Amendment4.pdf

1-

DEUTZ CORPORATION

ENGINE COMPLETION CATALOG

SECT. 43.6 FAN DRIVES

ENGINE MODEL KIT#I CODE ETLPAGE REMARKS

BF4M 2012/C 029-4608 05076334 290 MM HIGH, RATIO 1:1.0

SPL 05077668 05078810,05113595 f~'hi~ 7~'"I"". , BF6M 2012/C 029-4609 05076334 290 MM HIGH, RATIO 1:1.0 ,JA!.i~, , ,~O~ SPL 05076321 05078810,05077668,05113595 r/!' :1 r i., 2 ~,.; --~ )·,Y' AI" ii •.'W "t" /'_BF4M 2012/C 029-4614 05076379 360 MM HIGH, RATIO 1:1.0 If '.~ // I 5 ~

SPL 05078810 05077668,05113595

\ ..~ilR!l. 8

BF6M 2012/C 029-4615 05076379 360 MM HIGH, RATIO 1:1.0

'.tW

SPL 05076321 05078810,05077668,05113595

SECT. 43.7 CLUTCH PTO

(SEE NEXT PAGE FOR SPECIFICA nONS).

PTO TYPE KIT# PTO MODEL # REMARKS

TWIN DISC PTO 999-8119 CX106P501 FITS SAE #5 HSG. I SAE 6.5" FLYWHEEL

TWIN DISC PTO 999-8120 CX108P401 FITS SAE #4 HSG. I SAE 8" FLYWHEEL

TWIN DISC PTO 999-8121 CX110P301 FITS SAE #3 HSG. I SAE 10" FLYWHEEL (72MM PILOT)

TWIN DISC PTO 999-8122 SP111P301 FITS SAE #3 HSG. I SAE 11.5" FLYWHEEL

TWIN DISC PTO 999-8123 SP211P301 FITS SAE #3 HSG. I SAE 11.5" FLYWHEEL

TWIN DISC PTO 999-8124 SP314P101 FITS SAE #1 HSG. I SAE 14" FLYWHEEL (80MM PILOT)

NACO PTO 999-0520 411294AM FITS SAE #5 HSG. I SAE 6.5" FLYWHEEL 1#f:Roft'tJ NACO PTO 999-0521 431026AM FITS SAE #4 HSG. I SAE 8" FLYWHEEL v\~~ ~

NACO PTO 999-0522 436003AMI FITS SAE #3 HSG. I SAE 10" FLYWHEEL (62MM PILOT)

NACO PTO 999-0306 434510AM FITS SAE #3 HSG. I SAE 11.5" FLYWHEEL (72MM PILOT)

NACO PTO 999-0307 434845AM FITS SAE #3 HSG. I SAE 11.5" FLYWHEEL

CHECK WITH DC-NORCROSS FOR LEAD TIME ON ITEMS WITH 'SPL' STOCK CODE

REV. 01/2009

CLUTCH PTO SPECIFICATIONS

TWIN-DISC CLUTCH

APPLICATION DUTY CLASSIFICATION

MAX TORQUE CLUTCH MAX. HP RATING APPROX. SHAFT

DEUTZ TWIN-DISC SAE SAE CLASS 1 CLASS 2 CLASS 3 CLASS 4 WEIGHT LENGTH DIAMETER

SA Kit MODEL # Hsg# Fly # Lb-Ft Nm Hp kW Hp kW Hp kW Lbs. kg. in. mm in. mm

999-8119 CX106P501 5 6.5 159 216 40.0 29.9 27.0 20.1 20.0 14.9 53 24.1 3.5 88.9 1.44 36.5...

999-8120 CX108P401 4 8 230 312 61.0 45.5 41.0 30.6 31.0 23.1 72 32.7 6 152 1.75 44.5...

999-8121 CX110P301 3 10 328 445 96.0 71.6 64.0 47.8 48.0 35.8 115 52.3 5.63 143 2.25 57.2- ~~. - - -.- 999-8122 SP111 P301 3 11.5 455 617 124.0 92.5 82.0 61.2 62.0 46.3 141 64.1 6.5 165 2.25 57.2- ..~---- .>

999-8123 SP211 P301 3 11.5 909 1233 247.0 184.3 165.0 123.1 124.0 92.5 155 70.5 6.5 165 2.5 63.5,. , ~ ..., ..

999-8124 SP314P01 1 14 2430 1793 564.0 420.9 376.0 280.6 282.0 210.4 425 192.0 10 254 3.94 100.0

NACO CLUTCH

MAX TORQUE CLUTCH TORQUE RATING APPROX. SHAFT

DEUTZ NACO SAE SAE CLASS 1 CLASS 2 CLASS 3 CLASS 4 WEIGHT LENGTH DIAMETER

SA Kit MODEL # Hsg# Fly # Lb-Ft Nm Lb-Ft Nm Lb-Ft Nm Lb-Ft Nm Lbs. kg. in. mm in. mm

999-0520 411294AM 5 6.5 83 113 41.7 56.5 27.8 37.7 20.8 28.3 53 24.1 3.5 88.9 1.44 36.5

999-0521 431026AM 4 8 140 190 70.0 95.0 46.7 63.3 35.0 47.5 72 32.7 6.0 152 1.75 44.5

999-0522 436003AM 3 10 307 416 153.3 208.1 102.2 138.7 76.7 104.0 115 52.3 5.5 140 2.25 57.2

999-0306 434510AM 3 11.5 467 633 233.3 316.6 155.6 211.1 116.7 158.3 141 64.1 6.5 165 2.25 57.2

999-0307 434845AM 3 11.5 933 1266 466.7 633.2 311.1 422.1 233.3 316.6 155 70.5 6.5 165 2.5 63.5

Rating Class examples Class 1 Centrifugal pumps, hydraulic pumps, irrigation pumps Class 2 Line shafts with uniform load, gensets, elevator drives Class 3 Blowers & fans, centrifugal compressors, multi-cylinder piston pumps, conveyor drives, feeder drives Class 4 Crane & hoist drives, chipper drives, tub grinders, multi-cylinder recip compressors, mud pumps, crusher drives

Applicability For engine model applicability, consult the appropriate engine technical data sheet to obtain peak torque and/or rating information.

Consult engine specification to determine the flywheel and housing configuration.

