin off.
Lightly oil the rubber gasket of the new oil filter

cartridge.
If a torsion lock is fitted, slide clamps up into

position and tighten screws.
Catch any escaping oil.
Screw in the new cartridge finger tight against

the gasket.
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!
6.2 Fuel System
6.2.1 Renewing Fuel Filter
25880 0
Close fuel stopcock.

Undo fuel filter cartridge with commercial tool
and spin off.
Catch any escaping fuel.
When working on the fuel system,

keep open flames away!
Do not smoke!
25882 0
25881 0
Clean sealing surface of filter carrier if

necessary.
Apply light film of oil or diesel fuel to rubber
gasket of new fuel filter cartridge.
Tighten fuel filter cartridge firmly.

Open fuel stopcock.
Check for leaks.
Screw in the cartridge finger tight against the

gasket.
Bleeding of the fuel system is not necessary.

6
6.2.2 Replace fuel oil leak line
6.2 Fuel System
6.2.3 Fuel Pre-filter Element

Clean/Replace if necessary
3
1
4
2
6
3
5
7
31 891 0
Close the fuel shut-off valve.

Remove valve cover.
Loosen and remove banjo bolts 7.
Remove rubber hoses 1, 3, 4, unions 2 and Orings 6 and dispose of in accordance with environmental regulations; banjo union 5 and banjo
bolt 7 can be re-used.
Connect new oil leak line (complete) with banjo
union 5 to rubber hoses.
Fasten oil leak line using existing banjo bolt 7 and
two new O-rings 6.
Re-fit valve cover.
Open fuel shut-off valve.
Check for leaks after start-up.
31 811 2
Clean (purge) - remove water:

Turn off engine or, in the case of a changeover 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 without
using force) the drain cock 8 and close the
drain 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 if
necessary)
Tighten the cover 2 with the screws 3
diagonally (torque 6 Nm)
Check the cover 2 for proper fit and leaks
Bleed the fuel system, see 6.2.3.
The connection of a warning system

(lamp/horn) via contacts 7 is specified.
Immediate maintenance is necessary when
the warning system is triggered.
Naked flames are prohibited
when working on the fuel
system! Do not smoke!
Dispose of old fuel in an environmentally friendly way!
6.3 Cooling System

6.3.2 Draining Cooling System
6.3.3 Filling / Bleeding Cooling

System
The degree of soiling of the cooler units is

dependent on the type of engine application.
Fill with coolant and bleed cooling system

according to manufacturers instructions.
The danger of soiling is increased due to

residues of oil and fuel on the engine. Check
extra carefully, therefore, for leakages when
applications involve high dust fallout.
More severe soiling can occur, e.g. in the case
of:
Construction site application due to heavily
dust-laden air.
In view of the varying conditions of application,
the cleaning intervals must be determined from
case to case. The cleaning intervals stated in
the table can be taken as guide values.
Checking / Cleaning Intervals
Guide Values
Engine Application
(RH)
2000
Ships, gensets in enclosed

spaces, pumps
1000
Vehicles on paved roads
500
Mobile gensets
250
Vehicles on construction sites and

unpaved roads, Construction
equipment, compressors, underground mining equipment
125
Farm equipment
33 545 0
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.
Be careful when draining hot

coolant. Danger of scalding!
Catch drained coolant and dispose
of in accordance with antipollution regulations!
6.3 Cooling System

6.3.4 Cleaning engine
- with compressed air
B
A
- with cold cleaning agent
A
B
1
26 454 1
Blow compressed air onto engine

Wash out loosened dirt particles from V-space
with water jet.
Make sure that drain holes 1 of V-space are free.
26 455 0
Spray engine with commercial cold cleansing

agent and let stand for about 10 min.
Then spray clean with strong water jet (do not
spray water directly onto sensitive components
such as alternator, starter, wiring, electronic
components).
Let engine run up to operating temperature

after each wet-cleaning procedure allowing
any remaining water to evaporate, thus
avoiding corrosion.
Make sure that drain holes 1 of V-space are free.
Clean only with engine stationary

6
The degree of soiling of the combustion air

cleaner depends on the amount of dust
contained in the air and the size of the filter
used. If very dusty air is to be expected, a
cyclone-type precleaner can be fitted to the air
cleaner.
Consequently, the cleaning intervals cannot be
fixed generally, but have to be determined from
case to case.
When a dry-type air cleaner is used, when indicated by the service indicator or switch.
Air cleaner servicing is needed when :
Service Indicator
the red sector 1 is fully visible when the
engine is off.
Service Switch
the yellow pilot light comes on when the
engine is running.
After having carried out service work, reset the
signal by pressing the button of the service
indicator. The service indicator is ready to
resume its function.
25885 1
6.4.2 Dry-Type Air Cleaner

Dust Discharge Valve
Filter Cartridge
Check cartridge for damage to filter paper (by
shining the paper through with a light), and
inspect sealing element. Renew if necessaray.
After having serviced the filter cartridge five
times, or after two years at the latest, renew
safety 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 in
position and secure fastening clamps 1.
25889 0
25888 1
Empty dust discharge valve 1 by pressing apart

lips of discharge slot as indicated by the
arrows.
Release fastening clamps 1.
Clean discharge slot from time to time.
Clean cartridge, replace at least once a year.
Remove any caked dirt by pressing together

the upper section of the valve.
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 manufacturers
instructions.
Take off hood 2 and remove cartridge 3.
Never clean filter cartridge with

petrol (gasoline) or hot liquids!

6
6.4.3 Emptying Cyclone-Type

Precleaner
6.4.4 Cleaning Oil Bath Air Cleaner
25886 0
Undo wing nut 1 and remove cover 2.

Remove collector bowl 3 from lower section 4
and empty. Remove leaves, straw and other
foreign matter from lower section of
precleaner.
Reposition collector bowl 3 onto lower section
4, fasten cover 2 in place by tightening wing
nut 1.
25887 0
Turn engine off and wait about 10 minutes for

the oil to drain from filter housing 1.
Fill oil cup with engine oil up to the mark

(arrow) (for viscosity, see 4.1.2).
Release snap clips 2 and remove oil cup 3

together with filter element 4. If necessary,
press element out with a screwdriver, taking
care not to damage rubber gasket 5.
Refit oil cup and element to filter housing and

secure with snap clips.
Remove dirty oil and sludge. Clean oil cup.

Clean filter element 4 in diesel fuel and allow to
drip-dry.
Clean filter housing 1 if very dirty.
Inspect and replace rubber gaskets 5 and 6 if
necessary.
Never clean air cleaner with petrol

(gasoline)!
Dispose of old oil in accorrdance
with anti-pollution regulations!
6.5 Belt Drives

6.5.1 Checking Alternator V-Belt
26 261 1
26 403 0
Checking
Inspect entire V-belt for damage
Renew damaged V-belts.
After installing new belts, run engine for 15
minutes, then check belt tension.
Use a belt tension gauge (see 9.3) to check belt
tension.
Place indicator arm 1 into gauge.
Position gauge on V-belt 2, midway between
the pulleys, with flange 3 on bottom of
gauge against the edge of belt.
6.5.2 Retensioning / Renewing

Alternator V-Belt
Press slowly on the black pad 4 at right

angles to belt 2 until the spring is heard or
felt to trigger.
Carefully remove the gauge without altering
the position of the indicator arm 1.
Read off the value: Turn the gauge sideways
to see the exact spot where the top of the
black indicator arm 1 intersects scale 5
(arrow). For settings, see 9.1.
If necessary, retension belt and measure
again.
Check / retension and renew Vbelts only with the engine off. Refit
belt guard, if provided.
25 997 0
Retensioning
Slacken hex. bolts 1, 2 and 3.
Turn lock nut 2 in direction A until correct Vbelt tension is attained.
Tighten bolts 1, 2 and 3.

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 in
position.
Tighten bolts 1, 2 and 3 until correct V-belt
tension is attained (see Section 6.5.1).
6.5 Belt Drives
6.6 Adjustments
6.6.1 Checking / Adjusting Valve

Clearances
2
2
EX
IN
26 406 0
Before adjusting valve clearance, allow engine

to cool down for at least 30 minutes. The oil
temperature should be below 80 C (176 F).
Position crankshaft as per schematic, see
6.6.1.1.
Slacken bolts 1.
Remove rocker cover 2 together with gasket 3.
26 404 0
Check valve clearance 1 between rocker arm/

tappet contact face 2 and valve stem 3 with
feeler gauge (there should only be a slight
resistance when feeler blade is inserted).
For permissible valve clearance, see 9.1.

6
IN
EX
IN
6
7
EX
26 405 0
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 4
tightened (wrench), the correct valve
clearance 1 is attained.
Check the valve clearances at each of the
remaining cylinders and adjust if necessary.
Refit rocker cover (together with new gasket if
necessary).
6.6 Adjustments
6.6 Adjustments
6.6.1.1 Valve Clearance Adjustment Schematic
Firing Order BF6M 1015:

A1 B3 A3 B2 A2 B1
Sequence
Firing Order BF8M 1015:

A1 B4 A4 B1 B3 A3 B2 A2
Valve overlap A1 B3 A3 B2 A2 B1
A1 B4 A4 B1 B3 A3 B2 A2
Adjusting
B3 A3 B2 A2 A1 B4 A4 B1
B2 A2 B1 A1 B3 A3
6.6 Adjustments
A1 A2 A3
A1 A2 A3 A4
B1 B2 B3
B1 B2 B3 B4
A1 A2 A3
A1 A2 A3 A4
B1 B2 B3
B1 B2 B3 B4
Adjustment
Turn crankshaft according to sequence shown
in the diagram (starting with cyl. 1).
The valves of the relevant cylinder overlap,
marked in white, (exhaust valves about to
close, inlet valves about to open). Adjust
clearance of valves, marked in black,
according to schematic. Mark the respective
rocker arm with chalk to show that the
adjustment has been done.
26 407 0
6.7 Accessories
6.7.1 Battery
6.7.1.1 Checking Battery and Cable
Connections
6.7.1.2 Checking Electrolyte Level
25895 0
24232 3
Keep battery clean and dry.
Remove cell caps 1.
Undo soiled terminals.
If electrolyte test elements 2 are fitted:

The level should be high enough to wet the
bottom of these.
Clean battery plus and minus poles and

terminals and apply a film of acid-free and acidresistant grease.
When reconnecting, ensure good contact of
terminals. Fasten clamping bolts finger tight.
If no such elements are provided :

Check to make sure that the level is 10-15 mm
above the top edge of the plates.
Top up with distilled water if necessary.
Fit cell caps back in position.
6.7.1.3 Checking Specific Gravity of

Electrolyte
25896 0
Measure the specific gravity of the individual

cells with a commercial hydrometer.
The measured values (see adjacent table)
indicate the state of charge of the battery.
During the measurement, the temperature of
the electrolyte should preferably read 20 C.
6.7 Accessories
6
Specific Gravity
in [kg/l]
in [B (degrees Baum) *]
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 B (degrees Baum) is obsolete and rarely used today.
The gases emitted by the battery

are explosive! Avoid formation of
sparks in the vicinity of battery,
keep away any open flames!
Do not allow acid to come into
contact with skin or clothing!
Wear protective goggles!
Do not place tools on battery!
6.7 Accessories
6.7.2 Three-Phase Alternator
6.7.3 Lifting Tackle
Notes on the three-phase system:

When the engine is running, never disconnect
the cables between battery, alternator and
regulator.
Where it is, however, necessary, to start and

operate the engine without battery, disconnect
the regulator from the alternator before
starting.
Be sure not to confuse the battery terminals.

Renew a defective charging pilot light bulb
immediately.
Engine cleaning: Do not spray with water/
steam jet directly against alternator!
Warm up engine to allow water residues to
evaporate.
For transporting the engine, always use the

proper lifting tackle.
Do no loosen connecting cable between battery

and alternator during engine operation.
Remove lifting tackle.

Do not start engine with lifting tackle fitted.
26 409 0
The habit of touching a lead against frame to

check whether it is live must under no
circumstances be applied with a three-phase
electric system.
In case of electric welding, connect the earth
terminal of the welding unit direct to the part to
be welded.
Always use the proper lifting

tackle!
26 410 0
Troubleshooting
7
7.1 Diagnosis Chart
Troubleshooting
7
If engine problems occur, they frequently have
their cause in improper operation or
maintenance of the engine.
So, in case of trouble, always check first
whether the operating and maintenance
instructions have been observed.
A helpful Diagnosis Chart is to be found on the
opposite page.
If you cannot identify the cause of the trouble
or are unable to rectify it yourself, contact your
service representative.
Before starting, make sure that

nobody is standing in the
immediate vicinity of the engine or
driven machine.
After repairs :
Important: Never start engine with the speed
governor removed.
Disconnect battery terminals!
7.1 Diagnosis Chart
7.1 Diagnosis Chart
Troubleshooting
Troubles
Engine fails (or difficult) to start
Engine starts, but runs unevenly or stalls
Engine becomes too hot, temperature monitor gives warning (coolant)
Engine gives poor performance
Engine not working on all cylinders
Engine has little or no oil pressure
Engine oil consumption excessive
Engine smokes blue
white
black
Causes
Not declutched (declutch where possible)
Below start limit temperature
Engine shutdown lever still in stop position (shutdown solenoid defective)
Oil level too high

Oil level too low
Excessive inclination of engine

Speed control lever set to middle position

Dirty air cleaner / defective turbocharger

Air cleaner service switch/indicator defective
LDA* defective (leaking line)

Charge air pipe leaking
Coolant pump defective

Charge air cooler dirty
Coolant heat exchanger dirty
Coolant thermostat does not open
Battery defective or discharged
* LDA = manifold pressure compensator
Remedial Measure
Check
P
Adjust
E
Renew
W
Clean
R
Top up
A
Lower level
S
Bleed
L
Section
Operation
P
P
P
P
S
P/E
P/E
Combustion Air P / W
P
P
P/W
Cooling System P / R
P/R
P/R
P
Electrics
P
Table 1 of 2
Troubleshooting
7
Troubles
Engine fails (or difficult) to start
Engine starts, but runs unevenly or stalls
Engine becomes too hot, temperature monitor gives warning
Engine gives poor performance
Engine not working on all cylinders
Engine has little or no oil pressure
Engine oil consumption excessive
Engine smokes blue
white
black
Causes
Cable connection to starter loose or oxidized
Starter defective or pinion does not engage

Incorrect valve clearance
Leaking injection line

Vent pipe clogged (coolant heat exchanger)
Flame-type heater plug system defective

Injector defective
Air in fuel system (lack of fuel)

Fuel filter / prefilter contaminate

Incorrect lube oil SAE class or quality grade
Fuel quality grade not corresponding to specification under 4.2.1

Lack of coolant
7.1 Diagnosis Chart

Remedial Measure
Check
P
Adjust
E
Renew
W
Clean
R
Top up
A
Lower Level
S
Bleed
L
Section
Electrics
P
P
Engine
E
P
P/R
P
P/W
P/L
P/R/W
Operating Media W
P/W
P/A
Engine Preservation
8
8.1 Preservation
Engine Preservation
8
8.1 Preservation
8.1 Preservation
If the engine is to be shut down for an extended

period, it is necessary to take preservation
measures to prevent rust formation. The
preservation measures described here will protect
the engine for a period of up to about 6 months.
Before reusing the engine, the preservatives must
be removed,.
Anti-corrosion oils to Specification:

MIL-L 21260B
TL 9150-037/2
Nato Code C 640 / 642
Recommended cleansing agent for removing
preservatives:
Petroleum benzine (hazardous materials
class A3)
Preserving the Engine:
Clean engine (in case of need with cold
cleansing agent).
Clean cooling system according to
manufacturers instructions.
Run engine until warm and stop.
Drain engine oil, see 6.1.2, and fill in anticorrosion 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.
26 408 0
Run engine for about 10 minutes.
Drain off anti-corrosion agent, see 6.3.3.
Stop engine.
Removing Engine Preservatives:
Turn engine several times by hand.

When turning engine with starter, move
shutdown lever to stop position.
Remove anti-corrosion agent from the grooves

of the V-belt pulleys.
Remove V-belt 2 and store in wrapped

condition.
Fit V-belt 2. Retension, if necessary, after short

period of operation, see 6.5.
Spray grooves of V-belt pulleys with anticorrosion agent.

