sdmo user and maintenance manual.pdf

7/16/2019 SDMO User and maintenance manual.pdf

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User and maintenance manualfor generating sets

R66

33501719801NE_2_1



1. Preface ..................................................................................................................................................................................................3

1.1. General recommendations .......................................................................................................................................................3

1.2. Pictograms and their meanings................................................................................................................................................4

1.3. Instructions and safety regulations...........................................................................................................................................8

1.3.1 General advice.........................................................................................................................................................................8

1.3.2 Risks related to exhaust gases and fuels.................................................................................................................................9

1.3.3 Risks related to toxic products .................................................................................................................................................9

1.3.4 Risk of fire, burns and explosion............................................................................................................................................10

1.3.5 Risks related to electrical networks........................................................................................................................................10

1.3.6 Dangers presented by electric currents (first aid)...................................................................................................................11

1.3.7 Risks related to moving the set..............................................................................................................................................11

1.4. Identifying sets ....................................................................................................................................................................... 12

2. General description..............................................................................................................................................................................14

2.1. Description .............................................................................................................................................................................14

2.2. Technical specifications .........................................................................................................................................................20

2.3. Fuel and consumables...........................................................................................................................................................22

2.3.1 Specifications.........................................................................................................................................................................22

2.3.1.1. Oil grades..................................................................................................................................................................22

2.3.1.2. Specifications of coolants..........................................................................................................................................23

3. Installation............................................................................................................................................................................................25

3.1. Unloading............................................................................................................................................................................... 25

3.1.1 Safety during unloading.........................................................................................................................................................25

3.1.2 Instructions for unloading.......................................................................................................................................................25

3.1.2.1. Slings ........................................................................................................................................................................ 25

3.1.2.2. Fork lift truck..............................................................................................................................................................25

3.2. Fluid retention.........................................................................................................................................................................26

3.3. Choice of location...................................................................................................................................................................27

3.4. Electricity................................................................................................................................................................................ 28

3.5. Special arrangements ............................................................................................................................................................29

4. Trailer...................................................................................................................................................................................................30

4.1. Trailer linkage.........................................................................................................................................................................30

4.2. Check before towing...............................................................................................................................................................30

4.3. Operation ...............................................................................................................................................................................31

4.4. Unhitching the trailer ..............................................................................................................................................................31

4.5. Implementation for installation................................................................................................................................................32

4.6. Break transmission adjustment..............................................................................................................................................32

4.7. Faults and repairs...................................................................................................................................................................34

4.8. Electrical connection diagram.................................................................................................................................................35

4.9. Complete wheels technical information..................................................................................................................................35

5. Preparation before operating the set ...................................................................................................................................................36

5.1. Installation checks.................................................................................................................................................................. 36

5.2. Checks after starting the generating set.................................................................................................................................36

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6. Using the generator set........................................................................................................................................................................36

6.1. Pre-Start Inspection................................................................................................................................................................36

6.2. Generator set with NEXYS control panel................................................................................................................................39

6.2.1 Control panel presentation .....................................................................................................................................................39

6.2.1.1. Introduction to pictograms .........................................................................................................................................40

6.2.2 Manual starting.......................................................................................................................................................................41

6.2.3 Switching off...........................................................................................................................................................................42

6.2.4 Alarms and faults....................................................................................................................................................................42

6.2.5 Faults and alarms - Details.....................................................................................................................................................42

6.3. Generator set with TELYS control panel ................................................................................................................................45

6.3.1 Control panel presentation .....................................................................................................................................................45

6.3.1.1. View of the front panel...............................................................................................................................................45

6.3.1.2. Description of the screen...........................................................................................................................................47

6.3.1.3. Description of the pictograms in zone 1.....................................................................................................................48



6.3.1.6. Display of messages in zone 4..................................................................................................................................52

6.3.2 Starting...................................................................................................................................................................................56

6.3.3 Switching off...........................................................................................................................................................................57

6.3.4 Alarms and faults....................................................................................................................................................................57

6.3.4.1. Viewing alarms and faults..........................................................................................................................................57

6.3.4.2. Activation of an alarm or fault....................................................................................................................................58

6.3.4.3. Activation of an alarm and a fault..............................................................................................................................59

6.3.4.4. Engine fault codes display.........................................................................................................................................60

6.3.4.5. Horn reset..................................................................................................................................................................61

7. Maintenance schedule.........................................................................................................................................................................62

7.1. Reminder of use.....................................................................................................................................................................62

7.2. Engine ....................................................................................................................................................................................62

7.3. Alternator................................................................................................................................................................................62

8. Battery..................................................................................................................................................................................................63

8.1. Storage and transport.............................................................................................................................................................63

8.2. Battery setting into service......................................................................................................................................................64

8.3. Check.....................................................................................................................................................................................64

8.4. Load preconization .................................................................................................................................................................65

8.5. Faults and remedies ...............................................................................................................................................................66

9. Appendix..............................................................................................................................................................................................67

9.1. Appendix A – Engine user and maintenance manual.............................................................................................................67

9.2. Appendix B - Alternator user and maintenance manual .......................................................................................................191

9.3. Appendix C - Common spare parts ......................................................................................................................................243

9.4. Appendix D - List of J ohn Deere - Volvo and Perkins fault codes.........................................................................................245

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1. Preface

1.1. General recommendations

Thank you for choosing an electrical generating set from our company.

This manual has been designed to help you operate and maintain your electrical generating set correctly. The information contained in this manual is taken from technical data available at the time of print. In line with our policy of continually

improving the quality of our products, this information may be amended without warning.

Read the safety instructions attentively in order to prevent any accidents, faults or damage. These instructions must always befollowed.

You are likely to encounter several warning symbols in this manual.

Danger

This symbol indicates an immediate danger to human health and life in case of exposure. Failure tofollow the corresponding advice entails serious consequences for human health and life in case of exposure.

Warning

This symbol draws attention to the potential risks to human health and life in case of exposure. Failure to followthe corresponding advice entails serious consequences for human health and life in case of exposure.

Important

This symbol indicates a dangerous situation if the warning is not heeded.Failure to follow the corresponding advice risks resulting in minor injury of personnel or damage to any otherobject in case of exposure.

In order to obtain optimum efficiency and the longest possible life for the electrical generating sets, maintenance operations must becarried out according to the periods indicated in the attached preventative maintenance tables. If the electrical generating set is usedunder dusty or unfavourable conditions, some of these periods will be shorter.

Ensure that all repairs and adjustments are carried out by personnel who have received appropriate training. Dealers have thisqualification, and can answer all of your questions. They can also supply you with spare parts and other services.

The left and right sides can be seen from the back of the electrical generating set (the radiator is at the front).

Our electrical generating sets have been designed so that damaged or worn parts can be replaced by new or reconditioned partsthereby reducing the out of action period to a minimum.For any replacement of parts, contact your nearest dealer for our company who will have the necessary equipment and can offerproperly trained and informed staff to carry out maintenance, parts replacement and even total reconditioning of generating sets.

Contact your local dealer for the available repair manuals and to make the necessary arrangements for training personnel inimplementation and maintenance.

Important

Some user and maintenance manuals for the engines fitted to generating sets cover control units and includethe start-up and shutdown procedures for the engines.As the generating sets are fitted with control units that are specific to the generating sets, only the informationthat appears in the documentation for the generating sets' control units should be taken into consideration.In addition, according to the manufacturing criteria of the generating sets, some engines may be fitted withspecific electrical wiring different to that described in the engine documentation.

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1.2. Pictograms and their meanings

Safety notices are clearly mounted on the equipment to draw the operator's or maintenance technician's attention to the potentialdangers and explain the action to be taken in the interest of safety. These notices are reproduced in this publication for ease of dentification by the operator.Replace any notice that is missing or illegible.

Caution: dangerPublications deliveredwith the generating setmust be referred to

Caution: risk of explosion

Caution: risk of electric shock

Protective clothingmust be worn

Naked flames andunprotected lightsprohibited.No smoking

Caution: toxicmaterials Eyes and ears must beprotected Entry prohibited to non-authorised persons

Caution:pressurised fluids

Periodic maintenancemust be carried out

J et washing prohibited

Caution: hightemperature, riskof burns

Battery level must bechecked

Earth

Caution: rotatingor moving parts(risk of gettingcaught in themachinery)

Lifting point must beused

Caution: corrosive product

Fork pockets forlifting

Retention tank levelhigh

c Important: refer to the documentation accompanying the generating set.d Important: emission of toxic exhaust gases. Do not use in a confined or badly ventilated

area.

c d

Figure 1.1: Pictograms and their meanings

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WARNING: DANGER

This symbol warns of a safety hazard. The presence of this symbol indicates a riskof injury.

Observe the safety instructions and precautions for use.

Important:Carefully read the instructions supplied with the generating set before using orservicing the equipment.

WARNING: DANGER

Risk of electrocution Do not touch the cables or connections when the generating set is in operation. Switch off the generating set for maintenance operations.

DANGER

Use diesel fuel only.

The fuel is highly flammable, handle with care. Do not smoke near thegenerating set or expose it to a naked flame or sparks. Shut down the generating set engine before filling the fuel tank. Fill with fuel

outside. To prevent fire risks, clean the generating set regularly. Wipe away any dirt and

traces of grease or fuel.

WARNING: DANGER

The exhaust gases from the engine are toxic and can affect health or evencause death.

Use the generating set outdoors only, in well ventilated areas, or fit an exhaustextension to discharge the exhaust gases outside.

Figure 1.2: Pictograms and their meanings

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WARNING: DANGER

Hot coolant can cause serious burns. Switch off the engine. Do not remove the filler cap until it is completely cold. Do not open the radiator when it is hot.

DANGER

Rotating parts can cause serious injury.

Do not operate the generating set with the doors open. Do not remove the enclosures. Shut down the generating set before any maintenance or servicing

operation.

DANGER

Avoid any contact with the exhaust pipes, turbochargers and silencers.Keep flammable materials away from hot parts.

Wait for the machine to cool down completely before touching it.

WARNING: DANGER

The gas from the battery electrolyte is explosive. Keep the batteries awayfrom any flames.

The battery electrolyte (sulphuric acid) is toxic. Risk of poisoning.

Figure 1.2 (continued): Pictograms and their meanings

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WARNING: DANGER

A poor earth connection can lead to serious injuries or death. Always connect the earth terminal of the generating set to an external earth

terminal.

WARNING

Voltage selector This function should be used by qualified persons only.

WARNING

Adjust the output voltage correctly before connecting a load.

WARNING

The voltage selector must not be used when the generating set is operating.

Figure 1.2 (continued): Pictograms and their meanings

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1.3. Instructions and safety regulations

THESE SAFETY GUIDELINES ARE IMPORTANT

f you do not understand or have any questions about any point in this manual, contact your dealer who will explain it to you or give youa demonstration. A list of risks and precautionary measures to take follows. You should also refer to any local and national regulationsthat apply in accordance with your own jurisdiction.

KEEP THIS MANUAL

This manual contains important instructions which must be followed when installing or carrying out maintenance on a generating set orbatteries.

1.3.1 General advice

Use9 The operating and safety instructions must be made known to operating personnel. They will be regularly updated.9 Read and understand the manuals provided with the generating set, pump unit or lighting column properly. The manufacturer's

instructions must remain at the disposal of technicians, if possible in situ.9 The facility must be operated under the direct or indirect supervision of a person appointed by the operator, who is familiar with the

operation of the facility, and the dangers and drawbacks of the products used or stored in the facility.9 Do not wear loose clothing, or get close to machines in operation. Note that the fans are not clearly visible when the engine is

running.9 Warn personnel present to keep their distance during operation.9 Do not run the generating set, pump unit or lighting column without refitting the protective covers and closing all the access doors.9 Never let a child touch the generating set, pump unit or lighting column, even when shut down.9 Avoid operating the generating set, pump unit or lighting tower in the presence of animals (disturbance, scares, etc.).9 Engage the parking brake when the generating set or lighting tower on its trailer is installed on the operating site. When chocking

the trailer on a slope; ensure that there is nobody in the path of the trailer.9 Never start the engine without an air filter or exhaust.9 Engine with turbocharger: never start the engine without fitting the air filter. The compressor wheel rotating inside the turbocharger

may cause serious bodily injury. Foreign objects in the inlet pipe may cause mechanical damage.9 Engine with air preheating (starting components): never use a starting spray or any other similar starter assistance product. Upon

contact with the starting component, an explosion may occur in the inlet tube, causing bodily injury.9 Do not touch the lighting column lights when they are switched on.

Maintenance

9 Follow the maintenance table and its instructions.9 Always use tools in good condition which are suited to the work to be done. Ensure you have understood the instructions before

beginning any operation.9 Goggles should be worn when carrying out maintenance operations and watches, bracelets etc. should be removed.9 Fit only original parts.9 Disconnect the battery and the pneumatic starter (if fitted) before undertaking any repairs, to prevent the engine from starting

accidentally. Fit a panel over the controls to prevent any attempt to start.9 Only use the correct crankshaft turning techniques for turning the crankshaft manually. Do not try to turn the crankshaft by pulling it

or levering the fan. This method may cause serious bodily or material damage, or damage the vanes of the fan, reducing theservice life of the fan.

9 Clean off any trace of oil, fuel or coolant using a clean cloth.9 Do not use a soapy solution containing either chlorine or ammonia, as these two chemicals prevent bubble formation.9 Never use petrol or other inflammable substances to clean the parts. Use only approved cleaning solvents. 9 Do not use a high pressure cleaner for cleaning the engine and equipment. The radiator, hoses, electrical components, etc. may

be damaged.9 Avoid accidental contact with parts at high temperatures (exhaust manifold, exhaust).9 Before any maintenance operation on a lighting column light, cut the electrical power supply and wait for the bulbs to cool down.

Consumables9 Observe regulations in force concerning use of fuel before using your generating set, pump unit or lighting tower.9 Under no circumstances use seawater or any other corrosive or electrolytic product in the cooling circuit.

Environment9 The operator must take the necessary measures to comply with the aesthetics of the site of use. The whole site must be

maintained in a good state of cleanliness.9 The premises must be kept clean, and be regularly cleaned so as to avoid accumulation of dangerous materials or pollutants and

dust, which could ignite or cause an explosion. The cleaning equipment must be suited to the risks posed by the products anddust.

9The presence of dangerous or combustible materials inside premises housing combustion devices shall be limited to the operatingrequirements.

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9 Facilities must be operated under the constant supervision of a qualified person, who must regularly check that the safety devicesare operating correctly and ensure that the combustion devices have the correct fuel supply.

9 Apart from the combustion devices, it is prohibited to use fire in any form. This restriction must be clearly displayed.9 Spreading of waste water, sludge and waste is prohibited.9 The fuels to be used must correspond to those featured in the declaration file and the specifications recommended by the

combustion device manufacturer.9 The fuel is considered to remain in the same physical state as when it is introduced into the combustion chamber.9 Burning of waste in the open air is prohibited.9 Always protect your hands when checking for leaks. Pressurised liquids may penetrate body tissue and cause serious damage.

Risk of blood contamination.9 Drain and dispose of engine oil in a specially provided container (fuel distributors can collect your used oil).9 Except by special agreement, once closed, the gas supply main unit must only be re-opened by the gas distributor. However, the

user may access it under certain conditions. Check these for each site.

1.3.2 Risks related to exhaust gases and fuels

Danger

The carbon monoxide present in exhaust gases may cause death if the concentration levels in the air breathed are too high. Alw ays use generat ing sets, pump units or lighting towers in a wel l-vent ilated place where gases cannotaccumulate.In case of indoor use:9 Be sure to evacuate exhaust gases outdoors.9 Provide appropriate ventilation so that personnel present are not affected.

9 Observe the local regulations in force for generating sets, pump units or lighting towers, as well as local regulations for use of fuel

(petrol, diesel fuel and gas) before using your generating set, pump unit or lighting tower.9 Fuel filling should be carried out when the engine is off (except for generating sets with an automatic filling system).9 Engine exhaust gases are toxic: do not run the generating set, pump unit or lighting column in unventilated premises. If installed in

a ventilated room, additional requirements for fire and explosion protection must be observed.9 A leaking burnt gas exhaust may increase the sound level of the generating set, pump unit or lighting column. To check on its

efficiency, regularly examine the burnt gas exhaust.9 Pipes must be replaced as soon as their condition demands it.

1.3.3 Risks related to toxic products

Warning

The corrosion inhibitor contains alkali.Do not swallow it.This substance should not come into contact with theeyes. In the event of contact with the eyes, rinseimmediately with plenty of water for at least 15minutes. Avoid prolonged or repeated contact with the skin. Inthe event of contact with the skin, wash thoroughlywith water and soap. CONSULT A DOCTORIMMEDIATELY. KEEP THE PRODUCT OUT OFTHE REACH OF CHILDREN.

The anti-rust product is toxic and dangerous if absorbed. Avoid all contact with the skin and eyes.Read the instructions on the packaging.

Glycol is a toxic product and dangerous if absorbed. Avoid all contact with the skin and eyes. Read theinstructions on the packaging.

9 Caution: fuels and oils are dangerous to inhale. Ensure proper ventilation, and use a protective mask.9 Never expose the equipment to liquid splashes or rainfall, and do not place it on wet ground.9

The battery electrolyte is harmful to skin and especially eyes. If splashes get into eyes, rinse immediately with running water and/or a 10% diluted boric acid solution.9 Wear protective eyewear and strong base resistant gloves for handling the electrolyte.

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1.3.4 Risk of fire, burns and explos ion

Danger

The engine should not be operated in environments containing explosive products. As not all of theelectrical and mechanical components are shielded, there is a risk o f sparks forming.

9 Make sure not to create sparks or flames, and not to smoke near the batteries, as the electrolyte gases are highly flammable(especially if the battery is charging). Their acid also poses a risk to the skin, and in particular to the eyes.

9 Never cover the generating set, pump unit or lighting tower with any material during operation or just after shutdown (wait for theengine to cool).

9 Do not touch hot parts such as the exhaust pipe, or put combustible materials on it.9 Keep all flammable or explosive materials (e.g. petrol, oil, cloth, etc.) out of the way when the set is running.9 Proper ventilation is required for your generating set, pump unit or lighting column to work properly. Without this ventilation, the

engine would very quickly rise to an excessively high temperature, causing accidents or damage to the equipment and tosurrounding property.

9 Do not remove the radiator cap if the engine is hot and the coolant is pressurised, due to risks of burns.9 Depressurise the air, oil and cooling circuits before removing or disconnecting all the fittings, pipes or connected components.

Watch out for the possible presence of pressure when disconnecting a device from a pressurised system. Do not try to findpressure leaks by hand. Oil at high pressure can cause bodily damage.

9 Some preservative oils are flammable. Also, some are dangerous to inhale. Ensure proper ventilation. Use a protective mask.

9 Hot oil causes burns. Avoid contact with hot oil. Check that the system is no longer pressurised before carrying out anyprocedures. Never start or run the engine with the oil filler cap off (oil may splash out).

9 Never coat the generating set, pump unit or lighting column with a thin layer of oil to protect it from rust.9 Never top up the oil or coolant if the generating set, pump unit or lighting column is running, or if the engine is hot.9 A generating set can only operate when stationary, and cannot be installed on a vehicle or other mobile equipment, without a prior

study taking into account the various specific features of using the generating set.

1.3.5 Risks related to electrical networks

9 The electrical equipment supplied with the generating set complies with standard NF C15.100 (France), or with the standards of thecountries in question.

9 The earth connection must be installed in accordance with the standards in force in each country in question, and with the neutralsystem sold.

9 Read the manufacturer's identification plate carefully. The values for voltage, power, current and frequency are shown. Check thatthese values match the supply use.

9Never accidentally touch stripped cables or loose connections.9 Never handle a generating set with wet hands or feet.

9 Maintain electrical wires and connections in good condition. Using equipment in poor condition can lead to electrocution anddamage to equipment.

9 Always disconnect the power to the equipment or facility (generating set voltage, battery voltage and network voltage) before any

operation.9 The electrical connections must be made in accordance with current standards and regulations in the country of use.9 Do not use faulty, poorly insulated or provisionally connected wires.9 Never reverse the positive and negative terminals on batteries when connecting them. This could cause severe damage to the

electrical equipment. Follow the wiring diagram supplied by the manufacturer.9 The generating set should not be connected to any other power sources, such as the mains supply network. In specific cases

where there is to be a connection to existing electrical networks, this must only be installed by a qualified electrician, who shouldtake the operating differences of the equipment into account, according to whether the mains supply network or generating set isbeing used.

9 Protection against electric shocks is ensured by an assembly of specific equipment. If this needs to be replaced, it should be bycomponents with identical nominal values and specifications.

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9 If the protective plates (blanking covers) need to be removed to route cables, the protector (blanking cover) must be refitted whenthe operations are finished.

9 Due to high mechanical stresses, use only strong flexible wiring with rubber sheathing, compliant with IEC 245-4, or equivalentwiring.

1.3.6 Dangers presented by electric currents (first aid) First aid

In the event of an electric shock, shut off the power immediately and activatethe emergency stop on the generating set or lighting column. If the voltagehas not yet been cut off, move the victim out of contact with the live conductoras quickly as possible. Avoid direct contact both with the live conductor andthe victim's body. Use a dry plank of wood, dry clothes or other non-conductive materials to move the victim away. The live wire may be cut withan axe. Take great care to avoid the electric arc that will be generated by this.

Begin emergency procedures

Resuscitation

If breathing has stopped, begin artificial respiration at once in the same place the accident took place unless the victim or operator's lifecould be endangered by this.In the event of cardiac arrest, carry out cardiac massage.

1.3.7 Risks related to moving the set To unload the generating sets, pump units or lighting columns from their transport support brackets under optimum safety andefficiency conditions, you must ensure that the following points are observed:9 The lifting machinery or equipment is suited to the work required, in good condition and with sufficient lifting capacity.9 The slings are positioned in the rings provided for this operation, the forklift arms are resting fully underneath all of the base frame

cross-beams, or the lifting bars are inserted in the apertures provided for this purpose in the base to lift the entire generating set(according to models).

9 For completely safe working conditions and to prevent damage to the components fitted on the upper edge of the set, pump unit orlighting column, the generating set, pump unit or lighting column must be lifted up with an adjustable boom. All the chains andcables must be parallel with each other, and as perpendicular as possible with the upper edge of the generating set, pump unit or

lighting column.9 If other equipment fitted on the generating set, pump unit or lighting column alters its centre of gravity, special lifting devices may benecessary to maintain correct balance and completely safe working conditions.

9 The ground must be able to withstand the load of the generating set, pump unit or lighting column and its lifting machinery withoutstress (otherwise, put down beams of sufficient strength in a stable configuration).

9 Position the generating set, pump unit or lighting column as close as possible to its place of use or transport, in a clear space withfree access.

9 Never perform work on a generating set, pump unit or lighting tower just hanging from a lifting device.

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1.4. Identify ing sets

Generating sets and their components are identified by means of identification plates.The precise rules for identifying each major component (engine, alternator etc.) are set out in each manufacturer's documentationcontained in the appendices of this manual.

1 - Generating set2 - Manufacturer name3 - Model4 - Serial number5 - Year of manufacture6 - Rated output (kVA and kW) according to the ISO

8528-1 standardPRP: main powerESP: emergency power

7 - Rated power factor8 - Maximum altitude of the site above sea level (m)

for the rated power

9 - Maximum ambient temperature for the rated power(°C)

10 - Rated frequency (Hz)11 - Generating set rotation speed (RPM)12- Rated voltage (V)13 - Rated current (A)14 - Weight (kg)15 - CE marking16 - Non CE standard marking

(e.g.: GOSSTANDART)17 - Sound pressure18 - Sound power

Figure 1.3: Example of generating set identification plate

Figure 1.4: Examples of engine identification plates

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Figure 1.5: Examples of alternator identification plates

Control box

Figure 1.6: Example of control box identification plate

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2. General description

2.1. Descr iption

Overview

Figure 2.1: General description of the generating set

1 Electric sockets 7 Circuit breaker2 Connection termination box 8 Starter battery3 Circuit breakers 9 Control unit4 External emergency stop 10 Chassis5 Protective grilles 11 Filling with fuel6 Battery charge alternator

11

3 4 5

6

7

8

9

10

1

2

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Fittings

Socket control panels and terminals by enclosure type:

TYPE 2 - HI05

12

MAX CONNECTION CABLE CROSS-SECTION 185MM²Ø M12 BOLT; Ø M12 NUT

1

2

TO CIRCUIT BREAKERSN1 R1 S1 T1

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TYPE 2 TT EDF OPTION HI05

12

MAX CONNECTION CABLE CROSS-SECTION 185MM²Ø M12 BOLT; Ø M12 NUT

NF C15-100 EARTHINGSYSTEM

EDF EARTHINGSYSTEM

Connect to the earthing rod EDF earth

N1 R1 S1 T1

TO CIRCUIT BREAKERS

21

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M128/M129 50Hz FR

C 32

2423124485

C60N

C16

multi 9

23201

ID

MERLINGERIN

multi 9

63A

8

9

7

5

4

3

2

61

multi9

C 60N

32A400V

12801

3P+N+

IP44

BALS

123456789

DIFFERENTIAL SWITCH (Q10) 4x63A 30 mAX03 16A 400V SOCKET16A CIRCUIT BREAKER (Q08)X08 16A 230V SOCKET4x32A CIRCUIT BREAKER (Q02)4x16A CIRCUIT BREAKER (Q03)X02 32A 400V SOCKET16A DIRUPTOR CIRCUIT BREAKER (Q05)X05 16A 230V SOCKET

1

2

3

4

5

6

7

8

9

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M128/M129 50Hz EU

400V

12567

3P+N+

IP44

BALS

63A

24234

C 63

C 60N

multi 9multi 9

8

9

7

5

4

3

2

61

23196

ID

MERLINGERIN

multi9

40A

24485

C 60N

C 16

multi 9

123456789

DIFFERENTIAL SWITCH (Q10) 4x40A 30 mAX03 16A 400V SOCKET16A CIRCUIT BREAKER (Q09)X09 16A 230V SOCKET4x63A CIRCUIT BREAKER (Q01)4x16A CIRCUIT BREAKER (Q03)X01 63A 400V SOCKET16A DIRUPTOR CIRCUIT BREAKER (Q05)X05 16A 230V SOCKET

1

2

3

4

5

6

7

8

9

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M128/M129 50Hz UK

123456

DIFFERENTIAL SWITCH (Q03) 4x40A 30 mAX01 125A 400V 3P+N+T SOCKET1X32A DIRUPTOR CIRCUIT BREAKER (Q04, Q05, Q06)4x63A CIRCUIT BREAKER (Q02)X02 63A 400V 3P+N+T SOCKETX04, X05, X06 32A 220V SOCKET

1

2

3

4

5

6

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2.2. Technical speci fications Range / Generating set type RENTAL POWER / R66

Weights and Dimensions

Dimensions wi th standard tank

Dimensions l x w x h: 2300mm x 1080mm x 1680 mm

Weight: 1470kg dry weight 1670kg in operating configuration

Hood:M128

Noise level:66 dB @ 7 m92 Lwa

Dimensions with high autonomy tank

Dimensions l x w x h:2344mm x 1080mm x 1900mm

Weight:1697kg dry weight 2087kg in operating configuration

Hood:M128-DW

Noise level:66 dB @ 7 m92 Lwa

Output

Voltage Hz Phase Load factor Max current (A)

Emergency/PrimeEmergency power

1

kW / kVAPrime power

2

kW / kVA

400/230 50 3 0.8 95 / 86 53 / 66 48 / 60

1) ESP: Stand-by output available for emergency use under variable charge up to 200hrs per year as per lSO 8528-1, no overloadavailable under these service conditions.

2) PRP: Main output available continuously under variable load for an unlimited time period per year as per ISO 8528-1, an overload of 10% one hour every 12 hours is available, as per ISO 3046-1.