For side load limits and additional technical information, please consult the following manufacturer documents:

Twin-Disc Bulletin 308-S NACO Power Take-Off Service Manual

PTO kits do not include mounting hardware

Clutch PTO Specifications, 1/29/2007

Ell no.: 05067385 Exhaust pipe

Equipment:

Output:

ETL scope:

Constr. Group: 41

00010515068 0000036,9 kW

EU516986

Engine type:

Speed:

10506 73851

Item Material Kit MSVS QuantunitOrd Designation(en)

D 2011 L04 I 2500 1/min

ST Exhaust pipe

Designation(en) Remark

DEUTZ®

SERPIC © 02.14

I 001

04191392 Kit? Exhaust pipe-

Catalog3501E Truck Valves & Lanyard Valve

Truck Valve V404P Hose to Male Pipe Temperature Range: _30° to +250° F

PART HOSE PIPE

FLOW L M N

NO. 1.0. THREAD

V404P·6·6 318 318 .281 2.35 1.36 .94

V404P·10·6 5/8 318 .406 2.75 1.31 1.15

\v <?f.P?oSt~ ~ L-\~

Truck Valve V404PH Hose to Male Pipe with Pin Handle Temperature Range: _30° to +250° F

PART HOSE PIPE

FLOW L M N

NO. 1.0. THREAD

V404PH-10-6 5/8 318 .406 2.47 1.31 1.09

Truck Valve SV404P Hose to Male Pipe Temperature Range: _30° to +250° F

PART HOSE PIPE

FLOW L M NNO. 1.0. THREAD

SV404P-10-8 5/8 112 .468 3.71 2.31 1.34

SV404P-12-6 314 318 .436 3.73 2.31 1.34

SV404P-12-8 314 1/2 .562 3.73 2.31 1.34

Truck Valve V405P Female Pipe to Male Pipe Temperature Range: _30° to +250° F

PART

FEMALE MALE

NO.

PIPE PIPE FLOW L M N

THREAD THREAD

V405P-6-6 318 318 .406 2.72 .91 1.19

V405P-6-8 318 1/2 .406 2.95 .91 1.31

V405P-8-8 1/2 1/2 .562 3.15 1.17 1.34

Truck Valve V408NTA Tube to Male Pipe Temperature Range: _30° to +250° F

PART TUBE PIPE

FLOW L M N

NO. SIZE THREAD

V408NTA-8-8 1/2 112 .328 3.28 1.15 1.19

Parker

Truck Valve V409F Flare to Male Pipe Temperature Range: _30° to +250° F

PART TUBE PIPE

FLOW L M N

NO. SIZE THREAD

V409F-8-6 1/2 318 .406 3.07 1.31 1.00

V409F-8-8 1/2 112 .406 3.28 1.31 1.19

V409F-10-8 5/8 1/2 .500 3.47 1.50 1.25

V409F-12-8 314 1/2 .562 3.70 2.31 1.34

Truck Valve V410NTA r:

CLOSED

:-Wll IITube to Male Pipe Temperature Range: _30° to +250°

FPART TUBE PIPE

FLOW L M N

NO. SIZE THREAD

V410NTA-8-8 1/2 1/2 .328 3.58 1.38 1.31

Truck Valve V412F Tube to Male Pipe Temperature Range: _30° to +250° F

PART TUBE PIPE

FLOW L M N

NO. SIZE THREAD

V412F-10-8 5/8 1/2 .500 3.60 1.38 1.31

LV91 HF-4-SUB

Lanyard Valve LV91 Temperature Range: -40° to +200° F

PART PIPE CABLE LENGTH

NO. THREAD INCHES

LV91-4-036 1/4 36

LV91-4-048 1/4 48

LV91-4-060 1/4 60

LV91 HF-4-SUB 1/4 --

E21 Parker Hannifin Corporation Fluid System Connectors Otsego, Michigan

Parker Hannifin Corporation Tube Fittings Division Columbus, Ohio http://www.parker.com/tfd

Pipe Fittings and Port Adapters

Dimensions and pressures for reference only, subject to change.

F5OG

Female Pipe Adapter

SAE-ORB / NPTF

SAE 090156

TUBE

FITTING

PART #

END SIZE

C

HEX

(in.)

D2

DRILL

L (in.)

LL

AFTER

ASSY

(in.)