Close coolant inlet and outlet openings 3 and
air intake opening 4.
Close exhaust discharge opening.
Remove plugs 1, 3 and 4 and plug from

exhaust discharge opening.
Fill in coolant according to instructions of
radiator manufacturer.
Start up engine.
Specification Data
9
9.1 Engine Specifications and Settings
9.2 Torque Wrench Settings
9.3 Tools
Specification Data
9
Model 1015
Number of cylinders
Cylinder arrangement
Bore
Stroke
Total displacement
Compression ratio
Working cycle / combustion system
Direction of rotation
[mm]
[mm]
[cm3]
[]
Weight incl. cooling system

[approx. kg]
Weight w/o cooling system acc. to DIN 70020-A [approx. kg]
Engine power
[kW]
Speed
Valve clearance, engine cold 5)
Injector opening pressure
Commencement of delivery
Firing order
BF6M 1015
BF8M 1015
1)
2)
11906
15874
90 Vee-angle
132
145
11906
15874
17
4-stroke TC engine/direct injection
counter-clockwise
Consult headquarters
830
190-240 1)
1060
250-320 1)
830
228-300 1)
1060
304-400 1)
[rpm]
[mm]
[bar]
[CA BTDC]
)
inlet 0.25
/ exhaust 0.3 + 0,1
290 bar
1
)
1-8-4-5-7-3-6-2
1-6-3-5-2-4
+ 0,1
1-6-3-5-2-4
A1-B3-A3-B2-A2-B1
V-belt tension:
Alternator 55 amperes
Alternator 120 amperes
BF6M 1015 C/ CP BF8M 1015 C / CP
A1-B4-A4-B1-B3-A3-B2-A2
[N]
[N]
Engine power, speed, commencement of delivery, etc. are stamped on the rating plate, see 2.1.
Retension after running for 15 minutes under load.
A1-B3-A3-B2-A2-B1
tension / retension 2)
450 / 200-350 50
550 / 300-450 50
1-8-4-5-7-3-6-2
A1-B4-A4-B1-B3-A3-B2-A2
Specification Data

Model 1015
BF6M 1015
Cooling system
Coolant quantity
Perm. cont. coolant temperature engine outlet
Temperature difference between
coolant inlet / outlet
Thermostat starts opening at
Thermostat fully open from
[C]
[C]
[C]
Coolant pump
Delivery pressure in
Delivery rate in
[bar]
[m3/h]
Lubrication
SAE oil (see 4.1)
Min. oil pressure with engine warm (120 C)
at low idle / rated speed
Oil capacity (initial filling) without filter
Oil capacity (initial filling) engine-mounted filter
Oil capacity (initial filling), separate filter
3)
[approx. lit.]
[C]
17
+ MFK*
BF8M 1015
liquid-cooled / cooling system protection

21 + MFK*
17 + MFK*
max.103
21 + MFK*
max.5
87 2
102
22,5
4)
30
4)
22,5 4)
30 4)
forced-feed lubrication
15 W 40
[bar]
[approx. lit.]
[approx. lit.]
[approx. lit.]
1,0
3)
34
36* 3)
38 3)
3)
45
47* 3)
50 3)
Approximate figures can vary depending on the design. Decisive is always the upper dipstick mark.
3 bar at engine speed n = 2100 rpm -1
5)
see 6.1.1 (# only synthetic lube oil, see.4.1.2.1)
MFK
* Engine radiator
4)
BF6M 1015 C/ CP# BF8M 1015 C// CP#
34 3)
36* 3)
38 3)
45 3)
47* 3)
50 3)
Specification Data
9
9.2 Torque Wrench Settings

Preloading [Nm]
Location
1st
Stage
2nd
Stage
3rd
Stage
Tightening [ deg.]
1st
Stage
2nd
Stage
3rd
Stage
4th
Stage
Total
[Nm]
Rocker cover
22
Inspection Cover
22
Rocker arm setscrew
20
rigid mounting
30
Notes
45
Mount
flexible mounting
106
Air intake manifold
21
Exhaust manifold
61
Oil drain plug
100
Injector mounting
60
Injection line mounting
25
Oil pan
24
27
Coolant drain plug
38
Pin-type heater plugs / pipe union
engine mounted
or separate
Specification Data
9.3 Tools
V-belt Tension Gauge
26002 0
The V-belt tension gauge can be obtained under

order number 8115 + 8120 from:
Fa. WILBR
Postfach 14 05 80
D-42826 Remscheid
Notes
en
Warnings to Place on Equipment
Warning in the Manual
CALIFORNIA
CALIFORNIA
Diesel engine exhaust and some of its

constituents are known to the State of
California to cause cancer, birth
defects, and other reproductive harm.
Diesel engine exhaust and some of its

constituents are known to the State of
California to cause cancer, birth
defects, and other reproductive harm.
or
CALIFORNIA
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
Notes
CALIFORNIA PROPOSITION 65 INFORMATION
TO CALIFORNIA CUSTOMERS AND
TO 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 following
two methods of compliance with Proposition 65 requirements by manufactures of off-road equipment containing diesel engines. (The court
order 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 after
January 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 the
equipment. 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 warning
in 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 conspicuous
size and format. If the warning is provided in an on-screen display, the warning must contain the language in the attachment and must be
provided 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.
en
Notes
9
Service
en
Order-No.: 0312 0806
Knowing its DEUTZ

DEUTZ has always stood for excellence in motor
construction, pioneering many developments in
the industry. As an independent motor manufacturer, we offer worldwide a comprehensive range of diesel and gas motors
spanning from 4kW to 7,400kW. Our products are
perfectly tailored to meet our customers individual
requirements.
Over 1.4 million DEUTZ motors do their job
reliably all over the world. We are determined to
preserve the high standard of performance and
dependability of our motors, thus keeping our
customers satisfied at all times. Therefore we are
represented worldwide through a network of highly
competent service partners who will meet the
needs of our customers, wherever they are.
This is why DEUTZ is not only the name for motors
which pack a lot of inventive genius. DEUTZ also
means reliable service and comprehensive support
to enhance your motors performance.
This index Sales & Service offers you an overview
of the DEUTZ partners in your vicinity, including the
products for which they are responsible and the
range of services provided. But even when no direct
product responsibility is mentioned, your DEUTZ
partner will be happy to help you with expert advice.
The Index is constantly updated. Please ask your
DEUTZ service partner for the latest edition.
DEUTZ AG at your service.
Order-No.: 0312 0807 (CD-ROM)

DEUTZ AG
Deutz-Mlheimer Str. 147-149
D-51057 Kln
Obtainable from the local service Partner reponsible
for you or from:
Phone: 0049-221-822-0
Telefax: 0049-221-822-5304
Telex: 8812-0 khd d
http://www.deutz.de
10
Ersatzteilliste
Spare Parts Catalogue
Catalogue de Pices de
Rechange
Lista de Piezas de Repuesto
1015
Ersatzteilliste
Spare Parts Catalogue
Catalogue de Pices de Rechange
Lista de Piezas de Repuesto
Lista de peas sobresselentes
Listino parti di ricambio
Onderdelenlijst
Reservdelslista
Reservedelsliste
Varaosaluettelo
Reservedelsliste
K
Yedek para Listesi

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0312 1887
Lista czci zamiennych

1
2004
Rechts 1
ETL 11.08.2004.p65
22.09.04, 13:53
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Vorwort
Sehr geehrter Kunde
Service
die Motoren der Marke DEUTZ sind fr ein breites

Anwendungsspektrum entwickelt. Dabei wird
durch ein umfangreiches Angebot von Varianten
sichergestellt, da die jeweiligen speziellen Anforderungen erfllt werden.
Seit jeher steht DEUTZ fr bahnbrechende Entwicklungen im Motorenbau. Als unabhngiger

Motorenhersteller bieten wir weltweit eine komplette Palette von Diesel- und Gasmotoren im
Leistungsbereich von 4 bis 7.400 kW an. Unsere
Produkte sind auf die Anforderungen unserer
Kunden perfekt zugeschnitten.
Ihr Motor ist dem Einbaufall entsprechend ausgerstet, das heit nicht alle in dieser Ersatzteilliste
dargestellten Bauteile und Komponenten sind an
Ihrem Motor dargestellt.
Obwohl die Grafiken weitgehend nicht mit allen
Details dargestellt sind, knnen die einzelnen
Varianten deutlich unterschieden werden, so
da das fr Ihren Motor relevante Ersatzteil leicht
herauszufinden ist. ber Positions-, Baugruppen- und Motornummer wird in jedem Fall das
richtige Ersatzteil ermittelt.
Bitte beachten Sie bei dieser Ersatzteilbestellung
unsere Bestellhinweise (siehe nachfolgende
Beispielgrafiken), damit wir Ihnen schnell und
zuverlssig die bentigten Ersatzteile in der jeweils dem letzten nderungsstand entsprechenden Ausfhrung liefern knnen.
Fr Ihre Rckfragen stehen wir Ihnen gerne
beratend zur Verfgung.
Ihre
DEUTZ AG
2004
Motornummer
Weltweit verrichten mehr als 1,4 Millionen DEUTZ

Motoren zuverlssig ihren Dienst. Die Einsatzbereitschaft unserer Motoren und damit die
Zufriedenheit unserer Kunden wollen wir erhalten. Daher sind wir weltweit mit einem Netz von
kompetenten Partnern vertreten, dessen Dichte
der regionalen Verteilung unserer Motoren entspricht.
So ist DEUTZ nicht nur der Name fr Motoren mit
Erfindungsgeist. Sondern auch fr ein komplettes Leistungspaket rund um den Motor und einen
Service, auf den Sie sich verlassen knnen.
Bitte tragen Sie hier die Motornummer ein. Sie

erleichtern hierdurch die Abwicklung bei Kundendienst-, Reparatur- und Ersatzteilfragen.
Gegenber Darstellungen und Angaben dieser

Ersatzteilliste sind technische nderungen, die
zur Verbesserung der Motoren notwendig werden, vorbehalten. Nachdruck und Vervielfltigung jeglicher Art, auch auszugsweise, bedarf
unserer schriftlichen Genehmigung.
Einen berblick ber die DEUTZ Partner in ihrer

Nhe, ber deren Produkt-Zustndigkeiten und
Service-Leistungen. Aber auch wenn keine direkte Produkt-Zustndigkeit vermerkt ist, hilft Ihnen der DEUTZ Partner mit kompetenter Beratung
weiter.
Ihre DEUTZ AG
D-51057 Kln
Telefon:
0049-221-822-0
Telefax:
0049-221-822-5304
Telex:
8812-0 khd d
http://www.deutz.de
2 de
Hndlerstempel
Vorwort
DEUTZ Dieselmotoren
Original DEUTZ Teile
DEUTZAustauschkomponenten
sind das Produkt jahrelanger Forschung und

Entwicklung. Das dadurch gewonnene fundierte know how in Verbindung mit hohen Qualittsanforderungen ist die Garantie fr die Herstellung von Motoren mit langer Lebensdauer, hoher
Zuverlssigkeit und geringem Kraftstoffverbrauch. Es ist selbstverstndlich, da auch die
hohen Anforderungen zum Schutz der Umwelt
erfllt werden.
unterliegen den gleichen strengen Qualittsanforderungen wie die DEUTZ Motoren. Weiterentwicklungen, zur Verbesserung der Motoren
werden selbstverstndlich auch bei den Original DEUTZ Teilen eingefhrt. Nur die Verwendung von nach neuesten Erkenntnissen gefertigten Original DEUTZ Teilen bietet die Gewhr
einwandfreier Funktion und hoher Zuverlssigkeit.
DEUTZ Austauschkomponenten
sind eine preiswerte Alternative.
Selbst-verstndlich gelten auch hier
wie fr Neuteile hchste Qualittsma-stbe. In Funktion und Zuverlssigkeit sind DEUTZ Austauschkomponenten
den Original DEUTZ Teilen gleichwertig.
SERVICE
Vorsicht bei laufendem Motor
Asbest
Wenden Sie sich bei Betriebsstrungen und

Ersatz-teilfragen an eine unserer zustndigen
Service-Vertretungen. Unser geschultes Fachpersonal sorgt im Schadensfall fr eine schnelle
und fach-gerechte Instandsetzung unter Verwendung von Original DEUTZ Teilen.
Wartungsarbeiten oder Reparaturen nur bei abgestelltem Motor durchfhren. Evtl. entfernte
Schutzvorrichtungen nach Abschlu der Arbeiten wieder montieren. Bei Arbeiten am laufenden Motor soll die Arbeitskleidung fest anliegen.
Nur bei abgestelltem Motor tanken. Motor nie in
geschlossenen Rmen laufen lassen
Vergiftungsgefahr.
3 de
Bei diesem Motor verwendete

Dichtungen sind asbestfrei. Bitte
verwenden Sie bei Wartungsund Reparaturarbeiten entsprechende Ersatzteile.
2004
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Preface
Dear Customer
Service
DEUTZ engines are developed to meet the

requirements of a wide range of applications. An
extensive program of variant options gives them
their high flexibility.
DEUTZ has always stood for excellence in

engine construction, pioneering many developments in the industry. As an independent
enginemanufacturer, we offer - worldwide acomprehensive range of diesel and gas
engines spanning from 4kW to 7,400kW. Our
products are perfectly tailored to meet our
customers individual requirements.
Your engine is custom-made, i.e. specifically

equipped for your requirement, which means
that not all of the components and assemblies
contained in this catalogue are fitted to your
engine.
The greater part of the illustrations does not depict
all details, and yet you will find it easy to
differentiate between versions and thus to
identify the parts pertaining to your engine model.
Fig. Item No., Assembly Group No., Engine Serial
No. are the codes that infallibly lead to selection
ordering hints (see graphic examples below).
This allows speedy and reliable
When placing your order, please observe our
ordering hints. This allow speedy and reliable
delivery of the required parts that are based on
latest engineering standards.
If there are any questions, please do not hesitate
to contact us.
Sincerely,
DEUTZ AG
2004
Engine Serial No.
Over 1.4 million DEUTZ engines do their job reliably

dependability of our engines, thus keeping our
engines which pack a lot of inventive genius
engine's performance. Therefore we are
represented worldwide through a network of
highly competent service partners who will meet
the needs of our customers, wherever they are.
This is why DEUTZ is not only the name for motors
which pack a lot of inventive genius. DEUTZ also
means reliable service and comprehensive
support to enhance your motors performance.
An overview of the DEUTZ partners in your
area,their product responsibilities and range of
services provided. But even when no direct
product responsibility is mentioned, your DEUTZ
partner will be happy to help you with expert
advice.
DEUTZ AG at your service.
D-51057 Kln
Phone:
0049-221-822-0
Telefax:
0049-221-822-5304
Telex:
8812-0 khd d
http://www.deutz.de
4 en
Please enter your engine serial no. here. This will

facilitate dealing with your questions concerning
after-sales service, repair and spare parts.
This Spare Parts Catalogue is subject to engineering changes necessary for engine advancement. All rights reserved. No part of this publication may be reprinted or reproduced in any form,
without our prior permission in writing.
Dealers stamp
Preface
DEUTZ Diesel Engines
Genuine DEUTZ Parts
DEUTZ Exchange Components
are products based on long-standing research

and development. The profound know-how
acquiredin conjunction with high quality requirements guarantee that engines leaving our
works achieve a long life, high reliability and
excellent fuel economy. Naturally, they also attain
best ratings as regards environmental
protection.
are subject to equally stringent quality requirements as the engines themselves. Improvements in engine design are guaranteed to fit the
genuine DEUTZ parts. To ensure that your engine
will retain its functions and high reliability, you
should use genuine DEUTZ parts only.
are a low-cost alternative. Of

course, they are subject to the same
high quality requirements as new
parts. And as regards functions and
reliability, DEUTZ exchange components equal
genuine DEUTZ parts.
SERVICE
Beware of the Running Engine
Asbestos
In case of operational trouble with your equipment or queries about spare parts please contact
your nearest service dealership. Our skilled
staff of service exoerts will trace and remedy
any defect quickly, using genuine DEUTZ parts.
Be sure to shut down the engine before

performing maintenance or repair work. After
repair, put back in place any removed panels and
guards. When doing work on the running engine,
working clothes should fit tightly so that loose
ends cannot get caught. Do not run the engine in
enclosed rooms.- Danger of intoxication
5 en
Gaskets used for this engine do not

contain asbestos. Please use suitable spare parts when carrying out
maintenance and repairs.
2004
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Avant-propos
Numro du moteur
Cher client,
Service
les moteurs de la marque DEUTZ ont t

dvelopps pour une gamme tendue d'applications. Il existe un grand choix de variantes
rpondant aux exigences spciales demandes
dans chaque cas.
DEUTZ est depuis toujours synonyme dinnovation

dans le domaine de la construction de moteurs. En
notre qualit de fabricant indpendant, nous
offrons une gamme complte de moteurs diesel et
gaz dune puissance de 4 7 400 kW dans le
monde entier. Nos produits son parfaitement
adapts aux exigences de nos clients.
Votre moteur est quip pour le cas dapplication

envisag, ce qui signifie que toutes les pices et
composants reprsents dans ce catalogue de
pices de rechange ne sont pas monts sur votre
moteur.
Bien que les graphiques ne reprsentent pas
tous les dtails, les variantes se distinguent
nettement les unes des autres, si bien que vous
trouverez sans problme la pice de rechange
correspondant votre moteur. Les numros de
rfrence, de lorgane et du moteur permettent
en tous les cas de retrouver la pice de rechange
que vous cherchez.
Aujourdhui, plus de 1,4 million de moteurs DEUTZ

tournent dans le monde entier. Notre double
objectif est dassurer la fiabilit de nos moteurs et
de garantir la satisfaction de nos clients. Cest
pourquoi nous sommes repr-sents aux quatre
coins de la plante par un rseau de partenaires
comptents qui correspond la rpartition
rgionale de nos moteurs.
DEUTZ, ce nest donc pas seulement une marque
innovatrice de moteurs. Cest aussi une gamme
complte de services autour du moteur, cest aussi
un nom sur lequel vous pouvez toujours compter.
Lors de votre commande de pices de rechange

veuillez respecter nos indications de commande, (cf. les tableaux graphiques suivants)
afin que nous puissons vous fournir rapidement
et srement les pices de rechange demandes
dans la version correspondante ractualise.
Voici un aperu des concessionnaires DEUTZ les

plus proches et de leurs comptences techniques
et des services quils vous offrent. Et mme sil nest
pas directement spcialis dans le produit qui vous
intresse, votre partenaire DEUTZ pourra vous
conseiller avec comptence.
Nous restons votre entire disposition pour

toute question complmentaire.
Votre DEUTZ AG
DEUTZ AG
2004

D-51057 Kln
Tlphone: 0049-221-822-0
Tlfax: 0049-221-822-5304
Tlx:
8812-0 khd d
http://www.deutz.de
6 fr
Veuillez incrire ici le numro du moteur. Vous

facilitez ainsi le rglement des questions du
Service aprs-vente ainsi que tous les problmes de rparation et de pices de rechange.
Nous nous rservons le droit de procder dans

cette liste de pices dtaches toutes
modifications techniques utiles visant amliorer
la qualit des moteurs. Toute rimpression ou
reproduction du prsent document, faite mme
titre exceptionnel, exige notre autorisation crite.
Cachet du concessionnaire
Avant-propos
Les moteurs Diesel DEUTZ
Pices de rechange DEUTZ
Composants de rechange DEUTZ
sont le fruit de longues recherches et dun

dveloppment continu. Le solide savoir-faire
ainsi acquis conjugu des exigences leves
en matire de qualit est la garantie de fabrication
de moteurs longue dure de vie, haute fiabilit
et faible consommation en carburant. Il va de soi
que les moteurs doivent aussi respecter des
exigences leves en matire de protection de
lenvironnement.
Elles sonts soumises aux mme niveau

dexigence de qualit que les moteurs DEUTZ.
Toute progrs visant amliorer les moteurs est
naturellement immdiatement adpot pour les
pices dorgine DEUTZ. Seule lutilisation de
pices dorigine DEUTZ dorigine fabriques
selon des mthodes ultramodernes garantit un
fonctionnement irrprochable et une haute
fiabilit.
Les composants de rechange