Engine data

Manufacturer / model JOHN DEERE 4045TF120

Type 4-cycles, Turbo

Cylinder configuration 4 XL

Cubic capacity 4.48L

Rotation speed 1500 Rpm

Max emergency/prime power at nominal speed 68 / 61 kW

Adjustment type Mechanical

Fuel consumption

110 % (emergency power) 17.5L/h

100 % main power 16 L/h

75 % main power 12L/h

50 % main power 8.5 L/h

Fuel

Fuel type DieselStandard fuel tank 180 L

High autonomy fuel tank 390 L

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Lubrication

Oil capacity with filter 13.5LMin. Oil pressure 1 barNominal oil pressure 5 barOil consumption (100 % load) 0.016 L/hOil sump capacity 12.5 L

Type of lubricant Genlub

Cooling

Engine capacity with radiator 23.6LMax coolant temperature 105 °CFan power 2 kWVentilator air flow 2.53 m3/sRefrigerant type Gencool

Thermostat 82-94 °C

Emissions

HC 150 mg/Nm3CO 190 mg/Nm3NoX 3800 mg/Nm3PM 60 mg/Nm3

Al ternator data

Compliant with NEMA MG21 standards, UTE NF C51.111,VDE 0530, BS 4999, IEC 34.1, CSA

The alternator is protected against short circuits Vacuum impregnation, epoxy winding, IP23 protection rating

Type LEROY SOMER LSA432M45Number of phases 3Power factor (cos Phi) 0.8Number of poles 4Excitation type AREPVoltage regulator R438Short-circuit current 3 INNumber of bearings 1Coupling Direct

Control unit(s)

NEXYS

Standard specifications:Frequency meter, Voltmeter, AmmeterAlarms and faults:Oil pressure, Coolant temperature, Fail to start, Overspeed,Alternator min/max, Fuel level low, Emergency shutdownEngine parameters:Working hours counter, Engine speed, Battery voltage, Fuel Level,Air Preheating

TELYS

Standard specifications:Voltmeter, Ammeter, Frequency meterAlarms and faults:Oil pressure, Water temperature, Start failure, Overspeed,Alternator min/max, Battery voltage min/max, Emergency stopEngine parameters:

Timer, Oil pressure, Water temperature, Fuel level, Engine speed,Battery voltage

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2.3. Fuel and consumables

All specifications (product features) are given in the motor and alternator maintenance manuals attached to this manual.n addition, we recommend the consumables to be used in the "specifications" section.

2.3.1 Specifi cations

2.3.1.1. Oil gradesEngine Oil

Make Type Make Type J ohn Deere J ohn Deere PLUS-50

J ohn Deere AllGenPARTS GENLUB TDX 15W40

MITSUBISHI All GenPARTS GENLUB TDX 15W40Volvo All GenPARTS GENLUB TDX 15W40

GENLUB TDX 15W-40Top-of-the-range lubricant recommended for diesel engines: for generating sets used under severe conditions.

USES:

9 Particularly suited to more modern engines with or without turbochargers, intercoolers, or sophisticated injection systems (e.g.HEUI, injector-pumps)

9 Al l types of use: can cope with the most demanding applications9 Depolluted engines: complies with EURO 2 and EURO 3 technology and can be used with all types of diesel fuel, especially

ecological diesel with low sulphur content.

PERFORMANCE:

ACEA E3API CH-4

9 Meets level E3 of the specifications defined by European manufacturers in the ACEA standards 98 edition.

ADVANTAGES:

9 Less frequent oil services: this product has been put to the test during thousands of hours of use on worksites under varyingconditions, demonstrating its high quality.

9 Conformity with new environmental legislation: adherence to new anti-pollution standards required for new EURO 2 andEURO 3 engines.

SPECIFICATIONS:

SAE Grade 15W-40

Density at 15°C 0.883

Cinematic viscosity at 40 °C Cinematicviscosity at 100 °C

10514.1

mm2/s (cSt)mm2/s (cSt)

Viscosity index 140

Dynamic viscosity at -15 °C 3000 mPa.s(cP)

Pour point - 30 °CFlash point 220 °C

Sulphated ash content 1.4 % weight

Values given as examples only)

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2.3.1.2. Specifications of coolantsEngine Coolants

Make Type Make Type J ohn Deere All GenPARTS GENCOOL PC -26°C

Mitsubishi LLCMITSUBISHI All

GenPARTS GENCOOL PC -26°CVolvo All GenPARTS GENCOOL PC -26°C

GenCOOL PC -26High-protection coolant, approved by manufacturers.GenCOOL PC -26 is a ready-to-use, highly protective coolant which is produced from an antifreeze recommended by the majority of European manufacturers.

y It is made from antifreeze and G 48 inhibitors.

y It protects up to -26°C.

y It is free from nitrates, amines and phosphates.

y It is a clear, fluorescent orange liquid.

REFERENCES/APPROVALS (for the ant ifreeze):

HEAVY GOODS VEHICLE LIGHTER VEHICLES

Approved by MTU, MERCEDES BENZ, MAN, KHD, GENERALMOTORS

Conforms with VOLVO, IVECO, VAN HOOL and STAYR TRUCK specifications

Approved by BMW, VOLKSWAGEN, MERCEDES, PORSCHE

Conforms with VOLVO, OPEL, SEAT and SKODA specifications

Conforms wi th the NF R 15.601 standard

REINFORCED ANTI-CORROSION FEATURES:

y Protects against high-temperature corrosion by oxidisation of ethylene (cylinder head protection).

y Protects against high-temperature cavitation (top of cylinder and coolant pump protection)

y Non-corrosive for seals and hoses.

y Improves the efficiency and longevity of the cooling system.

y GenCOOL PC -26 is especially recommended for engines fitted with aluminium or light alloy radiators.

HIGH TEMPERATURE SUITABILITY:

y Provides good conditions for thermal exchange.

y Perfect stability at high temperatures.

y GenCOOL PC -26 is specially adapted for engines with high power densities.

LONG LASTING PROTECTION:

y High alkaline reserve/stability and longevity of corrosion inhibitors

y Maintains its technical properties during prolonged use at high temperatures (neutralisation of acids).

y Ensures maximum heat transfer without the build up of deposits in the cooling system

y GenCOOL PC -26 ensures optimum protection against overheating and corrosion in extreme conditions of vehicle use.

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PACKAGING/STORAGE:

y GenCOOL PC -26 is supplied in 210 l metallic barrels with smooth interior linings.

y It can be stored for 2 years in its original container and packaging.

y Avoid zinc coated containers.

RECOMMENDATIONS FOR USE:

y Compatible with the original fluid.

y It is recommended that the cooling system is completely drained when replacing the fluid.

SPECIFICATIONS UNITS SPECIFIED VALUES TRIALMETHODS

Density at 20°C kg/m3 1,059 +/- 3 R 15-602-1

pH pH 7.5 to 8.5 NF T 78-103

Alkal in ity reserve ml >=10 NF T 78-101

Boiling point °C 105 +/- 2 R 15-602-4

Freezing point: °C -26 +/- 2 NF T 78-102Glassware corrosion :(test with antifreeze) mg/test piece R 15-602-7

- Copper +/- 2.6

- Weld +/- 0.5

- Brass +/- 2.3

- Steel +/- 1.6

- Cast iron +/- 0.8

- Cast aluminium +/- 1.0

Corrosion on warm plate(test with antifreeze) mg/(cm²week) +/- 0.17 R 15-602-8

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3. Installation

3.1. Unloading

3.1.1 Safety during unloading

To unload electrical generating sets from their transport supports under optimum safety and efficiency conditions, you need to ensurethat the following points are observed:

- Lifting machinery or equipment appropriate to the work required.- Slings positioned in the eyes provided for this operation or lifting arms resting fully underneath the chassis cross members.- Ground able to take the load of the set and the lifting machinery without stress (otherwise lay down beams of sufficient strength and

stability).- Set put down as close as possible to its point of use or transportation, in a clear area with free access.

Example of equipment to be used:9 crane, slings, cross bar, safety catch, shackles.9 Fork lift truck.

3.1.2 Instructions for unloading

3.1.2.1. Slings

n Attach the lifting vehicle slings to the rings on the generating set designed for this procedure. Hang the slings carefully.

o Check that the slings are correctly attached and the equipment is solid.

p Lift the generating set carefully.

q Direct and stabilise the set towards the chosen position.

r Carefully set down the equipment while continuing to position it.

s Release the slings, then detach and remove the lifting rings.

3.1.2.2. Fork l ift truck

n Position the forklift arms under the base frame (except with generating sets fitted with "forklift pockets", in which case position theforklift arms in these pockets), making sure that only its cross-members are resting on the arms.

o Lift the equipment, handling it gently.

p Set down the generating set in its unloading position.

Figure 3.1: Transporting a generating set using a forklift truck

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3.2. Fluid retention

Any outflow of the fluids contained in the generating sets (fuel, oil and coolant, or rainwater or condensation) will be collected in aretention container if the generating set is fitted with this option.The containers have a capacity which allows 110% of the fluids contained in the generating set fitted with this option to be collected.Three different fittings are available.

Diagram 3.2: Fluid retention container integrated into the tank chassis.

Diagram 3.3: Offset fluid retention container underneath the generating set chassis.

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Diagram 3.4: Offset fluid retention container integrated into the chassis and tank.

Generating sets fitted with the offset tank option (DW) above also have a high level indicator in the retention container.

In all cases, the retention containers must be regularly checked to ensure they contain no fluid (fuel, oil and coolant, or rainwater orcondensation). If necessary, drain the containers either via the drain port or by using the drain pump (for containers fitted with thispump).

9 Note: Never allow these fluids to drain onto the ground; ensure they are collected in a designated container.

3.3. Choice of location

It should be determined on the basis of use. There are no specific rules governing the choice of location, other than proximity to theelectric distribution panel and disturbances caused by the noise. However, fuel supply, burnt gas evacuation, and the direction of thesegases and the noises emitted should be taken into account.

The choice of its position will be based on carefully considered compromise!

Examples of problems that may be encountered:

Incorrect exhaust and ventilation Ground too uneven or soft.

Set incorrectly positioned

Reduced access

Fuel filling impossible Opening cover doors impossible

Diagram 3.5: Examples of problems that may be encountered

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3.4. Electr ici ty

a) Connections - general informationAs with low voltage electrical installations, use and maintenance is governed by standard NFC 15.100 (France) or by the standards in the relevantcountry, based on international standard IEC 60364-6-61.They must also adhere to the regulations in the NFC 15.401 application guide (France) or to the regulations and standards in the relevant country.

b) Power cables

These can be unipolar or multipolar according to the power of the generating set.Power cables should preferably be installed in ducts or on a cable tray for this purpose.The cable cross-section and number of cables should be determined according to the cable type and the current standards to beobserved in the country of installation. The choice of conductors must comply with international standard IEC 30364-5-52.

Three phase - Calculation hypothesisFitting method =wiring in cable runs or non perforated trays.Permissible voltage drop =5%Multiconductors or single conductor joined when precision 4X…(1)Cable type PVC 70°C (e.g. H07RNF).Ambient temperature =30°C.

Cable sizes

0 - 50m 51 - 100m 101 - 150m

Circuit breakercalibre

(A) mm²/AWG mm²/AWG mm²/AWG

10 1.5 / 14 2.5 / 12 4 / 1016 2.5 / 12 4 / 10 6 / 920 2.5 / 12 4 / 10 6 / 925 4 / 10 6 / 9 10 / 732 6 / 9 6 / 9 10 / 740 10 / 7 10 / 7 16 / 550 10 / 7 10 / 7 16 / 563 16 / 5 16 / 5 25 / 380 25 / 3 25 / 3 35 / 2100 35 / 2 35 / 2 4X(1X50) / 0125 (1) 4X(1X50) / 0 4X(1X50) / 0 4X(1X70) / 2/0160 (1) 4X(1X70) / 2/0 4X(1X70) / 2/0 4X(1X95) / 4/0250 (1) 4X(1X95) / 4/0 4X(1X150) / 2350MCM 4X(1X150) / 2350MCM400 (1) 4X(1X185) / 0400MCM 4X(1X185) / 0400MCM 4X(1X185) / 0400MCM

630 (1) 4X(2X1X150) / 2x 2350MCM 4X(2X1X150) / 2x 2350MCM 4X(2X1X150) / 2x 2350MCM

Single phase - Calculation hypothesisFitting method =wiring in cable runs or non perforated trays.Permissible voltage drop =5%Multiconductors.Cable type PVC 70°C (e.g. H07RNF).Ambient temperature =30°C.

Cable sizes

0 - 50m 51 - 100m 101 - 150mCircuit breaker

rating (A)mm²/AWG mm²/AWG mm²/AWG

10 4 / 10 10 / 7 10 / 716 6 / 9 10 / 7 16 / 5

20 10 / 7 16 / 5 25 / 325 10 / 7 16 / 5 25 / 332 10 / 7 25 / 3 35 / 240 16 / 5 35 / 2 50 / 050 16 / 5 35 / 2 50 / 063 25 / 3 50 / 0 70 / 2/080 35 / 2 50 / 0 95 / 4/0100 35 / 2 70 / 2/0 95 / 4/0125 50 / 0 95 / 4/0 120 / 2250MCM

c) Battery cablesnstall the battery or batteries in the immediate vicinity of the electric starter motor. The cables will be connected directly from thebattery terminals to the starter motor terminals.The primary instruction to follow is to ensure that the polarities between the battery and starter motor match. Never reverse the positive

and negative battery terminals when connecting them. This could cause severe damage to the electrical equipment.The minimum cross-section of the cables will be 70 mm

2. It varies according to the power of the starter motor but also the distance

between the batteries and the set (voltage drops on the line).

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d) Safety guidelinesReferences: NFC 15-100:2002 (France) - IEC: 60364-5-54

In order to protect personnel against electric shocks, this generating set is equipped with a differential residual current protector"factory" set to trigger instantly, with a sensitivity of 30 mA.

Important

Any modification to this setting could endanger personnel. Any modification would render the user liable, and

must only be performed by qualified and authorised personnel.When the generating set is disconnected from a facility after use, the master differential protector must bereturned to its "factory" settings, and this must be checked by trained personnel.

For effective protection against electric shocks, the generating set needs to be earthed. To do this, use a copper wire, with a minimumcross-section of 25 mm

2for a stripped cable and 16 mm

2for an insulated cable, connected to the generating set earth socket and a

galvanised steel earthing rod embedded vertically into the ground.

The earthing rod resistance value should comply with the values shown in the table below.Note: use the highest differential setting from the installation as a guideline.

The resistance value is calculated in the following way:

For a default voltage of 25 V and a default current of 30 mA, this rod must be of a minimum length of: see table below

Nature of groundLength of

rod inmetres

Thick arable land,moist compact ballast

1

Lean arable land,Gravel, coarse ballast

1

Bare stony soils, dry sand,impermeable rock

3.6 To obtain an equivalent length, you can use several earthing rodsconnected in parallel and set apart by at least their length.Example: 4 interconnected 1 metre rods separated by 1 metre.

Note: For the United States (National Electrical Code reference NFPA-70). The generating set must be earthed. To do this, use a copper wire with a minimum cross-section of 13.3 mm² (or AWG 6, at most)connected to the generating set earth socket and a galvanised steel earthing rod fully embedded into the ground vertically.

This earthing rod embedded fully in the ground must have a minimum length of 2.5 m.

3.5. Special arrangements

Generating sets are not fitted with protection against power surges caused by drops in atmospheric pressure or manoeuvring. The company does not accept any responsibility regarding damage caused by these occurrences.However, lightning conductors can be installed, on the understanding that this does not give total protection.

R = UlI Δn

Maximum resistance value of the earth socket R (Ω) according to the differential unit operationalcurrent (operation time should not be longer than 1 second).

I Δndifferential

Earth R(Ω)

Ul: 50 V

Earth R(Ω)

Ul: 25 V≤ 30 mA 500 >500100 mA 500 250300 mA 167 83500 mA 100 50

1A 50 253A 17 85A 10 510A 5 2.5

The Ul value: 25 V is required for work site installations, and livestock buildings, etc.

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4. Trailer

4.1. Trailer linkage

Before attaching the trailer, check the trailer hook on the tow vehicle; it should fit the trailer ring perfectly.

Danger

Trying to tow a trailer wi th a non-matching device (bar, wires, cords, etc.) could lead to serious accidents. Also check:- no incipient fractures or excessive wear on the hitching system.- locking system is operating properly.

To hitch the trailer, proceed as follows:

n Lock the wheels to stop the trailer from moving.

o Lift up the rear trailer supports and lock them.

p Release the parking brake.

q Release the locking levers for the draw bar arms and adjust the ring to the same height as the vehicle hook.

r Hitch the trailer, remove the locks on each side of the wheels then lift up the front wheel fully using its handle.

s Connect the electrical circuit of the trailer to that of the tow vehicle.

t Hook the handbrake safety wire onto the hook on the tow vehicle.

Diagram 4.1 : Coupling a trailer

4.2. Check before tow ing

Before towing, check the following:9 Tightness of the generating set enclosure bolts.9 Wheel tightness.9 Hitching hook locked.9 Tyre pressure.9 Signalling lights working, for "on-road" trailers.9 Enclosure doors closed.9 Parking brake released, for "on-road" trailers.9 Guide wheels (jockey wheels) and stands lifted (if fitted).9 Towbar arm locking levers tightened and pinned (if fitted with an adjustable towbar).9 Brake test, for "on-road" trailers.9 Safety cable fitted, for "on-road" trailers.

Tow vehicle

Trailer

CORRECT

Tow vehicle

Trailer

CORRECT

Tow vehicle

Trailer

INCORRECT

Tow vehicle

Trailer

INCORRECT

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4.3. Operation

"On-site" trailer These trailers are not fitted with a main brake, and so cannot be braked in motion; the tyres allow for a maximum speed of 27 km/h. Soit is absolutely prohibited to exceed this speed.Nor are these trailers fitted with signalling lights. On-road use is prohibited."On-road" trailer

The driving speed must be suited to the condition of the road and the handling of the trailer.

Driving at high speed causes heating of the tyres; so it is important to stop from time to time, and check them. Excessive heating maycause a puncture, and therefore a serious accident. For reversing manoeuvres, remember to lock the inertia brake.

Warning

Particular attention must be paid to the tightness of the wheels on new vehicles.In the first few miles' driving, heating of the brake hubs and drums will actually reduce the wheel tightness. Itis therefore essential to check the tightness every 6 miles (10 kilometres) until no further loosening is noted.Nonetheless the tightness must be checked whenever you are about to tow the trailer.

Lights/signalling (only for "on-road" trailers)Warning lights are obligatory for on-road driving. Signalling must comply with regulations in force in the country of use.

Figure 4.2: Example of French signalling

4.4. Unhitching the trailer This operation should be carried out on horizontal, flat, stable ground.

n Lock the wheels.

o Lower the front wheel.

p Disconnect the road signals wire.

q Refit the hitch using the wheel to release the hook ring from the tow vehicle.

r Engage the handbrake.

s Release the tow vehicle.

Red rear lights+direction indicators

+stop lights

Front reflective devices (white)

Side reflective devices (orange)

Rear reflective devices (red

triangle)

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4.5. Implementation for installation

Operations to be carried out:9 Ensure that the ground is strong enough for the assembly not to sink into it.9 Unhitch the trailer.9 Immobilise the trailer by placing chocks under the wheels.9 Fully engage the parking brake (if fitted).9 Using the front wheel, position the generating set as close to horizontal as possible.9

Lower the stands (if fitted), and lock them.

4.6. Break transmission adjustment

Important

- The handbrake is used only as a parking brake.- Setting is carried out starting with the brakes moving to the brake control.

n After fitting the wheels on the axle, turn the wheels in the FORWARD direction (on all RA 2 type brakes, check that the adjustmentscrew 8 reaches the “FORWARD” stop on the brake backing plate).

o Adjust the brake setting using screw 8, with the cables not connected to the cross bar(s). The shoes should rub the drum slightly.

p Connect the brake cables to the cross bars(s) and tighten the nuts and lock nuts, leaving the end of the threaded end protrudingby around 10 mm (Fig. 4.4).

IMPORTANT: Wherever possible, cables must cross over to achieve the highest possible gain curve (Fig. 4.5).

q Check that the parking lever 1 is in the ‘REST” position and that the compensating spring 4 is completely free on its rod (unscrewthe nuts 5 fully).

r Check that the hook slide 2 is not compressed and the yoke 3 is in the pulled out position.

s Fit the transmission and adjust the assembly using the tensioner 6 until a gap (J 1) of 1 mm max is obtained between the linkage 9and slide 2.

t Adjust the compensating spring 4 at one end pressing it against the anchorage plate, and at the other end leaving a 2 mm gap (J 2)max between the spring and nuts 5.

u Tighten all the lock nuts.

Checking the setting (trailer on axle stands):

n Pull the parking lever 2 notches - the wheels cannot turn in a FORWARD direction. The wheels can turn in REVERSE (adjustment screw 8 switches to the REAR position).

o Pull the parking lever fully. The wheels will not turn either in FORWARD or REVERSE and the cross bar(s) must remain parallel with the axle body.

¾ Check the transmission setting after 180 miles (300 km) (running in period) and if necessary adjust the gap (J 1) using thetensioner.

Parking

¾ The lever must be fully pulled up, so that the compensating spring is fully compressed.¾ Every 900 miles (1500 km), check the braking settings and distribution on all the wheels.

mportant

¾ The brake controls are designed to draw trailers behind flexible suspension touring vehicles. If used behind an HGV, be sureto provide the fitted ball joint with a shock absorber to prevent premature wear.

¾ During any manoeuvres with the trailer coupled, do not turn more than 90° or force reverse.

¾ The specifications of our brake controls are indicated on a manufacturer's plate, and the items on this should be supplied to uswhen requesting replacement parts, in particular for the shock absorber, of a special type, approved by the Service des Minesto correspond to European standards (it is advisable to have a spare shock absorber to enable instant repairs).

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Figure 4.3: Braking transmission

Figure 4.4: Cross bar fitting Figure 4.5: Tandem bearing fitting

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4.7. Faults and repairs

Fault observed Origin Solutions

Erratic braking of trailer - Faulty shock absorber Replace the shock absorber- J aws worn Replace the jaws- J aws not run in Fault will disappear only after running in- Incorrect linkage setting Adjust the setting- Significant friction on the slide Grease the sliding parts

- Slide corrosion Remove the corrosion and grease

Braking too weak

- Coupling height does not match that of thetowing vehicle

Adjust the height so that the two parts arein the same horizontal plane

- Incorrect linkage setting Adjust the settings- Incorrect brake setting Adjust the settings- High levels of dust in the drums Remove the dust- J aws, springs, drums damaged Replace the damaged parts

Drum temperature abnormally high

- Brake cables or link rod damaged Replace the damaged parts- Incorrect linkage setting Adjust the settings- Interfering parts on the slide Remove, clean and grease- Corroded slide Remove the corrosion and grease

- Damage to slide guide ringsReplace the rings (and possibly the slide)and grease

erky braking

- Faulty shock absorber Replace the shock absorber

- Cross-bar(s) not balanced Adjust the cross-bar(s)- Different brake setting on the two sides Adjust the brake settings

- Cables damaged or incorrectly fittedReplace the damaged partsRefit the cables

Trailer tending to swerve upon braking

- Poor load distribution Check the load distribution- Damage to slide or to guide rings Replace the faulty parts and grease- Slide corrosion Remove the corrosion and grease- Tie rod damaged Replace the tie rod and adjust the settings

- Linkage damaged or incorrectly setReplace the damaged parts and adjust thesettings

When starting the trailer holds back thetowing vehicle

- Brake on Loosen the brake- Head worn (see wear indicator) Replace the head

Play in the coupling head- Ball joint worn Replace the ball joint- Compensating spring incorrectly set Adjust the setting- Braking system incorrectly set Adjust the setting- Notched sector damaged Replace the sector and adjust the setting- Lever ratchet worn Replace the lever and adjust the setting

Parking braking too weak

- Cable ruptured Replace the cable and adjust the setting

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4.8. Electrical connection diagram

Figure 4.6: Electrical connection diagram

4.9. Complete wheels technical in formation

TYRES COMPLETEWHEELS

Dimensions Indices Diameter (mm)Cross section

(mm)Radius under load

(mm)Load(Kg)

Pressure(bar)

135 R 13 70 T 550 134 265 335 2.4145 R 13 75 T 566 145 272 387 2.4155 R 13 79 T 578 150 277 437 2.4

145/70 R 13 71 T 534 150 259 345 2.5155/70 R 13 75 T 548 147 263 387 2.5185/70 R 13 86 T 594 185 285 530 2.5165 R 14 C 98 N 622 172 284 650 3.8

155/70 R12 100 N 525 155 244650800

6.25

185 R 14 C 102 P 650 188 316

675

850 4.5195 R 14 C 106 P 666 198 32 950 4.5195/50 x 10 98 N 450 190 - 750 6.0

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5. Preparation before operating the set

Danger

The inspections referred to in thi s section enable the electrical generator set to operate.Specific ski lls are required to carry out these operations.They must only be entrusted to personnel with the necessary skills.Failure to fol low these instructions in any way could result in malfunction or very serious accidents.

5.1. Installation checks • check that the general recommendations given in the installation section (ventilation, exhaust, fluids, etc.) are observed.

• carry out the level checks (oil, water, diesel fuel, battery).

• check the generating set earth connection is earthed.

• check that the electrical connections are in order.

5.2. Checks after starting the generating set • carry out the mechanical checks (oil pressure, water temperature, absence of noise etc.)

• carry out the electrical checks (voltage and frequency)

• carry out the safety checks (emergency stop, oil pressure, water temperature etc.)

6. Using the generator set 6.1. Pre-Start Inspection nspecting the engine compartmentnspect the engine carefully.Wipe all the grease fittings and caps before carrying out any maintenance in order to reduce the risk of contaminating the circuits.

Checking the engine oil level

Important

- Do not top up the oil if the oil level is not below the low level marker.- Do not exceed the hatched areaThe oil level is correct if it is within the hatched area.

n Check the oil level using the dipstick (A).o Top up the oil as required.

Use an oil whose viscosity is suited to the seasonal conditions.

p Pour the oil through the rocker cover filling port (B).

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Checking the coolant level

Warning

Fluid may abruptly exit the cooling circuit and cause serious burns.Only remove the filler cap once the engine and cap have cooled sufficiently to enable them to be handled with barehands. Firstly, loosen the cap slightly by one notch to eliminate any pressure, then remove it.

n Remove the cap from the radiator (E) and check the coolant level. The level should reach the lower section of the filler neck.

o Fill the radiator with the appropriate coolant if the level is too low.

p Check for leaks in the cooling circuit.

Checking the air filter

Important

The maximum authorised vacuum in the air filter is 6.25 kPa (0.06 bar; 1.0 psi) (25 in water).A clogged filter element limits the engine's air intake.

If the air filter is fitted with a dust control valve (C), press the tip of the valve to evacuate any accumulated dust particles.

Check the air filter clogging indicator (D). If the indicator is red,clean the air filter.

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Checking the fuel filters

Danger

The fuel is highly flammable and its vapours are combustible.The fuel filter(s) must only be bled when the engine is stopped and cold.

Note: Engines with a mechanical supply circuit have a single fuel filter whilst electronically controlled engines (DE10 and high pressure

common rail fuel circuits) have two fuel filters (primary and final). In addition, fuel filters in electronically controlled engines may be fittedwith a water presence sensor. An indicator on the instrument panel warns the operator that the water must be drained from the filtercup.

nspect fuel filters (C) and (D) as follows, in order to detect any traces of water or debris:

n Undo the drain plug(s) (A) at the bottom of the fuel filter(s) or cup(s) by two or three turns.

o Loosen the air drain plugs(s) (B) by two full turns and drain the water into a suitable container.

p When the fuel begins to flow out, tighten the drain plugs.

q Bleed the supply circuit.

A – Drain plugB – Air bleed plugC – Main fuel filterD – Final fuel filter

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6.2. Generator set w ith NEXYS control panel

6.2.1 Control panel presentation

Diagram 6.1: View of the front side

c Emergency stop button for switching off the generating set in the event of a fault which could endanger personnel or damage

equipment

d Key switch for starting up/shutting down the module and RESET function

e Electronic card protection fuse

f Screen-scroll button, press successively to access the various screens which are available

g STOP button, press to switch off the generating set

h START button, press to switch on the generating set

i Normal operation LEDs and alarm and fault warning LEDs

j Slot reserved for panel fascia options

k Mounting bolt.

l LCD for displaying alarms and faults, operating states, electrical and mechanical quantities

2

1

3

5

9 9

9

6

7

8 4

9

10

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Diagram 6.2 – Description of the LEDs

A lit LED indicates:

c Module being supplied (green, lights up and remains lit)

d Emergency stop activated (control panel or external emergency stop) (red, lights up and remains lit)

e Visualisation of starting phase and speed/voltage stabilisation (flashing) and generating set operating OK or set ready to

generate (green, lights up and remains lit)

f General alarm (orange, flashing)

g General fault (red, flashing)

6.2.1.1. Introduction to pictograms

The pictograms are as follows:

Operating temperatureFuel

Overspeed

Non-starting fault

Starting on external command

PreheatingAir intake

Oil pressure

Battery

Delay

Diagram 6.3: View of pictograms

¾ The "fuel level" pictogram is used to display the fault, the alarm and the fuel level.¾ The "operating temperature" and "oil pressure" pictograms are used to display the fault and analog value.¾ The "overspeed" and "non-starting fault" pictograms are used to display the fault.¾ The "battery" pictogram is used to display the "alternator charge" fault and to indicate the battery voltage.