Dynamic Pressure

(x 1,000 PSI)1

UN/UNF-2A

NPTF -S -SS -B

2-1/8 F5OG 5/16 - 24 1/8 - 27 9/16 0.094 0.91 0.61 6.0 6.0 3.3

4-1/8 F5OG 7/16 - 20 1/8 - 27 9/16 0.172 1.00 0.64 6.0 6.0 3.3

4-1/4 F5OG 7/16 - 20 1/4 - 18 3/4 0.172 1.16 0.80 6.0 6.0 3.3

5-1/8 F5OG 1/2 - 20 1/8 - 27 5/8 0.234 1.06 0.70 6.0 6.0 3.3

5-1/4 F5OG 1/2 - 20 1/4 - 18 3/4 0.234 1.19 0.83 6.0 6.0 3.3

6-1/8 F5OG 9/16 - 18 1/8 - 27 11/16 0.297 1.00 0.61 6.0 6.0 3.3

6-1/4 F5OG 9/16 - 18 1/4 - 18 3/4 0.297 1.16 0.77 6.0 6.0 3.3

6-3/8 F5OG 9/16 - 18 3/8 - 18 7/8 0.297 1.28 0.89 6.0 6.0 3.3

6-1/2 F5OG 9/16 - 18 1/2 - 14 1 1/8 0.297 1.53 1.14 5.0 6.0 3.3

8-1/8 F5OG 3/4 - 16 1/8 - 27 7/8 0.391 0.80 0.36 6.0 6.0 3.3

8-1/4 F5OG 3/4 - 16 1/4 - 18 7/8 0.391 1.13 0.69 6.0 6.0 3.3

8-3/8 F5OG 3/4 - 16 3/8 - 18 7/8 0.391 1.28 0.84 6.0 6.0 3.3

8-1/2 F5OG 3/4 - 16 1/2 - 14 1 1/8 0.391 1.50 1.06 5.0 6.0 3.3

10-1/4 F5OG 7/8 - 14 1/4 - 18 1 0.500 0.81 0.31 5.0 6.0 3.3

10-3/8 F5OG 7/8 - 14 3/8 - 18 1 0.500 1.31 0.81 5.0 6.0 3.3

10-1/2 F5OG 7/8 - 14 1/2 - 14 1 1/8 0.500 1.53 1.03 5.0 6.0 3.3

10-3/4 F5OG 7/8 - 14 3/4 - 14 1 3/8 0.500 1.63 1.13 4.0 4.0 2.6

12-1/4 F5OG 1 1/16 - 12 1/4 - 18 1 1/4 0.656 1.00 0.41 6.0 6.0 3.3

12-3/8 F5OG 1 1/16 - 12 3/8 - 18 1 1/4 0.656 1.34 0.41 5.0 6.0 3.3

12-1/2 F5OG 1 1/16 - 12 1/2 - 14 1 1/4 0.656 1.41 0.82 5.0 6.0 3.3

12-3/4 F5OG 1 1/16 - 12 3/4 - 14 1 3/8 0.656 1.72 1.13 4.0 4.8 3.1

14-1/2 F5OG 1 3/16 - 12 1/2 - 14 1 3/8 0.719 1.06 0.47 5.0 5.0 3.3

14-3/4 F5OG 1 3/16 - 12 3/4 - 14 1 3/8 0.719 1.69 1.10 4.0 4.0 2.6

16-1/2 F5OG 1 5/16 - 12 1/2 - 14 1 1/2 0.844 1.00 0.41 5.0 6.0 3.3

16-3/4 F5OG 1 5/16 - 12 3/4 - 14 1 1/2 0.844 1.50 0.91 4.0 4.8 2.6

16-1 F5OG 1 5/16 - 12 1 - 11 1/2 1 5/8 0.875 1.88 1.29 3.0 3.6 1.9

20-1 F5OG 1 5/8 - 12 1 - 11 1/2 1 7/8 1.078 1.00 0.41 3.0 3.6 1.9

20-1 1/2 F5OG 1 5/8 - 12 1 1/2 - 14 2 1/4 1.078 2.16 1.56 2.5 3.0 1.6

20-1 1/4 F5OG 1 5/8 - 12 1 1/4 - 11 1/2 2 1.078 1.97 1.38 3.0 3.0 1.9

24-1 F5OG 1 7/8 - 12 1 - 11 1/2 2 1/8 1.344 1.00 0.41 3.0 3.6 1.9

24-1 1/4 F5OG 1 7/8 - 12 1 1/4 - 11 1/2 2 1/8 1.312 1.94 1.35 2.5 2.5 1.6

24-1 1/2 F5OG 1 7/8 - 12 1 1/2 - 11 1/2 2 1/4 1.344 2.00 1.41 2.0 2.4 1.3

32-2 F5OG 2 1/2 - 12 2 - 11 1/2 2 7/8 1.781 2.06 1.47 2.0 2.4 1.3

The Kongsberg Automotive Vernier Control is the premium mechanical control for setting engine RPM, controlling regulating valves or for other precise remote adjustments. This latest design offers a larger grip for easier feel and two internal ball-bearings for smoother adjustment.

Applications for the Vernier Control range from generator sets, to manual throttles for warm up, on a wide variety of on and off-road vehicles.

VeRnieR ConTRol europe: Christopher Martin Road, Basildon, essex SS14 3eS, UK Tel: +44 (0) 1268 522 861 north America: 640 north lewis Road limerick, PA 19468 USA Tel: +1 610 495 7011 www.kongsbergautomotive.com email: info.pps@ka-group.com h a n d s - o n c o n t r o l at a glance

• Fast and Simple installation - can be mounted independently to the dash and then connected to the cable on the other side of dash or firewall.

• Coarse Adjustment - depress top of grip and pull the Vernier knob out until an approximate rpm or setting is achieved.

• Fine Adjustment - rotate Vernier knob for precise adjustment

• Adjustable Brake - accurate settings can be maintained through vibration or governor back pressure by setting the correct amount of friction on the brake.

• Fast Shutdown - simply depress top of grip and simultaneously push in the knob for immediate shutdown.

• Recommended for loads up to 20 lbs.

• 3" cable travel. Travel can be reduced using stop collar.

auxiliary hand controls ti-07-020.0

VeRnieR ConTRol

Series Description end Type Cable Series Part number (cable only)

Cable Series Part number (cable w/head)

Min.

Bend

Radius “A” “B” “C” “D”

“e” Dia.

“F” Dia.

“G” Thread UnF-2A

30l open 307141 317341 6” - - - - .26 - -

30l Bulkhead 307142 317342 6” - - 1.88 1.00 .26 .38 -

30l Clamp 307143 317343 6” - - 1.31 - .26 .38 -

30 Bulkhead 307144 317344 8” 8.88 5.00 1.44 .88 .26 .44 .187-32

30 Clamp 307145 317345 8” 8.19 4.31 1.13 .88 .26 .38 .187-32

40 Bulkhead 307146 317346 8” 9.13 5.13 1.76 1.00 .43 .62 .250-28

40 Clamp 307147 317347 8” 8.50 4.50 1.38 1.00 .43 .56 .250-28

Vernier Hardware and Accessories

Part number

30l Stop Collar 037693

30l Clamp 043229

30l Pivot 047639

30l Pivot 047640

30l Pivot 047641

30l Bulkhead Adapter Kit 300673

30l Clamp Adapter Kit 302485

30C Clamp to Bulkhead Kit 304307

40C Clamp to Bulkhead Kit 304308

Control Head 317310

Measuring and ordering

• Cable length stamped on the cable is the overall length that is achieved when the vernier control head is attached to the cable.

• All l-type cables are measured to the point where the core wire exits the cable conduit.

• Cables with rod-type end fittings are measured to the rod end.

• A Quick Release Vernier Control can be ordered as two separate items. Use part number 317310 for the Vernier Control Head.

Then order the desired cable part number, immediately followed by the desired cable length expressed in inches (order in 1 ft.

increments.) Cables over 20 ft. are special order.

X X X X X X - X X - X X X

TRAVel (3" STAnDARD)*

CABle SeRieS PART nUMBeR CABle lenGTH in inches (Place 0 in first position if less than 100")

PART nUMBeRinG SYSTeM length length

3" Travel

Depress to release easy grip knob designed for fingertip adjustment, 6 1/4 turns per inch.

Coupling nut disconnects head from cable for fast, easy installation

11/16-16UnF-2A

6 3/16 when connected

3/4-16UnF-2A

2 1/4

4 1/4 Brake release product range and specifications

ENGINE COMPLETION CATALOG

SECT. 41.1 STARTING AID, PENCIL TYPE GLOW PLUG

ENGINE MODEL KIT#/CODE ETL PAGE REMARKS

BF4M1013/E/C 029-2687 05070225 12 VOLT, WITHOUT STARTING ACCESSORIES,

SPL 05071693 AND AMBIENT TEMP. SENSOR CONTROL UNIT. .-:~

05071707 05111190,05074490

BF4M1013/E/C 029-2688 05070279 24 VOLT, WITHOUT STARTING ACCESSORIES,

SPL 05071693 AND AMBIENT TEMP. SENSOR CONTROL UNIT.

05071707 05074490,05111090

BF6M1013/E/C/P 029-2698 05051776 12 VOLT, INCLUDES STARTING ACCESSORIES,

SPL 05070225 AND AMBIENT TEMP. SENSOR CONTROL UNIT.