DEUTZ sont une alternative. L
aussi, de mme que pour les
pices neuves, on applique des
normes de qualit leves. Du
point de vue fonctionnement et fiabilit les
composants de rechange DEUTZ sont quivalents aux pices de rechange DEUTZ.
SERVICE
Prcaution prendre quand

le moteur marche
Amiante
En cas de panne dexploitation et pour toute

question relative des pices de rechange
veuillez vous adresser notre point de service
responsable pour votre secteur. Notre personnel qualifi assure une remise en tat rapide
et approprie de votre moteur en nutilisant que
des pices dorigine DEUTZ.
Neffectuer les travaux dentretien ou les rparations que lorsque le moteur est arrt. A la fin des
travaux, remonter les dispositifs de protection
ayant t dposs. Lors de travaux faire sur
le moteur en marche, les vtements de travail
doivent bien coller au corps. Ne faire le plein que
lorsque le moteur est arrt. Ne jamais faire
fonctionner les moteurs dans des locaux ferms.
Danger dasphyxie !
7 fr
Les joints utilises pour ces

moteurs sont exempts damiante.
Veuillez employer, lors des travaux d'entretien et de rparation,
les pices de rechange correspondantes.
2004
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Prefacio
Estimado cliente:
La confianza de saber que es DEUTZ
Los motores de la marca DEUTZ se han

desarrollado han desarrollado para una amplia
gama de aplicaciones. Una extensa oferta de
variantes garantiza que se cumplan las
exigencias especiales de cada caso.
Le rogamos que tenga en cuenta nuestras

indicaciones al confeccionar su pedido de
repuestos para que le podamos suministrar
rpida y eficazmente los repuestos requeridos
en el modelo correspondiente al ltimo estado de
modificacin.
DEUTZ siempre ha estado a la vanguardia de la

industria de fabricacin de motores. Como marca
independiente, ofrecemos, a escala mundial,
una gama muy completa de motores diesel y de
gas, con potencias comprendidas entre 4kW y
7400kW. Nuestros productos estn estudiados
para satisfacer plenamente las exigencias de
nuestros clientes.
Ms de 1.400.000 motores DEUTZ funcionan con
toda fiabilidad en distintas partes del mundo.
Estamos dispuestos a mantener la disponibilidad
operacional de nuestros motores y de este modo
la satisfaccin de nuestros clientes. Por ello, estamos representados mundialmente por una red de
socios competentes cuya proximidad y distribucin regional corresponde a nuestros motores.
As pues, DEUTZ no es tan slo el nombre de un
motor fruto del genio creador. Sino tambin un paquete de servicios completo para el motor y una
asistencia tcnica en la que puede Ud. confiar.
Un resumen de los centros de DEUTZ ms
cercanos, los productos de los que se ocupa cada
centro y la gama de servicios disponibles. Pero
incluso cuando no se mencione un producto
determinado, puede Ud. estar seguro que su
centro de asistencia DEUTZ tendr mucho gusto
en asesorarle y ayudarle en todo lo que pueda.
En caso de dudas, estamos a su disposicin para

asesorarle.
El registro se actualiza peridicamente. No dude

en solicitar la ltima edicin a su centro de
asistencia DEUTZ.
Su motor se ha equipado de acuerdo con el caso

de montaje. Esto significa que en su motor no
estn montados todos los componentes
descritos en esta lista de repuestos
Pese a que la mayora de los grficos no contiene
todos los detalles, se pueden distinguir bien las
diferentes variantes de modo que resulta fcil
identificar el repuesto corres-pondiente a su
motor. El repuesto correcto para cada caso se
determina a travs de los nmeros de posicin,
de grupo constructivo y de motor.
DEUTZ AG
2004
No. de motor
Registre registrar en estas casillas el No. de

motor. As facilita la tramitacin de cuestiones de
servicio postventa, reparaciones y repuestos.
Nos reservamos el derecho de efectuar, frente

a las representaciones e indicaciones de esta
Lista de repuestos, las modificaciones tcnicas
necesarias para perfeccionar los motores. Para
la reimpresin y reproduccin en cualquier forma, tambin en la de extractos, se requiere
nuestra autorizacin por escrito.
DEUTZ AG
A su servicio.
DEUTZAG
D-51057 Kln
Tlfono: 0049-221-822-0
Telefax: 0049-221-822-5304
Telex:
8812-0 khd d
http://www.deutz.de
8 es
Sello del distribuidor
Prefacio
Motores diesel DEUTZ
Piezas originales de DEUTZ
Componentes de recambio de
DEUTZ
son el producto de trabajos de investigacin y

desarrollo de muchos aos. Los conocimientos
fundamentados que se han ganado con ello junto
con las altas exigencias de calidad es la garanta
de la fabricacin de motores con una larga
durabilidad, una alta eficacia y un bajo consumo
de combustible. Se sobreentiende que se
cumplen tambin las elevadas exigencias para la
proteccin del medioambiente.
estn sometidas a las mismas exigencias de

calidad rigurosas que los motores DEUTZ. Los
avances para mejorar los motores se aplican de
igual forma a las piezas originales de DEUTZ. Slo
el empleo de piezas originales de DEUTZ originales farbricados segn los conocimientos ms
recientes garantiza un funcionamiento correcto
y alta fiabilidad.
Los componentes de recambio

de DEUTZ constituyen una
alternativa econmica frente a
piezas originales de DEUTZ.
Naturalmente rigen tambin aqu,
igual que para piezas nuevas, elevadsimas exigencias de calidad. Los componentes de
recambio DEUTZ equivalen a las piezas originales de DEUTZ en cuanto a funcionamiento y
fiabilidad.
SERVICE
Precaucin con el motor en marcha
Amianto
En caso de anomalas en el funcionamiento y

cuestiones sobre repuestos, dirjase a uno de
nuestros centros responsables del servicio
tcnico a uno de nuestros Servicos Oficioles.
Nuestro personal especializado y cualificado se
ocupar de arreglar efecientemente y con rapidez cualquier desperfecto, utilizando repuestos
originales DEUTZ.
Realizar trabajos de mantenimiento o reparacin

nicamente con el motor parado. Volver a montar
una vez terminados los trabajos los dispositivos
de proteccin quitados eventualmente. En caso
de que se tengan que efectuar trabajos con el
motor en marcha, debe ajustarse bien la ropa de
trabajo debe tocar al cuerpo para evitar accidentes. Suministrar combustible nicamente con
el motor parado. No hacer funcionar nunca el
motor en locales cerrados peligro de intoxicacin.
9 es
Las juntas utilizadas en este

motor estn exentas de amianto
(asbesto). Para trabajos de mantenimiento y reparacion utilizar los
repuestos correspondientes.
2004
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Prefcio
Prezado cliente:
Servios
Os motores da marca DEUTZ foram desenvolvidos para um espectro de aplicao vasto.

Assegura-se ao mesmo tempo cumprimento das
exigncias particulares correspondentes atravs
da ampla oferta de variantes.
Desde sempre que a DEUTZ responsvel por

progressos revolucionrios na construo de
motores. Como fabricante independente de
motores oferecemos em todo o mundo uma gama
completa de motores a Diesel e a gs numa gama
de potncia de 4 a 7.400 kW. Os nossos produtos
so desenvolvidos medida das exigncias dos
nossos clientes.
O seu motor encontra-se equipado de acordo

com o tipo de montagem, isto , no esto
embutidas no mesmo todas as peas e partes
componentes representadas na sua lista de
peas sobresselentes.
Embora os grficos no se encontrem
amplamente representados com todos os
pormenores, possvel distinguir claramente
cada uma das variantes, de forma a encontrar-se facilmente a pea sobresselente
de importncia para o seu motor. possvel,
em todo o caso, verificar a devida pea
sobresselente correcta.
Quanto ao pedido de peas sobresselentes
queira, por favor, observar as nossas
instrues para encomendas (veja os grficos
de exemplo que seguem), a fim de podermos
fornecer-lhe rpida e seguramente as peas
sobresselentes requeridas de acordo com a
correspondente verso da ltima alterao
actualizada.
Estamos sua inteira disposio para um
aconselhamento no caso de quaisquer pedido
de informao que nos dirigir.
A sua
DEUTZAG
2004
Em todo o mundo mais de 1,4 milhes de motores

DEUTZ executam o seu servio com eficcia.
Queremos conservar a confiabilidade operacional dos nossos motores e, com ela a
satisfao dos nossos clientes. por este facto
que estamos representados em todo o mundo
com uma rede de competentes parceiros cuja
representao corresponde distribuio regional dos nossos motores.
Deste modo, a DEUTZ no s o nome de
motores com esprito inovativo, como tambm de
um completo conjunto de servios relacionados
o motor e de uma assistncia tcnica de perfeita
confiana.
Consulte a informao fornecida pelos parceiros
DEUTZ da sua rea, as suas competncias de
produtos e prestaes de servios. E, mesmo na
ausncia de um registo de competncia de
produtos directo, qualquer parceiro DEUTZ
estaria disponvel para dar o seu conselho
competente.
Nmero do motor
Indique aqui, por favor, o nmero do motor.

Facilitar, com isso, o processamento com a assistncia tcnica, as reparaes e as questes
de peas sobresselentes.
Reservamonos o direito proceder a alteraes

de ordem tcnica na representao e nos dados
desta lista de peas sobresselentes que se
tornem neces-srias para o aperfeioamento
dos motores. Toda e qualquer reimpresso e
reproduo, mesmo s em parte, requere a
nossa autorizao por escrito.
A sua
Deutz AG
D-51057 Kln
Telefone: 0049-221-822-0
Fax:
0049-221-822-5304
Telex:
8812-0 khd d
http://www.deutz.de
10 pt
Carimbo do vendedor
Prefcio
Os motores diesel DEUTZ
Peas originais DEUTZ
ComponentesdesubstituioDEUTZ
so produto de longos anos de pesquisa e

desenvolvimento. O know how consolidado
assim adquirido constitui, aliado s grandes
exigncias de qualidade, a garantia para o
fabrico de motores com uma vida til longa
elevada fiabilidade de servio e um consumo
reduzido de combustvel.
evidente de igual modo, so respeitados os
elevados requisitos de preservao do meio
ambiente.
esto sujeitas s mesmas exigncias severas

de qualidade para os motores DEUTZ. Naturalmente que se introduzem aperfeioamentos
tambm nas peas originais DEUTZ para o
melhoramento dos motores. Somente o emprego de peas e partes originais fabricadas de
acordo com os conhecimentos mais modernos
poder garantir um funcionamento perfeito e um
elevado grau de fiabilidade.
Os Componentes de substituio
DEUTZ so uma alternativa econmica para as peas sobresselentes
originais DEUTZ.
Naturalmente que vigoram aqui, tal,
como para as peas novas, os padres mais
elevados de qualidade.
Os Componentes de substituio DEUTZ so
equivalentes na sua funo e confiabilidade s
peas sobresselentes DEUTZ.
SERVIOS
Precauo com o motor em

funcionamento
Amianto
No caso de avarias operacionais e de possveis

consultas relacionadas com peas e partes
sobressalentes, queira dirigir-se a uma das
nossas representaes autorizadas de servio.
O nosso pessoal tcnico especializado procurar, em caso de uma avaria, proceder a uma
reparao rpida e tecnicamente competente,
com a aplicao de peas originais DEUTZ.
Proceder aos trabalhos de manuteno e s

reparaes apenas com o motor desligado.
Depois de ter terminado os trabalhos preciso
uma nova montagem de dispositivos protectores, eventualmente removidos. No caso de
efectuar trabalhos com o motor em funcionamento, o vesturio de trabalho dever estar justo
ao corpo. Enchimento de combustvel apenas
com o motor desligado. Nunca se deve deixar o
motor a trabalhar num recinto fechado, porque
existe o perigo de intoxicao.
11 pt
As vedaes utilizadas neste

motor so isentas de amianto.
Utilizar, por favor, as correspendentes peas sobresselentes
nos trabalhos de manuteno e
reparao.
2004
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Prefazione
Egregio cliente,
DEUTZ: un nome che vuol dire

eccellenza!
i motori DEUTZ raffreddati ad agua sono stati sviluppati per un ampio spettro duso. Grazie ad una
vasta offerta di varianti viene garantito che verr
fatto fronte alle rispettive esigenze particolari.
DEUTZ, da sempre sinonimo di innovazione nel

settore della fabbricazione dei motori, un
fabbricante indipendente che offre sul mercato
mondiale una gamma completa di motori diesel
ed a gas di potenza compresa fra 4 e 7400 kW.
Noi forniamo prodotti perfettamente adatti alle
specifiche esigenze dei nostri clienti.
Il Suo motore allestito secondo lo specifico caso

di montaggio, vale a dire che non tutti gli elementi
ed i componenti illustrati nel Suo listino dei pezzi
di ricambio sono integrati nel Suo motore.
Nonostante i grafici non siano illustrati con tutti i
dettagli, si possono distinguere chiaramente le
singole varianti, cos che facile trovare con
facilit il pezzo di ricambio importante per il Suo
motore. In ogni caso verr rilevato il pezzo di
ricambio giusto tramite numero di posizione, di
gruppo di assemblaggio e di motore.
Per lordinazione di pezzi di ricambio voglia
osservare le nostre indicazioni per lordina-zione
al fine di permetterci di fornirle in modo celere e
sicuro i pezzi di ricambio necessari nella relativa
versione, conforme allultima modifica.
Siamo a Vs. completa disposizione per eventuali
chiarimenti.
Sua
DEUTZ AG
Oggi, pi di 1,4 milioni di motori DEUTZ sono in

attivit in tutto il mondo. Noi perseguiamo un
duplice obiettivo: garantire la massima affidabilit
dei nostri prodotti e garantire un elevato livello di
soddisfazione ai nostri clienti. Ecco perch
abbiamo istituito una rete mondiale di partner, la cui
densit funzione diretta del numero di motori
in attivit in ciascuna regione.
DEUTZ non solamente un marchio innovatore
di motori, ma anche una gamma completa di
servizi in grado di accentuare le loro
caratteristiche di affidabilit ed un nome su cui
potrete sempre contare.
Voglia annotare qui il numero del motore. In

questo modo faciliter il disbrigo in caso di
questioni relative allassistenza tecnica, alla
riparazione ed ai pezzi di ricambio.
Rispetto allillustrazione ed alle indicazioni di

questa lista dei pezzi di ricambio, ci si riserva
quelle modifiche tecniche che sono necessarie
per migliorare i motori. Per la ristampa e la
riproduzione di qualsiasi tipo necessaria la
nostra autorizzazione scritta.
Segue una panoramica dei partner DEUTZ vicini

a voi, inclusa la gamma di servizi offerti e le famiglie
di prodotti per cui essi possono assicurarvi una
manutenzione specializzata. Qualora non
potessero fornirvi un aiuto diretto, potranno in
ogni caso consigliarvi con competenza.
Il Vostro DEUTZ AG
D-51057 Kln
Telefono:
0049-221-822-0
Telefax:
0049-221-822-5304
Telex:
8812-0 khd d
http://www.deutz.de
2004
Numero del motore
12 it
Timbro del concessionario
Prefazione
I motori Diesel DEUTZ
I pezzi di ricambio DEUTZ
Componenti intercambiali DEUTZ
sono il prodotto di numerosi anni di ricerca e

sviluppo. Il solido know how cos ottenuto in
combinazione con elevate esigenze qualitative
la garanzia per la fabbricazione di motori aventi
lunga durata, elevata affidabilit ed un basso
consumo di combustibile. Enaturale che si faccia
fronte anche alle elevate esigenze a favore della
protezione ambientale.
sono soggetti alle stesse severe esigenze qualitative poste ai motori DEUTZ. I perfezionamenti
atti a migliorare i motori vengono naturalmente
introdotti anche per i pezzi di ricambio originali.
Soltanto luso di pezzi di ricambio originali, fabbricati secondo le pi attuali conoscenze, offre
la garanzia di un perfetto funzionamento e di
elevata affidabilit.
I componenti intercambiabili DEUTZ

sono unalternativa economica ai
pezzi di ricambio originali.
Naturalmente anche qui, come per i
pezzi nuovi, valgono massimi criteri
qualitativi. I componenti intercambiablili DEUTZ
sono equivalenti ai pezzi di ricambio per ci che
concerne il loro funzionamento ed affidabilit.
SERVICE
Prudenza con il motore acceso
Ambianto
In caso di avarie o richieste di ricambi, rivolgersi

immediatamente ai nostri Centri di Assistenza
autorizzati. Il nostro personale appositamente
addestrato a disposizione in caso di guasto per
un intervento rapido, garantendo l'uso di ricambi
originali DEUTZ.
Eseguire i lavori di manutenzione o di riparazione

solo con motore spento. Al termine dei lavori rimontare i dispositivi di sicurezza eventualmente
asportati. Per lavori da eseguire con il motore acceso, labbigliamento da lavoro deve aderire
bene al corpo. Fare rifornimento di combustibile
solo con motore spento. Non lasciare il motore
acceso in locali chiusi pericolo di avvelenamento.
13 it
Le guarnizioni utilizzate per questo

motore sono esenti da amianto.
Per i lavori di manutenzione e
di riparazione fate uso degli
appositi ricambi.
2004
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Voorwoord
Geachte klant,
Service
De motoren van het merk DEUTZ werden

ontwikkeld voor een breed toepassingsspectrum. Door middel van een uitgebreid
aanbod van varianten wordt er steeds weer
voor gezorgd dat er aan de betreffende
specifieke eisen wordt voldaan.
Van oudsher staat de naam DEUTZ voor

baanbrekende ontwikkelingen op het gebied van
de constructie van motoren. Als onafhankelijke
motorenfabrikant bieden wij wereldwijd een
compleet assortiment diesel- en gasmotoren met
een vermogen van 4 tot 7.400 kW. Onze
producten zijn perfect afgestemd op de eisen
van onze klanten.
Uw motor werd uitgerust in overeenstemming

met de specifieke inbouwsituatie. Dat wil zeggen
dat uw motor niet al de onderdelen die in deze lijst
werden opgenomen bevat.
Hoewel de tekeningen in de meeste gevallen niet
alle details bevatten, kunnen de verschillende
uitvoeringen duidelijk onderscheiden worden,
zodat u het voor uw motor relevante onderdeel
gemakkelijk kunt vinden. Met behulp van het
positie-, het constructie- en het motornummer
kunt u het juiste onderdeel in ieder geval bepalen.
Gelieve bij het bestellen van onderdelen rekening
te houden met onze bestelaanwijzingen (zie
onderstaande voorbeeldtekeningen), zodat wij
u de benodigde onderdelen snel en in hun juiste
uitvoering kunnen leveren.
Voor nadere inlichtingen staan wij geheel te uwer
beschikking.
Wereldwijd vervullen ruim 1,4 miljoen DEUTZmotoren hun taak op betrouwbare wijze. Wij
willen de bedrijfszekerheid van onze motoren, en
op die manier ook de tevredenheid van onze
klanten, consolideren. Daarom zijn wij wereldwijd vertegenwoordigd via een netwerk van
competente dealers, waarvan de dichtheid
overeenstemt met de regionale verspreiding van
onze motoren.
Zo staat DEUTZ niet alleen voor innovatieve
motoren maar ook voor een compleet
dienstenpakket rondom de motor en voor een
service waar u steeds op kunt rekenen.
Er bestaat een overzicht van de DEUTZ-dealers
in uw omgeving, van hun productverantwoordelijkheid en hun onderhoudsdiensten.
Maar ook wanneer een bepaalde DEUTZ-dealer
u niet rechtstreeks aan een bepaald product kan
helpen, zal hij u in ieder geval deskundig kunnen
adviseren.
Motornummer:
Noteer hier het motornummer. Op die manier

vereenvoudigt u de afhandeling van eventuele klantenservice-, reparatie- en onderdelenkwesties.
Technische wijzigingen ten opzichte van de