Symbols for electric andmechanical sizes

1 2 3 4 5

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6.2.2 Manual starting

Danger

Check that the generating set circuit breaker has tr iggered.

nConnect the generating set battery.

o Turn the key switch to the ON position (without forcing it)

9 All of the LEDs light up for 2 seconds, to confirm that they are operating correctly.9 If the LEDs do not light up, check the protection fuse and replace it if necessary.9 All the items on the screen are displayed for 2 seconds.9 Only the "ON" LED remains lit to indicate that the module is powered up.9 The following screen appears.

The first line displays the motor speed in RPM. The second line displays the battery voltage involts (V).

9 Check the battery voltage (min. 12 V)

p Press (once briefly) the green "START" button.

9 If the motor is equipped with an air preheating system, there is a 10-second delay before the motor starts (preheatingactivation period).

9 The following screen appears.

The third line displays the air preheating timeremaining (with pictograms representing aresistor and an hourglass).

9 If the motor is not fitted with an air preheating system or once the preheating delay has elapsed, the engine starts up(start of a cycle comprising 3 attempts to start up the engine).9 The following screen appears.

Warning

The number of successive and automatic starting attempts is limited to 3.

Note: the LED flashes as soon as the START button is pressed and continues to flash until the frequency stabilises if a "measurements" card has not been inserted and until the frequency and voltage stabilise if a "measurements" card has beeninserted.

Following stabilisation, the LED light comes oncontinuously.

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6.2.3 Switching off

n Trigger the circuit breaker located at the base of the centre console.

o Let the motor run under no load for 1 to 2 minutes to allow it to cool.

p Press the "STOP" button to stop the generating set.

q Switch off the MICS Nexys module by switching the key to "OFF" (without forcing it).

6.2.4 Alarms and faults

The appearance of a fault or an alarm causes the following screento be displayed (one or more pictograms or a fault code along withthe SOS message are displayed).

The user can access the following screens by pressing the key

The fault or alarm screen will disappear once the fault or alarm has been removed.Only one fault is displayed on this screen (the fault which caused the generating set to stop).f one or more faults have appeared after the first fault, they can only be displayed after the first fault has been reset (press "Reset" asmany times as the number of faults present).Note: an alarm can appear at the same time as a fault.

6.2.5 Faults and alarms - Details

List o f faults which will cause the generating set to stop and generate a pictogram

Low coolant level fault: indicates that the level of coolant is low inthe radiator (linked to a two second time delay).OrOverload or short-circuit fault (optional): with the circuit breaker SDcontact closing (overload or short-circuit), the generating set

switches off immediately also causing the main circuit breaker tobe triggered.

Associated message

Additional fault linked to message opposite: is displayed in thefollowing two cases:

¾ Differential fault (1)¾ insulation fault (2)

(1) Differential fault (optional): with a differential fault causing theactivation of the differential relay, the generating set stopsimmediately also causing the main circuit breaker to betripped.

(2) Insulation fault (optional): with an insulation fault causing theactivation of the control unit performing insulation, thegenerating set stops immediately.

Associated message

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Underspeed fault: indicates an incorrect rotation speed(below 1000 rpm).

Associated message

Emergency stop or external emergency stop fault.

Associated message

"STOP" fault activated if the "STOP" button is pressed whilstthe "AUT" LED is flashing to indicate that the generating setis operating in automatic mode.

Associated message

List of faults which wil l cause the generating set to stop and generate a fault code

Oil pressure fault: Indicates that the oil pressure is incorrect.

Associated pictogram

Engine temperature fault: Indicates that the enginetemperature is too high.


Non-starting fault: Indicates that there have been threeconsecutive unsuccessful starting attempts.


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Overspeed fault: Indicates an excessive generating set runningspeed.


Low fuel level fault: Indicates the need to top up the fuel.


List o f alarms associated with a pictogram

Low fuel level alarm: Indicates the need to fill up with fuel.


"Alternator charging fault" alarm indicates a problem affecting thealternator charging rate.


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6.3. Generator set wi th TELYS cont rol panel

6.3.1 Control panel presentation

6.3.1.1. View of the f ront panel

Diagram 6.4 - View of the front panel

1 Emergency stop button (AU) for switching off the generating set in the event of a fault which could endanger personnel or damageequipment.

2 Key switch for switching the module on/off.3 Electronic board protection fuse.4 Scrolling and selection wheel for scrolling through the menus and screens and selecting items simply by pressing the wheel.5 STOP button, press to switch off the generating set.6 START button, press to switch on the generating set.7 Power ON LEDs and alarm/fault warning LEDs.8 Location of USB ports.9 Mounting bolt.10 LCD for displaying alarms and faults, operating statuses, electrical and mechanical quantities.11 ESC button: for returning to the previous selection and for default RESET function.4

12 MENU button for accessing the menus.13 Lighting for the emergency stop button.

2

1

3

5

67

8 49 10

9

11

12

13 9 9

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Diagram 6.5 – Description of the LEDs

A lit LED indicates:1 Alarm activated (flashing yellow).2 Fault found (flashing red).3 Module on (green, on continuously).

Diagram 6.6 – Close-up of USB ports

1 USB key connection (HOST): file transfer between USB key and TELYS and vice versa.2 Connection for microcomputer (DEVICE):

¾ file transfer between PC and TELYS and vice versa,¾ main module power supply.

3 Protective cover.

1 2 3

2

3

1

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6.3.1.2. Descript ion of the screen

The screen is backlit and requires no contrast adjustments. This screen is divided into 4 zones.

n

o p

SERIAL No.: 08030010000SOFTWARE: 5.3.5NOMINAL VOLTAGE: 400V

FREQUENCY: 50Hz NOMINAL KW: 320kWEARTH SYSTEM: TNS

q Diagram 6.7: Description of the screen (example)

n Zone 1: in this zone, the status of the generating set is displayed

o Zone 2: in this zone, pictograms relating to dimensions measured are displayed, as well as Alarm and Fault pictograms

p Zone 3: in this zone, the measured values corresponding to the measured dimensions are displayed with the corresponding units

of measurement

q Zone 4: in this zone, messages relating to the control of the generating set and the menus are displayed.

Note: the information displayed on measurements, alarms and faults as well as messages and menus relating to control of thegenerating set will depend on the equipment level of each generating set. Certain screens may therefore not be present.

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6.3.1.3. Descript ion of the pictograms in zone 1

Pictograms in zone 1

Pictograms Display Activation conditions

Fixed TELYS in manual mode (MANU)

"MANU" Mode

FlashingFor 5 seconds when switching from AUTO modeto MANU mode

Fixed TELYS in automatic mode (AUTO)

"AUTO" Mode

FlashingFor 5 seconds when switching from MANUmode to AUTO mode

Flashing Generating set in start-up phase

Fixed Generating set started

FixedGenerating set stabilised (voltage andfrequency)

Flashing (appearance of constant movementfrom left to right)

The generating set is powering the installation

Fixed The installation is supplied

Not used

Not used

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Alarm and fault pictograms in zone 2All the pictograms in this zone are activated when TELYS is initialised.

Data displayed

Fuel level indicator

Alarm / Faultlow fuel level

Alarm / Faulthigh fuel level

Coolant level / temperature indicator

AlarmLow level

fault

High levelfault alarm

AlarmHightemperaturefault

No preheatingfaultalarm

Battery

Min battery

voltage(flashing)

Max batteryvoltage (flashing) Battery charge indicator(flashing bars)

Oil pressure / temperature indicator

Oil pressureAlarm / Fault

High or low oil levelAlarm /Fault

High or low oiltemperatureAlarm / Fault

Emergency stop

Emergency stop fault

Overload or short circuit

Tripping of circuit breaker following an overloador short circuit

Engine speed

Underspeed fault Overspeed fault Non-starting fault

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Pictograms in zone 3

All the pictograms in these zones are activated when TELYS is initialised. The pictograms below are given as examples.

Generating set stopped

Screenno.

Pictograms Data disp layed

Fuel Level Indicator

Indication of Temperature of High Temperaturecoolant (HT) (units according to settings menu)

Indication of Battery Voltage

P1

Indication of Oil Temperature (units according tosettings menu)

Generating set start-up or generating set started or generating set switching off in progress

Screenno.


Engine Speed Indication

Indication of Temperature of High Temperaturecoolant (units according to settings menu)

Indication of Oil Pressure (units according to settings)

P2

Indication of Oil Temperature (units according tosettings menu)

Generating set started

Screenno.



Alternator composite Voltage Indicator

Total Active Power Indicator

P3Default

screen in

operation

Alternator Frequency Indicator

U12 Alternator composite Voltage Indicator



P4


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Screenno.


V1 Alternator single Voltage Indicator



P5





P6



Single phase Alternator current indicatorP7


Single phase Alternator current indicator

Two phase Alternator current indicator

Three phase Alternator current indicator

P8

Neutral Alternator current indicator

Total Active Power Indicator

Total Reactive Power Indicator

Total Effective Power Indicator

P9

Total Power Factor Indicator (lagging or leading)


Indication of Battery VoltageP10

Indication of Battery Amps

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Screen order of appearance according to network type with the generating set on.

Type of network

Order of appearance 3P+N 3P 2P+N 1P+N

1 P3 P3 P3 P32 P4 P4 P6 P73 P5 P8 P8 P9

4 P8 P9 P9 P25 P9 P2 P2 P106 P2 P10 P107 P10

Change screens by using the scrolling and selection wheel.When the wheel is rotated clockwise, the screens scroll upwards and vice-versa.The screens scroll in a loop.E.g.: On three-phase +neutral network, then screen 7, then screen 1 and vice-versa.

6.3.1.6. Display of messages in zone 4

The display (zone 4), among other things, displays messages relating to the operation of the generating set. The messages are as follows:

nitialisation of TELYS

Screen no. Screen Data disp layed

G 1Initialisation of TELYS when the power is switchedon and/or when loading a configuration

G 2

SERIAL No.: 08030010000SOFTWARE: 6.1.0NOMINAL VOLTAGE: 400VFREQUENCY: 50Hz NOMINAL KW: 320kWEARTH SYSTEM: TNS

Generating set serial no.Software version of TELYSAlternator Nominal VoltageAlternator Nominal FrequencyNominal Active OutputNeutral PointBar graph indicating the display delay of the screen

Generating set stopped

Screen

no.

Screen Data disp layed

G 3

OPERATIONMANUAL

Press STARTto start

24/08/2005 13:12

Operating mode - generating set in Manual Modeready to startDate and time (depending on settings)

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Screenno.


G 4

OPERATIONAUTO

WARNINGSTART-UP POSSIBLE

IMMEDIATELY

24/08/2005 13:12

Operating mode - generating set in Auto Modeready to startDate and time (depending on settings)

G 5

WARNING

AUTOMATIC Start

19 min 30 sec

24/08/2005 13:12

Operating mode - generating set in Auto Mode withprogrammed startCountdown to micro disconnection delay or EJ P

notice delay (for France only)Date and time (depending on settings)

Generating set start-up

Screenno.


G 6START-UP

IN PROGRESS

24/08/2005 13:12

Operating phase - generating set in starting phaseDate and time (depending on settings)

G 7

AIR PREHEATING

10 seconds

24/08/2005 13:12

Operating phase - air preheating prior to startinggenerating setCountdown for air preheating delayDate and time (depending on settings)

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Generating set started

Screenno.


G 8Defaultscreen

AVAILABLE POWER

75%

24/08/2005 13:12

Operating phase – generating set in operation –stable voltage and frequencyAvailable powerDate and time (depending on settings)

G 9

AUTOMATIC STOPIN PROGRESS

LOAD SUPPRESSION1 min 30 sec

24/08/2005 13:12

Operating mode - operation in Auto ModeOpening of power supply device (motorised circuit

breaker or source changeover switch controlled by TELYS)Countdown for the mains return delay OR the loadtest delayDate and time (depending on settings)

G 10

AUTOMATIC STOPIN PROGRESS

COOLING DOWN1 min 30 sec

24/08/2005 13:14

Operating mode - operation in Auto ModeGeneration set cooling in progressCountdown for Engine Stop delay (cooling) OR

Gradual Stop delay (Coolant temperature) OROverload Gradual Stop delay OR OFF load testdelayDate and time (depending on settings)

Generating setstop

Screenno.

ScreenData displayed

G 11OFF

IN PROGRESS

24/08/2005 13:16 Generating set stop in progressDate and time (depending on settings)

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Operating mode changeover (switching from Manual Mode to Auto Mode following auto start demand)

Screenno.


G 12

Start DemandAUTO

Do you wish to changeto Auto Mode?

WARNINGImmediate start

OK Esc Operating mode - operation in Manual ModeAUTOMATIC start demand

Generating set stop request due to fault or by pressing STOP in Auto Mode

Screenno.


G 13

Manual Modeactivated

Do you wish to changeto AUTO mode?

OK Esc

Operating mode - operation in Auto Mode(generating set in operation)Warning message for switching to Manual Modeafter the STOP button has been pressed or a faulthas appeared

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6.3.2 Starting

Danger

Check that the generating set circuit breaker has triggered.

nConnect the generating set battery

o Turn the key switch to the ON position (without forcing it to the ON position), the ON lamp will light up (if the lamp does not

light up, check and replace the fuse if necessary)

p Test the Alarm and Fault LEDs (menu 15 – TEST LAMPS)

1 ACTIONS

1/5

11 MANUAL <>AUTO12 CONTROL LOAD13 TEST GENERATING SET14 PROGRAMS15 TEST LAMPS12 OK Esc

q Press "Esc" several times to return to the following home menu

OPERATION

MANUAL

Press START

to start

24/08/2005 13:12

rCheck the battery voltages Press START:

AIR PREHEATING

10 seconds

24/08/2005 13:12 If the engine is equipped with an

air preheating system, there is adelay (adjustable) before theengine starts (preheatingactivation period).

If the motor is not fitted with anair preheating system or once thepreheating delay has elapsed,the engine starts up (start of acycle comprising 3 attempts tostart up the engine).

START-UPIN PROGRESS

24/08/2005 13:12

Warning: the number of successiveand automatic starting attempts islimited to 3.

The following pictogram will flash

AVAILABLE POWER

100.0%

24/08/2005 13:12

The following pictogram is displayed

The following information is displayed

Speed of rotation

Coolant temperature

Oil pressure

Oil Temperature

O p t i o n s

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6.3.3 Switching off

n Open the circuit breaker

¾ manually OR ¾ by selecting menu 12 "CONTROL LOAD"

The following display will disappear (supply stopped)

o Press the STOP button

p The following screen is displayed and the generating set will stop

OFF

IN PROGRESS

24/08/2005 13:12

q Switch TELYS off by turning the key to "OFF" (without forcing it to the "OFF" position).

6.3.4 Alarms and faults

6.3.4.1. Viewing alarms and faults

Alarms and faults are displayed as follows:

c Alarms

All alarms will cause:

¾ the yellow LED to flash "General alarm".

In conjunction with this LED:¾ a flashing pictogram appears on the LCD screen

representing the circuit affected by the alarm and theassociated indicator, if present

(example)

¾ message on graphic display (example)

FAULT

ALARMLow Fuel Level

25/12/05 15:30

OK=HELP

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d Faults

All faults will cause:

¾ the generating set to stop: immediate or gradual stop (coolant temperature and overload or short circuit)

¾ the red LED to flash "General fault".

n conjunction with this LED:¾ a flashing pictogram appears on the LCD screen

representing the circuit affected by the fault and theassociated indicator, if present

(example)

¾ message on graphic display (example)

FAULT

FAULTOil Pressure

25/12/05 15:30

OK=HELP

Faults have priority over alarms. Faults are displayed in the descending order of their appearance (from the most recent to the oldest).

6.3.4.2. Act ivation of an alarm or fault

The appearance of an alarmor a fault causes the corresponding screen to be displayed (examples below)

FAULT

ALARMLow coolant Level

06/10/06 10:30

OK=HELP

FAULT

FAULTEmergency Stop

06/10/06 15:30

Esc=RESET OK=HELP Press OK (on the scrolling and selection wheel) to access the help message if it is available (example below)

HELP

Check the levelfuel

Esc=EXIT f the alarm is no longer active, it is reset automatically (cause disappears).Press Esc to reset a fault:

- reset acknowledged if the cause of the fault has been removed- reset not performed if the cause of the fault is still present.

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6.3.4.3. Act ivation of an alarm and a fault

The appearance of an alarmand a fault causes:¾ The yellow and red LEDs to flash¾ the related screen to be displayed (example below)

FAULTS 1/2

FAULTEmergency Stop25/12/05 15:30

Esc=RESET OK=LIST If several faults are present, the number of faults isdisplayed at the top of the screen.

The faults list can be accessed by pressing OK (of the scrolling and selection wheel) (examples below)

FAULTS1/2

FAULT 25/12/05 15:30Emergency StopALARM 25/12/05 15:30Low Fuel Level12 OK=HELP Esc

Press Esc to return to the previous screen.Press OK to go to the HELP screen (help on thehighlighted fault)Use the scrolling and selection wheel to scroll throughthe list of faults.

HELP

Check:- Emerg. Stop Pos.- Connector(s)

Esc If the alarm is no longer active, it is reset automatically (cause disappears).Press Esc to reset a fault:

- reset acknowledged if the cause of the fault has been removed- reset not performed if the cause of the fault is still present.

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6.3.4.4. Engine faul t codes displayCertain alarms and engine faults generate specific fault codes. These codes are standardised according to the J 1939 and/or J 1587standards, except for MTU engines that have a specific transmission protocol (see appendix, if applicable).

Terminology used by the SAE CAN J1939 standard

SPN: Suspect ParameterNumber

This represents the system or component at fault, for example: SPN 100, indicates an oil pressureproblem or a problem with the oil pressure sensor.

FMI: Failure Mode identifier This represents the type of fault that has occurred. This may be an electrical, mechanical or equipmentfault.

Terminology used by VOLVO

SID: System Identifier This term, used in the J 1587 standard, has an equivalent in the J 1939 standard (SPN).However, this term corresponds, more particularly, to an assembly of components, for example, the

injection system.

PID: Parameter Identifier This term, used in the J 1587 standard, has an equivalent in the J 1939 standard (SPN).However, this term corresponds, more particularly, to a specific component, for example, a sensor.

PPID: Parameter Identifier This term, used in the J 1587 standard, has an equivalent in the J 1939 standard (SPN).PPID corresponds to PID, but is only used by VOLVO.

FMI: Failure Mode identifier This represents the type of fault that has occurred. This may be an electrical, mechanical or equipmentfault. VOLVO uses a SID-FMI or PID-FMI or PPID-FMI combination.

Terminology used by PERKINS

CID: Component parameter This term used by PERKINS has an equivalent in the J1939 standard (SPN).

FMI: Failure Mode identifier

This represents the type of fault that has occurred. This may be an electrical, mechanical or equipment

fault.

Terminology used by JOHN DEERE

SPN: Suspect ParameterNumber

This represents the system or component at fault, for example: SPN 100, indicates an oil pressureproblem or a problem with the oil pressure sensor.

FMI: Failure Mode identifier This represents the type of fault that has occurred. This may be an electrical, mechanical or equipmentfault.

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Terminology used by MTU

Displaying faults The MDEC general system faults are indicated on the equipment in the following way: fault codenumbers (generated by the ECU - Engine control unit).

In the event of a fault, the screen will display the following message:

FAULT

ALARM ENGINE GENERAL 110 18

25/12/2005 15:30

OK=HELP

Engine fault code.Pressing OK will display fault finding information.In addition, appendix D indicate the meaning of thecode. The checking and maintenance operations tocarry out in order to solve the fault are included in theuser and maintenance manuals of the enginessupplied with the generating set documentation.

For J OHN DEERE (J D), PERKINS (PE) and VOLVO (VO) engines, the codes displayed are SPN and FMI codes.

6.3.4.5. Horn resetDepending on the settings made (menu 363 - HORN), the activation of an alarm and/or a fault leads to the hornsounding and the following screen appearing:

HORN STOPPRESS OK

25/12/2005 15:30

This screen will display first any messages relating tothe alarms and faults that appear as soon as OK ispressed.

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7. Maintenance schedule

7.1. Reminder of use

The maintenance interval frequency and the operations to be carried out are outlined in the maintenance schedule, given as a guideline.N.B. the environment in which the generating set is operating determines this schedule.f the generating set is used in extreme conditions, shorter intervals between maintenance procedures should be observedThese maintenance intervals only apply to generating sets running on fuel, oil and coolant which conform to the specifications given in this

manual.

7.2. Engine

OPERATION10 h /1 day

500 hours1000 hrs /every year

2000 hrs /every

2 years

2500 hrs /every

3 years As required

Inspect the engine compartment Check the engineoil/fuel/refrigerant levels

Check the air filter cloggingindicator (a)

Drain the water and sedimentfrom the fuel filter(s)

Drain the engine oil and replacethe filter (b)

Replace the fuel filter element(s) Check the tension of the beltsand the automatic tensioner (c)

Check the valve clearances andadjust if necessary (d)

Clean the breather Check the air inlet circuit (withhoses and unions)

Check the cooling circuitpressure

Check the damper (6 cyl.) (e) Check the engine speed and the

regulator droop

Drain and flush the coolingcircuit (f)

Clean the air filter element (a) Check the thermostat and theinjectors (g)

a) Clean the air filter when the clogging indicator is red. Replace the filter element after it has been cleaned 6 times, or once a year.b) Drain the oil and change the filter after the first 100 hours of operation.c) Check the tension of the belt every 500 hours on 3029 and 4039 engines, and on 4045 and 6068 engines fitted with a manual

tensioner. Check the automatic tensioner every 1000 hours/once a year on 4045 and 6068 engines.d) This operation should be carried out by one of our agents. After the first 500 hours of operation then every 1000 hours for 3029 and

4039 engines. Every 2000 hours for 3029 and 4039 engines.e) Operation to be carried out by one of our agents. The Damper must be changed every 4500 hours /every 5 years.

f) Using J ohn Deere COOL GARD coolant, drain and flush the cooling circuit every 2500 hours/every 3 years. In all other cases, carryout this operation every 2000 hours/every 2 yearsg) Operation to be carried out by one of our agents. Replace the injectors every 5000 hours and the thermostat every 10000 hours. If n doubt about the operation of one of these components, contact one of our agents.

7.3. Alternator ¾ After 20 hours in operation, check the tightness of all the mounting bolts, the general condition of the machine and the various

electrical connections of the installation.¾ The bearings fitted on the machine are greased for life to around the service life of the grease (depending on use) =20 000 hours

or 3 years.

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8. Battery

Danger

Fit the battery so that it is properly ventilated.

Maintenance should only be carried out by qualified personnel.

If replacing the batteries, use the same type of batteries. Do not throw the old battery in the fire.

Only use insulated tools (the operator should not be wearing a watch, chain or any metal object).

Never use sulphuric acid or acid water to top up the electrolyte level. Use an approved battery fluid.

Batteries release oxygen and hydrogen gas, which are flammable.

Never bring flames or sparks near the battery (risk of explos ion).

Discharge any static electricity before handling the batteries by first touching an earthed metal surface.

Do not use the battery when the fluid level is below the minimum required level Using a battery with a low

electrolyte level could result in an explosion.

Do not short the battery terminals with a tool or other metal object.

When disconnecting battery cables, remove the cable from the negative (-) terminal first. When reconnecting

the battery, connect the posit ive lead (+) first.

Charge the battery in a well-ventilated place, with all the fil ler caps opened.

Ensure that the battery terminals are correctly tightened. A loose cable clamp can cause sparks that could

result in an explosion.

Before servicing electrical components or performing electric welding, set the battery switch to the [OFF]

position or disconnect the battery negative cable (-) to cut of f the electrical current.

Electrolyte contains dilute sulphuric acid. Careless handling of the battery causing contact with sulphuric

acid could damage your eyesight or cause burns.

Wear safety goggles and rubber gloves when working with the battery (topping-up fluid, charging, etc.)

If electrolyte comes into contact with your skin or clothes, wash it off immediately with plenty of water, then

carefully wash the area with soap.

If electrolyte comes into contact with your eyes, rinse immediately with plenty of water and seek medical

attention as soon as possible.

If electrolyte is accidentally swallowed, gargle with plenty of water and drink large quantities of water. Consult

a doctor immediately.

Large quantities of electrolyte should be rinsed off using a neutralising agent. A common method is touse a solution of 500g of bicarbonate of soda diluted in 4 litres of water. The bicarbonate of soda

solution should be added until the reaction has finished (lather). The remaining liquid should be rinsed

off with water and left to dry.

9 Dry batteries do not require any servicing9 Batteries ready for use must be recharged at the latest when the acid density drops below 1.20.

8.1. Storage and transport 9 Batteries ready for use must be stored in a cool and dry place (frost-free) protected from the sun (self-discharge).9 Batteries must be transported and stored vertically (risk of acid spillage)9 Leave the terminal cover on the positive terminal

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8.2. Battery setting into service

¾ Batteries filled with acid have a density of 1.28 g/ml and are charged.¾ In the case of dry batteries, fill each battery cell with acid up to the maximum level mark or to 15 mm above the plates. Let the

battery rest for 20 minutes.¾ Before fitting the battery, stop the engine and any power consumer, clean the terminals and give them a light coating of grease.

When connecting, connect the positive terminal (+) first, and then the negative terminal (-).

8.3. Check

Acid density Charge status Vol tage when idle

1.27 100% Above 12.60 V1.25 80% 12.54 V1.20 60% 12.36 V From 50 % recharge

1.19 40% 12.18 V Risk of sulphation

1.13 20% Under 11.88 V Unusable

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8.4. Load preconization

9 Very discharged or sulphated batteries can no longer regenerate or charge in a generating set.Note: Sulphation is the formation of whitish lead sulphate deposit on the plates which becomes hard and insoluble in acid. Thisdeposit reduces the active surface of the plates and increases their internal resistance.

Important

A discharged battery may become irreparably damaged. Recharge it immediately

Battery charge

When several batteries are connected together, the following points should be checked:9 Are the batteries connected in series?9 Is the voltage chosen exact? 1 x 12 V battery, 3 x 36V batteries9 Adjust the charge current to the lowest battery.9 The power difference between the batteries must be as low as possible.

Example of charge:9 12V 60 Ah battery =charging current 6 A9 Charge status: 50% (acid density 1.21/voltage when idle 12.30V)

9 The battery should be recharged to 30Ah9 Charge factor: 1.29 Ah x 1.2 =36 Ah to be charged9 Charging current: 6A approximately 6 hours charging required.

Recharging is complete when the battery voltage and the acid density stop increasing.

→ The charging current must always be 1/10th

of the nominal capacity of the battery.

The power of the charger must be suitable for the battery to be charged and the charging time available. You need to use an automatic charger able to provide a sufficient voltage and charging current, as well as a compensation voltage tohandle spontaneous battery discharge.

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8.5. Faults and remedies

Fault observed Probable origin Measures or observations

The acid heats up when a new battery isfilled

- Incorrect composition- Incorrect storage- Prolonged storage in a damp place

- Cool- Load- Check the acid density

The acid escapes through the filler holes - Overfilled battery - Reduce the battery fluid level

Acid level too low

- Battery tray not leaktight

- Excessive charge voltage leading to asignificant accumulation of gas

- Replace the battery

- Check the charger and repair if necessary

Acid level too lowncorrect operation from start-up

- Insufficient charge- Short circuit in the power circuit- Consumption fault

- Recharge- Check the electrical installation

Acid density too high- The battery has been filled with acid

instead of battery fluid

- Reduce the acid level by filling withdistilled water. Repeat the operation if necessary

Starting problemsStarting test incorrect

- Battery empty- Battery exhausted or faulty- Capacity too low- Battery sulphated

- Recharge the battery- Fit a new battery

Battery terminals melted- Incorrect electrical connection- Battery cabling incorrect

- Tighten the ends of the battery cables,or replace them if necessary

One or two cells release a lot of gas athigh charge- Cell(s) faulty - Fit a new battery

The battery discharges very quickly

- Charge status too low- Short circuit in the current circuit- High self-discharge (through electrolyte

contamination etc.)- Sulphation (storage of discharged

battery)

- Check the load- Replace the battery

Short service life- Incorrect battery part no.- Repeated deep discharging- Battery stored too long without charge

- Define the correct battery part no. forthe recommended use

- It is recommended to charge the batteryusing a regulator

High water consumption- Overload- Charging voltage too high

- Check the charger (voltage regulator)

The battery explodes

-

Spark after battery charging- Short circuit- Connection or disconnection during

charging- Internal fault and low electrolyte level

- Replace the battery- Ventilate well

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9. Appendix

9.1. Appendix A – Engine user and maintenance manual

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User guide and maintenance manual

JJOOHHNN DDEEEERREE

EEnnggiinnee

33002299DDFF && TTFF112200

33002299TTFFSS && HHFFSS7700 ((TTFF && HHFF227700))

44004455TTFFSS7700 ((TTFF227700))

44004455DDFF227700 44004455HHFFSS7722 ((HHFF227755))

44004455HHFFSS7733 ((HHFF227799))

44004455HHFFSS8800 ((HHFF228800))

44004455HHFFSS8822 && 8833 ((HHFF228855))

66006688HHFFSS7722 ((HHFF227755)) 66006688HHFFSS7733 ((HHFF227799))

66006688HHFFSS8822 && 8833 ((HHFF228855))

66006688HHFFSS8899 ((HHFF448855))

OMCD16564

06/07/200933522039401_4_1

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E n g i n e s & P o w e r U n i t s

f o r G e n e r a t o r S e t s ( S a r a n - B u i l t )

O P E R A T O R ’ S M A N U A L E n g i n e s & P o w e r U n i t s

f o r G e n e r a t o r S e t s ( S a r a n - B u i l t )

O M C D 1 6 5 6 4 I S S U E G 9 ( A N G L A I S )

C A L I F O R N I A

P r o p o s i t i o n 6 5 W a r n i n g

D i e s e l e n g i n e e x h a u s t a n d s o m e o f i t s c o n s t i t u e n t s a r e k n o w n t o t h e S t a t e o f C a l i f o r n i a t o c a u s e c a n c e r ,

b i r t h d e f e c t s , a n d o t h e r r e p r o d u c t i v e h a r m .