05071694 05071708,05111190,05074490

BF6M1013/E/C/P 029-2699 05037960 24 VOLT, INCLUDES STARTING ACCESSORIES,

SPL 05070279 AND AMBIENT TEMP. SENSOR CONTROL UNIT.

05071694 05071708,05074490,05111090

BF6M1013/E/C/P 029-2700 05070225 12 VOLT, WITHOUT STARTING ACCESSORIES,

SPL 05071694 AND AMBIENT TEMP. SENSOR CONTROL UNIT.

05071708 05111190,05074490

BF6M1013/E/C/P 029-2701 05070279 24 VOLT, WITHOUT STARTING ACCESSORIES,

SPL 05071694 AND AMBIENT TEMP. SENSOR CONTROL UNIT.

05071708 05074490,05111090

SECT. 41.2 STARTING AID, MANIFOLD HEATER PLUG

ENGINE MODEL KIT#/CODE ETL PAGE REMARKS

ALL 2011 2200-1890 05063365 12 VOLT, WITHOUT STARTING ACCESSORIES,

05063419 W/O AMBIENT TEMP. SENSOR CONTROL UNIT,

d"WITH SINGLE GLOW PLUG.

ALL 2011 2200-1905 05063365 12 VOLT, WITHOUT STARTING ACCESSORIES,

05063419 WITH AMBIENT TEMP. SENSOR CONTROL UNIT,

05074134 WITH SINGLE GLOW PLUG.

ALL 2011 2200-1907 05068224 12 VOLT, WITHOUT STARTING ACCESSORIES, f;O~

05074136 WITH AMBIENT TEMP. SENSOR CONTROL UNIT,

WITH DUAL GLOW PLUG. L.IN£ 3

B/FLlFM 2011 2200-1908 05068225 24 VOLT 2 GLOW PLUGS, WITIMER RELAY

SPL 05074129

SECT. 41.3 STARTING ACCESSORIES, 12 VOLT

ENGINE MODEL KIT#/CODE ETL PAGE REMARKS

B/F3-6L 913/C/914 027-1365 05002414 FOR INTAKE PREHEAT; KIT INCLUDES: KEY [~TCD914 L6 SPL 05003736 SWITCH, KEY, LIGHTS, CONNECTORS

05003725 05016187,05022913

B/F3-6L 913/C/914 027-1367 05002414 FOR W/O INTAKE PREHEAT; KIT INCLUDES: ~'/\TCD914 L6 05003736 KEY SWITCH, KEY, LIGHTS, CONNECTORS " ~<: ~ 05003725 05004427,05016186 fr· '~,:QALL 914 027-1368 24 VOLT

SPL

ALL 1013/E 029-1430 05070159 FOR WITH OR WITHOUT INTAKE PREHEAT;INCL:

SPL 05051776 KEY SWITCH, KEY, CHARGE INDICATOR LIGHT,

ALL 2011 2200-1887 05051775 FOR WITH OR W/O INTAKE PREHEAT; INCLUDES

05068223 KEY SWITCH, 2 KEYS, SPADE CONNECTORS, OIL TEMPERATURE

INDICATOR LIGHT AND BULB,

CHECK WITH DC-NORCROSS FOR LEAD TIME ON ITEMS WITH 'SPL' STOCK CODE

SECT. 30.0 ENGINE WIRING HARNESS

ENGINE MODEL KIT#/ CODE ETL PAGE REMARKS

BF4M 2012/C 029-4784 05076333 KIT

SPL 05078876

BF6M 2012/C 029-4812 05076375 KIT

SPL 05071744 05071743,05078871

SECT. 30.1

ENGINE MODEL KIT#/CODE

EMR EXTENSION HARNESS

ETL PAGE

ALL 2011 2200-3764

SPL

ALL 1013/2012 029-6452

SPL

ALL 1013/2012 029-6453

SPL

TCD2012 12013 028-2874

SPL

TCD 2012/2013 028-2875

SPL

TCD 2015 2203-0301

SPL

2203-0302

SPL

TCD 2015

05079241 05113680

05072493 05072513

05072493 05072513

05113747 05072513

05113746 05072513

05069303 05072513 05069303 05072513

REMARKS

LENGTH 5 METER (for EMR2) 05072493,05072513

LENGTH 2.5 METER (for EMR2) 05076279, 05078406

LENGTH 5 METER (for EMR2) 05076279, 05078442

LENGTH 5 METER (for EMR 3, EDC 16 controller) 05076279,05113185

LENGTH 2.5 METER (for EMR 3, EDC 16 controller) 05076279,05113185

LENGTH 5 METER (for EMR 3, EDC 7 controller) 05076785,05076786,05079764 LENGTH 2.5 METER (for EMR 3, EDC 7 controller) 05076785,05076786,05079763

SECT. 30.2

ENGINE MODEL

LIFTING EYES

KIT#/CODE

B/F3-6L913/C/914 027-0935

ALL 1015 2201-1264

SPL

ALL 2011 2200-1260

ETL PAGE

05034243

05023574 05067847

05074361 05067562

REMARKS

HITCH LUG M16

KIT M20

't0 VV\:

KIT M12 l£ #Ji? 53

SECT. 30.3 EXHAUST MANIFOLD, OPENING AT FRONT

(BLOWER END)

ENGINE MODEL KIT#/CODE

F2UM2011 102011 L2/1 2200-0678

SPL

F3UM2011I 02011 L3/1 2200-2307

SPL

F4UM2011 2200-0680

SPL

2200-4773

SPL

02011 L041

01 TOITCD 2011 L4 III W

ETL PAGE

05074121

05069191

05069182

05069182 05114535 05114926

REMARKS

FOR ENGINES WITHOUT SIDE AIR DUCT

FOR ENGINES WITHOUT SIDE AIR DUCT

FOR ENGINES WITHOUT SIDE AIR DUCT

FOR ENGINES WITHOUT SIDE AIR DUCT

·CONTACT DEUTZ APPLICATION ENGINEERING DEPARTMENT

CHECK WITH DC-NORCROSS FOR LEAD TIME ON ITEMS WITH 'SPL' STOCK CODE

SECT. 40.1 STARTER, 12 VOLT

ENGINE MODEL KIT#/CODE ETL PAGE REMARKS

027-5597 05069739 3KW

SPL

029-0917 05070666 3kw

SPL 05071107 05072571,05072725

029-4196 05070197 3.0 KW DUST PROTECTED W/OUT SHIELD

SPL 05078342

029-6343 05078342 3.0 KW DUST PROTECTED WITH HEAT SHIELD

SPL 05077966 05070157

2200-3222 05079244 2.6KW

05079277

2200-2460 05079247 4.0 KW (12 VOLT HEAVY DUTY)

