TSN Priority III

1. General information

Deutz - Starter Motor

TSN Number : APP 2582
Priority : 3
Applicable to : XA(T,H)S 37-137 Dd - XA(T,H)S 70-300 Dd7
PGC : 401, 402, 403, 404
Responsible person : Nick Van Puyvelde

2. Document overview
This document describes the following:
1. General information ........................................................................................................................................................1
2. Document overview ........................................................................................................................................................1
3. Subject ...........................................................................................................................................................................1
4. Reason for this TSN .......................................................................................................................................................1
5. Description .....................................................................................................................................................................2
6. Application......................................................................................................................................................................2
7. Required parts ................................................................................................................................................................3
8. Planning ordering parts at ASC ......................................................................................................................................3
9. Reimbursement criteria ..................................................................................................................................................3
10. Reporting........................................................................................................................................................................3

3. Subject
Starter motor failures occurring after introduction of new starter motor in the Deutz 2011 engines.

4. Reason for this TSN

Starter motor failures started to show up in an elevated number after Deutz switched starter motor supplier (Bosch > Iskra).
Since this occurrence several discussions where held with Deutz AG, coming to a conclusion that only installation of a SSR
(Start Stop Relay) could resolve the issue.
In practice the shown damage will be a broken gear shaft or damaged gear teeth on the starter motor. This failure pattern is
caused by a collision between the pinion gear of the starter motor and gear rim of the flywheel.
Multiple causes can lead to starter motor failures:
- Bad operation by the customer
By cranking the machine without respecting the needed time in between 2 starting attempts (as described in
corresponding AIB’s), a collision between pinion gear and gear rim is very likely to occur.
Damages due to this misuse are to be classified as “customer abuse” and can be avoided by clearly instructing the
customer on how to use his machine in a correct way. (These failures are to be assessed as not warrantable)
- Hand primer pump defective
In the year 2005 the hand primer pump was introduced (ECB AIP 2335) to avoid starting problems, but also starter
motor failures. Recently we noticed that these hand primer pumps tend to fail from time to time, which also might
result in starter motor failures.

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 For this reason it is needed to always inspect the hand primer pump when a starter motor failure occurred. If a
failure of this hand primer pump is noticed, a “supplier failure report” should be created to inform the responsible
product company.
- Other causes
For multiple mechanical reasons (and in lesser extent electrical reasons) the steering signal to the starter motor can
fluctuate around its trigger level, causing the pinion gear to jump in & out the gear rim. This again might result in
gear collisions.

With the introduction of the SSR all above discussed failures can be avoided. This is one of the reasons why on future
machines this SSR option will be installed as standard on involved machine types (serial number of introduction will be
communicated in the coming ECB).

5. Description
The SSR should be installed at the right side of the machine, at the bottom of the rear baffle. Connections of the SSR should
point downwards in order to prevent for water ingress. For mounting on metal units, rivets or bolts are to be used; on PE
machines self tapping screws are most suitable.
Electrical connections are to be made as described below:

- Connections “50e” & “50f” to be connected as described in above schematic. Please note that they can not be swapped.
- Connection between “K4” and “K0” to be deleted
- “D+” connection is indicated as “WL” on the alternator
- “W” connection is indicated as “1” on the alternator; an extra electrical wire should be added.
- Other connections to be added as shown in above schematic

Electrical cables and cable clamps are to be installed with good workmanship to prevent for bad signals, short circuit …
It is advised to use current wire routings for mounting of additional wires.

6. Application
XA(T,H)S 37-137 Dd - XA(T,H)S 70-300 Dd7

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7. Required parts
Part Name Part Number Required Qty.
HOUSING 2913 1815 00 1
SOCKET CONTACT 2913 1816 00 6
GASKET 2913 1817 00 6
DUMMY PLUG 2913 1818 00 1
START STOP RELAY 2913 1819 00 1

8. Planning ordering parts at ASC

Parts are available from ASC.
As final solution is going to be made available in a couple of weeks, stocking above parts should be avoided.

9. Reimbursement criteria
Within warranty period: Standard warranty procedure and conditions
Out of warranty period: No coverage

10. Reporting
To be reported via standard warranty procedure.
If a failure occurs on a unit equipped with above solution, a failure report should be created in order to inform the responsible
product company.

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