tekeningen en gegevens in deze onderdelenlijst, die noodzakelijk zijn ter verbetering
van de motoren, blijven voorbehouden. Het
nadrukken of kopiren van deze gebruiksaanwijzing of gedeelten ervan, in welke vorm
dan ook, is niet toegestaan zonder onze
voorafgaande schriftelijke toestemming.
Uwe DEUTZ AG
DEUTZ AG
D-51057 Kln
2004
Tel.:
0049-221-822-0
Fax: 0049-221-822-5304
Telex: 8812-0 khd d
http://www.deutz.de
14 nl
Stempel handelaar
Voorwoord
DEUTZ-dieselmotoren
Originele DEUTZ-onderdelen
Tweedehands DEUTZ-onderdelen
zijn het resultaat van vele jaren van onderzoek en

ontwikkeling. De daardoor verworven knowhow staat samen met onze hoge kwaliteitseisen
garant voor motoren met een lange levensduur,
een hoge betrouwbaarheid en een laag
brandstofverbruik. En het spreekt vanzelf dat
onze dieselmotoren ook voldoen aan de hoge
eisen inzake milieubescherming.
zijn onderworpen aan dezelfde strenge

kwaliteitseisen als de DEUTZ-motoren. Nieuwe
ontwikkelingen ter verbetering van de motoren
worden natuurlijk ook doorgevoerd op de
originele DEUTZ-reserveonderdelen. Alleen het
gebruik van originele DEUTZ-onderdelen, die op
basis van de nieuwste inzichten worden ontwikkeld, garandeert een onberispelijke werking
en een hoge betrouwbaarheid.
Tweedehands DEUTZ-onderdelen
vormen een voordelig alternatief
voor nieuwe originele onderdelen.
Natuurlijk gelden ook hier zeer hoge
kwaliteitsnormen, net als bij nieuwe onderdelen.
Inzake werking en betrouwbaarheid zijn tweedehands DEUTZ-onderdelen gelijkwaardig aan
nieuwe onderdelen.
SERVICE
In geval van storingen en met vragen omtrent

reserveonderdelen kunt u terecht bij een van
onze service-vertegenwoordigingen. Ons geschoolde vakpersoneel zorgt in geval van schade of storingen voor een snelle en vakkundige
reparatie met originele DEUTZ-onderdelen.
Voorzichtig bij draaiende motor
Onderhoudswerkzaamheden en reparaties
mogen alleen bij uitgeschakelde motor worden
doorgevoerd. Eventueel verwijderde beschermplaten enz. moeten na de werkzaamheden
opnieuw worden gemonteerd. Bij werkzaamheden aan draaiende motoren dient men nauw
aansluitende werkkleding te dragen. Tank alleen
bij uitgeschakelde motor. Laat de motor nooit in
een gesloten ruimte draaien wegens vergiftigingsgevaar.
15 nl
Asbest
De in deze motor gebruikte

pakkingen zijn vrij van asbest.
Gebruikt u bij onderhouds- en
reparatiewerkzaamheden
a.u.b. onderdelen van dezelfde
kwaliteit.
2004
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Frord
Bste kund,
Service
Motornumret:
Deutz motorer har utvecklats fr att tcka ett brett

anvndningsomrde. Tack vare ett omfattande
utbud av varianter skerstlls att alla speciella
krav uppfylls.
Sedan lng tid tillbaka str DEUTZ fr

banbrytande utveckling inom motorbyggnad.
Som oberoende motortillverkare erbjuder vi ett
komplett sortiment av diesel- och gasmotorer i
effektomrdet 4 kW till 7 400 kW ver hela vrlden.
Vra produkter r perfekt utformade fr att klara
de krav som vra kunder stller.
Ange motornumret hr. Drmed underlttar du

hanteringen vid frgor som rr kundtjnst,
reparationer eller reservdelar.
Din motor r alltid rtt utrustad infr monteringen,

vilket i praktiken innebr att vissa av de delar och
komponenter som finns i den hr reservdelslistan
inte finns i din motor.
Trots att inte alla detaljer visas p ritningarna, r
det enkelt att skilja p de olika varianterna. Drmed
r det ltt att hitta den reservdel som passar till just
din motor. Den korrekta reservdelen faststlls via
positionsnummer, modulnummer och motornummer.
Beakta vra bestllningsanvisningar vid bestllning
av reservdelar (se nedanstende exempel), s
att vi snabbt och tillfrlitligt kan leverera de
ndvndiga reservdelarna i det utfrande som
motsvarar den senaste ndringsstatusen.
Vi hjlper grna till om du har ngra frgor.
Din
DEUTZ AG
I hela vrlden arbetar mer n 1,4 miljoner DEUTZmotorer p ett tillfrlitligt stt. Vi vill behlla vra
motorers funktionsskerhet och drmed vra
kunders beltenhet. Drfr representeras vi
globalt av kompetenta partner, vars koncentration motsvarar den regionala frdelningen.
Drmed str namnet DEUTZ inte bara fr
innovativa motorer utan ven fr ett komplett
tjnstepaket som rr motorerna och en service
som du kan lita p.
Hr fr du en verblick ver DEUTZ partner i din
nrhet och om deras produktansvar och service.
ven om det inte finns ngot direkt produktansvar, s hjlper DEUTZ partner nd till med
kompetent rdgivning.
Din
DEUTZAG
D-51057 Kln
Telefon: 0049-221-822-0
Telefax: 0049-221-822-5304
Telex:
8812-0 khd d
http://www.deutz.de
2004
Vi frbehller oss att gra tekniska ndringar,

ndvndiga fr att frbttra motorerna ytterligare,
gentemot de bilder och uppgifter som finns i den
hr reservdelslistan. Varje typ av kopiering och
mngfaldigande, ven delar av den, krver vrt
skriftliga tillstnd.
16 s v
terfrsljarens stmpel
Frord
DEUTZ-dieselmotorer
DEUTZ originaldelar
DEUTZUtbyteskomponenter
Detta r en produkt som krvt mnga rs

forskning och utveckling. Den drigenom uppbyggda kunskapen utgr, i frbindelse med hga
kvalitetskrav, en garanti fr tillverkning av motorer
med lng livslngd, hg tillfrlitlighet och lg
brnslefrbrukning. Det r sjlvklart att ven de
hga kraven betrffande miljskydd uppfylls.
Dessa underkastas samma hrda kvalitetskrav

som DEUTZ-motorerna. Vidareutvecklingar fr
att frbttra motorerna infrs naturligtvis ven
betrffande DEUTZ originaldelar. Endast vid anvndning av DEUTZ originaldelar, som tillverkats
enligt den senaste kunskapen, gr det att garantera felfri funktion och hg tillfrlitlighet.
DEUTZ Utbyteskomponenter utgr

ett prisvrt alternativ. Naturligtvis
gller ven hr hgsta kvalitetskrav,
precis som p nya delar. Nr det
gller funktion och tillfrlitlighet r
DEUTZ utbyteskomponenter likvrdiga med
DEUTZ originaldelar.
SERVICE
Var frsiktig nr motorn gr
Asbest
Vnd dig till ngon av vra servicerepresentanter vid driftstrningar och frgor som rr
reservdelar. Vra utbildade fackmn reparerar
motorn snabbt och korrekt med hjlp av DEUTZ
originaldelar.
Utfr underhllsarbeten och reparationer endast

nr motorn r avstngd. Stt tillbaka eventuellt
borttagna skyddsanordningar efter att arbetet
har avslutats. Om arbete mste utfras medan
motorn gr, s ska arbetsklderna sitta ttt mot
kroppen. Lt aldrig en motor g i ett slutet rum - det
finns d risk fr frgiftning.
17 s v
De ttningar som anvnds i den

hr motorn r asbestfria. Anvnd
endast sdana reservdelar vid
underhllsarbeten och reparationer.
2000
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Kre kunde!
Service
Motornummer
De vskeklede motorer fra firmaet DEUTZ er

udvik-let til et bredt anvendelsesspektrum.
Derved sikres det p grund af det omfattende
udbud af varianter, at de individuelle specielle
krav kan opfyldes.
Fra tidernes morgen har DEUTZ vret

ensbetydende med banebrydende udviklinger
inden for fremstillingen af motorer. Som uafhngig motorfabrikant tilbyder vi over hele
verden et komplet spektrum af dieselog gasmotorer med en effekt p 4 til 7.400 kW. Vore
produkter er perfekt skrddersyet efter vore
kunders behov.
Notr motornummeret her. Derved lettes afviklingen i forbindelse med service-vrksted, reparation og bestilling af reservedele.
Deres motor er udstyret, s den svarer til

brugstilfldet; d.v.s. at ikke alle elementer og
komponenter, som er afbildet i denne reservedelsliste, er monteret p Deres motor.
Selv om de grafiske afbildninger ikke kan vises
med alle detaljer, kan man tydeligt se forskel p de
enkelte varianter, s De let kan finde de
reservedele, som er relevante til Deres motor.
Ved hjlp of positions-, type- og motornummeret kan man altid finde frem til den rigtige
reservedel.
Frste gang De bestiller reservedele, bedes De
bemrke vore bestillingshenvisninger, s vi
hurtigt og korrekt kan finde frem til de ndvendige
reservedele i den udfrelse, som svarer til den
nyeste ndringstilstand.
Vi str gerne til rdighed, hvis De har sprgsml.
Deres
DEUTZ AG
2004
Over hele verden udretter mere end 1,4 millioner

DEUTZ-motorer deres arbejde til alles tilfreds0hed. Vi nsker at bevare vore motorers
anvendelsesberedskab og dermed ogs vore
kunders tilfredshed. Derfor er vi over hele verden
reprsenteret af et helt net af kompetente
partnere, hvis tthed svarer til vore motorers
regionale fordeling.
Sledes er DEUTZ ikke kun navnet p motorer til
stadig nye opgaver, men ogs p en komplet
servicepakke med hensyn til alt, hvad der har med
motorer at gre, og med en service, De kan stole
p.
Ret til tekniske ndringer, som bliver ndvendige

til forbedring af motorerne, forbeholdes.
Eftertryk og mangfoldiggrelse af enhver art,
ogs i uddrag, kun tilladt med vores skriftlige
samtykke.
Over disses produkt-kompetancer og serviceydelser. Men selvom der ikke direkte er angivet
nogen produkt-kompetance, hjlper DEUTZpartneren Dem videre med en kompetent
rdgivning.
Deres DEUTZ AG
D-51057 Kln
Telefon:
0049-221-822-0
Telefax:
0049-221-822-5304
Telex:
8812-0 khd d
http://www.deutz.de
18 da
Forhandlerens stempel
Forord
DEUTZ-dieselmotorer
Original dele
DEUTZudskiftningskomponenter
er produktet af mange rs forskning og udvikling.

Det velunderbyggede knowhow, vi dermed har
vun-det, i forbindelse med hje kvalitetskrav er
Deres garanti for en produktion af motorer med
lang leve-tid, hj plidelighed og lavt brndstofforbrug. Det er en selvflge, at de hje krav mht.
beskyttelsen af miljet ogs opfyldes.
underligger de samme strenge kvalitetskrav som

DEUTZ-motorerne. Videreudviklinger til forbedring af motorerne bliver naturligvis ogs anvendt
ved original dele. Kun hvis man anvender- originale dele, som er udfrdiget efter de nyeste
erkendelser, har man sikkerhed for en upklagelig funktion og hj plidelighed.
DEUTZ-udskiftningskomponenter er et prisbilligt alternativ til originale dele. Selvflgelig glder

ogs her de hjeste kvali-tetskrav
som ved de nye dele. DEUTZudskiftnings-komponenter fungerer lige s godt
og er lige s plidelige som originale dele.
SERVICE
Forsigtig, nr motoren lber
Asbest
I tilflde af driftsforstyrrelser og ved reservedelssprgsml kan De henvende Dem til en af

vores ansvarlige service-reprsentationer.
Vores skolede fag-personale srger i tilflde af
skader for en hurtig og faglig korrekt istandsttelse under anvendelse af originale dele.
Vedligeholdelsesarbejder og reparationer m
kun gennemfres, nr motoren er slet fra. Evt.
fjernede beskyttelsesanordninger skal atter
monteres p, nr arbejderne er afsluttet. Ved
arbejder med lbende motor m man ikke bre
lsthngende tj. Der m kun fyldes brndstof
p med motoren slet fra. Lad aldrig motoren lbe
i lukkede rum fare for forgiftning.
19 da
Pakningerne, som er anvendt til

denne motor, er asbestfrie. Anvend venligst ved vedligeholdelsesog reparationsarbejde tilsvarende
reservedele.
2004
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Esipuhe
Hyv asiakas
Hyv tiet, se on DEUTZ.
DEUTZ-moottorit on kehitetty laajaa kyttjkuntaa silmllpiten. Niinp tarjolla on laaja

valikoima moottorivaihtoehtoja, jotka tyttvt
asiakkaiden vaihtelevat moottoritarpeet.
DEUTZ on edustanut jo alunalkaen uraauurtaavia

uudistuksia moottorinrakennusalalla. Riippumattomana moottorinvalmistajana tarjo-amme
ympri maailmaa tydellisen valikoiman diesel- ja
kaasumoottoreita, joiden suorituskyky vaihtelee
vlill 4 - 7400 kW. Tuotteemme on sovitettu
tydellisesti asiakkaittemme vaatimusten mukaan.
Moottorinne on toimitettu tietyin varustein, eivtk

kaikki tss varaosaluettelossa esiintyvt osat
vlttmtt kuulu moottorinne varusteisiin.
Vaikka kaaviokuvat eivt sisll kaikkia yksityiskohtia, eri vaihtoehdot on kuitenkin helppo erottaa
toisistaan moottorillenne trkeiden varaosien
tunnistamiseksi. Position, rakenneryhm- ja
moottorinumeron avulla pystytn joka tapauksessa toimittamaan oikea varaosa.
Varaosia tilattessa on noudatettava annettuja
tilausohjeita, jotta pystymme nopeasti ja varmasti
toimittamaan tarvittavat, kyseisen mallin viimeisint teknist kehityst vastaavat varaosat.
Annamme mielelln listietoja ja vastaamme
kysymyksiinne.
DEUTZ AG
Yli 1,4 miljoonaa DEUTZ-moottoria tytt

ympri maailmaa luotettavasti tehtvns.
Tarkoituksenamme on silytt moottoreidemme
kyttvalmius ja tten asiakkaittemme tyytyvisyys. Tst syyst olemme edustettuina
ympri asiantuntevan edustajaverkoston kautta,
jonka tiheys vastaa moottoreidemme alueellista
levinneisyytt.
DEUTZ-nimi ei merkitse nin vain keksijhenkisi
moottoreita. , vaan mys moottoreihin liittyv
kokonaispakettia ja palvelua, johon voitte luottaa.
Yleiskatsaus DEUTZ-edustajista, heidn edustamistaan tuotteista ja palveluista antavat teille
kokonaiskuvan verkostostamme. Ja vaikka yksilllist tuote-edustusta ei olisikaan mainittu, DEUTZedustaja auttaa sinua eteenpin asiantuntevalla
neuvonnalla.
DEUTZAG
D-51057 Kln
Puh.: 0049-221-822-0
Telefax: 0049-221-822-5304
Telex: 8812-0 khd d
http://www.deutz.de
2004
20 fn
Mottorinumero:
Merkitk thn moottorinumero. Sen ilmoittaminen helpottaa asioiden ksittely huolto-,

korjaus- ja varaosakysymyksien yhteydess.
Tmn varaosaluettelon kuvauksien ja tietojen

suhteen pidtmme oikeuden muutoksiin, jotka
ovat tarpeellisia moottorin teknisen kehityksen
kannalta. Kaikenlaiseen jlkipainosten ja kopioiden tekoon, mys osittain, tarvitaan kirjallinen
lupamme.
Liikkeen leima
Esipuhe
DEUTZ dieselmoottorit
Alkuperiset DEUTZ varaosat
DEUTZvaihto-osat
ovat monien vuosien tutkimuksen ja kehittelyn tulos. Nin saavutettu know-how yhdistettyn korkeisiin laatuvaatimuksiin on tae pitkikisten, luotettavien ja vhn polttoainetta kuluttavien
moottreiden valmistukselle. On itsestn selv,
ett mys tarkat ympristn suojelua koskevat
mrykset on otettu huomioon.
tyttvt samat, tiukat laatuvaatimukset kuin

DEUTZ-moottoritkin. Moottorien parantamiseen
kytetty kehityst sovelletaan mys DEUTZ
varaosiin. Moitteeton toiminta ja luotettavuus on
taattu kyttmll ainoastaan viimeisimmn
tekniikan mukaan valmistettuja alkuperisi
DEUTZ varaosia.
DEUTZ-vaihto-osat ovat edullinen

vaihtoehto alkuperisille DEUTZ
varaosille.
On mys itsestn selv, ett
nille osille asetetaan samat korkeat laatuvaatimukset kuin uusillekin osille. Toiminnaltaan ja luotettavuudeltaan DEUTZ vaihtoosat ovat samanarvoisia alkuperisten DEUTZ
varaosien kanssa.
SERVICE
Varo moottorin kydess
Asbesti
Kyntihiriiss ja varaosakysymyksiss kntyk DEUTZ-edustajanne puoleen. Vauriotapauksessa koulutettu henkilkunta huolehtii

nopeasta ja asianmukaisesta korjauksesta
kyttmll alkuperisi DEUTZ-osia.
Huolto- tai korjaustyt saa suorittaa ainoastaan

moottorin ollessa pysytettyn. Mahdollisesti irrotetut suojalaitteet on asennettava tiden ptytty jlleen paikoilleen. Huollettaessa kyv
moottoria tyvaatetus ei saa olla liian vlj.
Moottori on pysytettv tankkauksen ajaksi.
Moottoria ei saa koskaan kytt suljetuissa
tiloissa myrkytysvaara.
21 fn
Tss moottorissa kytetyiss

tiivisteiss ei ole asbestia.
Huolto- ja korjaustiss pyydmme kyttmn vastaavia
varaosia.
2004
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Allment
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Motornummer:
Kjre kunde,
Service
Vskekjlte motorer av merket DEUTZ er utviklet

med tanke p mange forskjellige bruksomrder.
Et bredt spekter av varianter sikrer at mange
forskjellige spesielle krav kan oppfylles.
Deutz har alltid sttt for en banebrytende utvikling

av motorer. Som uavhengig motorprodusent
tilbyr vi verden over et komplett utvalg av dieselog gassmotorer med en effekt p 4 til 7.400 kW.
Vre produkter er perfekt tilpasset vre kunders
krav.
Din motor er utstyrt for det aktuelle bruksomrde.