SPL

2200-3499 05079245 12V 2.6 KW, DUST PROTECTED W/OUT SHIELD

SPL 05079277

2200-3500 05069189 12V 2.6 KW, DUST PROTECTED WITH HEAT SHIELD

SPL 05079245 05079277

2200-2027 05069189 (HEAT SHIELD ONLY)

SPL

3101-0353 05112024 12V2.0 KW

SPL

913/914

ALL 1013

1013/2012/2013

1013/2012/2013

ALL 2011

ALL 2011

ALL 2011

ALL 2011

ALL 2011

All 2008 12009

STARTER 24 VOLTSEC:T. 40.2

ENGINE MODEL

913/914

KIT#/CODE

027-0457

ETLPAGE

05069740

REMARKS

4.0KW

BF6L 913/C 027-0461

SPL

029-3632

SPL

05003655 05027024 05070157 05078343

5.4KW

1013/2012/2013 4.0 KW DUST 1WATER PROTECTED

~"'"u tJG'ALL 2011 2200-3501

SPL

05079246 05079278

4.0 KW DUST PROTECTED

TCD2015 V6N8 6.6 KW DUST AND WATER PROTECTED2203-0828

SPL

KIT#/CODE ETL PAGE REMARKS

027-0823 05116002 12 VOLT; INTAKE OPENING @ BLOWER END

05003471 05003735,05091015,05034248,05003743,05075190,05075022

027-0824 05003471 24 VOLT; INTAKE OPENING @ BLOWER END

05005912 05031677,05003743,05075297,05063952,05075305 ~t027-0833 05003471 12 VOLT; INTAKE OPENING@ FLYWHEEL END

SPL 05003735 05091015,05003804,05034248,05003743

05075190,05075022

027-3294 05003471 12 VOLT; INTAKE OPENING @ FLYWHEEL END

SPL 05003735 05091015,05034248,05006962,05003743

05075190,05075022

027-5736 05003471 12 VOLT, W/DIAPHRAGM FUEL LIFT PUMP

SPL 05034248 05050239, 05069742

027-3663 05003471 12 VOLT: INTAKE OPENING AT FLYWHEEL END

SPL 05003735 05091015,05034248,05050239,05003743,05075190,05075022

027-7359 05034248 12 VOLT, INTAKE OPENING BLOWER END

05063953 05079590

SECT. 40.3 STARTING AID, INTAKE PREHEAT, FLAME TYPE

ENGINE MODEL

B/F3-6L 913/C

B/F3-6L 913/C

F6L 913

F4L 913

BF4L913

BF4L 913

F3L9141 0914 L3

CONTINUED ON NEXT PAGE

CHECK WITH DC-NORCROSS FOR LEAD TIME ON ITEMS WITH 'SPL' STOCK CODE

EP250™ Panel Operation and Troubleshooting

463-3000-01 Rev D. 23-Sep-2013 1 © 2006-2013 LOFA Industries, Inc. All rights reserved.

LOFA, the LOFA logo, CANplus and EP250 are trademarks of LOFA Industries, Inc. All rights reserved.

Windows is a registered trademark of Microsoft Corporation.

EP250 Panel Operation and Troubleshooting

2 463-3000-01 Rev D. 23-Sep-2013

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463-3000-01 Rev D. 23-Sep-2013 3

Introduction This document provides general information on LOFA™ EP250 panel operation and troubleshooting. EP250 control panels are a flexible platform for diesel engine control, monitoring, and protection, featuring LOFA’s powerful First Fault Diagnostics (FFD). After pinpointing the initial failure, FFD stores it in memory and alerts the end user via a single bright LED. FFD monitors battery charge, low oil pressure, high temperature, over speed and up to three additional contact closure inputs. The field configurable, expandable microprocessor-based solid-state design uses high-power semiconductors instead of outdated electromechanical relays to ensure reliable high-current switching.

Some of the EP250 configurable features include:

Automatic preheat duration

Afterglow duration

Failure indication with shutdown or indication only

Over-speed shutdown

Normally open or normally closed shutdown switches

The EP250 features LOFA’s new modular Function Enhancement Packs (FEP). The plug-and-play

FEP modules allow various feature upgrades to be easily added to the standard platform. FEPs include:

Automatic Start/Stop Operation

Precision Actuator Control

Custom OEM Solutions

All standard panels include feature a 12 inch wiring harness terminating into a sealed weather proof plug. This robust universal wiring connection performs well in harsh environments and allows interchanging a number of different panels and harnesses. This design allows for simplified installation as well as a flexible means to incorporate custom plug-and-play engine wiring harnesses and standard harness extension

Note

The engine harness is not included with the panel.

A number of standard engine harnesses are available or

LOFA can develop a custom harness for you exact needs.

Generic harnesses in various lengths are available for field customization.

Warning!

When replacement parts are required, LOFA Industries recommends using replacement parts supplied by LOFA or parts with equivalent specifications.

Failure to heed this warning can lead to premature failure, product damage, personal injury or death.

4 463-3000-01 Rev D. 23-Sep-2013

Important Safety Information The warnings in this publication are not all inclusive.

LOFA Industries cannot anticipate every potential hazard.

Appropriate safety rules and precautions should be followed with any tool, work method or operating procedure.

Improper procedures, tools and materials may cause damage or make the equipment unsafe to operate.

Only persons with appropriate training, skills and tools should perform these functions.

Improper operation, maintenance or repair of this product can be dangerous and may result in injury or death.

Do not operate or perform any maintenance or repair on this product until all operation, maintenance and repair information is read and understood.

The information, specifications, and illustrations in this publication are based on information available at the time of publication.

All items are subject to change at any time without notice.

463-3000-01 Rev D. 23-Sep-2013 5

Operation

Turning the panel key to the run position starts a self-test which causes all LEDs to illuminate once, activates the alarm output for one second and enables the fuel run/stop solenoid output. After self-test, the LEDs indicate the state of the inputs they monitor. The normal indications are battery charge and oil pressure on most applications. If these LEDs are not illuminated at this time it may indicate the inputs are not properly connected.

The Preheat LED is illuminated when the key switch is turned to the run position if automatic preheat is configured or if an external preheat control is connected (See Preheat Options).

Preheat time varies from application to application. After waiting for the Preheat LED to extinguish, the engine is cranked by turning and holding the key switch in the start position until the engine starts. The key switch is spring loaded to return automatically to the run position when released. The Preheat LED is illuminated during afterglow if enabled.

Note

The key switch is equipped with a mechanical start locking device.

An attempt to crank the engine again can only be made by turning the key switch to the off position to reset the start locking mechanism.

If the engine is not started within 10 seconds of turning on the panel, the fuel run/stop solenoid output is turned off to prevent battery discharge when the key switch is left in the run position.