I f t h i s p r o d u c t c o n t a i n s a g a s o l i n e e n g i n e :

W A R N I N G

T h e e n g i n e e x h a u s t f r o m t h i s p r o d u c t c o n t a i n s c h e m i c a l s k n o w n t o t h e S t a t e o f C a l i f o r n i a t o c a u s e c a n c e r , b i r t h d e f e c t s o r o t h e r r e p r o d u c t i v e h a r m .

T h e S t a t e o f C a l i f o r n i a r e q u i r e s t h e a b o v e t w o w a r n i n g s .

J o h n D e e r e U s i n e D e S a r a n ( T h i s m a n u a l r e p l a c e s O M C D 1 6 5 6 4 F 8 )

E u r o p e a n V e r s i o n P R I N T E D I N G E R M A N Y

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I n t r o d u c t i o n

C o n t i n u e d o n n e x t p a g e D P S G , C D 0 3 5 2 3 , 1 - 1 9 - 0 6 J U L 0 9 - 1 / 2

F o r e w o r d

T H I S M A N U A L C O V E R S t h e f o l l o w i n g e n g i n e s f o r g e n e r a t o r s e t s :

N o n E m i s s i o n C e r t i f i e d E n g i n e s ( M e c h a n i c a l F u e l S y s t e m )

C D 3 0 2 9 D F 1 2 0

C D 3 0 2 9 D F 1 2 8

C D 3 0 2 9 T F 1 2 0 C D 3 0 2 9 T F 1 5 8

C D 4 0 3 9 D F 0 0 8

C D 4 0 3 9 T F 0 0 8

C D 4 0 4 5 D F 1 5 8

C D 4 0 4 5 H F 1 2 0

C D 4 0 4 5 H F 1 5 8

C D 4 0 4 5 T F 1 2 0

C D 4 0 4 5 T F 1 5 8

C D 4 0 4 5 T F 2 2 0

C D 4 0 4 5 T F 2 5 8

C D 6 0 6 8 H F 1 2 0

C D 6 0 6 8 H F 1 5 8

C D 6 0 6 8 H F 2 5 8

C D 6 0 6 8 T F 1 5 8

C D 6 0 6 8 T F 2 2 0

C D 6 0 6 8 T F 2 5 8

E m i s s i o n C e r t i f i e d E n g i n e s ( S t a g e I I a c c o r d i n g t o D i r e c t i v e 9 7 / 6 8 / E C )

C D 3 0 2 9 H F S 7 0 ( M e c h a n i c a l F u e l S y s t e m )

C D 3 0 2 9 H F U 7 0 ( M e c h a n i c a l F u e l S y s t e m )

C D 3 0 2 9 T F S 7 0 ( M e c h a n i c a l F u e l S y s t e m )

C D 3 0 2 9 T F U 7 0 ( M e c h a n i c a l F u e l S y s t e m )

C D 4 0 4 5 H F S 7 2 ( D E 1 0 F u e l S y s t e m )

C D 4 0 4 5 H F S 7 3 ( H P C R S y s t e m , 2 - V a l v e H e a d ) C D 4 0 4 5 H F U 7 2 ( D E 1 0 F u e l S y s t e m )

C D 4 0 4 5 H F U 7 9 ( H P C R S y s t e m , 2 - V a l v e H e a d )

C D 4 0 4 5 T F S 7 0 ( M e c h a n i c a l F u e l S y s t e m )

C D 4 0 4 5 T F U 7 0 ( M e c h a n i c a l F u e l S y s t e m )

C D 6 0 6 8 H F S 7 2 ( D E 1 0 F u e l S y s t e m )

C D 6 0 6 8 H F S 7 3 ( H P C R S y s t e m , 2 - V a l v e H e a d )



C D 6 0 6 8 H F U 7 2 ( D E 1 0 F u e l S y s t e m )



E m i s s i o n C e r t i f i e d E n g i n e s ( E P A T i e r 2 )

C D 3 0 2 9 T F 2 7 0 ( M e c h a n i c a l F u e l S y s t e m )

C D 4 0 4 5 T F 2 7 0 ( M e c h a n i c a l F u e l S y s t e m )

C D 6 0 6 8 H F 2 7 5 ( V P 4 4 F u e l S y s t e m )

C D 6 0 6 8 H F 4 7 5 ( H P C R S y s t e m , 4 - V a l v e H e a d )

E m i s s i o n C e r t i f i e d E n g i n e s ( E P A T i e r 3 )

C D 4 0 4 5 H F S 8 0 ( M e c h a n i c a l F u e l S y s t e m )




C D 6 0 6 8 H F S 8 3 ( H P C R S y s t e m , 2 - V a l v e H e a d ) C D 6 0 6 8 H F S 8 9 ( H P C R S y s t e m , 4 - V a l v e H e a d )

R E A D T H I S M A N U A L c a r e f u l l y t o l e a r n h o w t o o p e r a t e a n d s e r v i c e y o u r e n g i n e c o r r e c t l y . F a i l u r e t o d o s o c o u l d r e s u l t i n p e r s o n a l i n j u r y o r e q u i p m e n t d a m a g e .

T H I S M A N U A L S H O U L D B E C O N S I D E R E D a p e r m a n e n t p a r t o f y o u r e n g i n e a n d s h o u l d r e m a i n w i t h t h e e n g i n e w h e n y o u s e l l i t .

M E A S U R E M E N T S I N T H I S M A N U A L a r e g i v e n i n m e t r i c . U s e o n l y c o r r e c t r e p l a c e m e n t p a r t s a n d f a s t e n e r s . M e t r i c a n d i n c h f a s t e n e r s m a y r e q u i r e a s p e c i f i c m e t r i c o r i n c h w r e n c h .

W R I T E E N G I N E S E R I A L N U M B E R S a n d o p t i o n c o d e s i n t h e s p a c e s i n d i c a t e d i n t h e S e r i a l N u m b e r S e c t i o n .

A c c u r a t e l y r e c o r d a l l t h e n u m b e r s . Y o u r d e a l e r a l s o n e e d s t h e s e n u m b e r s w h e n y o u o r d e r p a r t s . F i l e t h e i d e n t i f i c a t i o n n u m b e r s i n a s e c u r e p l a c e o f f t h e e n g i n e o r m a c h i n e .

R I G H T - H A N D A N D L E F T - H A N D s i d e s a r e d e t e r m i n e d b y s t a n d i n g a t t h e d r i v e o r f l y w h e e l e n d ( r e a r ) o f t h e e n g i n e a n d f a c i n g t o w a r d t h e f r o n t o f t h e e n g i n e .

S E T T I N G F U E L D E L I V E R Y b e y o n d p u b l i s h e d f a c t o r y s p e c i f i c a t i o n s o r o t h e r w i s e o v e r p o w e r i n g w i l l r e s u l t i n l o s s o f w a r r a n t y p r o t e c t i o n f o r t h i s e n g i n e .

I n f o r m a t i o n r e l a t i v e t o e m i s s i o n s r e g u l a t i o n s D e p e n d i n g o n f i n a l d e s t i n a t i o n , t h i s e n g i n e c a n m e e t t h e e m i s s i o n s r e g u l a t i o n s a c c o r d i n g t o t h e U S E n v i r o n m e n t a l P r o t e c t i o n A g e n c y ( E P A ) , C a l i f o r n i a A i r R e s o u r c e s B o a r d ( C A R B ) a n d f o r E u r o p e , t h e D i r e c t i v e 9 7 / 6 8 / E C r e l a t i n g t h e m e a s u r e s a g a i n s t t h e e m i s s i o n s o f g a s e o u s a n d p a r t i c u l a t e s p o l l u t a n t s f r o m i n t e r n a l c o m b u s t i o n e n g i n e s . I n t h i s c a s e a n e m i s s i o n l a b e l i s s t u c k o n t h e e n g i n e .

E m i s s i o n r e g u l a t i o n s p r o h i b i t t a m p e r i n g w i t h t h e e m i s s i o n - r e l a t e d c o m p o n e n t s l i s t e d b e l o w w h i c h w o u l d r e n d e r t h a t c o m p o n e n t i n o p e r a t i v e o r t o m a k e a n y a d j u s t m e n t o n t h e e n g i n e b e y o n d p u b l i s h e d s p e c i f i c a t i o n s . I t i s a l s o i l l e g a l t o i n s t a l l a p a r t o r c o m p o n e n t w h e r e t h e p r i n c i p a l e f f e c t o f t h a t c o m p o n e n t i s t o b y p a s s , d e f e a t , o r r e n d e r i n o p e r a t i v e a n y e n g i n e c o m p o n e n t o r d e v i c e w h i c h w o u l d a f f e c t t h e e n g i n e c o n f o r m a n c e t o t h e e m i s s i o n s r e g u l a t i o n s . T o s u m m a r i z e , i t i s i l l e g a l t o d o a n y t h i n g e x c e p t r e t u r n t h e e n g i n e t o i t s o r i g i n a l p u b l i s h e d s p e c i f i c a t i o n s .

0 7 2 2 0 9

P N = 2

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D P S G , C D 0 3 5 2 3 , 1 - 1 9 - 0 6 J U L 0 9 - 2 / 2

L i s t o f e m i s s i o n - r e l a t e d c o m p o n e n t s : - F u e l i n j e c t i o n p u m p - I n t a k e m a n i f o l d - T u r b o c h a r g e r - C h a r g e a i r c o o l i n g s y s t e m

- P i s t o n

C A L I F O R N I A P R O P O S I T I O N 6 5 W A R N I N G

D i e s e l e n g i n e e x h a u s t a n d s o m e o f i t s c o n s t i t u e n t s a r e k n o w n t o t h e S t a t e o f C a l i f o r n i a t o c a u s e c a n c e r , b i r t h d e f e c t s a n d o t h e r r e p r o d u c t i v e h a r m .

0 7 2 2 0 9

P N = 3

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0 7 2 2 0 9

P N = 4

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C o n t e n t s

P a g e

I d e n t i f i c a t i o n V i e w s I d e n t i f i c a t i o n v i e w s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 1 - 1

M a i n t e n a n c e R e c o r d s U s i n g m a i n t e n a n c e r e c o r d s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 2 - 1 1 0 0 H o u r s o f o p e r a t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 2 - 1 5 0 0 H o u r s o f o p e r a t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 2 - 2 1 0 0 0 H o u r s o f o p e r a t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 2 - 2 1 5 0 0 H o u r s o f o p e r a t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 2 - 3 2 0 0 0 H o u r s o f o p e r a t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 2 - 3 2 5 0 0 H o u r s o f o p e r a t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 2 - 4 3 0 0 0 H o u r s o f o p e r a t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 2 - 4 3 5 0 0 H o u r s o f o p e r a t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 2 - 5 4 0 0 0 H o u r s o f o p e r a t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 2 - 5 4 5 0 0 H o u r s o f o p e r a t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 2 - 6 5 0 0 0 H o u r s o f o p e r a t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 2 - 6 5 5 0 0 H o u r s o f o p e r a t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 2 - 7 6 0 0 0 H o u r s o f o p e r a t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 2 - 7 6 5 0 0 H o u r s o f o p e r a t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 2 - 8 7 0 0 0 H o u r s o f o p e r a t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 2 - 8 7 5 0 0 H o u r s o f o p e r a t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 2 - 9 8 0 0 0 H o u r s o f o p e r a t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 2 - 9 8 5 0 0 H o u r s o f o p e r a t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 2 - 1 0 9 0 0 0 H o u r s o f o p e r a t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 2 - 1 0 9 5 0 0 H o u r s o f o p e r a t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 2 - 1 1 1 0 0 0 0 H o u r s o f o p e r a t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 2 - 1 1

S e r i a l N u m b e r s P o w e r T e c h l a b e l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 3 - 1 E n g i n e s e r i a l n u m b e r p l a t e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 3 - 1 R e c o r d e n g i n e s e r i a l n u m b e r . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 3 - 2 E n g i n e o p t i o n c o d e s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 3 - 3 R e c o r d f u e l i n j e c t i o n p u m p m o d e l n u m b e r . . . . . . . 0 3 - 4

R e c o r d E n g i n e C o n t r o l U n i t ( E C U ) S e r i a l N u m b e r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 3 - 5 R e c o r d H i g h - P r e s s u r e F u e l P u m p

M o d e l N u m b e r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 3 - 5

S a f e t y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 5 - 1

F u e l s , L u b r i c a n t s a n d C o o l a n t D i e s e l F u e l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 - 1 H a n d l i n g a n d S t o r i n g D i e s e l F u e l . . . . . . . . . . . . . . . . . . . . . 1 0 - 1 D i e s e l E n g i n e B r e a k - I n O i l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 - 2 D i e s e l E n g i n e O i l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 - 2 L u b r i c a n t S t o r a g e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 - 3

P a g e

M i x i n g o f L u b r i c a n t s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 - 3 D i e s e l E n g i n e C o o l a n t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 - 3 O p e r a t i n g i n W a r m T e m p e r a t u r e C l i m a t e s . . . . . . . 1 0 - 4

O p e r a t i n g t h e E n g i n e U s i n g D i a g n o s t i c G a u g e t o A c c e s s

E n g i n e I n f o r m a t i o n ( O p t i o n a l e q u i p m e n t ) . . . . 1 5 - 1 M a i n M e n u N a v i g a t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 - 1 E n g i n e C o n f i g u r a t i o n D a t a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 - 3

A c c e s s i n g S t o r e d T r o u b l e C o d e s . . . . . . . . . . . . . . . . . . . . . 1 5 - 5 A c c e s s i n g A c t i v e T r o u b l e C o d e s . . . . . . . . . . . . . . . . . . . . . . 1 5 - 7 E n g i n e S h u t d o w n C o d e s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 - 9

A d j u s t i n g B a c k l i g h t i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 - 1 0 A d j u s t i n g C o n t r a s t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 - 1 2 S e l e c t i n g U n i t s O f M e a s u r e m e n t . . . . . . . . . . . . . . . . . . . . . . 1 5 - 1 3 S e t u p 1 - U p D i s p l a y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 - 1 5 S e t u p 4 - U p D i s p l a y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 - 2 1 B r e a k - i n p e r i o d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 - 2 5 S t a r t i n g t h e e n g i n e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 - 2 5 C o l d w e a t h e r o p e r a t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 - 2 6

U s i n g a b o o s t e r b a t t e r y o r c h a r g e r . . . . . . . . . . . . . . . . . . . 1 5 - 2 8 E n g i n e o p e r a t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 - 2 9 S t a n d b y p o w e r u n i t s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 - 2 9 S t o p p i n g t h e e n g i n e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 - 2 9 C h a n g i n g G e n e r a t o r F r e q u e n c y . . . . . . . . . . . . . . . . . . . . . . . 1 5 - 2 9

M a i n t e n a n c e O b s e r v e s e r v i c e i n t e r v a l s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 0 - 1 U s e c o r r e c t f u e l s , l u b r i c a n t s a n d c o o l a n t . . . . . . . . . . 2 0 - 1 M a i n t e n a n c e i n t e r v a l c h a r t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 0 - 1

M a i n t e n a n c e / D a i l y o r e v e r y 1 0 h o u r s D a i l y p r e s t a r t i n g c h e c k s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 5 - 1

M a i n t e n a n c e / 5 0 0 h o u r s C h a n g i n g e n g i n e o i l a n d f i l t e r . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 0 - 1 R e p l a c i n g f u e l f i l t e r e l e m e n t ( s ) . . . . . . . . . . . . . . . . . . . . . . . . . 3 0 - 4 C h e c k i n g b e l t ( 3 0 2 9 a n d 4 0 3 9 E n g i n e s ) . . . . . . . . . . 3 0 - 5 C h e c k i n g b e l t ( 4 0 4 5 a n d 6 0 6 8 E n g i n e s

w i t h m a n u a l t e n s i o n e r ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 0 - 6

M a i n t e n a n c e / 1 0 0 0 h o u r s / 1 y e a r C l e a n i n g c r a n k c a s e v e n t t u b e . . . . . . . . . . . . . . . . . . . . . . . . . . 3 5 - 1 C h e c k i n g a i r i n t a k e s y s t e m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 5 - 1 C h e c k i n g a u t o m a t i c b e l t t e n s i o n e r

( 4 0 4 5 a n d 6 0 6 8 E n g i n e s ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 5 - 2

C o n t i n u e d o n n e x t p a g e

O r i g i n a l I n s t r u c t i o n s . A l l i n f o r m a t i o n , i l l u s t r a t i o n s a n d s p e c i f i c a t i o n s i n t h i s m a n u a l a r e b a s e d o n t h e l a t e s t i n f o r m a t i o n a v a i l a b l e a t t h e t i m e o f p u b l i c a t i o n .

T h e r i g h t i s r e s e r v e d t o m a k e c h a n g e s a t a n y t i m e w i t h o u t n o t i c e .

C O P Y R I G H T © 2 0 0 9 D E E R E & C O M P A N Y

E u r o p e a n O f fi c e M a n n h e i m A l l r i g h t s r e s e r v e d .

A J o h n D e e r e I L L U S T R U C T I O N ® M a n u a l P r e v i o u s E d i t i o n s

C o p y r i g h t © 2 0 0 7 , 2 0 0 8

i 0 7 2 2 0 9

P N = 1

75/258



C o n t e n t s

P a g e

C h e c k a n d a d j u s t e n g i n e v a l v e c l e a r a n c e ( 3 0 2 9 a n d 4 0 3 9 E n g i n e s ) . . . . . . . . . . . . 3 5 - 3

P r e s s u r e t e s t i n g c o o l i n g s y s t e m . . . . . . . . . . . . . . . . . . . . . . . 3 5 - 5

M a i n t e n a n c e / 2 0 0 0 h o u r s / 2 y e a r s C h e c k a n d a d j u s t e n g i n e v a l v e

c l e a r a n c e ( 4 0 4 5 a n d 6 0 6 8 E n g i n e s ) . . . . . . . . . . . . 4 0 - 1

C h e c k i n g e n g i n e s p e e d ( M e c h a n i c a l f u e l s y s t e m ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 0 - 3

A d j u s t s p e e d d r o o p g o v e r n o r ( M e c h a n i c a l f u e l s y s t e m ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 0 - 3

C h e c k i n g c r a n k s h a f t v i b r a t i o n d a m p e r ( 6 - C Y L I N D E R E N G I N E O N L Y ) . . . . . . . . . . . . . . . . . . . . 4 0 - 4

M a i n t e n a n c e / 2 5 0 0 h o u r s / 3 y e a r s D r a i n a n d f l u s h c o o l i n g s y s t e m . . . . . . . . . . . . . . . . . . . . . . . . . 4 5 - 1

M a i n t e n a n c e / A s r e q u i r e d A d d i t i o n a l s e r v i c e i n f o r m a t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 0 - 1 D o n o t m o d i f y f u e l s y s t e m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 0 - 1 W e l d i n g N e a r E l e c t r o n i c C o n t r o l U n i t s . . . . . . . . . . . . . 5 0 - 2 K e e p E l e c t r o n i c C o n t r o l U n i t

C o n n e c t o r s C l e a n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 0 - 2 C l e a n o r r e p l a c e a i r f i l t e r ( o n e - p i e c e ) . . . . . . . . . . . . . . . 5 0 - 3 C l e a n o r r e p l a c e a i r f i l t e r e l e m e n t . . . . . . . . . . . . . . . . . . . . . 5 0 - 4 R e p l a c i n g f a n a n d a l t e r n a t o r b e l t ( 4 0 4 5

a n d 6 0 6 8 E n g i n e s ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 0 - 5 B l e e d i n g t h e f u e l s y s t e m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 0 - 5

T r o u b l e s h o o t i n g G e n e r a l t r o u b l e s h o o t i n g i n f o r m a t i o n . . . . . . . . . . . . . . . . 5 5 - 1 E n g i n e W i r i n g L a y o u t ( E l e c t r o n i c F u e l

S y s t e m W i t h S t a n a d y n e D E 1 0 I n j e c t i o n P u m p ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 5 - 2

E n g i n e W i r i n g L a y o u t ( E l e c t r o n i c F u e l S y s t e m W i t h D e n s o H i g h P r e s s u r e C o m m o n R a i l ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 5 - 3

E n g i n e t r o u b l e s h o o t i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 5 - 4 E l e c t r i c a l t r o u b l e s h o o t i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 5 - 8 D i s p l a y i n g O f D i a g n o s t i c T r o u b l e

C o d e s ( D T C s ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 5 - 9 U s i n g b l i n k c o d e m e t h o d f o r r e t r i e v i n g

D i a g n o s t i c T r o u b l e C o d e s ( D T C ’ s ) . . . . . . . . . . . . . . . 5 5 - 9 U s i n g d i a g n o s t i c g a u g e f o r r e t r i e v i n g

D i a g n o s t i c T r o u b l e C o d e s ( D T C ’ s ) . . . . . . . . . . . . . . . 5 5 - 1 0 L i s t i n g o f D i a g n o s t i c T r o u b l e C o d e s ( D T C s ) . . . . 5 5 - 1 1 I n t e r m i t t e n t F a u l t D i a g n o s t i c s ( W i t h

E l e c t r o n i c C o n t r o l s ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 5 - 1 3

S t o r a g e E n g i n e s t o r a g e g u i d e l i n e s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 0 - 1 P r e p a r i n g e n g i n e f o r l o n g t e r m s t o r a g e . . . . . . . . . . . . 6 0 - 1 R e m o v i n g e n g i n e f r o m l o n g t e r m s t o r a g e . . . . . . . . 6 0 - 1

S p e c i f i c a t i o n s G e n e r a l e n g i n e p a c k s p e c i f i c a t i o n s

( N o n - E m i s s i o n C e r t i f i e d E n g i n e s ) . . . . . . . . . . . . . . . . 6 5 - 1 G e n e r a l e n g i n e p a c k s p e c i f i c a t i o n s

( S t a g e I I E m i s s i o n C e r t i f i e d E n g i n e s ) . . . . . . . . . . 6 5 - 4

P a g e

G e n e r a l e n g i n e p a c k s p e c i f i c a t i o n s ( E P A T i e r 2 E m i s s i o n C e r t i f i e d E n g i n e s ) . . . . . . 6 5 - 6

G e n e r a l e n g i n e p a c k s p e c i f i c a t i o n s ( E P A T i e r 3 E m i s s i o n C e r t i f i e d E n g i n e s ) . . . . . . 6 5 - 7

U n i f i e d I n c h B o l t a n d S c r e w T o r q u e V a l u e s . . . . . . 6 5 - 8 M e t r i c B o l t a n d S c r e w T o r q u e V a l u e s . . . . . . . . . . . . . . . 6 5 - 9

i i 0 7 2 2 0 9

P N = 2

76/258



I d e n t i f i c a t i o n V i e w s

C o n t i n u e d o n n e x t p a g e D P S G , C D 0 3 5 2 3 , 3 - 1 9 - 2 2 J A N 0 7 - 1 / 3

I d e n t i f i c a t i o n v i e w s

C D 3 0 8 4 0

— U N

— 1 0 J A N 0 3

3 0 2 9 D F 1 2 8

0 1 - 1 0 7 2 2 0 9

P N = 7

77/258




C o n t i n u e d o n n e x t p a g e D P S G , C D 0 3 5 2 3 , 3 - 1 9 - 2 2 J A N 0 7 - 2 / 3

C D 3 0 8 4 1

— U N

— 1 0 J A N 0 3

4 0 4 5 H F 1 5 8

0 1 - 2 0 7 2 2 0 9

P N = 8

78/258




D P S G , C D 0 3 5 2 3 , 3 - 1 9 - 2 2 J A N 0 7 - 3 / 3

C D 3 0 8 4 2

— U N

— 1 0 J A

N 0 3

6 0 6 8 H F 2 5 8

0 1 - 3 0 7 2 2 0 9

P N = 9

79/258



M a i n t e n a n c e R e c o r d s

D P S G , C D 0 3 5 2 3 , 6 - 1 9 - 2 2 J A N 0 7 - 1 / 1

D P S G , C D 0 3 5 2 3 , 7 - 1 9 - 2 2 J A N 0 7 - 1 / 1

U s i n g m a i n t e n a n c e r e c o r d s

T o o b t a i n t h e b e s t p e r f o r m a n c e , e c o n o m y a n d s e r v i c e l i f e f r o m y o u r e n g i n e , e n s u r e s e r v i c e i s c a r r i e d o u t a c c o r d i n g t o t h i s p r e s e n t m a n u a l a n d r e c o r d e d i n t h e f o l l o w i n g p a g e s . I t i s r e c o m m e n d e d t h a t y o u r e n g i n e D i s t r i b u t o r o r y o u r D e a l e r c a r r y o u t t h i s s e r v i c e w o r k a n d s t a m p t h e a p p r o p r i a t e c a s e .

K e e p i n g a n a c c u r a t e a c c o u n t o f a l l s e r v i c e p e r f o r m e d o n y o u r e n g i n e w i l l g i v e m o r e v a l u e t o t h e m a c h i n e w h e n r e s e l l i t .

J o h n D e e r e o i l s a n d c o o l a n t s h a v e b e e n f o r m u l a t e d t o g i v e m a x i m u m p r o t e c t i o n a n d p e r f o r m a n c e t o y o u r e n g i n e . W e r e c o m m e n d o n l y g e n u i n e J o h n D e e r e s e r v i c e p r o d u c t s a n d r e p l a c e m e n t p a r t s .

T o p r o t e c t y o u r r i g h t s u n d e r t h e w a r r a n t y e n s u r e a l l

s c h e d u l e d s e r v i c e s a r e c a r r i e d o u t a n d r e c o r d e d . I f y o u r e n g i n e i s c o v e r e d b y e x t e n d e d w a r r a n t y , i t i s i m p o r t a n t t o m a i n t a i n t h i s r e c o r d f o r t h e d u r a t i o n o f t h e w a r r a n t y .