Derfor vil ikke alle deler og komponenter som er
oppfrt p denne reservedelslisten, vre montert p din motor.
Selv om bildene ikke alltid viser alle detaljer, kan
de enkelte variantene tydelig skilles fra
hverandre slik at det er lett finne frem til de
relevante reservedelene til din motor. Ved hjelp av
posisjonsnummer, komponentgruppenummer og
motornummer kan du i hvert enkelt tilfelle finne
frem til riktig reservedel.
Vi ber deg vennligst flge vre anvisninger ved
bestilling av reservedeler (se bildeeksempel
nedenfor) slik at vi kan levere de reservedelene
du har bruk for, raskt og sikkert og iflge de
seneste endringer.
Vi str gjerne til din disposisjon hvis du har
ytterligere sprsml.
Vennlig hilsen
DEUTZ AG
Verden over arbeider mer enn 1,4 millioner

DEUTZ motorer plitelig. Vi vil srge for
opprettholde motorenes driftsklarhet og dermed
vre kunders tilfredshet. Derfor er vi verden over
representert med et nett av kompetente partnere
som er tilpasset den regionale fordelingen av
vre motorer.
DEUTZ er dermed ikke bare et navn for innovative
motorer, men ogs for en komplett pakke med
ytelser for alt som har med motorer gjre og for
en service du kan stole p.
En oversikt over DEUTZ-partnere nr deg, hvilke
produkter de har ansvar for og hvilke servicetjenester de tilbyr. Og selv om en DEUTZ-partner
ikke er merket av med produktansvar for din
motor, kan han gi deg kompetent hjelp.
Vennlig hilsen DEUTZAG
DEUTZAG
D-51057 Kln
Telefon: 0049-221-822-0
Telefax: 0049-221-822-5304
Telex:
8812-0 khd d
http://www.deutz.de
2004
22 no
Vennligst noter motornummeret her. Dette gjr

behandlingen av sprsml angende service,
reparasjoner og reservedeler enklere.
Vi forbeholder oss tekniske foranderinger i vre

beskrivelser og opplysninger i denne instruksjonsboken som er ndvendig for forbedring
av motorene. Ettertrykk og kopiering p enhver
mte, ogs delvis, m ikke gjres uten vr
skriftlige tillatelse.
Forhandlerstempel
Allment
DEUTZ-dieselmotorer
Originaldeler
DEUTZ byttekomponenter
er resultatet av mangerig forskning og utvikling.

En omfattende know-how i forbindelse med
hye kvalitetskrav er garantien for fremstillingen
av motorer med lang levetid, stor plitelighet og
lavt drivstofforbruk Det er en selvflge at de
strenge miljkravene blir oppfylt.
er underkastet strenge kvalitetskrav p linje med

DEUTZ motorer. Videreutvikling for forbedre
vre motorer blir selvflgelig fulgt opp med forbedringer p originaldeler. Bruk derfor bare originaldeler som er fremstilt etter de nyeste
erfaringer for vre sikker p feilfri funksjon og
hy plitelighet.
DEUTZ byttekomponenter er et
billig alternativ til originaldeler.
Selvflgelig gjelder ogs her de
hyeste kvalitetskrav p samme
mte som for nye deler. Nr det
gjelder funksjon og plitelighet, er DEUTZ byttekomponenter likeverdige med originaldeler.
SERVICE
Vr forsiktig med motor i drift!
Asbest
Ta kontakt med en av vre ansvarlige servicerepresentanter ved driftsforstyrrelser og sprsml angende reservedeler. Vrt utdannete
fagpersonal srger for rask og fagmessig
reparasjon med DEUTZ originaldeler.
Vedlikeholdsarbeid og reparasjoner skal bare

utfres med avsltt motor. Monter alle beskyttelsesanordninger igjen etter avsluttet arbeid.
Bruk tettsittende arbeidsty ved arbeid p en
motor som gr. Tank bare med avsltt motor.
La aldri motoren g i lukkete rom - fare for
forgiftning!
23 no
Pakningene som benyttes i denne

motoren, er asbestfrie.
Bruk reservedeler uten asbest
ved vedlikeholds- og reparasjonsarbeid.
2004
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DEUTZ
.

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2004
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Sales & Service
DEUTZ
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.

, DEUTZ
.
DEUTZAG
D-51057 Kln
: 0049-221-822-0
:
0049-221-822-5304
:
8812-0 khd d
http://www.deutz.de
24 el

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2004
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nsz
Sayin msterimiz,
Servis
DEUTZ marka motorlar geni kullanm alanlar

iin gelitirilmitir. Sunulan geni model ve tip
eitleri ile her trl kullanm alannn
gerektirdii zel artlar yerine getirilebilmektedir.
Motor yapmnda r aan gelimeler demek

DEUTZ demektir. Biz, bamsz motor reticisi
olarak dnya genelinde 4 ile 7.400 kW
gcndeki dizel ve gaz motorlarn komple
palet halinde sunmaktayz. rnlerimiz
mterilerimizin beklentileri iin biilmi
kaftandr.
Sahip olduunuz motor bal olduu kullanm

amac ile donatlm olduundan, yedek para
listesinde gsterilmi olan tm eleman ve
paralar motorunuzda bulunmaz.
Gsterilmi olan grafikler tm ayrntlar
iermemesine ramen, motorunuz iin nemli
olan yedek para kolayca tespit edilebilir.
Pozisyon, yap grubu ve motor numaras
zerinden her halukarda, motorunuz ile ilgili
doru yedek para tespit edilebilir.
Bu yedek para sipariinde, ihtiyacnz olan
yedek paray en ksa zamanda, gvenilir ve
son deiiklik tipinde teslim edebilmemiz iin
sipari bilgilerini (baknz sonraki rnek
grafiklere) dikkate alnz.
Sormak istediiniz sorular olduunda bize
her zaman bavurabilirsiniz.
DEUTZ AG'niz
Motor numaras
Bugn dnya genelinde 1,4 milyondan daha

fazla sayda DEUTZ motoru hizmet
vermektedir. Motorlarmzn etkinliini ve
bununla birlikte mterilerimizin memnuniyetini
srdrmek istiyoruz. Bu nedenle btn
dnyada, yaylmlar motorlarmzn blgesel
dalmna uygun olan yetkin temsilciler bizleri
temsil etmektedir.
DEUTZ, bu ekilde sadece motorlar iin
yaratclk ruhuna sahip bir isim deil, bunun
yannda motorla ilgili tam bir hizmet paketi ve
gvenebileceiniz bir servis demektir.
Yedek para listesinde gsterilen ekillerde

ve teknik bilgilerinde, motorlarn gelitirilmesi
iin gerekli olan deiiklik yapma hakk sakldr.
Firmamzn yazl izni olmakszn, ksmen de
olsa her trl oaltma ve kopyalama yasaktr.
Bu dokman size DEUTZun en yaknnzdaki

temsilcileri, onlarn rn yetkileri ve servis
hizmetleri hakknda bilgi verir. Direk olarak
rn yetkisi olmasa da DEUTZ temsilcisi size
danma hizmeti vererek yardm eder.
DEUTZ AG'niz
D-51057 Kln
Telefon: 0049-221-822-0
Faks:
0049-221-822-5304
Teleks:
8812-0 khd d
http://www.deutz.de
2004
Ltfen buraya motor numarasn yazn.

Bylece mteri hizmetlerine, tamir ve yedek
para ile ilgili konularda kolaylk salanr.
26 tr
Satc mhr
nsz
DEUTZ Dizel motorlar
Orijinal DEUTZ Yedek Para
DEUTZ marka dizel motorlar, uzun yllardr yaplan

aratrma ve gelitirmenin rndr. Bu
aratrma ve gelitirmelerden elde edilen temel
uzmanlk bilgisi ve retimde uygulanan yksek
kalite standartlar, uzun mrl, yksek dayankl
ve dk yakt sarfiyatl motorlarn retilmesini
salamtr. Ayn zamanda evre koruma ile ilgili
tm ykmllkler de yerine getirilmitir.
Orijinal yedek paralar ayn DEUTZ

motorlarnda olduu gibi yksek kalite
standartlarna gre retilir. Motorlarn
iyiletirilmesi iin yaplan gelitirme
almalarnda olduu gibi yedek paralar
zerinde de gelitirmeler yaplmaktadr.
Yalnzca en son teknolojiye gre retilmi
olan orijinal DEUTZ yedek paralar, motorlarn
mkemmel fonksiyonunu, yksek dayankllk
ve gvenilirliini salar.
DEUTZ deitirme elemanlar

uygun fiyatl bir alternatiftir. Ayn
yeni yedek paralarda olduu
gibi bu paralar iin de yksek
kalite standartlar geerlidir.
DEUTZ deitirme elemanlarn ilevsellii ve
gvenirlilii orijinal yedek paralar ile ayndr.
SERVS
alan motorda dikkat
Asbest
Arza durumlarnda ve yedek para

konularnda bilgi edinmek iin yetkili
servislerimize bavurunuz. Eitimli kalifiye
personelimiz, orijinal DEUTZ paralar
kullanarak tamir almalarn yerine
getireceklerdir.
Bakm ve tamir almalar yalnzca almayan

motorda gerekletirilmelidir. Muhtemelen
sklm olan koruma dzenleri, bakm ve
tamir almalarndan sonra tekrar monte
edilmelidir. Motor alrken yaplan
almalarda bol i elbisesi giyilmemelidir. Yakt
dolum ilemini yalnzca motor almadnda
yaplmaldr. Motoru kesinlikle kapal
mekanlarda altrmayn - Zehirlenme
tehlikesi.
27tr
DEUTZ Deitirme elemanlar
Bu motorda kullanlan contalar

asbest malzemesi bulunmaz.
Bakm ve tamir almalarnda ltfen uygun yedek paralar kullann.
2004
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DEUTZ
.

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DEUTZ

. ,
,

4 7400 .
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DEUTZ AG
2004

1,4 DEUTZ.

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DEUTZ
,
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DEUTZ,
.

DEUTZ
.
DEUTZ AG
D-51057 Kln
: 0049-221-822-0
: 0049-221-822-5304
: 8812-0 khd d
http://www.deutz.de
28 ru
.

, .

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.

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DEUTZ
DEUTZ

.

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, DEUTZ.
,
DEUTZ.

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29 ru
DEUTZ

DEUTZ
.
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DEUTZ
DEUTZ.

.

.
2004
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2004
30 ar
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31 ar
2004
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Wprowadzenie
Szanowny odbiorco,
Serwis
chodzone ciecz silniki marki DEUTZ zostay

opracowane dla szerokiego zakresu
zastosowania. Bogata oferta rnych
wariantw zapewnia moliwo spenienia
wymaga specjalnych w poszczeglnych
przypadkach.
Wiadomo, to jest DEUTZ.Z nazw DEUTZ kojarzy

si od dawna otwierajcy nowe horyzonty
rozwj w dziedzinie budowy silnikw. Jako
niezaleny wytwrca silnikw dostarczamy na
caym wiecie ca gam silnikw Diesla i
silnikw gazowych o mocy od 4 do 7400 kW.
Nasze wyroby odpowiadaj dokadnie wymaganiom naszych odbiorcw.
Wyposaenie silnika zamwionego przez

Pastwo odpowiada przypadkowi okrelonemu
w zamwieniu, tzn. nie wszystkie czci
zamienne i czci skadowe z niniejszej listy
czci zamiennych zostay przedstawione w
Pastwa silniku.
Mimo, e zaczone rysunki nie zawieraj wielu
szczegw, s Pastwo w stanie wyranie
rozrni poszczeglne warianty tak, e
znalezienie czci zamiennych do Pastwa
konkretnego silnika nie sprawi trudnoci.
Poszukiwana cz zamienna moe by w
kadym przypadku bezbdnie znaleziona na
podstawie numeru pozycji, numeru podzespou
i numeru silnika.
Przy zamawianiu czci zamiennych prosimy
przestrzega naszych wskazwek do
zamwienia. Zapewni nam to moliwo
szybkiego i niezawodnego dostarczenia
potrzebnych
czci
zamiennych
z
kadorazowym uwzgldnieniem ostatnio
wprowadzonych zmian.
Na zapytania Pastwa zawsze z przyjemnoci
udzielimy odpowiedzi.
Z powaaniem
DEUTZAG
2004
Na caym wiecie wykonuje niezawodnie swoje

zadanie ponad 1,4 miliona silnikw firmy DEUTZ.
Jestemy zainteresowani w utrzymaniu wysokiej gotowoci do pracy naszych silnikw, a
tym samym w utrzymaniu zadowolenia naszych
odbiorcw. Dlatego te jestemy reprezentowani w caym wiecie przez sie kompetentnych przedstawicieli, ktrych gsto
rozmieszczenia odpowiada regional-nemu
rozmieszczeniu naszych silnikw.
Nazwa DEUTZ jest rwnoznaczna nie tylko z
pojciem silnikw o duchu wynalazczoci.
Oznacza ona te kompletny pakiet wiadcze
we wszystkich dotyczcych silnikw dziedzinach oraz serwis, ktremu Pastwo mog
zaufa.
Informacje o ich kompetencjach i wiadczeniach
serwisowych. Take w przypadkach, kiedy nie
wymieniono wprost okrelonych kompetencji,
przedstawiciel firmy DEUTZ udzieli Pastwu
kompetentnej porady.
Z powaaniem DEUTZ AG
D-51057 Kln
Telefon:
0049-221-822-0
Telefaks:
0049-221-822-5304
Teleks:
8812-0 khd d
http://www.deutz.de
32 pl
Numer silnika
Prosimy wpisa numer silnika. W ten sposb

uatwiacie Pastwo zaatwienie spraw
serwisu, napraw i czci zamiennych.
W opisie i danych, zawartych w niniejszej

licie czci zamiennych zastrzegamy sobie
prawo wprowadzenia zmian technicznych
koniecznych do ulepszenia silnika. Przedruk
i powielanie w jakikolwiek sposb, take w
postaci wycigw, wymaga naszej pisemnej
zgody.
Piecztka handlowca
Wprowadzenie
Silniki Diesla marki DEUTZ
Oryginalne czci zamienne marki

DEUTZ
Czci zastpcze marki DEUTZ
zostay opracowane w wyniku wieloletnich

bada i rozwoju. Zdobyte w wyniku tego solidne
know-how stanowi w poczeniu ze spenieniem wysokich wymogw jakoci gwarancj
produkcji silnikw o dugiej ywotnoci,
wysokiej niezawodnoci i niskim zuyciu
paliwa. Oczywicie zostay take spenione
wysokie wymagania ochrony rodowiska.
podlegaj tym samym surowym wymaganiom

jakoci, jak i silniki marki DEUTZ. W celu poprawy
jakoci silnikw podlegaj staemu rozwojowi
oczywicie take oryginalne czci zamienne
marki DEUTZ. Tylko zastosowanie oryginalnych
czci zamiennych marki DEUTZ, wykonanych
z wykorzystaniem najnowszej wiedzy, zapewnia nienaganne dziaanie i wysok niezawodno pracy.
Czci zastpcze marki DEUTZ

stanowi alternatyw korzystniejsz
cenowo. Oczywicie obowizuj
tu, jak i w stosunku do elementw
nowych, najwysze wymagania
jakociowe. Czci zastpcze marki DEUTZ s
co do dziaania i jakoci rwnowane oryginalnym czciom zamiennym marki DEUTZ.
rodki ostronoci przy pracujcym

silniku
Azbest
SERWIS
W przypadkach zakce eksploatacyjnych

oraz w sprawach czci zamiennych prosimy
zwrci si do jednego z naszych waciwych
przedstawicielstw serwisowych. Nasi wyszkoleni specjalici postaraj si w przypadkach
uszkodze o szybk i fachow napraw z
uyciem oryginalnych czci zamiennych marki
DEUTZ.
Czynnoci obsugowe i naprawy naley

wykonywa tylko przy zatrzymanym silniku.
Ewentualnie usunity osprzt ochronny naley
po zakoczeniu prac ponownie zamontowa.
Podczas prac przy pracujcym silniku odzie
robocza powinna cile przylega do ciaa. Silnik
mona tankowa tylko po jego zatrzymaniu.
Silnik nie moe w adnym przypadku pracowa
w zamknitym pomieszczeniu niebezpieczestwo zatrucia.
33 pl
Uszczelnienia zastosowane w
tym silniku s wolne od azbestu.
Do prac obsugowych i napraw
prosimy uywa odpowiednich
czci zamiennych.
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Service
Beispiel/Example
D
9 113 500
2
2
Motor 909
Service
Beispiel/Example
2004
Rechts 3
Service
Beispiel/Example
35
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Service
Order information
Indications de commande
Indicaciones para el pedido:
Please specify the following information when

ordering original DEUTZ parts:
Lors dune commande de pices dtaches

originales de DEUTZ, il est ncessaire de fournir
les indications suivantes:
Al solicitar piezas originales de DEUTZ ser

necesario indicar los siguientes datos:
- N de Motor:
- Engine no.
- n de moteur
- N de identificatin
- Ident no.
- n didentification
- Cantidad de piezas
- Quantity
- nombre
Document structure
Structure de la documentation
Estructuracin de la documentacin
- The picture diagrams in this spare list are

sorted according to engine assembly groups.
- Les tableaux illustrs de cette liste de pices

dtaches sont classs par groupe de
moteur.
- Las tablas con las ilustraciones de dichas

piezas de repuesto estn clasificadas de
acuerdo con el grupo constructivo de los
motores.
- The assemblies are listed in the engine

overview.
- The ident no. 06/59 is made up of the
assembly group (e.g. 06) and item number
(e.g. 59).
Explanation of symbols
- Les groupes constitutifs figurent dans le

rcapitulatif moteur.
- Le n didentification 06/59 est constitu
du n de groupe (p.ex. 06) et du n de position
(p.ex. 59).
assembly No. (e.g. 06)
-06-
Numro de groupe constitutif (p. ex. 06)
000
revision level (e.g. 000)
000
Indice de modification (p. ex. 000)
96
page number (e.g. 96)
96
Numro de page (p. ex. 96)
94
cross reference on continuation page

(e.g. 94)
94
Renvoi la page de suite (p. ex. 94)
A
2004
- El N de identificacin 06/59 consta del grupo

(v.g. 06) y de la posicin (v.g. 59).
Explication des symboles
-06-
A connection symbol
- always occurs at least in pairs
(e.g. A-A, B-B, C-C etc.)
- Los grupos constructivos se indican en el

resumen correspondiente del motor.
Symbole dassemblage
- se prsente toujours par paire
(p. ex. A-A, B-B, C-C)
36
Leyenda
-06-
nmero del grupo constructivo (p.ej. 06)
000
ndice de modificacin (p.ej. 000)
96
nmero de pgina (p.ej. 96)
94
referencia recproca a la pgina de

continuacin (p.ej. 94)
smbolo de enlace
- aparece siempre, por lo menos, como
pareja (p.ej. A-A, B-B, C-C, etc.)
Service
Dados necessrios para a
encomenda:
Dati di ordinazione
Bestelgegevens
Per lordinazione di pezzi di ricambio originali