The fuel run/stop solenoid output is turned off after 10 seconds even if preheating. As soon as the key switch is turned to the start position the solenoid output is enabled. The afterglow cycle begins when the key switch returns to the run position.

Note

If conditions do not warrant preheat, the engine may be started by turning the key to the start position without waiting for the preheat time to expire.

Panel instrument power, including the hour meter and voltmeter, is provided by the fuel run/stop solenoid output. If the instruments do not power up when the key is turned to the run position, this indicates a problem with the solenoid circuit (see Troubleshooting).

After the engine starts, the panel electronics ignore all shutdown conditions for the first 10 seconds. This delay eliminates the requirement to hold a by-pass override button during starting and allows the conditions such as oil pressure to normalize. The 10 second timer starts when the key switch returns to the run position.

Note

Starter input is required for correct panel operation. If the starter motor input is not activated (connected to battery positive) and the engine is started through another means (i.e. air starter) the engine will shutdown 10 seconds after the key switch is turned to the run position.

To prevent unintentional engine shutdowns caused by intermittent conditions (i.e., pressure spikes, coolant movement) the panel requires a constant 1 second fault input to cause engine shutdown.

Warning!

When used in combination with mechanical float type switches engine vibrations may prevent constant contact closure.

The panel can be configured to shutdown with no delay.

6 463-3000-01 Rev D. 23-Sep-2013

The panel has the ability to shut down the engine for over speed. Over speed will be indicated via a blinking Battery Charge LED. The panel senses RPM either by the frequency terminal of the alternator, proximity switch or magnetic pick-up with the optional magnetic pick-up amplifier/divider.

Preheat Options

Preheat Output Preheat is a 750 mA output for control of an external power relay with predetermined preheat and afterglow times. A relay should be selected with appropriate amperage capacity for the installed cold starting aid (glowplug, intake air heater, etc.). Applications using multiple cold starting aids may require multiple relays. Depending on specific configuration, this output may provide either high side (battery positive) or low side (ground) control.

Note

Consult engine documentation when selecting cold starting aid, power relay and heating specifications.

Preheat Indication Input

With this option, the preheat LED provides indication for an external preheat control. Depending on specific controls and configuration, this input can be configured to accept either high side

(battery positive) or low side (ground) control.

Indicators

Battery LED (Red)

A solidly illuminated Battery LED indicates a battery charge failure. A battery charge failure may be caused by a faulty alternator, broken drive belt or the alternator not excited. A battery voltage reading of approximately 14 volts on a 12 volt system (28 volts on a 24 volt system) while the engine is running indicates the battery is charging properly. Irregular blinking of the Battery

LED may indicate a failing charge circuit. The panel can be configured for battery charge failure to indicate only.

Over Speed Indication

A regularly blinking Battery LED indicates the configured over speed RPM has been exceeded.

Over speed is a configurable option that is disabled by default.

Oil Pressure LED (Red)

A solidly illuminated Oil Pressure LED indicates low oil pressure failure. The panel typically senses low oil pressure from a ground contact switch on the engine. When a sender/switch combination is used on the engine, the marking WK generally indicates the switch terminal. This input typically expects a normally closed switch (ground contact when oil pressure is low). A defective switch or shorting the shutdown input to ground can cause low pressure fault indication. Additionally, when using sender/switch combinations, swapping the WK and G terminal can cause unintended shutdowns. The panel can be configured for oil pressure failure to indicate only.

463-3000-01 Rev D. 23-Sep-2013 7

Warning!

Low oil pressure is not an indication of low oil level.

For best possible protection LOFA recommends using our solid-state oil level shutdown switch.

Note

Most shutdown switches are grounded through the switch body.

Do not use insulating sealant (i.e. Teflon tape) when installing switches.

Temperature LED (Red)

A solidly illuminated Temperature LED indicates high engine temperature failure. The panel typically senses high temperature from a ground contact switch on the engine. When a sender/switch combination is used on the engine, the marking WK or W generally indicates the switch terminal. This input typically expects a normally open switch (ground contact when engine temperature is too high). A defective switch or shorting the shutdown input to ground can cause over temperature fault indication. Additionally, when using sender/switch combinations, swapping the WK or W and G terminal can cause unintended shutdowns. The panel can be configured for temperature failure to indicate only.

Warning!

If the temperature switch is not in contact with coolant due to coolant loss the engine is not protected from overheating.

For best possible protection, LOFA recommends using our solid-state coolant level shutdown switch.

Note

Most shutdown switches are grounded through the switch body.

Do not use insulating sealant (i.e. Teflon tape) when installing switches.

Some thermostat housings are composites and do not provide ground for the switch.

AUX 1 LED (Red)

A solidly illuminated AUX 1 LED indicates auxiliary 1 failure (i.e., coolant level, oil level, belt breakage, hydraulic pressure, etc.). The panel typically senses failure using a ground contact switch. Auxiliary inputs are equipment specific and determined by the equipment manufacturer.

A defective switch or shorting the shutdown input to ground can cause fault indications. The panel can be configured for auxiliary 1 failure to indicate only.

A blinking AUX 1 LED indicates SW input failure. The panel typically senses failure using a ground contact switch. The SW input is equipment specific and determined by the equipment manufacturer. A defective switch or shorting the shutdown input to ground can cause fault indications.

AUX 2 LED (Red)

A solidly illuminated AUX 2 LED indicates an auxiliary switch 2 fault (i.e., air flow restriction, fuel level, etc.) but by default does not cause a shutdown. The panel typically senses failure using a

8 463-3000-01 Rev D. 23-Sep-2013 ground contact switch. Auxiliary inputs are equipment specific and determined by the equipment manufacturer. A defective switch or shorting the shutdown input to ground can cause fault indications. The panel can be configured with auxiliary 2 shutdown.

Preheat LED (Red)

A solidly illuminated Preheat LED is the panel preheat indication. When the LED extinguishes the preheat period is complete and the engine may be cranked. The LED illuminates again to indicate afterglow.

463-3000-01 Rev D. 23-Sep-2013 9

Gauges

Voltmeter

The voltmeter is connected to the fuel run/stop solenoid output. If the voltmeter does not indicate in the run position, this indicates a problem with the solenoid circuit. A battery voltage reading of approximately 14 volts on a 12 volt system (28 volts on a 24 volt system) while the engine is running indicates the battery is charging properly.

Tachometer

The tachometer indicates engine RPM using a frequency signal derived from the engine. This signal may be provided by an alternator frequency tap, proximity switch. An optional amplifier/divider can be added for use with a magnetic pickup.

Note

If the alternator is not excited (not charging), no frequency is generated and the tachometer will indicate 0 RPM.