1 0 0 H o u r s o f o p e r a t i o n

E n g i n e o i l , d r a i n

E n g i n e o i l f i l t e r , r e p l a c e

H o s e c o n n e c t i o n s , c h e c k

N u m b e r o f h o u r s : O b s e r v a t i o n : D e a l e r o r d i s t r i b u t o r s t a m p

D a t e :

J o b d o n e b y :

0 2 - 1 0 7 2 2 0 9

P N = 1 0

80/258




D P S G , C D 0 3 5 2 3 , 8 - 1 9 - 2 2 J A N 0 7 - 1 / 1

D P S G , C D 0 3 5 2 3 , 9 - 1 9 - 2 2 J A N 0 7 - 1 / 1

5 0 0 H o u r s o f o p e r a t i o n



F u e l f i l t e r , r e p l a c e

B e l t , c h e c k t e n s i o n a n d w e a r ( 3 0 0 - S e r i e s a n d P O W E R T e c h w i t h

m a n u a l t e n s i o n e r )

V a l v e c l e a r a n c e , a d j u s t ( 3 0 0 - S e r i e s )


D a t e :

J o b d o n e b y :

1 0 0 0 H o u r s o f o p e r a t i o n

E n g i n e o i l , d r a i n A i r i n t a k e s y s t e m , c h e c k



C h e c k b e l t a n d t e n s i o n i n g s y s t e m

C r a n k c a s e v e n t t u b e , c l e a n


D a t e :

J o b d o n e b y :

0 2 - 2 0 7 2 2 0 9

P N = 1 1

81/258




D P S G , C D 0 3 5 2 3 , 1 0 - 1 9 - 2 2 J A N 0 7 - 1 / 1

D P S G , C D 0 3 5 2 3 , 5 9 - 1 9 - 2 2 J A N 0 7 - 1 / 1









D a t e :

J o b d o n e b y :


E n g i n e o i l , d r a i n C o o l i n g s y s t e m , d r a i n a n d f l u s h ( i f C O O L - G A R D i s n o t u s e d )

E n g i n e o i l f i l t e r , r e p l a c e V a l v e c l e a r a n c e , a d j u s t ( P O W E R T e c h )

F u e l f i l t e r , r e p l a c e A i r i n t a k e s y s t e m , c h e c k

C h e c k b e l t a n d t e n s i o n i n g s y s t e m V i b r a t i o n d a m p e r , c h e c k



D a t e :

J o b d o n e b y :

0 2 - 3 0 7 2 2 0 9

P N = 1 2

82/258




D P S G , C D 0 3 5 2 3 , 6 0 - 1 9 - 2 2 J A N 0 7 - 1 / 1

D P S G , C D 0 3 5 2 3 , 6 1 - 1 9 - 2 2 J A N 0 7 - 1 / 1


E n g i n e o i l , d r a i n C o o l i n g s y s t e m , d r a i n a n d f l u s h ( i f C O O L - G A R D i s u s e d )







D a t e :

J o b d o n e b y :








D a t e :

J o b d o n e b y :

0 2 - 4 0 7 2 2 0 9

P N = 1 3

83/258




D P S G , C D 0 3 5 2 3 , 6 2 - 1 9 - 2 2 J A N 0 7 - 1 / 1

D P S G , C D 0 3 5 2 3 , 6 3 - 1 9 - 2 2 J A N 0 7 - 1 / 1









D a t e :

J o b d o n e b y :








D a t e :

J o b d o n e b y :

0 2 - 5 0 7 2 2 0 9

P N = 1 4

84/258




D P S G , C D 0 3 5 2 3 , 6 4 - 1 9 - 2 2 J A N 0 7 - 1 / 1

D P S G , C D 0 3 5 2 3 , 6 5 - 1 9 - 2 2 J A N 0 7 - 1 / 1


E n g i n e o i l , d r a i n V i b r a t i o n d a m p e r , r e p l a c e ( 6 c y l . )


B e l t , c h e c k t e n s i o n a n d w e a r ( 3 0 0 - S e r i e s a n d P O W E R T e c h w i t h m a n u a l t e n s i o n e r )



D a t e :

J o b d o n e b y :


E n g i n e o i l , d r a i n I n j e c t i o n n o z z l e s , r e p l a c e

E n g i n e o i l f i l t e r , r e p l a c e A i r i n t a k e s y s t e m , c h e c k

F u e l f i l t e r , r e p l a c e C o o l i n g s y s t e m , d r a i n a n d f l u s h ( i f C O O L - G A R D i s u s e d )




D a t e :

J o b d o n e b y :

0 2 - 6 0 7 2 2 0 9

P N = 1 5

85/258




D P S G , C D 0 3 5 2 3 , 6 6 - 1 9 - 2 2 J A N 0 7 - 1 / 1

D P S G , C D 0 3 5 2 3 , 6 7 - 1 9 - 2 2 J A N 0 7 - 1 / 1









D a t e :

J o b d o n e b y :








D a t e :

J o b d o n e b y :

0 2 - 7 0 7 2 2 0 9

P N = 1 6

86/258




D P S G , C D 0 3 5 2 3 , 6 8 - 1 9 - 2 2 J A N 0 7 - 1 / 1

D P S G , C D 0 3 5 2 3 , 6 9 - 1 9 - 2 2 J A N 0 7 - 1 / 1









D a t e :

J o b d o n e b y :








D a t e :

J o b d o n e b y :

0 2 - 8 0 7 2 2 0 9

P N = 1 7

87/258




D P S G , C D 0 3 5 2 3 , 7 0 - 1 9 - 2 2 J A N 0 7 - 1 / 1

D P S G , C D 0 3 5 2 3 , 7 1 - 1 9 - 2 2 J A N 0 7 - 1 / 1


E n g i n e o i l , d r a i n C o o l i n g s y s t e m , d r a i n a n d f l u s h ( i f C O O L - G A R D i s u s e d )







D a t e :

J o b d o n e b y :








D a t e :

J o b d o n e b y :

0 2 - 9 0 7 2 2 0 9

P N = 1 8

88/258




D P S G , C D 0 3 5 2 3 , 7 2 - 1 9 - 2 2 J A N 0 7 - 1 / 1

D P S G , C D 0 3 5 2 3 , 7 3 - 1 9 - 2 2 J A N 0 7 - 1 / 1









D a t e :

J o b d o n e b y :








D a t e :

J o b d o n e b y :

0 2 - 1 0 0 7 2 2 0 9

P N = 1 9

89/258




D P S G , C D 0 3 5 2 3 , 7 4 - 1 9 - 2 2 J A N 0 7 - 1 / 1

D P S G , C D 0 3 5 2 3 , 7 5 - 1 9 - 2 2 J A N 0 7 - 1 / 1









D a t e :

J o b d o n e b y :

1 0 0 0 0 H o u r s o f o p e r a t i o n

E n g i n e o i l , d r a i n C o o l i n g s y s t e m , d r a i n a n d f l u s h


F u e l f i l t e r , r e p l a c e T h e r m o s t a t , r e p l a c e


C r a n k c a s e v e n t t u b e , c l e a n I n j e c t i o n n o z z l e s , r e p l a c e

A i r i n t a k e s y s t e m , c h e c k


D a t e :

J o b d o n e b y :

0 2 - 1 1 0 7 2 2 0 9

P N = 2 0

90/258



S e r i a l N u m b e r s

D P S G , C D 0 3 5 2 3 , 1 1 - 1 9 - 1 0 J U L 0 9 - 1 / 1

D P S G , C D 0 3 5 2 3 , 1 2 - 1 9 - 2 2 J A N 0 7 - 1 / 1

P o w e r T e c h l a b e l

A l a b e l i s l o c a t e d o n t h e r o c k e r a r m c o v e r w h i c h i d e n t i f i e s e a c h e n g i n e a s a J o h n D e e r e P o w e r T e c h e n g i n e .

R G 8 0 4 1

— U N —

1 5 J A N 9 9

E n g i n e s e r i a l n u m b e r p l a t e

R G 8 0 0 7

— U N

— 1 5 J A N 9 9

4 0 4 5 a n d 6 0 6 8 E n g i n e s

C D 3 0 7 4 6

— U N

— 2 4 S E P 9 9

3 0 2 9 a n d 4 0 3 9 E n g i n e s

E a c h e n g i n e h a s a 1 3 – d i g i t J o h n D e e r e s e r i a l n u m b e r . T h e f i r s t t w o d i g i t s i d e n t i f y t h e f a c t o r y t h a t p r o d u c e d t h e

e n g i n e : ” C D ” i n d i c a t e s t h e e n g i n e w a s b u i l t i n S a r a n , F r a n c e

Y o u r e n g i n e ’ s s e r i a l n u m b e r p l a t e ( A ) i s l o c a t e d o n t h e r i g h t - h a n d s i d e o f c y l i n d e r b l o c k b e h i n d t h e f u e l f i l t e r f o r

4 0 4 5 a n d 6 0 6 8 e n g i n e s a n d n e a r t h e f u e l s u p p l y p u m p o n 3 0 2 9 a n d 4 0 3 9 e n g i n e s .

0 3 - 1 0 7 2 2 0 9

P N = 2 1

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D P S G , C D 0 3 5 2 3 , 1 3 - 1 9 - 2 2 J A N 0 7 - 1 / 1

R e c o r d e n g i n e s e r i a l n u m b e r

R e c o r d a l l o f t h e n u m b e r s a n d l e t t e r s f o u n d o n y o u r e n g i n e s e r i a l n u m b e r p l a t e i n t h e s p a c e s p r o v i d e d b e l o w .

T h i s i n f o r m a t i o n i s v e r y i m p o r t a n t f o r r e p a i r p a r t s o r w a r r a n t y i n f o r m a t i o n .

E n g i n e S e r i a l N u m b e r ( B )

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

E n g i n e M o d e l N u m b e r ( C )

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

C o e f f i c i e n t o f A b s o r p t i o n V a l u e ( D )

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

C D 3 0 7 0 5 B

— U N

— 2 4 A U G

9 9

3 0 2 9 a n d 4 0 3 9 e n g i n e p l a t e

C D 3 0 7 4 7 A

— U N

— 2 2 J A N 0 7

4 0 4 5 a n d 6 0 6 8 e n g i n e p l a t e

0 3 - 2 0 7 2 2 0 9

P N = 2 2

92/258




C o n t i n u e d o n n e x t p a g e D P S G , C D 0 3 5 2 3 , 1 4 - 1 9 - 2 2 J A N 0 7 - 1 / 2

E n g i n e o p t i o n c o d e s

C D 3 0 7 4 8 A

— U N

— 2 6 A U G 9 9

E n g i n e o p t i o n c o d e l a b e l

I n a d d i t i o n t o t h e s e r i a l n u m b e r p l a t e , O E M e n g i n e s h a v e a n e n g i n e o p t i o n c o d e l a b e l a f f i x e d t o t h e r o c k e r a r m c o v e r . T h e s e c o d e s i n d i c a t e w h i c h o f t h e e n g i n e o p t i o n s w e r e i n s t a l l e d o n y o u r e n g i n e a t t h e f a c t o r y . W h e n i n n e e d o f p a r t s o r s e r v i c e , f u r n i s h y o u r a u t h o r i z e d s e r v i c i n g d e a l e r o r e n g i n e d i s t r i b u t o r w i t h t h e s e n u m b e r s .

A n a d d i t i o n a l s t i c k e r m a y b e a l s o d e l i v e r e d ( i n a p l a s t i c b a g a t t a c h e d t o t h e e n g i n e o r i n s e r t e d i n t h e m a c h i n e d o c u m e n t a t i o n ) . I t i s r e c o m m e n d e d t o s t i c k t h i s o p t i o n c o d e l i s t s t i c k e r e i t h e r :

• O n t h i s p a g e o f y o u r O p e r a t o r ’ s m a n u a l b e l o w t h i s s e c t i o n . o r

• O n t h e ” E n g i n e O w n e r ’ s W a r r a n t y ” b o o k l e t u n d e r t h e t i t l e O P T I O N C O D E S ( E n g i n e m a n u f a c t u r i n g c o n f i g u r a t i o n ) .

N O T E : T h e M a c h i n e M a n u f a c t u r e r m a y h a v e a l r e a d y s t u c k i t a t a s p e c i f i c a c c e s s i b l e p l a c e ( i n s i d e t h e

e n c l o s u r e o r c l o s e t o a m a i n t e n a n c e a r e a ) .

T h e e n g i n e o p t i o n c o d e l a b e l i n c l u d e s a n e n g i n e b a s e c o d e ( A ) . T h i s b a s e c o d e m u s t a l s o b e r e c o r d e d a l o n g w i t h t h e o p t i o n c o d e s . A t t i m e s i t w i l l b e n e c e s s a r y t o f u r n i s h t h i s b a s e c o d e t o d i f f e r e n t i a t e t w o i d e n t i c a l o p t i o n c o d e s f o r t h e s a m e e n g i n e m o d e l .

T h e f i r s t t w o d i g i t s o f e a c h c o d e i d e n t i f y a s p e c i f i c g r o u p , s u c h a s a l t e r n a t o r s . T h e l a s t t w o d i g i t s o f e a c h c o d e i d e n t i f y o n e s p e c i f i c o p t i o n p r o v i d e d o n y o u r e n g i n e , s u c h a s a 1 2 - v o l t , 5 5 - a m p a l t e r n a t o r .

N O T E : T h e s e o p t i o n c o d e s a r e b a s e d o n t h e l a t e s t

i n f o r m a t i o n a v a i l a b l e a t t h e t i m e o f p u b l i c a t i o n . T h e r i g h t i s r e s e r v e d t o m a k e c h a n g e s a t a n y t i m e w i t h o u t n o t i c e .

I f a n e n g i n e i s o r d e r e d w i t h o u t a p a r t i c u l a r c o m p o n e n t , t h e l a s t t w o d i g i t s o f t h a t f u n c t i o n a l g r o u p o p t i o n c o d e w i l l b e 9 9 , 0 0 , o r X X . T h e l i s t o n t h e n e x t p a g e s h o w s o n l y t h e f i r s t t w o d i g i t s o f t h e c o d e n u m b e r s . F o r f u t u r e r e f e r e n c e s u c h a s o r d e r i n g r e p a i r p a r t s , i t i s i m p o r t a n t t o h a v e t h e s e c o d e n u m b e r s a v a i l a b l e . T o e n s u r e t h i s a v a i l a b i l i t y , e n t e r t h e t h i r d a n d f o u r t h d i g i t s s h o w n o n y o u r e n g i n e o p t i o n c o d e l a b e l i n t h e s p a c e s p r o v i d e d o n t h e f o l l o w i n g p a g e .

N O T E : N O T E : Y o u r e n g i n e o p t i o n c o d e l a b e l m a y n o t

c o n t a i n a l l o p t i o n c o d e s i f a n o p t i o n h a s b e e n a d d e d a f t e r t h e e n g i n e l e f t t h e p r o d u c i n g f a c t o r y .

I f o p t i o n c o d e l a b e l i s l o s t o r d e s t r o y e d , c o n s u l t y o u r s e r v i c i n g d e a l e r o r e n g i n e d i s t r i b u t o r s e l l i n g t h e e n g i n e f o r a r e p l a c e m e n t .

O p t i o n C o d e s

D e s c r i p t i o n O p t i o n C o d e s

D e s c r i p t i o n

E n g i n e B a s e C o d e : _ _ _ _ _ _ _ _

1 1 _ _ _ _ R o c k e r A r m C o v e r 5 0 _ _ _ _ O i l P u m p

1 2 _ _ _ _ O i l F i l l e r N e c k 5 1 _ _ _ _ C y l i n d e r H e a d W i t h V a l v e s

1 3 _ _ _ _ C r a n k s h a f t P u l l e y 5 2 _ _ _ _ A u x i l i a r y G e a r D r i v e

1 4 _ _ _ _ F l y w h e e l H o u s i n g 5 3 _ _ _ _ F u e l H e a t e r

1 5 _ _ _ _ F l y w h e e l 5 4 _ _ _ _ O i l h e a t e r

1 6 _ _ _ _ F u e l I n j e c t i o n P u m p 5 5 _ _ _ _ S h i p p i n g s t a n d

1 7 _ _ _ _ A i r i n l e t 5 6 _ _ _ _ P a i n t O p t i o n

1 8 _ _ _ _ A i r c l e a n e r 5 7 _ _ _ _ C o o l a n t I n l e t

1 9 _ _ _ _ O i l p a n 5 9 _ _ _ _ O i l C o o l e r

2 0 _ _ _ _ C o o l a n t p u m p 6 0 _ _ _ _ A d d - o n A u x i l i a r y D r i v e P u l l e y

2 1 _ _ _ _ T h e r m o s t a t C o v e r 6 2 _ _ _ _ A l t e r n a t o r M o u n t i n g

2 2 _ _ _ _ T h e r m o s t a t 6 3 _ _ _ _ L o w P r e s s u r e F u e l L i n e

0 3 - 3 0 7 2 2 0 9

P N = 2 3

93/258




D P S G , C D 0 3 5 2 3 , 1 4 - 1 9 - 2 2 J A N 0 7 - 2 / 2

D P S G , C D 0 3 5 2 3 , 1 5 - 1 9 - 2 2 J A N 0 7 - 1 / 1

O p t i o n C o d e s

D e s c r i p t i o n O p t i o n C o d e s

D e s c r i p t i o n

2 3 _ _ _ _ F a n D r i v e 6 4 _ _ _ _ E x h a u s t E l b o w

2 4 _ _ _ _ F a n B e l t 6 5 _ _ _ _ T u r b o c h a r g e r

2 5 _ _ _ _ F a n 6 6 _ _ _ _ T e m p e r a t u r e S w i t c h

2 6 _ _ _ _ E n g i n e C o o l a n t H e a t e r 6 7 _ _ _ _ E l e c t r o n i c T a c h o m e t e r S e n s o r

2 7 _ _ _ _ R a d i a t o r 6 8 _ _ _ _ D a m p e r

2 8 _ _ _ _ E x h a u s t M a n i f o l d 6 9 _ _ _ _ E n g i n e S e r i a l N u m b e r P l a t e

2 9 _ _ _ _ V e n t i l a t o r S y s t e m 7 2 _ _ _ _ E C U E l e c t r o n i c S o f t w a r e O p t i o n

3 0 _ _ _ _ S t a r t i n g M o t o r 7 4 _ _ _ _ A i r c o n d i t i o n e r C o m p r e s s o r M o u n t i n g

3 1 _ _ _ _ A l t e r n a t o r 7 5 _ _ _ _ A i r R e s t r i c t i o n I n d i c a t o r

3 2 _ _ _ _ I n s t r u m e n t P a n e l 7 6 _ _ _ _ O i l P r e s s u r e S w i t c h

3 5 _ _ _ _ F u e l F i l t e r 8 1 _ _ _ _ P r i m a r y F u e l F i l t e r

3 6 _ _ _ _ F r o n t P l a t e 8 3 _ _ _ _ E l e c t r o n i c S o f t w a r e

3 7 _ _ _ _ F u e l T r a n s f e r P u m p 8 4 _ _ _ _ E l e c t r i c a l W i r i n g H a r n e s s

3 9 _ _ _ _ T h e r m o s t a t H o u s i n g 8 6 _ _ _ _ F a n P u l l e y

4 0 _ _ _ _ O i l D i p s t i c k 8 7 _ _ _ _ A u t o m a t i c B e l t T e n s i o n e r

4 1 _ _ _ _ B e l t D r i v e n F r o n t A u x i l i a r y D r i v e 8 8 _ _ _ _ O i l F i l t e r

4 3 _ _ _ _ S t a r t i n g A i d 9 1 _ _ _ _ S p e c i a l E q u i p m e n t ( F a c t o r y I n s t a l l e d )

4 4 _ _ _ _ T i m i n g G e a r C o v e r w i t h G e a r s 9 4 _ _ _ _ V e h i c l e T i m i n g

4 5 _ _ _ _ B a l a n c e r S h a f t 9 5 _ _ _ _ I d e n t i f i c a t i o n l a b e l

4 6 _ _ _ _ C y l i n d e r B l o c k W i t h L i n e r s a n d C a m s h a f t 9 7 _ _ _ _ S p e c i a l E q u i p m e n t ( F i e l d I n s t a l l e d )

4 7 _ _ _ _ C r a n k s h a f t a n d B e a r i n g s 9 8 _ _ _ _ S h i p p i n g

4 8 _ _ _ _ C o n n e c t i n g R o d s a n d P i s t o n s

4 9 _ _ _ _ V a l v e A c t u a t i n g M e c h a n i s m s

R e c o r d f u e l i n j e c t i o n p u m p m o d e l n u m b e r

R e c o r d t h e f u e l i n j e c t i o n p u m p m o d e l a n d s e r i a l i n f o r m a t i o n f o u n d o n t h e s e r i a l n u m b e r p l a t e ( A ) .

M o d e l N o . _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ R P M _ _ _ _ _ _ _

M a n u f a c t u r e r ’ s N o . _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

S e r i a l N o . _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

C D 3 0 7 4 9

— U N

— 2 4 S E P 9 9

0 3 - 4 0 7 2 2 0 9

P N = 2 4

94/258




C D 0 3 5 2 3 , 0 0 0 0 1 8 9 - 1 9 - 0 6 F E B 0 7 - 1 / 1

C D 0 3 5 2 3 , 0 0 0 0 1 8 A - 1 9 - 0 6 F E B 0 7 - 1 / 1

R e c o r d E n g i n e C o n t r o l U n i t ( E C U ) S e r i a l N u m b e r

R e c o r d t h e p a r t n u m b e r a n d s e r i a l n u m b e r i n f o r m a t i o n f o u n d o n t h e s e r i a l n u m b e r l a b e l ( A ) o n t h e E n g i n e C o n t r o l U n i t ( E C U ) m o u n t e d o n o r n e a r t h e e n g i n e .

P a r t N o .

S e r i a l N o .

A — S e r i a l N u m b e r L a b e l

R G 1 4 6 3 5 —

U N

— 1 3 A P R 0 6

R e c o r d E n g i n e C o n t r o l U n i t ( E C U ) S e r i a l N u m b e r

R e c o r d H i g h - P r e s s u r e F u e l P u m p M o d e l N u m b e r

R e c o r d t h e h i g h - p r e s s u r e f u e l p u m p m o d e l a n d s e r i a l n u m b e r i n f o r m a t i o n f o u n d o n t h e s e r i a l n u m b e r p l a t e ( A ) .

M o d e l N o . R P M

M a n u f a c t u r e r ’ s N o .

S e r i a l N o .

A — S e r i a l N u m b e r P l a t e R

G 1 3 7 1 8

— U N

— 1 1 N O V 0 4

R e c o r d H i g h - P r e s s u r e F u e l P u m p S e r i a l N u m b e r

0 3 - 5 0 7 2 2 0 9

P N = 2 5

95/258



S a f e t y

D X , A L E R T - 1 9 - 2 9 S E P 9 8 - 1 / 1

D X , S I G N A L - 1 9 - 0 3 M A R 9 3 - 1 / 1

D X , W W , H P C R 1 - 1 9 - 0 7 J A N 0 3 - 1 / 1

R e c o g n i z e S a f e t y I n f o r m a t i o n

T h i s i s a s a f e t y - a l e r t s y m b o l . W h e n y o u s e e t h i s s y m b o l o n y o u r m a c h i n e o r i n t h i s m a n u a l , b e a l e r t t o t h e p o t e n t i a l f o r p e r s o n a l i n j u r y .

F o l l o w r e c o m m e n d e d p r e c a u t i o n s a n d s a f e o p e r a t i n g p r a c t i c e s .

T 8 1 3 8 9

— U N —

0 7 D E C 8 8

U n d e r s t a n d S i g n a l W o r d s

A s i g n a l w o r d — D A N G E R , W A R N I N G , o r C A U T I O N — i s u s e d w i t h t h e s a f e t y - a l e r t s y m b o l . D A N G E R i d e n t i f i e s t h e m o s t s e r i o u s h a z a r d s .

D A N G E R o r W A R N I N G s a f e t y s i g n s a r e l o c a t e d n e a r s p e c i f i c h a z a r d s . G e n e r a l p r e c a u t i o n s a r e l i s t e d o n C A U T I O N s a f e t y s i g n s . C A U T I O N a l s o c a l l s a t t e n t i o n t o s a f e t y m e s s a g e s i n t h i s m a n u a l .

T S 1 8 7

— 1 9

— 3 0 S E P 8 8

D o N o t O p e n H i g h - P r e s s u r e F u e l S y s t e m

H i g h - p r e s s u r e f l u i d r e m a i n i n g i n f u e l l i n e s c a n c a u s e

s e r i o u s i n j u r y . D o n o t d i s c o n n e c t o r a t t e m p t r e p a i r o f f u e l l i n e s , s e n s o r s , o r a n y o t h e r c o m p o n e n t s b e t w e e n t h e h i g h - p r e s s u r e f u e l p u m p a n d n o z z l e s o n e n g i n e s w i t h H i g h P r e s s u r e C o m m o n R a i l ( H P C R ) f u e l s y s t e m .

O n l y t e c h n i c i a n s f a m i l i a r w i t h t h i s t y p e o f s y s t e m c a n p e r f o r m r e p a i r s . ( S e e y o u r J o h n D e e r e d e a l e r . )

T S 1 3 4 3

— U N

— 1 8 M A R 9 2

0 5 - 1 0 7 2 2 0 9

P N = 2 6

96/258



S a f e t y

D P S G , C D 0 3 5 2 3 , 9 5 - 1 9 - 2 2 J A N 0 7 - 1 / 1

D X , R E A D - 1 9 - 1 6 J U N 0 9 - 1 / 1

E n g i n e l i f t i n g p r o c e d u r e

C A U T I O N : T h e o n l y r e c o m m e n d e d m e t h o d f o r l i f t i n g t h e e n g i n e i s w i t h J D G 2 3 E n g i n e L i f t i n g S l i n g ( A ) a n d s a f e t y a p p r o v e d l i f t i n g s t r a p s ( B ) t h a t c o m e w i t h e n g i n e . U s e e x t r e m e c a u t i o n w h e n l i f t i n g a n d N E V E R p e r m i t a n y p a r t o f t h e b o d y t o b e p o s i t i o n e d u n d e r a n

e n g i n e b e i n g l i f t e d o r s u s p e n d e d .

L i f t e n g i n e w i t h l o n g i t u d i n a l l o a d i n g o n l i f t i n g s l i n g a n d l i f t i n g s t r a p s o n l y . A n g u l a r l o a d i n g g r e a t l y r e d u c e s l i f t i n g c a p a c i t y o f s l i n g a n d s t r a p s .

N O T E : I f e n g i n e d o e s n o t h a v e l i f t i n g s t r a p s , u n i v e r s a l s t r a p s c a n b e p r o c u r e d t h r o u g h s e r v i c e p a r t s u n d e r

p a r t n u m b e r s J D - 2 4 4 - 1 a n d J D - 2 4 4 - 2 .

1 . I f n o t e q u i p p e d , i n s t a l l l i f t i n g s t r a p s a n d t o r q u e t o 2 0 0 N ∙ m ( 1 4 5 l b - f t ) .

2 . A t t a c h J D G 2 3 E n g i n e L i f t i n g S l i n g ( A ) t o e n g i n e l i f t i n g s t r a p s ( B ) a n d o v e r h e a d h o i s t .

I M P O R T A N T : L i f t i n g s t r a p s a r e d e s i g n e d t o l i f t t h e e n g i n e a n d a c c e s s o r i e s s u c h a s r a d i a t o r , a i r f i l t e r a n d o t h e r s m a l l c o m p o n e n t s . I f

R G 7 7 8 4

— U N —

1 1 N O V 9 7

l a r g e r c o m p o n e n t s , s u c h a s p o w e r t a k e - o f f , t r a n s m i s s i o n , g e n e r a t o r a i r c o m p r e s s o r . . . e t c , a r e a t t a c h e d t o e n g i n e , t h e l i f t i n g s t r a p s p r o v i d e d w i t h e n g i n e o r t h r o u g h p a r t s c h a n n e l a r e n o t i n t e n d e d f o r t h i s p u r p o s e . T e c h n i c i a n i s r e s p o n s i b l e f o r p r o v i d i n g a d e q u a t e l i f t i n g d e v i c e s u n d e r t h e s e s i t u a t i o n s . S e e m a c h i n e m a n u a l s f o r a d d i t i o n a l i n f o r m a t i o n o n r e m o v i n g e n g i n e f r o m m a c h i n e .

3 . C a r e f u l l y m o v e e n g i n e t o d e s i r e d l o c a t i o n .

F o l l o w S a f e t y I n s t r u c t i o n s

C a r e f u l l y r e a d a l l s a f e t y m e s s a g e s i n t h i s m a n u a l a n d o n y o u r m a c h i n e s a f e t y s i g n s . K e e p s a f e t y s i g n s i n g o o d c o n d i t i o n . R e p l a c e m i s s i n g o r d a m a g e d s a f e t y s i g n s . B e s u r e n e w e q u i p m e n t c o m p o n e n t s a n d r e p a i r p a r t s i n c l u d e t h e c u r r e n t s a f e t y s i g n s . R e p l a c e m e n t s a f e t y s i g n s a r e

a v a i l a b l e f r o m y o u r J o h n D e e r e d e a l e r . T h e r e c a n b e a d d i t i o n a l s a f e t y i n f o r m a t i o n c o n t a i n e d o n p a r t s a n d c o m p o n e n t s s o u r c e d f r o m s u p p l i e r s t h a t i s n o t r e p r o d u c e d i n t h i s o p e r a t o r ’ s m a n u a l .

L e a r n h o w t o o p e r a t e t h e m a c h i n e a n d h o w t o u s e c o n t r o l s p r o p e r l y . D o n o t l e t a n y o n e o p e r a t e w i t h o u t i n s t r u c t i o n .

K e e p y o u r m a c h i n e i n p r o p e r w o r k i n g c o n d i t i o n . U n a u t h o r i z e d m o d i f i c a t i o n s t o t h e m a c h i n e m a y i m p a i r t h e f u n c t i o n a n d / o r s a f e t y a n d a f f e c t m a c h i n e l i f e .