DEUTZ, indicare sempre i seguenti dati:
Bij bestelling van originele DEUTZ onderdelen

dienen de volgende gegevens verstrekt te worden:
- No. del motore
- motornummer
- Codice didentificazione
- identificatienummer
- Quantit pezzi
- aantal
- Quantidade
Struttura della docomentazione
Esquema da documentao
- Le tavole di questa lista dei pezzi di ricambio

sono suddivise secondo i gruppi costruttivi
dei motori in base alle unit dei motori
Gebruiksaanwijzing voor documentatie
Para encomendar as peas originais DEUTZ

necessrio indicar os seguintes dados:
- N do motor
- N de identificao
- As figuras representativas das peas

sobres-salentes esto agrupadas pelos
mdulos do motor.
- Os elementos mdulos so apresentados na
vista geral do motor.
- O N de identificao 06/59 consiste a partir
do nmero do mdulo (por ex. 06) e da posio
(por ex. 59)
Explicao dos smbolos

-06-
Nmero dos mdulos (p.ex. 06)
000
Algarismo varivel (p.ex. 000)
96
Nmero de pgina (p.ex. 96)
94
Referncia transversal pgina de

continuao (p.ex. 94)
Smbolo de conexo
- introduzir sempre, no mnmo, em
pares (p.ex. A-A, B-B, C-C etc.)
- Gli elementi costruttivi sono specificati nella

vista panoramica del motore
- Il codice didentificazione 06/59 costituito
dall'unit costruttivo (per es. 06) e dalla
posizione(per es. 59)
- De afbeeldingen in deze onderdelenlijst zijn

geordend naar deelsamenstelling.
- De constructiegroepen zijn in het overzicht
van de motoren vermeld.
- Het identificatienummer (bijv. 06/59) is
opgebouwd uit de deelsamenstelling (bijv.
06), gevolgd door de positie (bijv. 59).
Legenda
-06-
Numero dell'unit dellelemento

costruttivo (ad esempio 06)
000
Numero variabile (ad esempio 000)
96
Numero della pagina (ad esempio. 96)
94
Riferimento incrociato alla pagina di

continuazione (ad esempio 94)
Simbolo di collegamento
- compare sempre almeno a coppie
(ad esempio A-A, B-B, C-C, ecc.)
37
Verklaring van de symbolen

-06-
Nummer van de constructiegroep (b.v. 06)
000
Modificatie cijfer (b.v. 000)
96
Paginanummer (b.v. 96)
94
Kruisverwijzing naar de volgende pagina

(b.v. 94)
Het aansluitsymbool
- verschijnt altijd minstens paarsgewijs
(bijv. A-A, B-B, C-C, enz.)
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Service
Bestllningsuppgifter
Bestillingsangivelser
Tilaustiedot
Fr bestllning av DEUTZ original reservdelar

krvs fljande uppgifter:
Ved bestillingen af originale DEUTZ-dele er det

ndvendigt med flgende angivelser:
Alkuperisten DEUTZ-varaosien tilauksen

yhteydess on ilmoitettava seuraavat tiedot:
- Motornr.
- motor-nr.
- moottori nro
- ID-nr.
- ident.-nr
- tunnusnro
- Antal
- antal
- kappalemr
Dokumentationens uppbyggnad
- Illustrationerna i denna reservdelslista r
sorterade enligt motorns moduler.
- Modulerna framgr i versikten ver motorn.
- ID-numret 06/59 bestr av modul (t.ex. 06) och
position (t.ex.59).
Symbolfrklaring
Dokumentationens opbygning
- Billederne i denne reservedelsliste er sorteret
efter motor-komponenter.
- Delmontagerne findes i motoroversigten.
Dokumentaation rakenne
- Tmn varaosaluettelon kuvat on ryhmitelty
moottorin rakenneryhmien mukaan.
- Rakenneryhmt kyvt selville moottorin
listasta.
- Ident-nr. 06/59 er opbygget af komponent

(f.eks. 06) og position (f.eks. 59).
- Tunnusnumero 06/59
koostuu rakenneryhmst (esim. 06) ja
osanumerosta (esim. 59).
Symbolforklaring
Symbolien selitykset
-06-
Modulnummer (t.ex. 06)
-06-
delmontagenummer (f.eks. 06)
-06-
Rakenneryhmnumero (esim. 06)
000
Frndringsnummer (t.ex. 000)
000
ndringsciffer (f.eks. 000)
000
Muutosnumero (esim. 000)
96
Sidnummer (t.ex. 96)
96
sidenummer (f.eks. 96)
96
Sivunumero (esim. 96)
94
Korsreferens till nsta sida

(t.ex. 94)
94
krydshenvisning til nste side

(f.eks. 94)
94
Ristiviittaus jatkosivulla
(esim. 94)
2004
Anslutningssymbol
- visas alltid minst parvis
(t.ex. A-A, B-B, C-C, osv)
tilslutningssymbol
- optrder altid mindst parvis
(f.eks. A-A, B-B, C-C osv.)
38
Liitntsymbooli
- ilmenee aina vhintn parittain
(esim. A-A, B-B, C-C, j.n.e.)
Service
Bestillingsangivelser
Sipari bilgileri
Ved bestilling av originale DEUTZ deler er

flgende opplysninger ndvendige:
DEUTZ:
Orijinal DEUTZ yedek para siparilerinde

aadaki bilgilerin belirtilmesi gereklidir:
- Motor-nr.
- .
- Motor-No.
- Ident-nr.
- .
- Kod No.
- Antall
- .
- Adet
Dokumentasjonsoversikt
Dokmantasyon yaps
-

.
-

- .
06/59 (.
06) (. 59)
- Yedek para listesindeki ekiller ve izimler

motor gruplarna gre ayrlmtr.
Sembol aklamalar
- Illustrasjonene i denne reservedelslisten er

sortert etter komponentgruppe.
- Komponentgruppen vises p motortegningen.
- Ident-nr. 06/59 bestr av konstruksjonsgruppe (f.eks 06) og posisjon (f.eks 59)
Symbolforklaring
-06-
Delenummer (f.eks. 06)
000
Endringsnummer (f.eks. 000)
96
Sidenummer (f.eks. 96)
94
Kryssreferanse p fortsettelsessiden.
(f.eks. 94)
Koblingssymbol
- Fres alltid opp parvis
(f.eks. A-A, B-B, C-C osv.)
- Her blmn nnde yap grubu listesi bulunur

- Kod No. 06/59, yap grubundan (rn. 06) ve
pozisyondan (rn. 59) olumaktadr.
-06-
(.06)
-06- Yap grubu numaras (rn. 06)
000
(. 000)
000 Deiim rakam (rn. 000)
96
96 (. 94)
96
94
94 (. 94)
94

(. -,
-, C-C ..)
A-
39
Sayfa numaras (rn. 96)

zleyen sayfaya ilikin eriim referans (rn. 94)
Balant sembol
- Daima en az iftli olarak yer alr
(rnein A-A, B-B, C-C, vs.)
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Service

Dane zamwieniowe
DEUTZ
:
Przy zamawianiu oryginalnych czci

zamiennych marki DEUTZ naley poda
nastpujce dane:
- Numer silnika (Motor-Nr.)

- Numer identyfikacyjny (Ident-Nr.)
- Ilo
-
-
Ukad dokumentacji
- Tabele zawierajce rysunki czci zamiennych s uszeregowane wedug podzespow silnika.
-

.
- Podzespoy s zestawione
elementw silnika.
- .
Objanienia symboli

-06-
( 06)
-06-
Numer podzespou (np. 06)
000
( 000)
000
Cyfra zmiany (np. 000)
96
( 96)
96
Numer strony (np. 96)
94

( 94)
94

-
( A-A, B-B, C-C . .)
2004
licie
- Numer identyfikacyjny (Ident-Nr.) 06/59 skada

si z podzespou (np. 06) i z pozycji (np. 59).
- 06/59
( 06)
( 59).
40
Odsyacz do strony z dalszym cigiem

(np. 94)
Symbol poczenia
- wystpuje zwykle co najmniej parami
(np. A-A, B-B, C-C itd.)
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Bildtafeln
Illustrations
Illustrations
Tablas con ilustraciones
Quadros de figuras
Tavole
Afbeeldingen
Planscher
Illustrationer
Bilder
Kuvat
ekiller

Rysunki
41
2004
DEUTZ AG
Service-Technik
Instandhaltungstechnik Motoren
D-51057 Kln
Tel.: ++49 (0)2 21-8 22-0
Fax: ++49 (0)2 21-8 22-53 58
Internet: www.deutz.de
Printed in Germany
All rights reserved
1st Edition, 12/04
the engine company
Order No.: 0312 1887
System Description
Electronic Engine Governor
EMR 2
EMR 2
Chapter Overview
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
10
Index
11
Connection Diagams
12
13
06/02
Page 61
EMR 2
Chapter Overview
10
11
12
12
Page 62
06/02
EMR 2
Table of Contents
Contents
Page
Introduction
65
Important Notes
2.1
2.2
2.3
2.4
2.5
2.6
Operating instructions
Installation guidelines
Damage
Customer side wiring, plug connection
Remove plug
Electrical welding
67
67
67
67
68
68
68
System Description
3.1
3.2
3.3
3.4
Utilization of the EMR 2

System overview
Description of functions
Basic equipment
System Functions
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
4.15
4.16
Overview features
Function extensions
Speed control
Set point settings
Fuel quantity limitation (performance curve)
Droop control
Engine start/stop
Displays / Outputs (monitoring function)
LDA function
Temperature-dependent start control
Speed throttling (input F 7)
Engine protection functions
Altitude correction
Fuel volume control
Emergency running (limp home)
Cold start installation
Interfaces
5.1
5.2
Diagnostic interface (basic function)

CAN-Bus interface
6.1
Function overview, pin assignment and configuration example
7.1
7.2
7.3
Self-diagnostic (without operating the diagnostic button)

Diagnostic with Button and Error Code
Diagnostic possibilities with the SERDIA software
Replacement of system components

Replacement EMR EMR 2
8.1
8.2
8.3
8.4
Features of the Replacement of the Control Unit

Features of the Replacement of the Actuator
Combination EMR, EMR 2, Control Unit and Actuator
06/02
69
69
69
70
70
71
72
73
74
76
77
78
78
79
81
81
81
81
82
82
82
82
83
83
83
85
86
87
87
90
98
99
99
99
100
100
Seite 63
EMR 2
Table of Contents
Technical Data
9.1
9.2
9.3
9.4
General Data
Signal Specification
Plug assignments
Sensor Data
101
101
102
103
105
10
107
11
Index
109
12
Connection diagrams
113
Appendix
115
115
116
117
118
12.1
12.2
12.3
12.4
Connection diagram - Vehicle side / Unit side

Connection diagram Engine side (sheet 1)
Connection diagram Engine side (sheet 2)
Connection diagram for CAN-Bus and Diagnostic Line
Seite 64
06/02
EMR 2
Introduction
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 be
recognized 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 extensions 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 notes
It is our aim to permanently improve and extend the contents of this brochure. For this purpose, the experiences of the circle of users can be particularly helpful.
Should you desire changes, extensions, improvements, etc., we would welcome your input (Engine maintenance technology department, VS-TI). Please make as much use of this as you wish. In this way, you are
assisting in making the next version more up-to-date. We pay close attention to every message and will
prepare a new issue of the brochure at the appropriate time. We thank you in advance for your cooperation.
6
Your
7
DEUTZ AG
Maintenance technology engines
10
11
12
13
06/02
Page 65
EMR 2
Introduction
10
11
12
12
Page 66
06/02
EMR 2
Important Notes
Important Notes
2.1
Operating instructions
IMPORTANT!
The purpose of this document is the explanation and clarification of the design and functions
of engines, engine components and systems.
The information contained herein always corresponds to the technical conditions valid at the
time 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 the
published and currently valid technical documentation, corresponding to the scope of delivery and function (such as operating instructions, switching diagrams, workshop manual,
repair and adjustment instructions, technical circulars, service information, etc.).
4
2.2
Installation guidelines
IMPORTANT!
For the mechanical installation of the apparatus, reference should be made to the applicable
issue of the Installation Guidelines for electronic systems of DEUTZ diesel engines. More
information can be obtained from the DEUTZ AG, dept. technical operation support.
REMARKS!
Sufficient ventilation of control unit and actuator must be ensured in order to prevent limitations of function and damage.
7
2.3
Damage
REMARKS!
Sensors and actuators may not be fitted individually to, or between, power sources for either
inspection or testing purposes but only in connection with the EMR 2, as there is a danger of
destruction!
REMARKS!
Despite polarity reversal protection in the control apparatus, it is necessary to prevent incorrect polarity. Incorrect polarity can damage control units!
REMARKS!
The plug connections of the control units are only dust and watertight when plugged into
mating connection! Until the mating connector has been plugged in, the control units must be
protected against spray water!
10
11
12
13
06/02
Seite 67
EMR 2
Important 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 wire
seals, plugs and sealing rings provided must be used.
IMPORTANT!
The connection between pins and individual wires must only be carried out with the proper
pinching tools.
REMARKS!
The voltage supply for inputs and outputs for the users must be able to be switched in a deenergized manner via the key switch (terminal 15) - not via continuous positive.
3
2.5
Remove plug
REMARKS!
Removing the 25-pole equipment plug and engine plug when the control unit is on, i.e. when
the voltage supply is on (terminal 15 on) is not permitted.
1. Voltage supply off

- only then 2. pull out equipment plug and engine plug
6
2.6
Electrical welding
REMARKS!
In order to prevent damage when carrying out ELECTRIC welding of the installation, the plug
connections at the control unit must first be pulled out.
REMARKS!
The ignition (terminal 15) must be switched off when working at the EMR 2.
10
11
12
12
Seite 68
06/02
EMR 2
System Description
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 DEUTZ
Diesel engines of the model series 1012/1013/2012/2013/1015 for applications in agricultural and construction machinery as well as in generating sets. It is designed for heavy duty also under difficult environmental conditions and possesses the corresponding protection classes.
The governor fulfils all the functions of the mechanical governor (variable speed governing, torque limitations, LDA function) and makes further functions available.
3.2
System overview
3
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 harnesses to the EMR control unit. The cabling on the plant side is carried out by the vehicle or plant manufacturer.
For arrangement on the engine and plant/vehicle side, see the following figure.
Engine-side equipment
Charge-air pressure
Control rod position sensor/
sensor (optional)
actuator
Set and vehicle-side equipment
-Control unit
Power supply
Multi function displays
Coolant temperature
sensor
Camshaft speed
Outputs (modifiable)
sensor
Inputs (modifiable)
(PWM/digital/analog)
Accelerator pedel
Hand operated throttle
(optional)
Cold start aid
(optional)
Functions changeover
10
switch
Start/Stop
Fuel temperature
Key-operated switch
11
(optional)
Diagnostic button
Fault indicator
12
lamp
Charge air temperature

2nd Speed sensor
(optional)
Lifting solenoid
Oil pressure sensor
(optional)
(optional)
(optional)
Diagnosis interface/
CAN-Bus
13
*with atmospheric pressure sensor (otional)
06/02
s_en 06/02
Page 69
EMR 2
System Description
3.3
Description of functions
The sensors attached to the engine provide the electronics in the control unit with all the relevant physical
parameters.
In accordance with the information of the current condition of the engine and the preconditions (accelerator
pedal etc.), the EMR 2 controls an actuator that operates the control rod of the injection pump and thus
doses 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 the
control 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 ensure
emergency 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. A
strong spring in the actuator presses the control rod in the de-energized condition into the zero position. As
a redundancy measure, an additional solenoid serves for switching off and this, independently of the actuator, 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 motorspecific data set and this is then fixedly assigned to the engine. Included in this are the various application
cases as well as the customers wishes regarding a particular scope of function. The result of this is that any
later alteration must be reported back to the DEUTZ AG so that, in case of replacement anywhere in the
world, 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 operation
of 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:
10
! Actuator (contains control rod travel sensor and positioning magnet)

! Speed sensor (camshaft)
! Coolant temperature sensor (NTC)
11
12
! Cable harness
Further components and installation are possible depending on the application case or the desired
functions (see chapters 4 and 6). The combination can be selected from the DEUTZ pocket handbook.
12
Seite 70
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EMR 2
System Functions
System Functions
The EMR 2 makes a broad range of functions available and these can be activated by the applicationdependent configuration and the allocation of the inputs and outputs. It makes possible signal exchange
between the engine (via the engine plug) and the EMR 2, as well as between the vehicle (via the vehicle
plug) 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 are
different 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.
3
!
!
!
!
!
!
!
!
!
!
Control rod travel

Speed
Coolant temperature
(Charge air pressure)
(Oil pressure)
(2nd speed)
(Coolant level)
(Charge air temperature)
(Fuel temperature)
(Tacho signal)
Set point input
EMR 2
Sensor inputs:
(Atm pressure sensor)
Micro
processor
Memory for
operating
software
!
!
!
!
!
!
Key-operated switch
(Pedal sensor)
(Throttle lever)
(Via CAN-Bus)
(Voltage 0 - 5 V)
(PWM signal)
Transfer switch for

functions
6
Interfaces
! ISO 9141
! CAN-Bus, SAE J1939
Energy supply
Memory for
Actuator functions
! Actuator
! (Switch-off magnet)
!
!
!
!
Parameters
Char. curve
Char. diagram
Faults
Display functions /
outputs
! Fault lamp
! (Warning signals)
! (Multi-function displays)
The functions shown in brackets are optional.
10
06/02
Because of the numerous possibilities of combinations, DEUTZ has defined function ranges. These can be
crossed off in the DEUTZ pocket handbook. The switching diagram for each function range should also be
noted especially for the wiring required on the customers side.
11
12
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EMR 2
System Functions
4.1
Overview features
Feature
Chapter
Description
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 signal

output 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
4.9
Smoke 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
4.15
Emergency running after failure of set point signal (e.g. using

accelerator pedal), the charge air sensor or the vehicle speed
signal
Selection of cold
start help installations
4.16
Failure of auxiliary control units, EMR 2 controls a selection

of heating flange, glow plugs or flame starting apparatus
Speed control
10
11
Data communication
Output of fault
fault blink codes
5
7.2
Interfaces, diagnostics and programming