The tachometer must be calibrated to the engine using standard procedures (see Tachometer

Calibration Instructions for details).

Oil Pressure Gauge

The gauge measures oil pressure with a resistance sender on the engine referenced to ground.

When a sender/switch combination is used on the engine, the marking G generally indicates the gauge terminal. The gauge expects a low resistance for low pressure and a higher resistance for higher pressure. If a powered gauge is not connected to the sender, the gauge will read full scale (pegged). A defective sender or shorting the gauge input to ground will cause the gauge to read no pressure. When using sender/switch combinations, swapping the WK and G terminal prevents the gauge from working and may cause unintended shutdowns.

Warning!

Low oil pressure is an indication of engine wear, not an accurate indication of low oil level.

Note

Senders and gauges must be matched to indicate correctly.

Most senders are grounded through the sender body.

Do not use insulating sealant (i.e. Teflon tape) when installing senders.

Temperature Gauge

The gauge measures engine temperature with a resistance sender on the engine referenced to ground. When a sender/switch combination is used on the engine, the marking G generally indicates the gauge terminal. The gauge expects a high resistance for low temperatures and a lower resistance for higher temperatures. If the gauge is not connected to the sender, the will be on read the minimum reading. A defective sender or shorting the gauge input to ground will cause the gauge to read full scale (pegged). When using sender/switch combinations, swapping the WK and G terminal prevents the gauge from working and may cause unintended shutdowns.

10 463-3000-01 Rev D. 23-Sep-2013

Warning!

If the temperature sensor is not in contact with coolant due to coolant loss the gauge will not accurately indicate engine temperature.

Note

Senders and gauges must be matched to indicate correctly.

Most senders are grounded through the sender body.

Do not use insulating sealant (i.e. Teflon tape) when installing senders.

Some thermostat housings are composites and do not provide ground for the sender.

Hourmeter

The hourmeter is connected to the fuel run/stop solenoid output. If the hourmeter does not count in the run position, this may indicate a faulty hourmeter or a problem with the solenoid circuit. If the engine shuts down or is not started within 10 second the hourmeter stops counting.

Additional Gauges

Additional gauges can be added by removing blind covers and installing the gauge. Power connections are provided with the standard configuration.

Harness

Sealed Connectors

The provided sealed weather proof plug includes a grey locking device which must be released to separate the connectors. Press the tab on the connector housing to release the connectors.

Warning!

LOFA does not recommend using dielectric grease or sealant with sealed connectors.

These chemicals may cause seal damage and allow water entry.

Use LOFA provided cavity plugs to seal the connector if wires are removed.

Unsealed Connectors

For unsealed connectors exposed to the elements, LOFA recommends using dielectric grease to protect contacts.

Warning!

LOFA does not recommend using sealant with unsealed connectors.

Sealant traps moisture in the connector and encourages corosion.

Harness Routing

The minimum routing of radius of the wiring harnesses should be at least two times the diameter of the wiring harness. Bends should be avoided within 1 inch (25 mm) of any connector in order to avoid seal distortion allowing moisture to enter the connector.

463-3000-01 Rev D. 23-Sep-2013 11

Note

For harness length in excess of 10 ft a relay must be added to the start solenoid circuit.

A relay may also be required for the fuel run/stop solenoid.

LOFA offers starter relay kits for mounting near the engine.

12 463-3000-01 Rev D. 23-Sep-2013

Battery Circuit Requirements

Battery Positive Connection

The electronic panel operates on either a 12 VDC or 24 VDC electrical systems. The unswitched battery positive connection to the panel is made at the weather proof connector. The panel provides switched positive battery protected by a 15 Amp fuse (12 V or 24 V systems).

Protection for the unswitched battery positive circuit is dependent on specific equipment configuration. The overload protection should not exceed 125% of the sum of all output currents plus 5 Amps for the panel. Powering the panel through dedicated circuits with appropriate overload protection reduces the possibility of panel damage.

Circuit breakers are preferred over in-line fuses for circuit protection. Over current protection devices should ideally be located in a central location. If automatic reset circuit breakers are used, consideration of the environment of the breaker is critical and may affect the trip point.

The trip point of some circuit breakers can be significantly reduced below the rated trip point if the circuit breaker is exposed to high temperatures.

Warning!

Disconnecting the battery while the engine is running may damage electrical components.

When using a battery disconnect switch, LOFA recommends using a

2 pole switch to disconnect both the battery and alternator output.

Battery Negative Connection (Grounding)

Warning!

Improper grounding can cause electrical noise, unreliable operation and may damage the panel or other components. All ground connections must be free from foreign materials, including paint, which may interfere with proper grounding.

A reliable ground must be provided for the panel.

LOFA recommends the ground connection be made directly to the battery negative.

Grounding through frame members is not recommended.

All ground paths must be capable of carrying any likely fault currents.

Do not reverse the battery polarity. Attempting to crank the engine when the polarity of the battery connections is reversed may damage the panel.

Note

A maximum of three ring terminals should be connected to a ground stud in order to ensure integrity of the ground connection. The use of more than three terminals can cause the connection to become loose.

Voltage Drop

If panel voltage drops below 6 volts for more than one tenth of a second, the panel may reset causing the self-test to reactivate and the engine to shut down after 10 seconds. Resetting the panel is equivalent to quickly turning the key switch to off and back to run without starting the

463-3000-01 Rev D. 23-Sep-2013 13 engine. Since the panel did not sense a start signal, the fuel run/stop solenoid deactivates after

10 seconds. Voltage drops can be caused by external equipment inrush current, improper wire sizes or faulty wiring. Relays may be needed for long wire runs.

Suppression of Voltage Transients (Spikes)

Warning!

The installation of voltage transient suppression at the transient source is required.

LOFA follows SAE recommended electrical environment practices.

Inductive devices such as relays, solenoids and motors generate voltage transients and noise in electrical circuits. Unsuppressed voltage transients can exceed SAE specifications and damage electronic controls.

I

Relays and solenoids with built-in voltage transient suppression diodes are recommended whenever possible. Refer to the illustration for proper installation of diodes when built-in voltage transient suppression is not available.

Locate inductive devices as far as possible from the components of the electronic panel. When using electric motors it may also be necessary to add isolation relays to eliminate voltage transients, noise and prevent back feed.

Note

LOFA harness assemblies typically include all required engine control suppression devices. Added equipment will require additional protection.

14 463-3000-01 Rev D. 23-Sep-2013

Welding on Equipment with Electronic Controls

Proper welding procedures are required to avoid damage to electronic controls, sensors, and associated components. The component should be removed for welding if possible.

The following procedure must be followed if the component must be welded while installed on equipment with electronic controls. This procedure will minimize the risk of component damage.