T S 2 0 1

— U N

— 2 3 A U G

8 8

I f y o u d o n o t u n d e r s t a n d a n y p a r t o f t h i s m a n u a l a n d n e e d a s s i s t a n c e , c o n t a c t y o u r J o h n D e e r e d e a l e r .

0 5 - 2 0 7 2 2 0 9

P N = 2 7

97/258



S a f e t y

D X , B Y P A S 1 - 1 9 - 2 9 S E P 9 8 - 1 / 1

D X , F I R E 1 - 1 9 - 0 3 M A R 9 3 - 1 / 1

D X , F I R E 2 - 1 9 - 0 3 M A R 9 3 - 1 / 1

P r e v e n t M a c h i n e R u n a w a y

A v o i d p o s s i b l e i n j u r y o r d e a t h f r o m m a c h i n e r y r u n a w a y .

D o n o t s t a r t e n g i n e b y s h o r t i n g a c r o s s s t a r t e r t e r m i n a l s . M a c h i n e w i l l s t a r t i n g e a r i f n o r m a l c i r c u i t r y i s b y p a s s e d .

N E V E R s t a r t e n g i n e w h i l e s t a n d i n g o n g r o u n d . S t a r t e n g i n e o n l y f r o m o p e r a t o r ’ s s e a t , w i t h t r a n s m i s s i o n i n

n e u t r a l o r p a r k .

T S 1 7 7

— U N

— 1

1 J A N 8 9

H a n d l e F u e l S a f e l y — A v o i d F i r e s

H a n d l e f u e l w i t h c a r e : i t i s h i g h l y f l a m m a b l e . D o n o t r e f u e l t h e m a c h i n e w h i l e s m o k i n g o r w h e n n e a r o p e n f l a m e o r s p a r k s .

A l w a y s s t o p e n g i n e b e f o r e r e f u e l i n g m a c h i n e . F i l l f u e l t a n k o u t d o o r s .

P r e v e n t f i r e s b y k e e p i n g m a c h i n e c l e a n o f a c c u m u l a t e d t r a s h , g r e a s e , a n d d e b r i s . A l w a y s c l e a n u p s p i l l e d f u e l .

T S 2 0 2

— U N

— 2 3 A U G 8 8

P r e p a r e f o r E m e r g e n c i e s

B e p r e p a r e d i f a f i r e s t a r t s .

K e e p a f i r s t a i d k i t a n d f i r e e x t i n g u i s h e r h a n d y .

K e e p e m e r g e n c y n u m b e r s f o r d o c t o r s , a m b u l a n c e s e r v i c e , h o s p i t a l , a n d f i r e d e p a r t m e n t n e a r y o u r t e l e p h o n e .

T S 2 9 1

— U N

— 2 3 A U G 8 8

0 5 - 3 0 7 2 2 0 9

P N = 2 8

98/258



S a f e t y

D X , F I R E 3 - 1 9 - 1 6 A P R 9 2 - 1 / 1

D X , W E A R - 1 9 - 1 0 S E P 9 0 - 1 / 1

D X , N O I S E - 1 9 - 0 3 M A R 9 3 - 1 / 1

H a n d l e S t a r t i n g F l u i d S a f e l y

S t a r t i n g f l u i d i s h i g h l y f l a m m a b l e .

K e e p a l l s p a r k s a n d f l a m e a w a y w h e n u s i n g i t . K e e p s t a r t i n g f l u i d a w a y f r o m b a t t e r i e s a n d c a b l e s .

T o p r e v e n t a c c i d e n t a l d i s c h a r g e w h e n s t o r i n g t h e p r e s s u r i z e d c a n , k e e p t h e c a p o n t h e c o n t a i n e r , a n d s t o r e

i n a c o o l , p r o t e c t e d l o c a t i o n . D o n o t i n c i n e r a t e o r p u n c t u r e a s t a r t i n g f l u i d c o n t a i n e r .

T S 1 3 5 6

— U N —

1 8 M A R 9 2

W e a r P r o t e c t i v e C l o t h i n g

W e a r c l o s e f i t t i n g c l o t h i n g a n d s a f e t y e q u i p m e n t a p p r o p r i a t e t o t h e j o b .

P r o l o n g e d e x p o s u r e t o l o u d n o i s e c a n c a u s e i m p a i r m e n t

o r l o s s o f h e a r i n g . W e a r a s u i t a b l e h e a r i n g p r o t e c t i v e d e v i c e s u c h a s e a r m u f f s o r e a r p l u g s t o p r o t e c t a g a i n s t o b j e c t i o n a b l e o r u n c o m f o r t a b l e l o u d n o i s e s .

O p e r a t i n g e q u i p m e n t s a f e l y r e q u i r e s t h e f u l l a t t e n t i o n o f t h e o p e r a t o r . D o n o t w e a r r a d i o o r m u s i c h e a d p h o n e s w h i l e o p e r a t i n g m a c h i n e .

T S 2 0 6

— U N

— 2 3 A U G 8 8

P r o t e c t A g a i n s t N o i s e

P r o l o n g e d e x p o s u r e t o l o u d n o i s e c a n c a u s e i m p a i r m e n t

o r l o s s o f h e a r i n g . W e a r a s u i t a b l e h e a r i n g p r o t e c t i v e d e v i c e s u c h a s e a r m u f f s o r e a r p l u g s t o p r o t e c t a g a i n s t o b j e c t i o n a b l e o r u n c o m f o r t a b l e l o u d n o i s e s .

T S 2 0 7

— U N

— 2 3 A U G 8 8

0 5 - 4 0 7 2 2 0 9

P N = 2 9

99/258



S a f e t y

D X , M S D S , N A - 1 9 - 0 3 M A R 9 3 - 1 / 1

C D , P T O - 1 9 - 2 2 J A N 0 7 - 1 / 1

H a n d l e C h e m i c a l P r o d u c t s S a f e l y

D i r e c t e x p o s u r e t o h a z a r d o u s c h e m i c a l s c a n c a u s e s e r i o u s i n j u r y . P o t e n t i a l l y h a z a r d o u s c h e m i c a l s u s e d w i t h J o h n D e e r e e q u i p m e n t i n c l u d e s u c h i t e m s a s l u b r i c a n t s , c o o l a n t s , p a i n t s , a n d a d h e s i v e s .

A M a t e r i a l S a f e t y D a t a S h e e t ( M S D S ) p r o v i d e s s p e c i f i c d e t a i l s o n c h e m i c a l p r o d u c t s : p h y s i c a l a n d h e a l t h h a z a r d s ,

s a f e t y p r o c e d u r e s , a n d e m e r g e n c y r e s p o n s e t e c h n i q u e s .

C h e c k t h e M S D S b e f o r e y o u s t a r t a n y j o b u s i n g a h a z a r d o u s c h e m i c a l . T h a t w a y y o u w i l l k n o w e x a c t l y w h a t t h e r i s k s a r e a n d h o w t o d o t h e j o b s a f e l y . T h e n f o l l o w p r o c e d u r e s a n d r e c o m m e n d e d e q u i p m e n t .

( S e e y o u r J o h n D e e r e d e a l e r f o r M S D S ’ s o n c h e m i c a l p r o d u c t s u s e d w i t h J o h n D e e r e e q u i p m e n t . )

T S 1 1 3 2

— U N —

2 6 N O V 9 0

S t a y C l e a r o f R o t a t i n g D r i v e l i n e s

E n t a n g l e m e n t i n r o t a t i n g d r i v e l i n e c a n c a u s e s e r i o u s

i n j u r y o r d e a t h .

K e e p m a s t e r s h i e l d a n d d r i v e l i n e s h i e l d s i n p l a c e a t a l l t i m e s . M a k e s u r e r o t a t i n g s h i e l d s t u r n f r e e l y .

W e a r c l o s e f i t t i n g c l o t h i n g . S t o p t h e e n g i n e a n d b e s u r e t h e P T O d r i v e l i n e i s s t o p p e d b e f o r e m a k i n g a d j u s t m e n t s o r p e r f o r m i n g a n y t y p e s e r v i c e o n t h e e n g i n e o r P T O - d r i v e n e q u i p m e n t .

T S 1 6 4 4

— U N

— 2 2 A U G 9 5

0 5 - 5 0 7 2 2 0 9

P N = 3 0

100/258



S a f e t y

D X , S E R V - 1 9 - 1 7 F E B 9 9 - 1 / 1

D X , A I R - 1 9 - 1 7 F E B 9 9 - 1 / 1

P r a c t i c e S a f e M a i n t e n a n c e

U n d e r s t a n d s e r v i c e p r o c e d u r e b e f o r e d o i n g w o r k . K e e p a r e a c l e a n a n d d r y .

N e v e r l u b r i c a t e , s e r v i c e , o r a d j u s t m a c h i n e w h i l e i t i s m o v i n g . K e e p h a n d s , f e e t , a n d c l o t h i n g f r o m p o w e r - d r i v e n p a r t s . D i s e n g a g e a l l p o w e r a n d o p e r a t e c o n t r o l s t o r e l i e v e p r e s s u r e . L o w e r e q u i p m e n t t o t h e g r o u n d . S t o p t h e

e n g i n e . R e m o v e t h e k e y . A l l o w m a c h i n e t o c o o l .

S e c u r e l y s u p p o r t a n y m a c h i n e e l e m e n t s t h a t m u s t b e r a i s e d f o r s e r v i c e w o r k .

K e e p a l l p a r t s i n g o o d c o n d i t i o n a n d p r o p e r l y i n s t a l l e d . F i x d a m a g e i m m e d i a t e l y . R e p l a c e w o r n o r b r o k e n p a r t s . R e m o v e a n y b u i l d u p o f g r e a s e , o i l , o r d e b r i s .

O n s e l f - p r o p e l l e d e q u i p m e n t , d i s c o n n e c t b a t t e r y g r o u n d c a b l e ( - ) b e f o r e m a k i n g a d j u s t m e n t s o n e l e c t r i c a l s y s t e m s o r w e l d i n g o n m a c h i n e .

O n t o w e d i m p l e m e n t s , d i s c o n n e c t w i r i n g h a r n e s s e s f r o m t r a c t o r b e f o r e s e r v i c i n g e l e c t r i c a l s y s t e m c o m p o n e n t s o r

w e l d i n g o n m a c h i n e .

T S 2 1 8

— U N

— 2 3 A U G 8 8

W o r k I n V e n t i l a t e d A r e a

E n g i n e e x h a u s t f u m e s c a n c a u s e s i c k n e s s o r d e a t h . I f i t i s n e c e s s a r y t o r u n a n e n g i n e i n a n e n c l o s e d a r e a ,

r e m o v e t h e e x h a u s t f u m e s f r o m t h e a r e a w i t h a n e x h a u s t p i p e e x t e n s i o n .

I f y o u d o n o t h a v e a n e x h a u s t p i p e e x t e n s i o n , o p e n t h e d o o r s a n d g e t o u t s i d e a i r i n t o t h e a r e a .

T S 2 2 0

— U N

— 2 3 A U G 8 8

0 5 - 6 0 7 2 2 0 9

P N = 3 1

101/258



S a f e t y

D X , F L U I D - 1 9 - 0 3 M A R 9 3 - 1 / 1

D X , T O R C H - 1 9 - 1 0 D E C 0 4 - 1 / 1

D X , P A I N T - 1 9 - 2 4 J U L 0 2 - 1 / 1

A v o i d H i g h - P r e s s u r e F l u i d s

E s c a p i n g f l u i d u n d e r p r e s s u r e c a n p e n e t r a t e t h e s k i n c a u s i n g s e r i o u s i n j u r y .

A v o i d t h e h a z a r d b y r e l i e v i n g p r e s s u r e b e f o r e d i s c o n n e c t i n g h y d r a u l i c o r o t h e r l i n e s . T i g h t e n a l l c o n n e c t i o n s b e f o r e a p p l y i n g p r e s s u r e .

S e a r c h f o r l e a k s w i t h a p i e c e o f c a r d b o a r d . P r o t e c t h a n d s a n d b o d y f r o m h i g h p r e s s u r e f l u i d s .

I f a n a c c i d e n t o c c u r s , s e e a d o c t o r i m m e d i a t e l y . A n y f l u i d i n j e c t e d i n t o t h e s k i n m u s t b e s u r g i c a l l y r e m o v e d w i t h i n a f e w h o u r s o r g a n g r e n e m a y r e s u l t . D o c t o r s u n f a m i l i a r w i t h t h i s t y p e o f i n j u r y s h o u l d r e f e r e n c e a k n o w l e d g e a b l e m e d i c a l s o u r c e . S u c h i n f o r m a t i o n i s a v a i l a b l e f r o m D e e r e & C o m p a n y M e d i c a l D e p a r t m e n t i n M o l i n e , I l l i n o i s , U . S . A .

X 9 8 1 1

— U N —

2 3 A U G 8 8

A v o i d H e a t i n g N e a r P r e s s u r i z e d F l u i d L i n e s

F l a m m a b l e s p r a y c a n b e g e n e r a t e d b y h e a t i n g n e a r

p r e s s u r i z e d f l u i d l i n e s , r e s u l t i n g i n s e v e r e b u r n s t o y o u r s e l f a n d b y s t a n d e r s . D o n o t h e a t b y w e l d i n g , s o l d e r i n g , o r u s i n g a t o r c h n e a r p r e s s u r i z e d f l u i d l i n e s o r o t h e r f l a m m a b l e m a t e r i a l s . P r e s s u r i z e d l i n e s c a n a c c i d e n t a l l y b u r s t w h e n h e a t g o e s b e y o n d t h e i m m e d i a t e f l a m e a r e a .

T S 9 5 3

— U N

— 1 5 M A Y 9 0

R e m o v e P a i n t B e f o r e W e l d i n g o r H e a t i n g A v o i d p o t e n t i a l l y t o x i c f u m e s a n d d u s t .

H a z a r d o u s f u m e s c a n b e g e n e r a t e d w h e n p a i n t i s h e a t e d b y w e l d i n g , s o l d e r i n g , o r u s i n g a t o r c h .

R e m o v e p a i n t b e f o r e h e a t i n g :

• R e m o v e p a i n t a m i n i m u m o f 1 0 0 m m ( 4 i n . ) f r o m a r e a t o b e a f f e c t e d b y h e a t i n g . I f p a i n t c a n n o t b e r e m o v e d , w e a r a n a p p r o v e d r e s p i r a t o r b e f o r e h e a t i n g o r w e l d i n g .

• I f y o u s a n d o r g r i n d p a i n t , a v o i d b r e a t h i n g t h e d u s t . W e a r a n a p p r o v e d r e s p i r a t o r .

• I f y o u u s e s o l v e n t o r p a i n t s t r i p p e r , r e m o v e s t r i p p e r w i t h s o a p a n d w a t e r b e f o r e w e l d i n g . R e m o v e s o l v e n t o r p a i n t s t r i p p e r c o n t a i n e r s a n d o t h e r f l a m m a b l e m a t e r i a l f r o m a r e a . A l l o w f u m e s t o d i s p e r s e a t l e a s t 1 5 m i n u t e s b e f o r e w e l d i n g o r h e a t i n g .

D o n o t u s e a c h l o r i n a t e d s o l v e n t i n a r e a s w h e r e w e l d i n g w i l l t a k e p l a c e .

T S 2 2 0

— U N

— 2 3 A U G 8 8

D o a l l w o r k i n a n a r e a t h a t i s w e l l v e n t i l a t e d t o c a r r y t o x i c f u m e s a n d d u s t a w a y .

D i s p o s e o f p a i n t a n d s o l v e n t p r o p e r l y .

0 5 - 7 0 7 2 2 0 9

P N = 3 2

102/258



S a f e t y

D X , R C A P - 1 9 - 0 4 J U N 9 0 - 1 / 1

D X , D U S T - 1 9 - 1 5 M A R 9 1 - 1 / 1

D X , D R A I N - 1 9 - 0 3 M A R 9 3 - 1 / 1

S e r v i c e C o o l i n g S y s t e m S a f e l y

E x p l o s i v e r e l e a s e o f f l u i d s f r o m p r e s s u r i z e d c o o l i n g s y s t e m c a n c a u s e s e r i o u s b u r n s .

S h u t o f f e n g i n e . O n l y r e m o v e f i l l e r c a p w h e n c o o l e n o u g h t o t o u c h w i t h b a r e h a n d s . S l o w l y l o o s e n c a p t o f i r s t s t o p t o r e l i e v e p r e s s u r e b e f o r e r e m o v i n g c o m p l e t e l y .

T S 2 8 1

— U N

— 2

3 A U G 8 8

A v o i d H a r m f u l A s b e s t o s D u s t

A v o i d b r e a t h i n g d u s t t h a t m a y b e g e n e r a t e d w h e n h a n d l i n g c o m p o n e n t s c o n t a i n i n g a s b e s t o s f i b e r s . I n h a l e d a s b e s t o s f i b e r s m a y c a u s e l u n g c a n c e r .

C o m p o n e n t s i n p r o d u c t s t h a t m a y c o n t a i n a s b e s t o s f i b e r s a r e b r a k e p a d s , b r a k e b a n d a n d l i n i n g a s s e m b l i e s , c l u t c h p l a t e s , a n d s o m e g a s k e t s . T h e a s b e s t o s u s e d i n t h e s e c o m p o n e n t s i s u s u a l l y f o u n d i n a r e s i n o r s e a l e d i n s o m e w a y . N o r m a l h a n d l i n g i s n o t h a z a r d o u s a s l o n g a s a i r b o r n e d u s t c o n t a i n i n g a s b e s t o s i s n o t g e n e r a t e d .

A v o i d c r e a t i n g d u s t . N e v e r u s e c o m p r e s s e d a i r f o r c l e a n i n g . A v o i d b r u s h i n g o r g r i n d i n g m a t e r i a l c o n t a i n i n g a s b e s t o s . W h e n s e r v i c i n g , w e a r a n a p p r o v e d r e s p i r a t o r .

A s p e c i a l v a c u u m c l e a n e r i s r e c o m m e n d e d t o c l e a n a s b e s t o s . I f n o t a v a i l a b l e , a p p l y a m i s t o f o i l o r w a t e r o n t h e m a t e r i a l c o n t a i n i n g a s b e s t o s .

T S 2 2 0

— U N

— 2 3 A U G 8 8

K e e p b y s t a n d e r s a w a y f r o m t h e a r e a .

D i s p o s e o f W a s t e P r o p e r l y

I m p r o p e r l y d i s p o s i n g o f w a s t e c a n t h r e a t e n t h e e n v i r o n m e n t a n d e c o l o g y . P o t e n t i a l l y h a r m f u l w a s t e u s e d w i t h J o h n D e e r e e q u i p m e n t i n c l u d e s u c h i t e m s a s o i l , f u e l , c o o l a n t , b r a k e f l u i d , f i l t e r s , a n d b a t t e r i e s .

U s e l e a k p r o o f c o n t a i n e r s w h e n d r a i n i n g f l u i d s . D o n o t u s e f o o d o r b e v e r a g e c o n t a i n e r s t h a t m a y m i s l e a d s o m e o n e i n t o d r i n k i n g f r o m t h e m .

D o n o t p o u r w a s t e o n t o t h e g r o u n d , d o w n a d r a i n , o r i n t o a n y w a t e r s o u r c e .

A i r c o n d i t i o n i n g r e f r i g e r a n t s e s c a p i n g i n t o t h e a i r c a n d a m a g e t h e E a r t h ’ s a t m o s p h e r e . G o v e r n m e n t r e g u l a t i o n s m a y r e q u i r e a c e r t i f i e d a i r c o n d i t i o n i n g s e r v i c e c e n t e r t o r e c o v e r a n d r e c y c l e u s e d a i r c o n d i t i o n i n g r e f r i g e r a n t s .

I n q u i r e o n t h e p r o p e r w a y t o r e c y c l e o r d i s p o s e o f w a s t e f r o m y o u r l o c a l e n v i r o n m e n t a l o r r e c y c l i n g c e n t e r , o r f r o m y o u r J o h n D e e r e d e a l e r .

T S 1 1 3 3

— U N

— 2 6 N O V 9 0

0 5 - 8 0 7 2 2 0 9

P N = 3 3

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F u e l s , L u b r i c a n t s a n d C o o l a n t

D X , F U E L 1 - 1 9 - 2 8 A P R 0 9 - 1 / 1

D X , F U E L 4 - 1 9 - 1 9 D E C 0 3 - 1 / 1

D i e s e l F u e l

C o n s u l t y o u r l o c a l f u e l d i s t r i b u t o r f o r p r o p e r t i e s o f t h e d i e s e l f u e l a v a i l a b l e i n y o u r a r e a .

I n g e n e r a l , d i e s e l f u e l s a r e b l e n d e d t o s a t i s f y t h e l o w t e m p e r a t u r e r e q u i r e m e n t s o f t h e g e o g r a p h i c a l a r e a i n w h i c h t h e y a r e m a r k e t e d .

D i e s e l f u e l s s p e c i f i e d t o E N 5 9 0 o r A S T M D 9 7 5 a r e r e c o m m e n d e d . R e n e w a b l e d i e s e l f u e l p r o d u c e d b y h y d r o t r e a t i n g a n i m a l f a t s a n d v e g e t a b l e o i l s i s b a s i c a l l y i d e n t i c a l t o p e t r o l e u m d i e s e l f u e l . R e n e w a b l e d i e s e l t h a t m e e t s E N 5 9 0 o r A S T M D 9 7 5 i s a c c e p t a b l e f o r u s e a t a l l p e r c e n t a g e m i x t u r e l e v e l s .

R e q u i r e d F u e l P r o p e r t i e s

I n a l l c a s e s , t h e f u e l s h a l l m e e t t h e f o l l o w i n g p r o p e r t i e s :

C e t a n e n u m b e r o f 4 5 m i n i m u m . C e t a n e n u m b e r g r e a t e r t h a n 5 0 i s p r e f e r r e d , e s p e c i a l l y f o r t e m p e r a t u r e s b e l o w

– 2 0 ° C ( – 4 ° F ) o r e l e v a t i o n s a b o v e 1 5 0 0 m ( 5 0 0 0 f t ) .

C o l d F i l t e r P l u g g i n g P o i n t ( C F P P ) s h o u l d b e a t l e a s t 5 ° C ( 9 ° F ) b e l o w t h e e x p e c t e d l o w e s t t e m p e r a t u r e o r C l o u d P o i n t b e l o w t h e e x p e c t e d l o w e s t a m b i e n t t e m p e r a t u r e .

F u e l l u b r i c i t y s h o u l d p a s s a m a x i m u m s c a r d i a m e t e r o f 0 . 4 5 m m a s m e a s u r e d b y A S T M D 6 0 7 9 o r I S O 1 2 1 5 6 - 1 .

S u l f u r C o n t e n t f o r I n t e r i m T i e r 4 a n d E U S t a g e I I I B E n g i n e s

• D i e s e l f u e l q u a l i t y a n d f u e l s u l f u r c o n t e n t m u s t c o m p l y w i t h a l l e x i s t i n g e m i s s i o n s r e g u l a t i o n s f o r t h e a r e a i n w h i c h t h e e n g i n e o p e r a t e s .

• U s e O N L Y u l t r a l o w s u l f u r d i e s e l ( U L S D ) f u e l w i t h a m a x i m u m o f 0 . 0 0 1 5 % ( 1 5 p p m ) s u l f u r c o n t e n t .

S u l f u r C o n t e n t f o r O t h e r E n g i n e s

• D i e s e l f u e l q u a l i t y a n d f u e l s u l f u r c o n t e n t m u s t c o m p l y w i t h a l l e x i s t i n g e m i s s i o n s r e g u l a t i o n s f o r t h e a r e a i n w h i c h t h e e n g i n e o p e r a t e s .

• U s e o f d i e s e l f u e l w i t h s u l f u r c o n t e n t l e s s t h a n 0 . 1 0 % ( 1 0 0 0 p p m ) i s S T R O N G L Y r e c o m m e n d e d .

• U s e o f d i e s e l f u e l w i t h s u l f u r c o n t e n t 0 . 1 0 % ( 1 0 0 0 p p m ) t o 0 . 5 0 % ( 5 0 0 0 p p m ) m a y r e s u l t i n R E D U C E D o i l a n d f i l t e r c h a n g e i n t e r v a l s . R e f e r t o t a b l e i n D i e s e l E n g i n e O i l a n d F i l t e r S e r v i c e I n t e r v a l s .

• B E F O R E u s i n g d i e s e l f u e l w i t h s u l f u r c o n t e n t g r e a t e r t h a n 0 . 5 0 % ( 5 0 0 0 p p m ) , c o n t a c t y o u r J o h n D e e r e d e a l e r .

I M P O R T A N T : D o n o t m i x u s e d d i e s e l e n g i n e o i l o r a n y o t h e r t y p e o f l u b r i c a t i n g o i l w i t h d i e s e l f u e l .

I m p r o p e r f u e l a d d i t i v e u s a g e m a y c a u s e d a m a g e o n f u e l i n j e c t i o n e q u i p m e n t o f d i e s e l e n g i n e s .

H a n d l i n g a n d S t o r i n g D i e s e l F u e l

C A U T I O N : H a n d l e f u e l c a r e f u l l y . D o n o t f i l l t h e f u e l t a n k w h e n e n g i n e i s r u n n i n g .

D O N O T s m o k e w h i l e y o u f i l l t h e f u e l t a n k o r s e r v i c e t h e f u e l s y s t e m .

F i l l t h e f u e l t a n k a t t h e e n d o f e a c h d a y ’ s o p e r a t i o n t o p r e v e n t w a t e r c o n d e n s a t i o n a n d f r e e z i n g d u r i n g c o l d w e a t h e r .

K e e p a l l s t o r a g e t a n k s a s f u l l a s p r a c t i c a b l e t o m i n i m i z e c o n d e n s a t i o n .

E n s u r e t h a t a l l f u e l t a n k c a p s a n d c o v e r s a r e i n s t a l l e d p r o p e r l y t o p r e v e n t m o i s t u r e f r o m e n t e r i n g .

M o n i t o r w a t e r c o n t e n t o f t h e f u e l r e g u l a r l y .

W h e n u s i n g b i o - d i e s e l f u e l , t h e f u e l f i l t e r m a y r e q u i r e m o r e f r e q u e n t r e p l a c e m e n t d u e t o p r e m a t u r e p l u g g i n g .

C h e c k e n g i n e o i l l e v e l d a i l y p r i o r t o s t a r t i n g e n g i n e . A r i s i n g o i l l e v e l m a y i n d i c a t e f u e l d i l u t i o n o f t h e e n g i n e o i l .

I M P O R T A N T : T h e f u e l t a n k i s v e n t e d t h r o u g h t h e f i l l e r c a p . I f a n e w f i l l e r c a p i s r e q u i r e d , a l w a y s r e p l a c e i t w i t h a n o r i g i n a l v e n t e d c a p .

W h e n f u e l i s s t o r e d f o r a n e x t e n d e d p e r i o d o r i f t h e r e i s a s l o w t u r n o v e r o f f u e l , a d d a f u e l c o n d i t i o n e r t o s t a b i l i z e t h e f u e l a n d p r e v e n t w a t e r c o n d e n s a t i o n . C o n t a c t y o u r f u e l s u p p l i e r f o r r e c o m m e n d a t i o n s .

1 0 - 1 0 7 2 2 0 9

P N = 3 4

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D X , E N O I L 4 - 1 9 - 1 3 S E P 0 6 - 1 / 1

C D , E N O I L - 1 9 - 0 1 J U L 0 9 - 1 / 1

D i e s e l E n g i n e B r e a k - I n O i l

N e w e n g i n e s a r e f i l l e d a t t h e f a c t o r y w i t h J o h n D e e r e E N G I N E B R E A K - I N O I L . D u r i n g t h e b r e a k - i n p e r i o d , a d d J o h n D e e r e E N G I N E B R E A K - I N O I L a s n e e d e d t o m a i n t a i n t h e s p e c i f i e d o i l l e v e l .

C h a n g e t h e o i l a n d f i l t e r a f t e r t h e f i r s t 1 0 0 h o u r s o f

o p e r a t i o n o f a n e w o r r e b u i l t e n g i n e . A f t e r e n g i n e o v e r h a u l , f i l l t h e e n g i n e w i t h J o h n D e e r e E N G I N E B R E A K - I N O I L .