Simplified fault diagnosis
12
12
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EMR 2
System Functions
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 (see
Chapter 8).
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EMR 2
System Functions
4.3
Speed control
Provision is made for various variations of speed control that must be programmed in advance (at the end
of the programming) depending on the application case (power generation, building or agricultural machines) 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 depending on the variant (pin assignment see Chapter 6.1):
Function
Variable speed
control
Genset
applications
10
Variable speed-,
Min/Max-control
Min/Max-control
11
12
12
Variant
Description
Variable speed
Pure variable speed governor without addition and switch-over functions
governor1)
Fixed speed governor Variable speed governor with fixed, pre-defined speed for gensets (1,500 or 1,800 rpm),
desired speed of rotation is defined in the
scope of customer supply (KLU).
Change-over
Variable speed governor with change-over
switching speed 1 /
switching possibility between two speeds.
2)
2
Change-over switVariable speed governor with change-over
ching speed fixed/
switching possibility between a fixed pro2)
grammed and a variable speed of revolution.
variable
Speed variable /
Variable speed governor with change-over
2)
switching possibility between:
freeze
freezing a current desired speed as set point
independent of the pedal setting, and a variable revolution.
Speed memory
Customer-specific solution for storing and
function
calling up two speeds of revolution.
Power generation
As for change-over switching fixed/variable
governor with adjuspeed. Without Load the speed can be adjustable speed range
sted in the speed range.
Power generation for As for change-over switching fixed/variable
network synchronisa- speed. The variable revolutions can be adjution or Load distribu- sted in the revolution range for network synchronization or load distribution.
tion
As for change-over switching fixed/variable
Power generation
speed the power generator, in fixed speed
governor with adjumode, can be used as the overdrive speed
stable speed and
switchable overdrive without loading, in variable mode or for
parallel switching.
speed
Variable speed,
Switching over between variable speed and
2)
Min/Max control.
Min/Max governor
Idling and end revolutions for vehicle
Min/Max governor1)
applications.
Remarks
Only one variant can be
selected
See also
system description
EMR Genset,
TN 0297 9939
1) Types of speed control

Variable 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 be
determined through various variants.
Min/Max control
For this type of control, the fuel injection quantity is determined on the basis of the desired value. the result of this is that, for
this type of control, a speed of revolution depending on the load situation is set. The idling (= Minimum) and the end
revolutions (= Maximum) are controlled taking into account the control parameter speed droop 1 and speed droop 2. The
basis for this type of control is the drive characteristic field.
2) Change-over switching see point 4.3.1.
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System Functions
4.3.1
Switchable speed functions
The conditions for the switchable variants are selected by means of a switch (Input pin 18, GND pin 17
V plug). The switch closes a contact to -UBatt.
The following is applicable for the switchable speed functions:
1
Switchable speed functions
(for a selectable)
Switch closed
(0/LOW)
Switch open1)
(1/HIGH)
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
1) With an open switch, the underlined conditions above are activated as preset values (default values).
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 the
engine 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 the
engine 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 zero
position and the fault lamp lights up. The engine is protected against excess revolutions also in this type of
operation.
After falling below the programmed recovery limit, the governing is again taken up and the fault lamp is
extinguished. The parameters Above speed limit and Recovery limit are adjustable.
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EMR 2
System Functions
4.4
Set point settings
The following variants for the set point settings of the governor can be configured:
Function
Variant
Set point setting Accelerator

value sensor
(SWG 1)
Description
Setting with potentiometer (5 V reference
voltage, max. 30 mA1), typ. 1 k linear, pin 25,
input pin 24, GND pin 23, V-plug2))
Voltage
Setting by means of external voltage (0.5 4.5 V, input pin 24, GND pin 23, V-plug)
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 k linear, pin 25, input pin 20,
GND pin 23 V-plug)
Memory
function
Freezing the current engine speed
Only possible in connection 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- Auxiliary for pedal

value sensor
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
Remarks
Replacement for
pedal value sensor
1) PIN 25: Imax=30 mA (Pedal value sensor and hand throttle combined).
2) V*plug = Vehicle plug / GND = Ground.
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EMR 2
System Functions
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 characteristic curve with 13 freely selectable speed support points. The sampling points must be support
points, whereby the sample of the engine is carried out with performance curve 1. The performance curve 2
is correspondingly corrected with the correction data of performance curve 1.
Function
Performance
curve
Variant
Description
Remarks
Performance
curve 1
Quantity limitation with a performance curve (performance curve 1)
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
Performance curve 1/ performance curve 2
Only 1 variant
can be selected
4
Switch open
(1/HIGH)1)
Performance curve 1
Switch closed
(0/LOW)
Performance curve 2
6
1) With open switches, the underlined conditions above are activated as default values.
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EMR 2
System Functions
4.6
Droop control
One of the features of the electronic governing is that, in contrast to mechanical governors, the P-Gradient
can 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-dependent P-gradient function by means of a characteristic curve with eight speed support points.
Function
Variant
Description
Remarks
P-gradient Constant P-gradient P-gradient is constant within the whole speed range.
Variable 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
Only one
variant can
be selected
4
Switchable variant
pin 21, GND pin 17 V-plug
Switch open
(1/HIGH)1)
Switch closed
(0/LOW)
P-Gradient 1/ P-Gradient 2
P-gradient 1
P-gradient 2
Constant / variable P-gradient
Constant
Variable
6
1) With open switches, the underlined conditions above are activated as default values..
4.7
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-energized
manner. With this setting, the controlling rod is moved to the stop position by the spring action of the actuator 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-Diagnostic).
Engine start/stop
9
Function
Engine start/stop
10
11
Variant
Description
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 switchingoff with the solenoid

(pin M 21) and M 1)
In addition, the engine is switched off by means of a solenoid (must be programmed in the control unit)
1) M 2: Engine plug, pin 2
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EMR 2
System Functions
4.8
Displays / Outputs (monitoring function)
By means of the digital PWM outputs and depending on the configuration, various signals can be displayed
and 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 serves 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
Display functions
Variant
Description
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
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
Overstepping limiting value

High/Low change-over switching
Warning signal oil pressure

Speed-dependent oil pressure control

High/Low change-over switching
Warning signal
charge air monitor
(pin variable)
General display for overstepping or falling below the limiting values
Freely selectable digital

output signal
By arrangement
10
Freely selectable measuring or calculation value

(PWM- signal)
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EMR 2
System Functions
Load collective
The EMR 2 measures the loading of the engine. For this purpose, the respective load and revolution regions
are allocated to the engine operating hours.
S1 to S9 are operating hours within the respective sector.
5
06/02
Torque referred to torquemax [%]
(torquemax)
7
100
S7
S8
S9
S4
S5
S6
S1
S2
S3
50
9
30
10
Speed [rpm]
11
1000
2000
4000
06/02
The load collective can only be displayed and printed with SERDIA.
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EMR 2
System Functions
4.9
LDA function
For mobile applications, the injection quantity for acceleration and dynamic load increase is limited with
reference to the charge air pressure (smoke quantity-characteristic field). Usage: protection of the exhaust
turbo supercharger and prevention of smoke ejection.
1
4.10
Temperature-dependent start control
In order to prevent smoke ejection and for optimizing the governing relationship, the start quantity, the
speed ramp and the governor parameters are controlled with reference to the temperature (required basic
function).
3
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 of
the 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 temperature exceeds the warning limit and/or
! the temperature exceeds the switch-off limit and, after a pre-warning period,
the engine is switched off
Charge air monitoring

! the temperature exceeds the warning limit and/or
! The temperature exceeds the switch-off limit and after a pre-warning period, the engine is
switched off.
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EMR 2
System Functions
Coolant monitoring

! the coolant level falls below the warning limit and/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. Two
different control unit variants are offered (with and without atmospheric pressure sensor).
3
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 the
field of application. These functions are necessary in order that, in an emergency, the operation can be continued with auxiliary speed. In detail, this function can be activated by
a)
b)
c)
d)
set point default

charge air pressure
vehicle speed signal and/or
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 and
b) 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 installation.
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EMR 2
Interfaces
Interfaces
The EMR 2 is equipped with various interfaces. The wiring is carried out on the customers side and must be
integrated in the vehicle plug. For pin assignment see the application-dependent switch diagrams.
1
5.1
Diagnostic interface (basic function)
The end programming of the EMR 2 is carried out via the serial diagnostic interface (according to
ISO 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 access
authorization. Furthermore, new control units can be programmed.
Communication is only possible with the electric power switched on.
4
5.2
CAN-Bus interface
The CAN-Bus interface (Controller Area Network) is increasingly being used in vehicles and is suitable for
measuring values and data exchange with one or more apparatus-side control units (hydraulics, drive control, 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 partner
and the aid of SERDIA (see Chapter 6).
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EMR 2
Interfaces
10
11
12
12
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EMR 2
Configuration and
Parameter Setting
The EMR 2 is specially programmed and configured for each individual engine, which means that the
EMR 2 contains a specially engine-specific data set. Configuration is carried out via the externally accessible diagnostic interface (ISO 9141) and is strongly dependent on the customers wishes, from the application cases and from the behaviour of a vehicle in operation.
Access to the various parameters is protected (by password) by means of access authorizations organized
on 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 Chapter
7.3).
Important!
Rebuilding, as well as alteration to the parameters can only be carried out in conjunction with
the 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 reported back to DEUTZ (see Service Note No. 0199-99-9287).
5
Type of operation
e.g. parallel operation
Other type of
operation
desired
Scope of function
Switching
diagrams
7
Part data set
9
Performance
dataset
Complete data set

see SERDIA handbook
10
11
Re-blocking
Other
performance data
desired
! Other set speed

! Other performance
! Other set speed and
other performance
Notification
to DEUTZ
12
see SM 0199-99-9287
06/02
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Configuration and
Parameter Setting
6.1
EMR 2
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
Pin
Input/Output
Sensor inputs
Speed sensor 1 (camshaft)
Speed sensor 2 (crankshaft)
Charge air sensor (LDA function)
Oil pressure sensor
Atmospheric pressure sensor (in control unit)
Coolant level sensor
Charge air temperature sensor
Fuel temperature sensor
Coolant temperature sensor
Control rod travel sensor
E
E
E
E
E
E
E
E
E
12, 13
10, 11
23, 24, 25
20, 21, 22
6, 8
4, 8
5, 8
9, 8
16, 17, 18, 19
E
E
E
E
E
E
E
E
E
!
!
!
Actuator functions
Operating solenoid
Dig. output (PWM)
Solenoid
E
E
E
14, 15
3
2
A
A
A
Default functions (set point defaults via)

Hand throttle
Voltage
Accelerator pedal (potentiometer)
CAN
PWM signal 1
PWM signal 2
V
V
V
V
V
V
23, 20, 25
23, 24
23, 24, 25
12, 13
17, 18
17, 21
E
E
E
E/A
E
E
!
!
-
V
V
V
17, 18
17, 21
17, 19
E
E
E
V
V
V
V
V
V
V
V
V
17, 18
17, 18
17, 18
17, 18
17, 19
12, 13
17, 21
17, 21
1, 14
E
E
E
E
E
E
E
E
!
!
V
V
V
V
V
4, (Cl. 15)
3, (Cl. 15)
15, (Cl.15)
16, (Cl. 15)
5, (Cl. 15)
A
A
A
A
A
!
!
!
!
Diagnostic interface
ISO 9141-L
ISO 9141-K
V
V
10
11
E/A
E/A
!
!
CAN-Bus (SAE J1939 protocol

CAN-H
CAN-L
V
V
12
13
E/A
E/A
!
!
Scope of function
Model No.
No. of connection diagram engine side
No.of connection diagram vehicle/plant side
Memory functions
Fixed speed (upper limit)
Fixed speed (lower limit)
Freeze current speed
Limit fuel quantity of a performance curve
Switch-over functions
speed 1 / 2
Fixed / variable speed
Freezing / variable speeds
Variable speed governor min/max regulation
Performance curve1 / 2
Performance curve1 / 2 / 3 (via CAN)
P-gradient 1 / 2
P-gradient const. / variable
Key-operated Start/Stop, energy supply
Display / output functions

Fault lamp
Warning coolant temperature
Warning oil pressure
speed
Torque (reserve)
Warning monitoring charge air
Freely selectable digital output signal
Freely selectable measuring or calculation value
Load collective
10
11
12
12
Scope of function
Plug
engine/vehicle
Functions
(Example1))
0211 2291
0029 3766
0419 9752
0419 9780
1) Above example applicable to genset series 1012/1013, single frequency generating sets.
Page 86
06/02
EMR 2
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.
+UBatt
15
Fault indicator lamp

Pin F 4
3
Diagnostic button
-UBatt
GND
Diagnostic button switch diagram
5
06/02
6
7.1
Self-diagnostic (without operating the diagnostic button)
The EMR 2 possesses numerous protection functions for the engine - depending on the available measuring points or sensors. Depending on the seriousness of the recognized fault, the engine may run on in
reduced mode (limp home), whereby the fault indicator lamp is continuously lit, or the engine is switched
off, 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 displays
of the corresponding sensors. A further source of faults could be falling below or exceeding the measuring
value 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 electronics
has been switched to emergency running (-speed), need the engine be switched off briefly with the keyoperated 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 with
the SERDIA diagnostic software (see Chapter 7.3).
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Seite 87

EMR 2
Key switch (terminal 15)

On
1
Off
Time
2
On
2s
Off
Case a) Lamp extinguished after 2 s: there is no active fault
Time
4
On
2s
Off
1s
1s
Case b) Lamp flashes after 2 s: there is at least one serious fault.

the engine cannot be started.
Time
6
On
Off
Case c) Continuous light: there is at least one fault.
Time
8
On
9
2s
tv
Off
Case d) As case c), only with monitoring delay tv dependent on
selected setting.
10
Time
11
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12
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EMR 2

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 the
self-diagnostic (2 s).
On
Off
Time
On
2s
Off
Time
e.g. warning lamp oil pressure
On
2s
Off
Time
06/02
10
11
12
13
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Seite 89

7.2
EMR 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 to
delete the fault memory 1. The Diagnostic button and the fault indicator lamp are situated in the moving
part of the vehicle.
1
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 is
depressed for a time period of 1 s to 3 s. The EMR 2 recognizes the request for a read out and starts to display the faults. (see blink code overview, Chapter 7.2.3). The read-out of the blink code is only possible after
extinguishing of fault indicator lamp or after the initialization phase of the operating program. This means
that the fault indicator lamp can also show continuous lighting after switching on if a fault has been recognized already after switching. The EMR 2 only shows active faults as blink codes.
Diagnostic button
On
1-3s
Off
Time
On
2s
0.4 s
0.4 s
5s
2s
2s
Off
0.8 s
0.8 s
Tim
06/02
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.
10
11
! 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 (2short flashes).
! Output of the flashing sequence of the first stored fault.
(example: fault number 01, speed sensor 1):
c after 2 s: 1long
d after 2 s: 1short
! After fault code output
e 5 s pause, then display of flashing or continuous light.
12
12
Seite 90
06/02
EMR 2

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 (2short 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 shown
again.
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11
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13
06/02
Seite 91

7.2.2
EMR 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. With
the aid of the diagnostic button it is possible to delete passive faults in fault memory 1. The fault memory 2
can only be deleted with SERDIA.
1
Diagnostic button
On
<2s
Off
Time
On
Off
Time
6
On
0.4 s
0.4 s
2s
Off
Time
06/02
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.
10
d All passive faults in faults in fault memory 1 are deleted.

e The deletion process is confirmed by three short flash impulses.
11
12
12
Seite 92
06/02
06/02
Sensors
No faults
Speed sensor 1
Speed sensor 2
Speed sensor
Excess speed switchoff
Set point sensor 1

accelerator pedal)
Set point sensor 2

(hand throttle)
Charge air pressure
Oil pressure
Coolant temperature
Charge air
temperature
Fuel temperature
01
02
03
04
05
06
07
08
09
10
11
Fault locality/
Fault description
(in SERDIA)
Fault
no.
Fault blink code overview
Revolutions
/ speed
acquisition
Zero error
display
Fault
group
7.2.3
2
2
2
2
2
2
2
190
190
84
190
91
201
102
100
110
105
174
2
2
2
2
2
2
2
1
2
3
4
5
6
7
SPN
31 524287
FMI
0,4 s 0,8 s 0,4 s
short long short
Blink code
Remarks
Help
Engine stop.
(see Chapter 4.3.3)
Speed was/is in excess of limit.e.
Check parameter (21). Check

speed settings.
Check cable connection and

Tacho. Replace if required.
See Chapter 4.15 influencing fault

Check sensor cable. Check
Fault at corresponding sensor entry reaction. With failure of the sensor, sensor and replace if required.
(e.g. short circuit or cable break). the associated monitoring function is
Check fault limits for sensor.
de-activated.
Check PID setting. Check rods. Check actuator and replace if required. Check cable to actuator (impulse on
incorrect speed). Check No. of teeth. For vehicles check for possible thrust mode.
Governor in emergency operation.

(see Chapter 4.15).
Tacho failed. Additional fault

impulses. Cable connection
interrupted.
Governor in emergency operation (if

sensor 2 available). Emergency
switch-off (if sensor 2 not available
Sensor failure. Distance from gear or failed).
Check distance. Check cable
too far. Additional fault impulses.
connection. Check sensor and
Cable joint interrupted.
replace if required.
Governor in emergency operation
(with sensor 1)
Emergency switch-off (if sensor 1
not available or failed).
No active faults present
Cause
EMR 2
Seite 93
10
11
12
13
10
11
12
12
Seite 94
Coolant temperature
warning
Charge air
temperature warning
Coolant level warning
Speed warning (with

thrust mode
operation).
Fuel temperature
warning
31
32
34
35
36
111
105
110
100
174
14 SID 190
Oil pressure warning
5
Check charge air. Check charge
air-temperature sensor and
cable.
Check parameters. Check speed

settings(21).
revolutions was/is above (top)

revolution speed limit. Thrust
mode function is active.
Fuel-temperature has exceeded

warning level.
Fault message (disappears when fuel Check fuel. Check fuel

temperature again drops below
temperature sensor and cable.
recovery level).
Check PID setting. Check rods. Check actuator and replace if required. Check cable to actuator. Check speed
sensor (impulses on incorrect speed). Check No. of teeth. For vehicles check for possible thrust mode.
See Chapter 4.3.3 Excess speed

protection.
Check coolant level. Check

coolant level sensor and cable.
Switch input Low coolant level is

Fault message.
active.
Charge air temperature has

exceeded warning level.
Fault message (disappears when

charge air temperature gain drops
below recovery level). After a delay
time - fill limitation.
Check engine (oil level, oil

pump). Check oil pressure
sensor and cable. Check oil
pressure warning line
characteristic.
Help
Check coolant. Check coolant

temperature sensor and cable.
Fault message (disappears when oil

pressure is again above recovery
limit).
After a delay time - fill limitation.
Remarks

Coolant temperature has exceeded coolant temperature again drops
warning level.
below recovery level). After a delay
time - fill limitation.
Oil pressure below speeddependent warning line

characteristic
Cause
30
0,4 s 0,8 s 0,4 s
short long short
SPN
Functional
fault
warning
9
FMI
Blink code
Fault locality/
Fault description
(in SERDIA)
Fault
no.
Fault
group

EMR 2
06/02
06/02
Actuator
Functional
fault,
switch-off
Fault
group
Oil pressure switchoff
Coolant temperature
switch-off
Charge air
temperature switchoff
Coolant level switchoff
Feedback
Reference feedback
Control travel
difference
Auto calibration
BOSCH-EDC pumps
faulty operation
41
42
44
50
52
53
59
Fault locality/
Fault description
40
(in SERDIA)
Fault
no.
105
111
110
SID 23
13 SID 23
13 SID 24
12 SID 24
100
SPN
FMI
0,4 s 0,8 s 0,4 s
short long short
Blink code
Remarks
Emergency switch-off. Actuator

cannot be operated.
Engine stop / start lock. Governor

No automatic actuator equalization cannot be taken into use. EDC
possible. Incorrect input of the
actuator calibration required
actuator reference values.
(see Chapter 8.4).
Injection pump/actuator jammed or

not connected. Difference between Fault message (disappears when
nominal/actual control travel is
difference is < 10 %).
> 10 % of the overall control path.
Actuator not connected. Fault in

actuator confirmation.
Switch input Low coolant level is Emergency stop. Start lock.

active.
Charge air temperature has

exceeded switch-off limit.
Coolant temperature has exceeded Emergency stop

switch-off limit.
Oil pressure below switch-off limit
Cause
Check actuator and replaced if

required. Check feedback cable.
Check voltage supply/cables.
Check fault limits and reference
values of the feedback. Program
the fault limits for feedback, save
values. Switch ignition off and on
again.Check again. If faulty,
inform DEUTZ-Service and carry
out automatic equalization again.
Set fault limits again.
Check actuator/actuator rods /

injection pump, replace if
required. Check actuator cable.
Check actuator, replace if

required. Check cable, check
fault limits for Rifeness
confirmation.
Check actuator, replace if

required. Check cable, check
fault limits for Confirmation.