Warning!

Do not ground the welder to electrical components such as the control ground or sensors. Improper grounding can cause damage to electrical components

Clamp the ground cable from the welder to the component being welded. Place the clamp as close as possible to the weld to reduce the possibility of damage.

1. Stop the engine. Turn the key switch to the OFF position.

2. Disconnect the negative battery cable from the battery.

3. Open any installed battery disconnect switch.

4. Unplug the panel if possible.

5. Connect the welding ground cable as close as possible to the area to be welded.

6. Protect the wiring harness from welding debris and spatter.

7. Use standard welding methods to weld the materials.

463-3000-01 Rev D. 23-Sep-2013 15

General Troubleshooting

For additional information, refer to engine manufacturer troubleshooting guide.

No response from starter motor

Possible Cause Possible Remedy

No battery voltage to starter

Verify wiring and battery connection (power and ground)

Battery discharged Charge or replace battery, verify alternator charging

Tripped overcurrent protection

Correct fault, replace or reset overcurrent protection

No signal from panel No power to panel (see Panel Troubleshooting below)

Defective starter solenoid Replace starter solenoid

Defective starter motor Replace starter motor

Engine will crank but not start

Possible Cause Possible Remedy

Engine not getting fuel Check fuel level, filter, fuel pump, verify no air in fuel lines

Fuel run/stop solenoid not engaged

See Fuel Solenoid Run/Stop Troubleshooting (below)

Tripped overcurrent protection

Correct fault, replace or reset overcurrent protection

No preheat (cold condition)

See Preheat Troubleshooting

Engine runs for 10 seconds and shuts down

Possible Cause Possible Remedy

Shutdown switch input active

Verify shutdown source exists, correct condition or correct faulty circuit

Battery not charging Verify alternator charging (see Alternator not charging battery below)

Control board did not sense start signal

Engine started through alternate method (i.e., manual air start, push start, etc.)

Defective panel See Panel Troubleshooting (below)

Engine runs longer than 10 seconds and shuts down

Possible Cause Possible Remedy

Shutdown switch input active

Correct engine fault, verify shutdown switch wiring

Circuit overload protection tripped

Correct overload, keep panel from overheating

(over 185° F/85° C)

Voltage transients (spikes) Add suppressor diodes, protect from nearby lightning strikes, shield induced spikes from other equipment, add electric motor control relay

Defective panel See Panel Troubleshooting (below)

16 463-3000-01 Rev D. 23-Sep-2013

Alternator not charging battery

Possible Cause Possible Remedy

Broken or slipping alternator drive belt

Adjust or replace alternator drive belt

Alternator not excited Verify excitation circuit connected, replace faulty regulator, add additional excitation resistor

Alternator output not connected

Install charge wire

Alternator not grounded Clean or add ground connection

Alternator faulty Replace faulty alternator

Fuel Run/Stop Solenoid Troubleshooting

Engine does not stop immediately

Possible Cause Possible Remedy

Back feed from motor (i.e., cooling fan)

Add relay or blocking diode

Sticking solenoid linkage Repair or replace solenoid linkage

Fuel valve without check valve

Install or repair check valve

Fuel run/stop solenoid does not engage

Possible Cause Possible Remedy

No power to solenoid Locate reason for lack of power and correct (Circuit overloaded?

Failed suppressor diode? Faulty wiring?)

No power to solenoid pull coil

Correct faulty wiring, check pull control circuit (see Power Box

Troubleshooting below)

Incorrect linkage adjustment

Adjust solenoid linkage

Faulty solenoid Replace solenoid

Failed suppressor diode Correct wiring (diode reversed?), replace suppressor diode

Optional e-stop engaged Disengage e-stop

Engine not getting fuel

Possible Cause Possible Remedy

Empty fuel tank Fuel engine

Clogged filter Replace filter

Air in fuel lines Bleed fuel lines

Low fuel pressure Replace faulty fuel pump and/or clogged filter

Faulty fuel pump Replace fuel pump, correct wiring fault (electric fuel pump)

463-3000-01 Rev D. 23-Sep-2013 17

Preheat Troubleshooting

Engine is hard to start in cold conditions

Possible Cause Possible Remedy

Start attempt before preheat complete

Wait for preheat time to elapse, crank as soon as time elapses

Incorrect preheat specification

Correct panel configuration, install correct panel

Heater faulty Replace heater

Heater relay faulty Replace relay

Preheat control not functioning

Correct wiring, correct panel configuration

Faulty panel See Panel Troubleshooting (below)

Engine produces excessive white smoke after starting

Possible Cause Possible Remedy

Afterglow not enabled Reconfigure panel

Heater faulty Replace heater

Heater relay faulty Replace relay

Preheat control not functioning

Correct wiring, correct panel configuration

Faulty panel See Panel Troubleshooting (below)

Panel Troubleshooting

Panel does not perform self-test

Possible Cause Possible Remedy

Tripped overcurrent protection

Correct fault, replace or reset overcurrent protection

Faulty connection to battery

Correct battery connections (see Battery Circuit Requirements above)

Panel performs normal self-test, engine cranks, runs and shuts down

Possible Cause Possible Remedy

Only Battery LED illuminated

Correct battery charge failure (see Battery not charging above)

Only Oil Pressure LED

Illuminated

Correct low oil pressure condition or faulty switch, correct wiring fault

Only Temperature LED

Illuminated

Correct overheating condition or faulty switch, correct wiring fault

Only Aux LED Illuminated Correct fault condition (i.e. v-belt, coolant level) or faulty switch, correct wiring fault

All normally closed shutdowns illuminate for one second (panel reset)

Add suppressor diodes, protect from nearby lightning strikes, shield induced spikes from other equipment, add electric motor control relay

18 463-3000-01 Rev D. 23-Sep-2013

Testing Shutdown Inputs

Shutdown switches signal a fault by ground contact in most systems. Shutdown operation can be verified by grounding the shutdown inputs individually. It may be necessary to remove the wire from the shutdown switch to perform this test.

Note

Most shutdown switches are grounded through the switch body.

Do not use insulating sealant (i.e. Teflon tape) when installing switches.

Some thermostat housings are composites and do not provide ground for the switch.

Document Revision History

Rev A: 22-May-2006 Corrected typographical errors

Rev B: 26-Oct-2006 Add symbols to Indicators, corrected typographical errors

Rev C: 8-Jan-2007 Updated schematics, removed Power Box information

Rev C.1: 28-Feb-2007 Added part numbers

Rev D: 23-Sep-2013 Updated format, removed DPG references, updated schematics.

Typical Schematics

The following pages show typical schematics.

Details vary from installation to installation.

See the specific schematics for installation for details.

J2

6 7 8 9 1

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