I f J o h n D e e r e E N G I N E B R E A K - I N O I L i s n o t a v a i l a b l e , u s e a d i e s e l e n g i n e o i l m e e t i n g o n e o f t h e f o l l o w i n g d u r i n g t h e f i r s t 1 0 0 h o u r s o f o p e r a t i o n :

• A P I S e r v i c e C l a s s i f i c a t i o n C E

• A P I S e r v i c e C l a s s i f i c a t i o n C D

• A P I S e r v i c e C l a s s i f i c a t i o n C C

• A C E A O i l S e q u e n c e E 2

• A C E A O i l S e q u e n c e E 1

A f t e r t h e b r e a k - i n p e r i o d , u s e J o h n D e e r e P L U S - 5 0 ™ o r o t h e r d i e s e l e n g i n e o i l a s r e c o m m e n d e d i n t h i s m a n u a l .

I M P O R T A N T : D o n o t u s e P L U S - 5 0 o i l o r e n g i n e o i l s m e e t i n g a n y o f t h e f o l l o w i n g d u r i n g t h e f i r s t 1 0 0 h o u r s o f o p e r a t i o n o f a n e w o r r e b u i l t e n g i n e :

A P I C J - 4 A C E A E 7

A P I C I - 4 P L U S A C E A E 6

A P I C I - 4 A C E A E 5

A P I C H - 4 A C E A E 4

A P I C G - 4 A C E A E 3

A P I C F - 4

A P I C F - 2

A P I C F

T h e s e o i l s w i l l n o t a l l o w t h e e n g i n e t o b r e a k - i n p r o p e r l y .

P L U S - 5 0 i s a t r a d e m a r k o f D e e r e & C o m p a n y .

D i e s e l E n g i n e O i l

U s e o i l v i s c o s i t y b a s e d o n t h e e x p e c t e d a i r t e m p e r a t u r e r a n g e d u r i n g t h e p e r i o d b e t w e e n o i l c h a n g e s .

D e p e n d i n g o n E m i s s i o n R e g u l a t i o n r e q u i r e m e n t s , t h e o i l r e c o m m e n d a t i o n s a r e d i f f e r e n t . R e f e r t o t h e c h a r t t o i d e n t i f y t h e p r o p e r o i l t o b e u s e d .

N o n E m i s s i o n C e r t i f i e d E n g i n e s a n d S t a g e I I o r E P A T i e r 2 E m i s s i o n C e r t i f i e d E n g i n e s

E P A T i e r 3 E m i s s i o n C e r t i f i e d E n g i n e s

J o h n D e e r e P L U S - 5 0 ™ ( P r e f e r r e d )

J o h n D e e r e P L U S - 5 0 ™ ( P r e f e r r e d )

A C E A - E 7 , A C E A - E 6 , A C E A - E 5 , A C E A - E 4

A C E A - E 7 , A C E A - E 6

M u l t i - v i s c o s i t y d i e s e l e n g i n e o i l s a r e p r e f e r r e d .

I f d i e s e l f u e l w i t h s u l f u r c o n t e n t g r e a t e r t h a n 0 . 5 % i s u s e d o r i f o i l d o e s n o t m e e t t h e c l a s s i f i c a t i o n a b o v e , r e d u c e t h e s e r v i c e i n t e r v a l b y 5 0 % .

D O N O T u s e d i e s e l f u e l w i t h s u l f u r c o n t e n t g r e a t e r t h a n 1 % . T

S 1 6 7 5

— U N

— 0 9 O C T 0 6

O i l V i s c o s i t i e s f o r A i r T e m p e r a t u r e R a n g e s

P L U S - 5 0 i s a t r a d e m a r k o f D e e r e & C o m p a n y

1 0 - 2 0 7 2 2 0 9

P N = 3 5

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D X , L U B S T - 1 9 - 1 8 M A R 9 6 - 1 / 1

D X , L U B M I X - 1 9 - 1 8 M A R 9 6 - 1 / 1

D X , C O O L 8 - 1 9 - 1 6 N O V 0 1 - 1 / 1

L u b r i c a n t S t o r a g e

Y o u r e q u i p m e n t c a n o p e r a t e a t t o p e f f i c i e n c y o n l y w h e n c l e a n l u b r i c a n t s a r e u s e d .

U s e c l e a n c o n t a i n e r s t o h a n d l e a l l l u b r i c a n t s .

W h e n e v e r p o s s i b l e , s t o r e l u b r i c a n t s a n d c o n t a i n e r s i n a n a r e a p r o t e c t e d f r o m d u s t , m o i s t u r e , a n d o t h e r

c o n t a m i n a t i o n . S t o r e c o n t a i n e r s o n t h e i r s i d e t o a v o i d w a t e r a n d d i r t a c c u m u l a t i o n .

M a k e c e r t a i n t h a t a l l c o n t a i n e r s a r e p r o p e r l y m a r k e d t o i d e n t i f y t h e i r c o n t e n t s .

P r o p e r l y d i s p o s e o f a l l o l d c o n t a i n e r s a n d a n y r e s i d u a l l u b r i c a n t t h e y m a y c o n t a i n .

M i x i n g o f L u b r i c a n t s

I n g e n e r a l , a v o i d m i x i n g d i f f e r e n t b r a n d s o r t y p e s o f o i l . O i l m a n u f a c t u r e r s b l e n d a d d i t i v e s i n t h e i r o i l s t o m e e t c e r t a i n s p e c i f i c a t i o n s a n d p e r f o r m a n c e r e q u i r e m e n t s .

M i x i n g d i f f e r e n t o i l s c a n i n t e r f e r e w i t h t h e p r o p e r f u n c t i o n i n g o f t h e s e a d d i t i v e s a n d d e g r a d e l u b r i c a n t p e r f o r m a n c e .

C o n s u l t y o u r J o h n D e e r e d e a l e r t o o b t a i n s p e c i f i c i n f o r m a t i o n a n d r e c o m m e n d a t i o n s .

D i e s e l E n g i n e C o o l a n t

T h e e n g i n e c o o l i n g s y s t e m i s f i l l e d t o p r o v i d e y e a r - r o u n d p r o t e c t i o n a g a i n s t c o r r o s i o n a n d c y l i n d e r l i n e r p i t t i n g , a n d w i n t e r f r e e z e p r o t e c t i o n t o - 3 7 ° C ( - 3 4 ° F ) .

J o h n D e e r e C O O L - G A R D i s p r e f e r r e d f o r s e r v i c e .

I f J o h n D e e r e C O O L - G A R D i s n o t a v a i l a b l e , u s e a l o w s i l i c a t e e t h y l e n e g l y c o l o r p r o p y l e n e g l y c o l b a s e c o o l a n t c o n c e n t r a t e i n a 5 0 % m i x t u r e o f c o n c e n t r a t e w i t h q u a l i t y

w a t e r . T h e c o o l a n t c o n c e n t r a t e s h a l l b e o f a q u a l i t y t h a t p r o v i d e s c a v i t a t i o n p r o t e c t i o n t o c a s t i r o n a n d a l u m i n u m p a r t s i n t h e c o o l i n g s y s t e m . J o h n D e e r e C O O L - G A R D m e e t s t h i s r e q u i r e m e n t .

F r e e z e p r o t e c t i o n

A 5 0 % m i x t u r e o f e t h y l e n e g l y c o l e n g i n e c o o l a n t i n w a t e r p r o v i d e s f r e e z e p r o t e c t i o n t o - 3 7 ° C ( - 3 4 ° F ) .

A 5 0 % m i x t u r e o f p r o p y l e n e g l y c o l e n g i n e c o o l a n t i n w a t e r p r o v i d e s f r e e z e p r o t e c t i o n t o - 3 3 ° C ( - 2 7 ° F ) .

I f p r o t e c t i o n a t l o w e r t e m p e r a t u r e s i s r e q u i r e d , c o n s u l t y o u r J o h n D e e r e d e a l e r f o r r e c o m m e n d a t i o n s .

W a t e r q u a l i t y

W a t e r q u a l i t y i s i m p o r t a n t t o t h e p e r f o r m a n c e o f t h e

c o o l i n g s y s t e m . D i s t i l l e d , d e i o n i z e d , o r d e m i n e r a l i z e d w a t e r i s r e c o m m e n d e d f o r m i x i n g w i t h e t h y l e n e g l y c o l a n d p r o p y l e n e g l y c o l b a s e e n g i n e c o o l a n t c o n c e n t r a t e .

I M P O R T A N T : D o n o t u s e c o o l i n g s y s t e m s e a l i n g a d d i t i v e s o r a n t i f r e e z e t h a t c o n t a i n s s e a l i n g a d d i t i v e s .

I M P O R T A N T : D o n o t m i x e t h y l e n e g l y c o l a n d p r o p y l e n e g l y c o l b a s e c o o l a n t s .

1 0 - 3 0 7 2 2 0 9

P N = 3 6

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D X , C O O L 6 - 1 9 - 0 3 N O V 0 8 - 1 / 1

O p e r a t i n g i n W a r m T e m p e r a t u r e C l i m a t e s

J o h n D e e r e e n g i n e s a r e d e s i g n e d t o o p e r a t e u s i n g g l y c o l b a s e e n g i n e c o o l a n t s .

A l w a y s u s e a r e c o m m e n d e d g l y c o l b a s e e n g i n e c o o l a n t , e v e n w h e n o p e r a t i n g i n g e o g r a p h i c a l a r e a s w h e r e f r e e z e p r o t e c t i o n i s n o t r e q u i r e d .

J o h n D e e r e C O O L - G A R D ™ I I P r e m i x i s a v a i l a b l e i n a c o n c e n t r a t i o n o f 5 0 % e t h y l e n e g l y c o l . H o w e v e r , t h e r e a r e s i t u a t i o n s i n w a r m t e m p e r a t u r e c l i m a t e s w h e r e a c o o l a n t w i t h l o w e r g l y c o l c o n c e n t r a t i o n ( a p p r o x i m a t e l y 2 0 % e t h y l e n e g l y c o l ) h a s b e e n a p p r o v e d . I n t h e s e c a s e s , t h e l o w g l y c o l f o r m u l a t i o n h a s b e e n m o d i f i e d t o p r o v i d e t h e s a m e l e v e l o f c o r r o s i o n i n h i b i t o r a s J o h n D e e r e C O O L - G A R D I I P r e m i x ( 5 0 / 5 0 ) .

I M P O R T A N T : W a t e r m a y b e u s e d a s c o o l a n t i n e m e r g e n c y s i t u a t i o n s o n l y .

F o a m i n g , h o t s u r f a c e a l u m i n u m a n d i r o n c o r r o s i o n , s c a l i n g , a n d c a v i t a t i o n w i l l o c c u r w h e n w a t e r i s u s e d a s t h e c o o l a n t , e v e n w h e n

c o o l a n t c o n d i t i o n e r s a r e a d d e d .

D r a i n c o o l i n g s y s t e m a n d r e f i l l w i t h r e c o m m e n d e d g l y c o l b a s e e n g i n e c o o l a n t a s s o o n a s p o s s i b l e .

C O O L - G A R D i s a t r a d e m a r k o f D e e r e & C o m p a n y

1 0 - 4 0 7 2 2 0 9

P N = 3 7

107/258



O p e r a t i n g t h e E n g i n e

C D 0 3 5 2 3 , 0 0 0 0 1 8 B - 1 9 - 2 2 J A N 0 7 - 1 / 1

C o n t i n u e d o n n e x t p a g e O U R G P 1 1 , 0 0 0 0 0 A 9 - 1 9 - 0 3 S E P 0 3 - 1 / 5

U s i n g D i a g n o s t i c G a u g e t o A c c e s s E n g i n e I n f o r m a t i o n ( O p t i o n a l e q u i p m e n t )

R G 1 3 1 3 2

— U N

— 0 9 S E P 0 3

D i a g n o s t i c G a u g e

A — D i a g n o s t i c G a u g e B — M e n u K e y

C — A r r o w K e y s D — E n t e r K e y

E — R e d ” S T O P E N G I N E ” I n d i c a t o r L i g h t

F — A m b e r ” W A R N I N G ” I n d i c a t o r L i g h t

N O T E : G e n e r a t o r s e t s p o w e r e d b y a n e l e c t r o n i c a l l y c o n t r o l l e d e n g i n e ( D E 1 0 o r H P C R f u e l s y s t e m ) c a n b e o p t i o n a l l y e q u i p p e d w i t h t h e d i a g n o s t i c g a u g e s h o w n . D e p e n d i n g o n t h e g e n e r a t o r s e t m a n u f a c t u r e r , o t h e r i n s t r u m e n t a t i o n s c a n b e u s e d . R e f e r t o t h e g e n e r a t o r s e t d o c u m e n t a t i o n f o r m o r e i n f o r m a t i o n .

T h e d i a g n o s t i c g a u g e ( A ) a l l o w s t h e o p e r a t o r t o v i e w m a n y r e a d o u t s o f e n g i n e f u n c t i o n s a n d t r o u b l e c o d e s ( D T C s ) . T h e g a u g e i s l i n k e d t o t h e e l e c t r o n i c c o n t r o l s y s t e m a n d i t s s e n s o r s . T h i s a l l o w s t h e o p e r a t o r t o m o n i t o r e n g i n e f u n c t i o n s a n d t o t r o u b l e s h o o t t h e e n g i n e s y s t e m s w h e n n e e d e d .

P r e s s t h e m e n u k e y ( B ) t o a c c e s s t h e v a r i o u s e n g i n e f u n c t i o n s i n s e q u e n c e . T h e d i s p l a y s c a n b e s e l e c t e d a s e i t h e r c u s t o m a r y E n g l i s h o r m e t r i c u n i t s . T h e f o l l o w i n g m e n u o f e n g i n e p a r a m e t e r s c a n b e d i s p l a y e d o n t h e d i a g n o s t i c g a u g e w i n d o w :

• E n g i n e h o u r s

• E n g i n e r p m

• S y s t e m v o l t a g e

• P e r c e n t e n g i n e l o a d a t t h e c u r r e n t r p m

• C o o l a n t t e m p e r a t u r e • O i l p r e s s u r e

• T h r o t t l e p o s i t i o n

• I n t a k e m a n i f o l d t e m p e r a t u r e

• C u r r e n t f u e l c o n s u m p t i o n

• A c t i v e s e r v i c e ( d i a g n o s t i c ) c o d e s

• S t o r e d s e r v i c e ( d i a g n o s t i c ) c o d e s f r o m t h e e n g i n e

• S e t t h e u n i t s f o r d i s p l a y

• V i e w t h e e n g i n e c o n f i g u r a t i o n p a r a m e t e r s

N O T E : E n g i n e p a r a m e t e r s w h i c h c a n b e a c c e s s e d w i l l v a r y w i t h t h e e n g i n e a p p l i c a t i o n . S i x l a n g u a g e s f o r r e a d o u t s a r e a v a i l a b l e a n d c a n b e s e l e c t e d d u r i n g s e t u p o f g a u g e .

T h e d i a g n o s t i c g a u g e i n c l u d e s a g r a p h i c a l b a c k l i t L i q u i d C r y s t a l D i s p l a y ( L C D ) s c r e e n . T h e d i s p l a y c a n s h o w e i t h e r a s i n g l e p a r a m e t e r o r a q u a d r a n t d i s p l a y s h o w i n g f o u r p a r a m e t e r s s i m u l t a n e o u s l y . T h e d i a g n o s t i c g a u g e u s e s t w o a r r o w k e y s ( C ) f o r s c r o l l i n g t h r o u g h t h e e n g i n e p a r a m e t e r l i s t a n d v i e w i n g t h e m e n u l i s t a n d a n e n t e r k e y ( D ) f o r s e l e c t i n g h i g h l i g h t e d i t e m s . T h e r e d ( E ) a n d a m b e r ( F ) l i g h t s a r e u s e d t o s i g n a l a c t i v e t r o u b l e c o d e r e c e i v e d b y t h e d i a g n o s t i c g a u g e .

M a i n M e n u N a v i g a t i o n N O T E : T h e e n g i n e d o e s n o t n e e d t o b e r u n n i n g t o

n a v i g a t e t h e d i a g n o s t i c g a u g e s c r e e n s . I f e n g i n e s t a r t u p i s d e s i r e d , S e e S t a r t i n g T h e E n g i n e . A l l o f t h e e n g i n e v a l u e s i l l u s t r a t e d o n t h e d i a g n o s t i c g a u g e i n d i c a t e t h e e n g i n e i s r u n n i n g .

1 . T u r n t h e k e y s w i t c h t o t h e O N p o s i t i o n . S t a r t i n g a t t h e s i n g l e o r f o u r e n g i n e p a r a m e t e r d i s p l a y , p r e s s t h e " M e n u " k e y .

R G 1 3 1 5 9

— U N

— 2 6 S E P 0 3

M e n u K e y

1 5 - 1 0 7 2 2 0 9

P N = 3 8

108/258




O U R G P 1 1 , 0 0 0 0 0 A 9 - 1 9 - 0 3 S E P 0 3 - 2 / 5

O U R G P 1 1 , 0 0 0 0 0 A 9 - 1 9 - 0 3 S E P 0 3 - 3 / 5

C o n t i n u e d o n n e x t p a g e O U R G P 1 1 , 0 0 0 0 0 A 9 - 1 9 - 0 3 S E P 0 3 - 4 / 5

2 . T h e f i r s t s e v e n i t e m s o f t h e " M a i n M e n u " w i l l b e d i s p l a y e d .

R G 1 3 1 6 0

— U N

— 0 2 O C T 0 3

M e n u D i s p l a y

3 . P r e s s i n g t h e " A r r o w " k e y s w i l l s c r o l l t h r o u g h t h e m e n u s e l e c t i o n s .

R G 1 3 1 6 1

— U N

— 0 2 O C T 0 3

M a i n M e n u I t e m s

4 . P r e s s i n g t h e r i g h t a r r o w k e y w i l l s c r o l l d o w n t o r e v e a l t h e l a s t i t e m s o f " M a i n M e n u " s c r e e n , h i g h l i g h t i n g t h e n e x t i t e m d o w n .

R G 1 3 1 6 2

— U N

— 2 6 S E P 0 3

L a s t I t e m s O n M a i n M e n u

1 5 - 2 0 7 2 2 0 9

P N = 3 9

109/258




O U R G P 1 1 , 0 0 0 0 0 A 9 - 1 9 - 0 3 S E P 0 3 - 5 / 5

O U R G P 1 1 , 0 0 0 0 0 A B - 1 9 - 0 3 S E P 0 3 - 1 / 6

C o n t i n u e d o n n e x t p a g e O U R G P 1 1 , 0 0 0 0 0 A B - 1 9 - 0 3 S E P 0 3 - 2 / 6

5 . U s e t h e a r r o w k e y s t o s c r o l l t o t h e d e s i r e d m e n u i t e m o r p r e s s t h e " M e n u B u t t o n " t o e x i t t h e m a i n m e n u a n d r e t u r n t o t h e e n g i n e p a r a m e t e r d i s p l a y .

R

G 1 3 1 6 3

— U N

— 0 2 O C T 0 3

U s e A r r o w B u t t o n s T o S c r o l l / Q u a d r a n t D i s p l a y

E n g i n e C o n f i g u r a t i o n D a t a

N O T E : T h e e n g i n e c o n f i g u r a t i o n d a t a i s a r e a d o n l y f u n c t i o n .

N O T E : T h e e n g i n e d o e s n o t n e e d t o b e r u n n i n g t o n a v i g a t e t h e d i a g n o s t i c g a u g e s c r e e n s . I f e n g i n e s t a r t u p i s d e s i r e d , S e e S t a r t i n g T h e E n g i n e . A l l o f t h e e n g i n e v a l u e s i l l u s t r a t e d o n t h e d i a g n o s t i c

g a u g e i n d i c a t e t h e e n g i n e i s r u n n i n g .


R G 1 3 1 5 9

— U N

— 2 6 S E P 0 3

M e n u K e y

2 . T h e m a i n m e n u w i l l b e d i s p l a y e d . U s e t h e " A r r o w " k e y s t o s c r o l l t h r o u g h t h e m e n u u n t i l " E n g i n e C o n f i g " i s h i g h l i g h t e d .

R G 1 3 1 6 4

— U N

— 0 7 O C

T 0 3

S e l e c t E n g i n e C o n f i g u r a t i o n

1 5 - 3 0 7 2 2 0 9

P N = 4 0

110/258




O U R G P 1 1 , 0 0 0 0 0 A B - 1 9 - 0 3 S E P 0 3 - 3 / 6

O U R G P 1 1 , 0 0 0 0 0 A B - 1 9 - 0 3 S E P 0 3 - 4 / 6

C o n t i n u e d o n n e x t p a g e O U R G P 1 1 , 0 0 0 0 0 A B - 1 9 - 0 3 S E P 0 3 - 5 / 6

3 . O n c e " E n g i n e C o n f i g " m e n u i t e m h a s b e e n h i g h l i g h t e d , p r e s s t h e " E n t e r " k e y t o v i e w t h e e n g i n e c o n f i g u r a t i o n d a t a .

R G 1 3 1 6 5

— U N

— 0 2 O C T 0 3

E n t e r K e y

4 . U s e t h e " A r r o w " k e y s t o s c r o l l t h r o u g h t h e e n g i n e c o n f i g u r a t i o n d a t a .

R G 1 3 1 6 6

— U N

— 2 9 S E P 0 3

U s e A r r o w K e y s T o S c r o l l

5 . P r e s s t h e " M e n u " k e y t o r e t u r n t o t h e m a i n m e n u .

R G 1 3 1 6 7

— U N

— 2 9 S E P 0 3

R e t u r n T o M a i n M e n u

1 5 - 4 0 7 2 2 0 9

P N = 4 1

111/258




O U R G P 1 1 , 0 0 0 0 0 A B - 1 9 - 0 3 S E P 0 3 - 6 / 6

O U R G P 1 1 , 0 0 0 0 0 A C - 1 9 - 0 3 S E P 0 3 - 1 / 6

C o n t i n u e d o n n e x t p a g e O U R G P 1 1 , 0 0 0 0 0 A C - 1 9 - 0 3 S E P 0 3 - 2 / 6

6 . P r e s s t h e " M e n u " k e y t o e x i t t h e m a i n m e n u a n d r e t u r n t o t h e e n g i n e p a r a m e t e r d i s p l a y .

R

G 1 3 1 5 9

— U N

— 2 6 S E P 0 3

E x i t M a i n M e n u

A c c e s s i n g S t o r e d T r o u b l e C o d e s

N O T E : T h e e n g i n e d o e s n o t n e e d t o b e r u n n i n g t o n a v i g a t e t h e d i a g n o s t i c g a u g e s c r e e n s . I f e n g i n e s t a r t u p i s d e s i r e d , S e e S t a r t i n g T h e E n g i n e . A l l o f t h e e n g i n e v a l u e s i l l u s t r a t e d o n t h e d i a g n o s t i c g a u g e i n d i c a t e t h e e n g i n e i s r u n n i n g .

F o r d e s c r i p t i o n o f t r o u b l e c o d e s , s e e c h a r t

i n T r o u b l e s h o o t i n g S e c t i o n .


R G 1 3 1 5 9

— U N

— 2 6 S E P 0 3

M e n u K e y

2 . T h e m a i n m e n u w i l l b e d i s p l a y e d . U s e t h e " A r r o w " k e y s t o s c r o l l t h r o u g h t h e m e n u u n t i l " S t o r e d C o d e s " i s h i g h l i g h t e d .

R G 1 3 1 6 8

— U N

— 0 2 O C T 0 3

S e l e c t S t o r e d C o d e s

1 5 - 5 0 7 2 2 0 9

P N = 4 2

112/258




O U R G P 1 1 , 0 0 0 0 0 A C - 1 9 - 0 3 S E P 0 3 - 3 / 6

O U R G P 1 1 , 0 0 0 0 0 A C - 1 9 - 0 3 S E P 0 3 - 4 / 6

C o n t i n u e d o n n e x t p a g e O U R G P 1 1 , 0 0 0 0 0 A C - 1 9 - 0 3 S E P 0 3 - 5 / 6

3 . O n c e t h e " S t o r e d C o d e s " m e n u i t e m h a s b e e n h i g h l i g h t e d p r e s s t h e " E n t e r " k e y t o v i e w t h e s t o r e d c o d e s .

R G 1 3 1 6 9

— U N

— 0 2

O C T 0 3

E n t e r K e y

4 . I f t h e w o r d " N e x t " a p p e a r s a b o v e t h e " A r r o w " k e y s , t h e r e a r e m o r e s t o r e d c o d e s t h a t m a y b e v i e w e d . U s e t h e " A r r o w " k e y t o s c r o l l t o t h e n e x t s t o r e d c o d e .

R G 1 3 2 4 5

— U N

— 0 2 O C T 0 3



R G 1 3 2 4 6

— U N

— 0 2 O C T 0 3


1 5 - 6 0 7 2 2 0 9

P N = 4 3

113/258




O U R G P 1 1 , 0 0 0 0 0 A C - 1 9 - 0 3 S E P 0 3 - 6 / 6

O U R G P 1 1 , 0 0 0 0 0 A D - 1 9 - 0 3 S E P 0 3 - 1 / 7

O U R G P 1 1 , 0 0 0 0 0 A D - 1 9 - 0 3 S E P 0 3 - 2 / 7

C o n t i n u e d o n n e x t p a g e O U R G P 1 1 , 0 0 0 0 0 A D - 1 9 - 0 3 S E P 0 3 - 3 / 7


R

G 1 3 1 5 9

— U N

— 2 6 S E P 0 3


A c c e s s i n g A c t i v e T r o u b l e C o d e s

N O T E : T h e e n g i n e d o e s n o t n e e d t o b e r u n n i n g t o n a v i g a t e t h e d i a g n o s t i c g a u g e s c r e e n s . I f e n g i n e s t a r t u p i s d e s i r e d , S e e S t a r t i n g T h e E n g i n e . A l l o f t h e e n g i n e v a l u e s i l l u s t r a t e d o n t h e d i a g n o s t i c g a u g e i n d i c a t e t h e e n g i n e i s r u n n i n g .

F o r d e s c r i p t i o n o f t r o u b l e c o d e s , s e e c h a r t

i n T r o u b l e s h o o t i n g S e c t i o n .

1 . D u r i n g n o r m a l o p e r a t i o n t h e s i n g l e o r f o u r p a r a m e t e r s c r e e n w i l l b e d i s p l a y e d .

R G 1 3 1 7 2

— U N

— 2 6 S E P 0 3

N o r m a l O p e r a t i o n

2 . W h e n t h e d i a g n o s t i c g a u g e r e c e i v e s a t r o u b l e c o d e f r o m a n e n g i n e c o n t r o l u n i t , t h e s i n g l e o r f o u r p a r a m e t e r s c r e e n w i l l b e r e p l a c e d w i t h t h e " W a r n i n g " m e s s a g e . T h e S P N a n d F M I n u m b e r w i l l b e d i s p l a y e d a l o n g w i t h a d e s c r i p t i o n o f t h e p r o b l e m a n d t h e c o r r e c t i v e a c t i o n n e e d e d .

I M P O R T A N T : I g n o r i n g a c t i v e t r o u b l e c o d e s c a n r e s u l t i n s e v e r e e n g i n e d a m a g e .

R G 1 3 2 4 0

— U N —

3 0 S E P 0 3

A c t i v e T r o u b l e C o d e s D i s p l a y e d

3 . I f t h e w o r d " N e x t " a p p e a r s a b o v e t h e a r r o w k e y s , t h e r e a r e m o r e t r o u b l e c o d e s t h a t c a n b e v i e w e d b y u s i n g t h e a r r o w k e y s t o s c r o l l t o t h e n e x t t r o u b l e c o d e .

R G 1 3 2 4 1

— U N

— 3 0 S E P 0 3


1 5 - 7 0 7 2 2 0 9

P N = 4 4

114/258




O U R G P 1 1 , 0 0 0 0 0 A D - 1 9 - 0 3 S E P 0 3 - 4 / 7

O U R G P 1 1 , 0 0 0 0 0 A D - 1 9 - 0 3 S E P 0 3 - 5 / 7

O U R G P 1 1 , 0 0 0 0 0 A D - 1 9 - 0 3 S E P 0 3 - 6 / 7

O U R G P 1 1 , 0 0 0 0 0 A D - 1 9 - 0 3 S E P 0 3 - 7 / 7


4 . T o a c k n o w l e d g e a n d h i d e t h e c o d e a n d r e t u r n t o t h e s i n g l e o r f o u r p a r a m e t e r d i s p l a y , p r e s s t h e " E n t e r " K e y .

R G 1 3 2 4 2

— U

N —

3 0 S E P 0 3

H i d e T r o u b l e C o d e s

5 . T h e d i s p l a y w i l l r e t u r n t o t h e s i n g l e o r f o u r p a r a m e t e r d i s p l a y , b u t t h e d i s p l a y w i l l c o n t a i n t h e w a r n i n g i c o n . P r e s s i n g t h e " E n t e r " k e y w i l l r e d i s p l a y t h e h i d d e n t r o u b l e c o d e .