Check charge air. Check charge

air-temperature sensor and
cable. Check switch-off limit.

Check switch-off limit.
Check engine (oil level, oil

pump). Check oil pressure
sensor and cable. Check oil
pressure -switch-off limit.
Help
EMR 2
10
11
12
13
Seite 95
12
12
Seite 96
12 SID 231
14 SID 231
12 SID 253
Error CAN Setp1
CAN-Bus controller
CAN interface
SAE J 1939
Cable break,
short circuit or
bus-error
Parameter
programming
(write EEPROM)
Cyclic program test
Cyclic RAM test
68
70
71
74
76
77
78
Error Hand Setp1
67
SID 51
SID 231
898
SID 254
12 SID 240
11 91
SID 60
Excess voltage
switch-off solenoid
Constant monitoring of working

memory shows error.
Constant monitoring of program

memory shows error (so-called
Flash-test).
Fault in parameter programming in

the governor fixed value memory.
Overflow in input buffer or a

transmission cannot be placed on
the bus.
CAN-controller for CAN-bus is

faulty. Fault removal despite reinitialising continuously not
possible
Fault (short circuit / cable break) at

digital output.
63
SID 51
Digital output 6, pin

M7
62
Digital output 3
(Switch-off solenoid,
pin M 2)
60
0,4 s 0,8 s 0,4 s
Emergency switch-off. engine cannot

be started.
Application-dependent.
Fault message.
Driver level is switched off.
Remarks
Memory
11
short long short
Cause
Communication
10
SPN
Hardware
inputs/
outputs
9
FMI
Blink code
Fault locality/
Fault description
(in SERDIA)
Fault
no.
Note values of parameters (3895

and 3896). Switch ignition off
and on again. Check again. If
faulty inform DEUTZ Service.
Switch ignition off and on again.

Check again. If faulty inform
DEUTZ Service
Check CAN connection, cable

connection. Check sensor and
replace if required.
Check CAN connection,

terminating resistor (see Chapter
12.4), Check control unit.
Check cable of digital output

(cable break or short circuit).
Help
Fault
group

EMR 2
06/02
06/02
Program
logic
Control unit
hardware
Fault
group
Power supply
(Actuator)
Reference voltage 1
Reference voltage 2
Reference voltage 4
Internal temperature
Atmospheric pressure
Parameter fault
(EEPROM retrieval or
checksum faulty).
Stack overflow
Internal fault
83
84
85
86
87
90
93
94
Fault locality/
Fault description
80
(in SERDIA)
Fault
no.
10
0,4 s 0,8 s 0,4 s
short long short
Blink code
SID 254
SID 254
SID 254
2
2
2
SID 253
SID 240
SID 254
2
2
12 108
12 171
SID 254
SPN
FMI
Remarks

power again in the normal range).
Auxiliary value 5 V
Check data for correct settings.

Save parameters. Switch ignition
off and on again. Check again. If
faulty inform DEUTZ Service.

DEUTZ Service.
Check voltage supply. Switch

ignition off and on again. Check
again. If faulty inform DEUTZ
Service.

DEUTZ Service.
Help
Note parameters (3897 and

Internal calculation fault (so-called Emergency switch-off. Engine cannot 3898). Switch ignition off and on
Stack overflow fault).
be started.
again. Check again. If faulty
inform DEUTZ Service.
No data found or checksum of data

is faulty (note: fault only occurs
during setting of parameter / saving Engine cannot be started.
or reset.).
Atmospheric pressure not in

permissible range.

power again in normal range).
Atmospheric pressure monitoring
function de-activated.
Internal temperature for control unit Fault message (disappears when

not in permissible range.
Reference voltage for actuator not

in the permissible range.
Power supply for actuator not in the Fault message (disappears when
permissible range.
Cause
EMR 2
10
11
12
13
Seite 97

7.3
EMR 2
Diagnostic possibilities with the SERDIA software
SERDIA (Service Diagnosis) is a software program with the aid of which the user can monitor the measurement value on a running diesel engine from a PC or Notebook computer and can thus recognize faulty operating behaviour.
! With a stopped engine, it is possible to enter certain parameters in a targeted manner from the PC into
the 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 be
read 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. Communication
with the control unit is carried out via a special EMR 2 protocol.
Working with SERDIA is described in a separate operating instruction.
10
11
12
12
Seite 98
06/02
EMR 2
Replacement of system
components
Replacement of system components
In case of malfunction, the individual system components such as sensors, control unit, actuators, can be
replaced 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. Only
the 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 application 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 be
carried out in two ways:
! By ordering a new control unit with information of the engine and part number (completion by DEUTZParts Logistics).
! Transferring the data set 1:1 from the old control unit to the new control unit (see SERDIA manual).
6
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 and
completed control unit with current data settings (see SM 0199-99-9287).
10
11
12
13
07/02
Page 99
Replacement of system
components
EMR 2
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
Actuator (EDC-actuator) and Bosch pump belong together (one TN). In the case of a replacement, the
actuator (with the pump) must be calibrated with the control unit. This calibration is necessary (with SERDIA
Level IIIa), because the new characteristic curves must be stored in the control unit.
8.4
Model series 1015
Combination EMR, EMR 2, Control Unit and Actuator
EMR control units, see also SM 0199-99-9334.

Control unit
Actuator EMR
1012/1013/2012
Actuator EMR 2
1012/1013/2012
EMR
Fault message
Engine cannot be started
EMR 2
EDC actuator
1015
Calibration
required
The EMR 2 control unit automatically recognizes the actuator EMR or EMR 2. In order to limit errors, therefore, an old EMR actuator can be combined with the EMR 2 control unit. In reverse, a new EMR 2
actuator is not accepted by the EMR control unit (fault message).
10
11
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12
Page 100
07/02
EMR 2
Technical Data
Technical Data
9.1
General Data
1
Designation
Technical data / Remarks
Nominal voltage
12 and 24 V DC, working range 10 ... 36 V DC,
Maximum cable length governorengine
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
EMV
Emitted interference to 95/54/EWG

interference 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)
engine starting is possible from 6 V
10
11
12
13
06/02
Page 101
EMR 2
Technical Data
9.2
Signal Specification
Pin1)
Pin type/Signal type
Technical data / Remarks

Inputs
F4, F6, F7, F18, F19,

F20, F21, F24,
Digital input
M6, M11, M21, M24
Ulow < 2 V, Uhigh > 6,5 V, Rpull = 4.7 k after +UBatt
F4
Digital input
Isink < 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 k,

Uref = 5 V 25 mV, Imax = 25 mA
F18, F21
PWM input
Ulow < 2 V, Uhigh > 6,5 V, Rpull = 4,7 k,

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 output
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 output
Isource < 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 output
faus < 500 Hz (typ. 100 Hz), Tan/Tper = 5 % ... 95 %
F16
Frequency output
with Pull-Up resistance Uaus = 0 ... +UBatt
Interfaces
10
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
1) Double assignment possible.
11
All outputs are short circuit-protected against negative and positive polarity of the battery.
12
12
Seite 102
06/02
EMR 2
Technical Data
9.3
Plug assignments
The 25-pole plugs of the EMR 2 control unit are mechanically coded (different part numbers). Because of
the different pins, the vehicle plugs (F) or the plant plugs (F) and engine plug (M) only into the sockets provided for them, so that incorrect plugging in is impossible.
9.3.1
Engine Plug (M)
Pin No.
Pb_mst1 06/02
Designation
Description
Reserve
Reserve
Output: digital 3
Digital output for solenoid1)
Output: digital 4
For heating flange (optional)/

glow plug (optional)
Input (optional) Temp 1
Fuel temperature2)
Input (optional) Temp 2
Charge air temperature
Input (optional) DigIn 5
Coolant level / oil level
Output: PWM2/digital 6
GND
Reference potential for analog signal at

pin 9
Input: analog 7
Analog input for

Coolant temperature sensor (NTC)
10
GND

pin 11
11
Multi-function input:
speed 2/DigIn 2
Digital input second engine speed

(crankshaft) (optional) and speed signal
(optional)
12
GND

pin 13
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)
23
GND
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)
1) For continuous power: < 4 A

2) Corresponds to special functionfuel temperature compensation at the EMR (0211 2571)
06/02
Page 103
10
11
12
13
EMR 2
Technical Data
9.3.2
Vehicle Plug (F) / Plant Plug
Pin-No.
Pb_fst1 06/02
10
Designation
Description
U Batt -
Negative pole at battery (clamp 31)
GND
Reference potential for signal
Output: digital 2
PWM or digital output,

various functions
Input / output: DigInOut
Fault lamp and diagnostic button
Output: PWM 1/Dig 1
PWM or digital output,

various functions
Multi-function input: DigIn 3
Genset applications/gear shift/motor

brake
Input: digital 10/velocity
Speed signal (tacho input)
NC
Not occupied
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 / Hand hand throttle/genset applications,

analog 3
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)
23
GND
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
11
12
12
Seite 104
06/02
EMR 2
Technical 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
Pins:
3
Temperature sensor (NTC), charge air
Pins:
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
6
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
Pins:
- 44 Impulse/camshafts-revolutions for model series 1012/2012

- 48 Impulse/camshafts-revolutions for model series 1013/2013
10
- 167 Impulse/camshafts-revolutions for model series 1015

2nd speed (optional):
Conn. locality
SAE-housing, crankshaft
Pins:
11
- 129 Impulse/crankshafts-revolutions for model series 1012/1013

- Clamp w (dynamo impulses)
12
13
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Technical Data
Coolant level sensor

Pins:
Measuring range:
Atmospheric pressure sensor

Depending on unit configuration, integrated into control unit, see Chapter 4.13
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11
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10
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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11
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10
11
12
12
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Index
11
Index
A
Actuator ..................................................................................................................................................... 100
Actuator functions ....................................................................................................................................... 86
Altitude correction ....................................................................................................................................... 82
Atmospheric pressure sensor .............................................................................................................. 82, 106
B
basic equipment .............................................................................................................................. 70, 71, 72
Blink codes .................................................................................................................................................. 90
C
CAN-Bus ...................................................................................................................................................... 86
CAN-Bus interface ....................................................................................................................................... 83
Charge air monitoring .................................................................................................................................. 81
Charge air pressure sensor ........................................................................................................................ 105
Cold start installation ................................................................................................................................... 82
Configuration ............................................................................................................................................... 85
Configuration example ................................................................................................................................. 86
Connection diagrams ................................................................................................................................. 113
Coolant level sensor .................................................................................................................................. 106
Coolant monitoring ...................................................................................................................................... 82
Coolant temperature monitoring .................................................................................................................. 81
Damages ...................................................................................................................................................... 67
Default functions .......................................................................................................................................... 86
Description of functions ............................................................................................................................... 70
Diagnostic button ........................................................................................................................................ 87
Diagnostic interface ............................................................................................................................... 83, 86
Display / output functions ............................................................................................................................ 86
Displays ....................................................................................................................................................... 79
Droop control ............................................................................................................................................... 78
E
Electrical welding ......................................................................................................................................... 68
Emergency running ...................................................................................................................................... 82
Engine plug ................................................................................................................................................ 103
Engine protection functions ......................................................................................................................... 81
Engine-start/stop ......................................................................................................................................... 78
Error code .................................................................................................................................................... 90
Excess speed protection ............................................................................................................................. 75
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EMR 2
Index
Fault blink code overview ............................................................................................................................ 93

Fault group ................................................................................................................................................... 93
Fault indicator lamp ..................................................................................................................................... 87
Fault lamp .................................................................................................................................................... 79
Fault locality/fault description ...................................................................................................................... 93
Fault memory ............................................................................................................................................... 92
Fault no. ....................................................................................................................................................... 93
Fuel quantity limitation (performance curve) ................................................................................................ 77
Fuel volume control ..................................................................................................................................... 82
Function control ........................................................................................................................................... 89
Function extensions ..................................................................................................................................... 73
Function overview ........................................................................................................................................ 86
Functions ..................................................................................................................................................... 86
I
4
Important notes ........................................................................................................................................... 67

Installation guidelines .................................................................................................................................. 67
Interfaces ............................................................................................................................................. 83, 102
Introduction .................................................................................................................................................. 65
5
L
6
LDA function ................................................................................................................................................ 81

Limp home ................................................................................................................................................... 82
Load collective ............................................................................................................................................. 80
M
Memory functions ........................................................................................................................................ 86
Min/Max control ........................................................................................................................................... 74
Monitoring function ...................................................................................................................................... 79
N
Notes ........................................................................................................................................................... 65
9
O
10
11
12
13
Oil pressure monitoring ................................................................................................................................ 81

Oil pressure sensor .................................................................................................................................... 105
Operating instructions ................................................................................................................................. 67
Output signals .............................................................................................................................................. 79
Outputs ................................................................................................................................................ 79, 102
P
Parameter setting ......................................................................................................................................... 85
Pin .............................................................................................................................................................. 102
Pin assignment ............................................................................................................................................ 86
Pin type ...................................................................................................................................................... 102
Plant plug ................................................................................................................................................... 104
Plug assignments ...................................................................................................................................... 103
Plug connection ........................................................................................................................................... 68
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EMR 2
Index
R
Replacement of system components .......................................................................................................... 99
Scope of function ........................................................................................................................................ 86

Second speed input ..................................................................................................................................... 75
Self-diagnostic ............................................................................................................................................. 87
Sensor data ................................................................................................................................................ 105
Sensor inputs ............................................................................................................................................... 86
SERDIA ........................................................................................................................................................ 98
Set point settings ......................................................................................................................................... 76
Signal specification .................................................................................................................................... 102
Signal type ................................................................................................................................................. 102
Software ....................................................................................................................................................... 98
Speed control .............................................................................................................................................. 74
Speed sensor ............................................................................................................................................. 105
Speed throttling ........................................................................................................................................... 81
Switchable speed functions ......................................................................................................................... 75
System description ...................................................................................................................................... 69
System functions ......................................................................................................................................... 71
System overview .......................................................................................................................................... 69
T
Technical data ........................................................................................................................................... 101
Temperature sensor (NTC), charge air ....................................................................................................... 105
Temperature sensor (NTC), coolant ........................................................................................................... 105
Temperature sensor (NTC), fuel ................................................................................................................. 105
Temperature-dependent start control ......................................................................................................... 81
U
Utilization of the EMR 2 ............................................................................................................................... 69
V
Variable speed regulation ............................................................................................................................ 74
Vehicle plug ............................................................................................................................................... 104
W
Wiring ........................................................................................................................................................... 68
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EMR 2
Index
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11
12
13
Seite 112
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EMR 2
Connection diagrams
12
Connection diagrams
The following connection diagrams present the maximum scope of the EMR2. Customer or model-specific
wishes 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 DEUTZ
customer representative before supply of the first engine as the switching diagram is not part of the documentation 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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EMR 2
12.1
Anschlussplan Fahrzeug-/Anlagenseite
Anhang/
Appendix
Connection diagram - Vehicle side / Unit side
geraeteseite 06/02
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Anhang
Appendix
12.2
Anschlussplan Motorseite (Blatt 1)
EMR 2
Connection diagram - Engine side (sheet 1)
motorseite1 06/02
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06/02
EMR 2
12.3
Anschlussplan Motorseite (Blatt 2)
Anhang/
Appendix
Connection diagram - Engine side (sheet 2)
motorseite2 06/02
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Anhang
Appendix
12.4
Anschlussplan fr CAN-Bus und Diagnoseleitung
EMR 2
Connection Diagram for CAN-Bus and Diagnostic Line
emsemr2 06/02
Seite/Page 118
06/02

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OPERATION / MAINTENANCE MANUAL

OPERATION, MAINTENANCE & TROUBLE

DESIGNED & MANUFACTURED BY:

AIR + MAK INDUSTRIES INC.

OPERATION / MAINTENANCE MANUAL

GENERAL SAFETY INSTRUCTIONS

DESCRIPTION AND OPERATION

5. Controls, Monitoring and Protection

ELECTRONICS AND ELECTRICAL MODULE

5. Pneumatic block diagram

6. Compressor lubrication circuit diagram

7. ASU Panel Description

8. Electro Pneumatic Panel

9. Electronic Pressure Control System

11. Control System Display Parameters

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

13. ASU Protection Systems and set limits

14. Special Interlocks

OPERATION / MAINTENANCE MANUAL

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

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

III.EMR Wiring details

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

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

MAINTENANCE & TROUBLE SHOOTING

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

2. Engine Trouble Shooting Symptoms

3. Compressor Trouble Shooting Symptoms

4. ASU Trouble Shooting Procedures & Techniques

OVERHAUL AND MAJOR REPAIR III

ILLUSTRATED PARTS CATALOGUE - IV

OPERATION / MAINTENANCE MANUAL

GENERAL SAFETY INSTRUCTIONS

Always wear protective glasses and protective shoes when working.

Rotating parts can cause cuts, mutilation or strangulation.

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

OPERATION / MAINTENANCE MANUAL

Always use correct tools that are in good condition.

OPERATION / MAINTENANCE MANUAL

Air start unit

Air start mode

Cold Cranking Ampere

Cubic feet per minute

Brake Horse Power

Cubic Feet Per Minute

Electro Magnetic Interference

Electro Magnetic Compatibility

Electronic Motor Regulator

G/kw hr Grams Per Kilowatt Hour

Gallons per minute

High Coolant Temperature

High Discharge Temperature

High Compressor Oil Temperature KN

Low Lube Oil Pressure

Low Compressor Oil Pressure

Original Equipment Manufacturer

Miles Per Hour

Printed Circuit Board

Pounds per Square Inch - Absolute

Pounds per Square Inch Gauge

Revolutions Per Minute

Pounds Per Minute