R G 1 3 1 7 6

— U N

— 2 6 S E P 0 3

A c t i v e T r o u b l e C o d e I c o n


6 . P r e s s i n g t h e " E n t e r " k e y o n c e a g a i n w i l l h i d e t h e t r o u b l e c o d e a n d r e t u r n t h e s c r e e n t o t h e s i n g l e o r f o u r p a r a m e t e r d i s p l a y .

R G 1 3 2 4 2

— U N

— 3 0 S E P 0 3

E n t e r K e y

7 . T h e s i n g l e o r f o u r p a r a m e t e r s c r e e n w i l l d i s p l a y t h e w a r n i n g i c o n u n t i l t h e t r o u b l e c o d e c o n d i t i o n i s c o r r e c t e d .

R G 1 3 2 4 3

— U N

— 0 1 O C T 0 3

A c t i v e T r o u b l e C o d e C o n d i t i o n

1 5 - 8 0 7 2 2 0 9

P N = 4 5

115/258




O U R G P 1 1 , 0 0 0 0 0 A E - 1 9 - 0 3 S E P 0 3 - 1 / 6

O U R G P 1 1 , 0 0 0 0 0 A E - 1 9 - 0 3 S E P 0 3 - 2 / 6

O U R G P 1 1 , 0 0 0 0 0 A E - 1 9 - 0 3 S E P 0 3 - 3 / 6

C o n t i n u e d o n n e x t p a g e O U R G P 1 1 , 0 0 0 0 0 A E - 1 9 - 0 3 S E P 0 3 - 4 / 6

E n g i n e S h u t d o w n C o d e s

1 . D u r i n g n o r m a l o p e r a t i o n t h e s i n g l e o r f o u r p a r a m e t e r s c r e e n w i l l b e d i s p l a y e d .

R G 1 3 1 7 2

— U N

— 2 6 S E P 0 3

N o r m a l O p e r a t i o n

2 . W h e n t h e d i a g n o s t i c g a u g e r e c e i v e s a s e v e r e t r o u b l e c o d e f r o m a n e n g i n e c o n t r o l u n i t , t h e s i n g l e o r f o u r p a r a m e t e r s c r e e n w i l l b e r e p l a c e d w i t h t h e " S h u t d o w n " m e s s a g e . T h e S P N a n d F M I n u m b e r w i l l b e d i s p l a y e d a l o n g w i t h a d e s c r i p t i o n o f t h e p r o b l e m a n d t h e c o r r e c t i v e a c t i o n n e e d e d .

I f t h e w o r d " N e x t " a p p e a r s a b o v e t h e a r r o w k e y s , t h e r e a r e m o r e t r o u b l e c o d e s t h a t c a n b e v i e w e d b y u s i n g t h e a r r o w k e y s t o s c r o l l t o t h e n e x t t r o u b l e c o d e .

R G 1 3 2

3 8

— U N

— 2 9 S E P 0 3

S h u t d o w n M e s s a g e

3 . T o a c k n o w l e d g e a n d h i d e t h e t r o u b l e c o d e a n d r e t u r n t o t h e s i n g l e o r f o u r p a r a m e t e r d i s p l a y , p r e s s t h e " E n t e r " k e y " .

I M P O R T A N T : I g n o r i n g t h e s h u t d o w n m e s s a g e c a n r e s u l t i n s e v e r e e n g i n e d a m a g e .

R G 1 3 2 3 9

— U N —

2 9 S E P 0 3

H i d e T r o u b l e C o d e

4 . T h e d i s p l a y w i l l r e t u r n t o t h e s i n g l e o r f o u r p a r a m e t e r d i s p l a y , b u t t h e d i s p l a y w i l l c o n t a i n t h e " S h u t d o w n " i c o n . P r e s s i n g t h e " E n t e r " k e y w i l l r e d i s p l a y t h e h i d d e n t r o u b l e c o d e .


R G 1 3 1 7 9

— U

N —

2 6 S E P 0 3

F l a s h i n g S h u t d o w n I c o n

1 5 - 9 0 7 2 2 0 9

P N = 4 6

116/258




O U R G P 1 1 , 0 0 0 0 0 A E - 1 9 - 0 3 S E P 0 3 - 5 / 6

O U R G P 1 1 , 0 0 0 0 0 A E - 1 9 - 0 3 S E P 0 3 - 6 / 6

O U R G P 1 1 , 0 0 0 0 2 3 7 - 1 9 - 2 1 O C T 0 3 - 1 / 6

C o n t i n u e d o n n e x t p a g e O U R G P 1 1 , 0 0 0 0 2 3 7 - 1 9 - 2 1 O C T 0 3 - 2 / 6

5 . P r e s s i n g t h e " E n t e r " k e y o n c e a g a i n w i l l h i d e t h e t r o u b l e c o d e a n d r e t u r n t h e s c r e e n t o t h e s i n g l e o r f o u r p a r a m e t e r d i s p l a y .

R G 1 3 2 3 9

— U

N —

2 9 S E P 0 3

R e d i s p l a y T r o u b l e C o d e

6 . T h e s i n g l e o r f o u r p a r a m e t e r s c r e e n w i l l d i s p l a y t h e s h u t d o w n i c o n u n t i l t h e t r o u b l e c o d e c o n d i t i o n i s c o r r e c t e d .


R G 1 3 1 8 0

— U N

— 2 6 S E P 0 3

S h u t d o w n I c o n

A d j u s t i n g B a c k l i g h t i n g


R G 1

3 1 5 9

— U N

— 2 6 S E P 0 3

M e n u K e y

2 . T h e m a i n m e n u w i l l b e d i s p l a y e d . U s e t h e " A r r o w " k e y s t o s c r o l l t h r o u g h t h e m e n u u n t i l " A d j u s t B a c k l i g h t " i s h i g h l i g h t e d .

R G 1 3 1 8 1

— U N —

0 2 O C T 0 3

S e l e c t A d j u s t B a c k l i g h t

1 5 - 1 0 0 7 2 2 0 9

P N = 4 7

117/258




O U R G P 1 1 , 0 0 0 0 2 3 7 - 1 9 - 2 1 O C T 0 3 - 3 / 6

O U R G P 1 1 , 0 0 0 0 2 3 7 - 1 9 - 2 1 O C T 0 3 - 4 / 6

C o n t i n u e d o n n e x t p a g e O U R G P 1 1 , 0 0 0 0 2 3 7 - 1 9 - 2 1 O C T 0 3 - 5 / 6

3 . O n c e t h e " A d j u s t B a c k l i g h t " m e n u i t e m h a s b e e n h i g h l i g h t e d , p r e s s t h e " E n t e r " k e y t o a c t i v a t e t h e " A d j u s t B a c k l i g h t " f u n c t i o n .

R G 1 3 1 8 2

— U N

— 0 2 O C T 0 3

P r e s s E n t e r K e y

4 . U s e t h e " A r r o w " k e y s t o s e l e c t t h e d e s i r e d b a c k l i g h t i n t e n s i t y .

R G 1 3 1 8 3

— U N

— 2 9 S E P 0 3

A d j u s t B a c k l i g h t I n t e n s i t y


R G 1 3 1 8 4

— U N

— 2 6 S E P 0 3


1 5 - 1 1 0 7 2 2 0 9

P N = 4 8

118/258




O U R G P 1 1 , 0 0 0 0 2 3 7 - 1 9 - 2 1 O C T 0 3 - 6 / 6

O U R G P 1 1 , 0 0 0 0 0 A F - 1 9 - 0 3 S E P 0 3 - 1 / 6

O U R G P 1 1 , 0 0 0 0 0 A F - 1 9 - 0 3 S E P 0 3 - 2 / 6

C o n t i n u e d o n n e x t p a g e O U R G P 1 1 , 0 0 0 0 0 A F - 1 9 - 0 3 S E P 0 3 - 3 / 6


R

G 1 3 1 5 9

— U N

— 2 6 S E P 0 3


A d j u s t i n g C o n t r a s t

1 . T u r n t h e k e y s w i t c h t o t h e O N p o s i t i o n . S t a r t i n g a t t h e s i n g l e o r f o u r e n g i n e p a r a m e t e r d i s p l a y p r e s s t h e " M e n u " k e y .

R G 1 3 1 5 9

— U N

— 2 6 S E P 0 3

M e n u K e y

2 . T h e m a i n m e n u w i l l b e d i s p l a y e d . U s e t h e " A r r o w " k e y s t o s c r o l l t h r o u g h t h e m e n u u n t i l " A d j u s t C o n t r a s t " i s h i g h l i g h t e d .

R G 1 3 1 6 1

— U N —

0 2 O C T 0 3

S e l e c t A d j u s t C o n t r a s t

3 . O n c e t h e " A d j u s t C o n t r a s t " m e n u i t e m h a s b e e n h i g h l i g h t e d , p r e s s t h e " E n t e r " k e y t o a c t i v a t e t h e " A d j u s t C o n t r a s t " f u n c t i o n .

R G 1 3 1 8 5

— U N

— 0 2 O C T 0 3


1 5 - 1 2 0 7 2 2 0 9

P N = 4 9

119/258




O U R G P 1 1 , 0 0 0 0 0 A F - 1 9 - 0 3 S E P 0 3 - 4 / 6

O U R G P 1 1 , 0 0 0 0 0 A F - 1 9 - 0 3 S E P 0 3 - 5 / 6

O U R G P 1 1 , 0 0 0 0 0 A F - 1 9 - 0 3 S E P 0 3 - 6 / 6

C o n t i n u e d o n n e x t p a g e O U R G P 1 1 , 0 0 0 0 0 B 0 - 1 9 - 0 3 S E P 0 3 - 1 / 7

4 . U s e t h e " A r r o w " k e y s t o s e l e c t t h e d e s i r e d c o n t r a s t i n t e n s i t y .

R G 1 3 1 8 6

— U N

— 2 9 S E P 0 3

A d j u s t C o n t r a s t I n t e n s i t y


R G 1 3 1 8 7

— U N

— 2 6 S E P 0 3


6 . P r e s s t h e " M e n u " k e y t o e x i t t h e m a i n m e n u a n d r e t u r n

t o t h e e n g i n e p a r a m e t e r d i s p l a y .

R G 1 3 1 5 9

— U N

— 2 6 S E P 0 3


S e l e c t i n g U n i t s O f M e a s u r e m e n t


R G 1 3 1 5 9

— U N

— 2 6 S E P 0 3

M e n u K e y

1 5 - 1 3 0 7 2 2 0 9

P N = 5 0

120/258




O U R G P 1 1 , 0 0 0 0 0 B 0 - 1 9 - 0 3 S E P 0 3 - 2 / 7

O U R G P 1 1 , 0 0 0 0 0 B 0 - 1 9 - 0 3 S E P 0 3 - 3 / 7

C o n t i n u e d o n n e x t p a g e O U R G P 1 1 , 0 0 0 0 0 B 0 - 1 9 - 0 3 S E P 0 3 - 4 / 7

2 . T h e m a i n m e n u w i l l b e d i s p l a y e d . U s e t h e " A r r o w " k e y s t o s c r o l l t h r o u g h t h e m e n u u n t i l " S e l e c t U n i t s " i s h i g h l i g h t e d .

R G 1 3 1 8 8

— U N — 0 2 O C T 0 3

S e l e c t U n i t s

3 . O n c e t h e " S e l e c t U n i t s " m e n u i t e m h a s b e e n h i g h l i g h t e d p r e s s t h e " E n t e r " k e y t o a c c e s s t h e " S e l e c t U n i t s " f u n c t i o n .

R G 1 3 1 8 9

— U N

— 0 2 O C T 0 3


4 . T h e r e a r e t h r e e c h o i c e s f o r u n i t s o f m e a s u r e m e n t ,

E n g l i s h , M e t r i c k P a o r M e t r i c B a r .

E n g l i s h i s f o r I m p e r i a l u n i t s , w i t h p r e s s u r e s d i s p l a y e d i n P S I a n d t e m p e r a t u r e s i n ° F .

M e t r i c k P a a n d M e t r i c b a r a r e f o r I S u n i t s , w i t h p r e s s u r e s d i s p l a y e d i n k P a a n d b a r r e s p e c t i v e l y , a n d t e m p e r a t u r e s i n ° C .

U s e t h e " A r r o w " k e y s t o h i g h l i g h t t h e d e s i r e d u n i t s o f m e a s u r e m e n t .

R G 1 3 1 9 0

— U N

— 2 6 S E P 0 3

S e l e c t D e s i r e d U n i t s

1 5 - 1 4 0 7 2 2 0 9

P N = 5 1

121/258




O U R G P 1 1 , 0 0 0 0 0 B 0 - 1 9 - 0 3 S E P 0 3 - 5 / 7

O U R G P 1 1 , 0 0 0 0 0 B 0 - 1 9 - 0 3 S E P 0 3 - 6 / 7

O U R G P 1 1 , 0 0 0 0 0 B 0 - 1 9 - 0 3 S E P 0 3 - 7 / 7

C o n t i n u e d o n n e x t p a g e O U R G P 1 1 , 0 0 0 0 0 B 1 - 1 9 - 0 3 S E P 0 3 - 1 / 1 8

5 . P r e s s t h e " E n t e r " k e y t o s e l e c t t h e h i g h l i g h t e d u n i t s .

R G 1 3 1 9 1

— U N — 3 0 S E P 0 3

P r e s s E n t e r K e y t o S e l e c t


R G 1 3 1 9 2

— U N

— 2 6 S E P 0 3


7 . P r e s s t h e " M e n u " k e y t o r e t u r n t o t h e e n g i n e p a r a m e t e r

d i s p l a y .

R G 1 3 1 5 9

— U N

— 2 6 S E P 0 3

P r e s s M e n u K e y

S e t u p 1 - U p D i s p l a y

1 . T u r n t h e k e y s w i t c h t o t h e O N p o s i t i o n . S t a r t i n g a t t h e s i n g l e e n g i n e p a r a m e t e r d i s p l a y , p r e s s t h e " M e n u " k e y .

R G 1 3 1 5 9

— U N

— 2 6 S E P 0 3

M e n u K e y

1 5 - 1 5 0 7 2 2 0 9

P N = 5 2

122/258




O U R G P 1 1 , 0 0 0 0 0 B 1 - 1 9 - 0 3 S E P 0 3 - 2 / 1 8

O U R G P 1 1 , 0 0 0 0 0 B 1 - 1 9 - 0 3 S E P 0 3 - 3 / 1 8


2 . U s e t h e " A r r o w " k e y s t o s c r o l l t h r o u g h t h e m e n u u n t i l " S e t u p 1 - U p D i s p l a y " i s h i g h l i g h t e d .

R G 1 3 1 9 3

— U N —

0 2 O C T 0 3


3 . O n c e " S e t u p 1 - U p D i s p l a y " m e n u i t e m h a s b e e n h i g h l i g h t e d p r e s s t h e " E n t e r " k e y t o a c c e s s t h e " S e t u p 1 - U p D i s p l a y " f u n c t i o n .

R G 1 3 1 9 4

— U N

— 0 2 O C T 0 3


4 . T h r e e o p t i o n s a r e a v a i l a b l e f o r m o d i f i c a t i o n o f t h e

1 - U p D i s p l a y . a . U s e D e f a u l t s – T h i s o p t i o n c o n t a i n s t h e f o l l o w i n g

e n g i n e p a r a m e t e r s f o r d i s p l a y : E n g i n e H o u r s , E n g i n e S p e e d , B a t t e r y V o l t a g e , % L o a d , C o o l a n t T e m p e r a t u r e a n d O i l P r e s s u r e .

b . C u s t o m S e t u p – T h i s o p t i o n c o n t a i n s a l i s t o f e n g i n e p a r a m e t e r s . E n g i n e p a r a m e t e r s f r o m t h i s l i s t c a n b e s e l e c t e d t o r e p l a c e a n y o r a l l o f t h e d e f a u l t p a r a m e t e r s . T h i s o p t i o n c a n b e u s e d t o a d d p a r a m e t e r s a v a i l a b l e f o r s c r o l l i n g i n t h e 1 - U p D i s p l a y .

c . A u t o m a t i c S c a n – S e l e c t i n g t h e s c a n f u n c t i o n w i l l

a l l o w t h e 1 - U p D i s p l a y t o s c r o l l t h r o u g h t h e s e l e c t e d s e t o f p a r a m e t e r s o n e a t a t i m e , m o m e n t a r i l y p a u s i n g a t e a c h .

R G 1 3 1 9 6

— U N

— 2 6 S E P 0 3

1 - U p D i s p l a y O p t i o n s

1 5 - 1 6 0 7 2 2 0 9

P N = 5 3

123/258




O U R G P 1 1 , 0 0 0 0 0 B 1 - 1 9 - 0 3 S E P 0 3 - 5 / 1 8

O U R G P 1 1 , 0 0 0 0 0 B 1 - 1 9 - 0 3 S E P 0 3 - 6 / 1 8


5 . U s e D e f a u l t s - T o s e l e c t " U s e D e f a u l t s " u s e t h e A r r o w k e y s t o s c r o l l t o a n d h i g h l i g h t " U s e D e f a u l t s " i n t h e m e n u d i s p l a y .

R G 1 3 1 9 5

— U N —

2 6 S E P 0 3

S e l e c t D e f a u l t s

6 . P r e s s t h e " E n t e r " k e y t o a c t i v a t e t h e " U s e D e f a u l t s " f u n c t i o n .

R G 1 3 1 9 7

— U N

— 2 9 S E P 0 3

D e f a u l t s S e l e c t e d

7 . T h e d i s p l a y p a r a m e t e r s a r e r e s e t t o t h e f a c t o r y d e f a u l t s , t h e n t h e d i s p l a y w i l l r e t u r n t o t h e " S e t u p 1 - U p D i s p l a y " m e n u .

R G 1 3 1 4 9

— U N

— 2 4 S E P 0 3

R e s t o r e d T o D e f a u l t s

1 5 - 1 7 0 7 2 2 0 9

P N = 5 4

124/258




O U R G P 1 1 , 0 0 0 0 0 B 1 - 1 9 - 0 3 S E P 0 3 - 8 / 1 8

O U R G P 1 1 , 0 0 0 0 0 B 1 - 1 9 - 0 3 S E P 0 3 - 9 / 1 8

C o n t i n u e d o n n e x t p a g e O U R G P 1 1 , 0 0 0 0 0 B 1 - 1 9 - 0 3 S E P 0 3 - 1 0 / 1 8

8 . C u s t o m S e t u p - T o p e r f o r m a c u s t o m s e t u p o f t h e 1 - U p D i s p l a y , u s e t h e a r r o w b u t t o n s t o s c r o l l t o a n d h i g h l i g h t " C u s t o m S e t u p " o n t h e d i s p l a y .

R G 1 3 1 9 8

— U N —

2 6 S E P 0 3

S e l e c t C u s t o m S e t u p

9 . P r e s s t h e " E n t e r " k e y t o d i s p l a y a l i s t o f e n g i n e p a r a m e t e r s .

R G 1 3 1 9 9

— U N

— 2 6 S E P 0 3

E n g i n e P a r a m e t e r s

1 0 . U s e t h e " A r r o w " k e y s t o s c r o l l t o a n d h i g h l i g h t a

s e l e c t e d p a r a m e t e r ( p a r a m e t e r w i t h a n u m b e r t o r i g h t o f i t ) .

R G 1 3 1 5 0

— U N

— 2 4 S E P 0 3

S e l e c t P a r a m e t e r s

1 5 - 1 8 0 7 2 2 0 9

P N = 5 5

125/258




O U R G P 1 1 , 0 0 0 0 0 B 1 - 1 9 - 0 3 S E P 0 3 - 1 1 / 1 8

O U R G P 1 1 , 0 0 0 0 0 B 1 - 1 9 - 0 3 S E P 0 3 - 1 2 / 1 8


1 1 . P r e s s t h e " E n t e r " k e y t o d e s e l e c t t h e s e l e c t e d p a r a m e t e r , r e m o v i n g i t f r o m t h e l i s t o f p a r a m e t e r s b e i n g d i s p l a y e d o n t h e 1 - U p D i s p l a y .

R G 1 3 2 1 9

— U N —

2 6 S E P 0 3

D e s e l e c t P a r a m e t e r s

1 2 . U s e t h e " A r r o w " k e y s t o s c r o l l a n d h i g h l i g h t t h e d e s i r e d p a r a m e t e r t h a t h a s n o t b e e n s e l e c t e d f o r d i s p l a y ( p a r a m e t e r w i t h o u t a n u m b e r t o r i g h t o f i t ) .

R G 1 3 1 5 1

— U N

— 2 4 S E P 0 3

S e l e c t D e s i r e d P a r a m e t e r s

1 3 . P r e s s t h e " E n t e r " k e y t o s e l e c t t h e p a r a m e t e r f o r i n c l u s i o n i n t h e S i n g l e E n g i n e P a r a m e t e r D i s p l a y .

1 4 . C o n t i n u e t o s c r o l l t h r o u g h a n d s e l e c t a d d i t i o n a l p a r a m e t e r s f o r t h e c u s t o m 1 - U p D i s p l a y . P r e s s t h e " M e n u " k e y a t a n y t i m e t o r e t u r n t o t h e " C u s t o m S e t u p " m e n u .

R G 1 3 2 2 0

— U N

— 2 6 S E P 0 3

S e l e c t P a r a m e t e r s F o r D i s p l a y

1 5 - 1 9 0 7 2 2 0 9

P N = 5 6

126/258




O U R G P 1 1 , 0 0 0 0 0 B 1 - 1 9 - 0 3 S E P 0 3 - 1 4 / 1 8

O U R G P 1 1 , 0 0 0 0 0 B 1 - 1 9 - 0 3 S E P 0 3 - 1 5 / 1 8


1 5 . A u t o m a t i c S c a n - S e l e c t i n g t h e s c a n f u n c t i o n w i l l a l l o w t h e 1 - U p D i s p l a y t o s c r o l l t h r o u g h t h e s e l e c t e d s e t o f p a r a m e t e r s o n e a t a t i m e . U s e t h e " A r r o w " k e y s t o s c r o l l t o t h e " A u t o m a t i c S c a n " f u n c t i o n .

R G 1 3 2 2 1

— U N —

2 6 S E P 0 3

A u t o m a t i c S c a n O f f

1 6 . P r e s s t h e " E n t e r " k e y t o t o g g l e t h e " A u t o m a t i c S c a n " f u n c t i o n o n .

R G 1 3 2 2 2

— U N

— 2 6 S E P 0 3

A u t o m a t i c S c a n O n

1 7 . P r e s s t h e " E n t e r " k e y a g a i n t o t o g g l e t h e " A u t o m a t i c S c a n " f u n c t i o n o f f .

R G 1 3 2 2 3

— U N

— 2 6 S E P 0 3

A u t o m a t i c S c a n O f f

1 5 - 2 0 0 7 2 2 0 9

P N = 5 7

127/258




O U R G P 1 1 , 0 0 0 0 0 B 1 - 1 9 - 0 3 S E P 0 3 - 1 7 / 1 8

O U R G P 1 1 , 0 0 0 0 0 B 1 - 1 9 - 0 3 S E P 0 3 - 1 8 / 1 8

O U R G P 1 1 , 0 0 0 0 0 B 2 - 1 9 - 0 3 S E P 0 3 - 1 / 1 4


1 8 . O n c e t h e " U s e D e f a u l t s " , " C u s t o m S e t u p " a n d " A u t o m a t i c S c a n " f u n c t i o n s h a v e b e e n s e t , p r e s s t h e " M e n u " k e y t o r e t u r n t o t h e m a i n m e n u .

R G 1 3 2 2 4

— U N —

2 6 S E P 0 3

M e n u K e y

1 9 . P r e s s t h e " M e n u " k e y t o e x i t t h e m a i n m e n u a n d r e t u r n t o t h e e n g i n e p a r a m e t e r d i s p l a y .

R G 1 3 1 5 9

— U N

— 2 6 S E P 0 3



1 . T u r n t h e k e y s w i t c h t o t h e O N p o s i t i o n . F r o m t h e s i n g l e o r f o u r e n g i n e p a r a m e t e r d i s p l a y , p r e s s t h e " M e n u " k e y .

R G 1 3 1 5 9 —

U N

— 2 6 S E P 0 3

M e n u K e y

2 . T h e m a i n m e n u w i l l b e d i s p l a y e d . U s e t h e " A r r o w " k e y s t o s c r o l l t h r o u g h t h e m e n u u n t i l " S e t u p 4 - U p D i s p l a y " i s h i g h l i g h t e d .

R G 1 3 2 2 5

— U N

— 0 2 O C T 0 3

S e l e c t S e t u p 4 - U p D i s p l a y

1 5 - 2 1 0 7 2 2 0 9

P N = 5 8

128/258




O U R G P 1 1 , 0 0 0 0 0 B 2 - 1 9 - 0 3 S E P 0 3 - 3 / 1 4

O U R G P 1 1 , 0 0 0 0 0 B 2 - 1 9 - 0 3 S E P 0 3 - 4 / 1 4


3 . O n c e t h e " S e t u p 4 - U p D i s p l a y " m e n u i t e m h a s b e e n h i g h l i g h t e d , p r e s s t h e " E n t e r " k e y t o a c t i v a t e t h e " S e t u p 4 - U p D i s p l a y " m e n u .

R G 1 3 2 2 6

— U N —

0 2 O C T 0 3


4 . T w o o p t i o n s a r e a v a i l a b l e f o r t h e 4 - U p D i s p l a y .

a . U s e D e f a u l t s – T h i s o p t i o n c o n t a i n s t h e f o l l o w i n g e n g i n e p a r a m e t e r s f o r d i s p l a y : E n g i n e S p e e d , B a t t e r y V o l t a g e , C o o l a n t T e m p e r a t u r e a n d O i l

P r e s s u r e .

b . C u s t o m S e t u p – T h i s o p t i o n c o n t a i n s a l i s t o f e n g i n e p a r a m e t e r s . E n g i n e p a r a m e t e r s f r o m t h i s l i s t c a n b e s e l e c t e d t o r e p l a c e a n y o r a l l o f t h e d e f a u l t p a r a m e t e r s .

R G 1 3 2 4 4

— U N

— 0 2 O C T 0 3

S e l e c t F a c t o r y D e f a u l t s

5 . T o r e s e t t h e d i s p l a y p a r a m e t e r s t o t h e f a c t o r y

d e f a u l t s , s c r o l l t o a n d h i g h l i g h t " U s e D e f a u l t s " . P r e s s t h e " E n t e r " k e y t o a c t i v a t e t h e " U s e D e f a u l t s " f u n c t i o n .

A m e s s a g e i n d i c a t i n g t h e d i s p l a y p a r a m e t e r s a r e r e s e t t o t h e f a c t o r y d e f a u l t s w i l l b e d i s p l a y e d , t h e n t h e d i s p l a y w i l l r e t u r n t o t h e " S e t u p 4 - U p D i s p l a y " m e n u .

R G 1 3 1 4 9

— U N

— 2 4 S E P 0 3

R e s t o r e d T o D e f a u l t s

1 5 - 2 2 0 7 2 2 0 9

P N = 5 9

129/258




O U R G P 1 1 , 0 0 0 0 0 B 2 - 1 9 - 0 3 S E P 0 3 - 6 / 1 4

O U R G P 1 1 , 0 0 0 0 0 B 2 - 1 9 - 0 3 S E P 0 3 - 7 / 1 4


6 . C u s t o m S e t u p - T o p e r f o r m a c u s t o m s e t u p o f t h e 4 - U p D i s p l a y , u s e t h e a r r o w b u t t o n s t o s c r o l l t o a n d h i g h l i g h t " C u s t o m S e t u p " o n t h e d i s p l a y .

R G 1 3 2 2 7

— U N

— 2 6 S E P 0 3

C u s t o m S e t u p

7 . T h e q u a d r a n t w i t h t h e h i g h l i g h t e d p a r a m e t e r v a l u e i s t h e c u r r e n t s e l e c t e d p a r a m e t e r . U s e t h e " A r r o w " k e y s t o h i g h l i g h t t h e v a l u e i n t h e q u a d r a n t y o u w i s h t o c h a n g e t o a n e w p a r a m e t e r .

R G 1 3 2 2 8

— U N

— 2 6 S E P 0 3

S e l e c t P a r a m e t e r s

8 . P r e s s t h e " E n t e r " k e y a n d a l i s t o f e n g i n e p a r a m e t e r s

w i l l b e d i s p l a y e d .

R G 1 3 2 2 9

— U N

— 2 6 S E P 0 3

L i s t O f E n g i n e P a r a m e t e r s

1 5 - 2 3 0 7 2 2 0 9

P N = 6 0

130/258




O U R G P 1 1 , 0 0 0 0 0 B 2 - 1 9 - 0 3 S E P 0 3 - 9 / 1 4

O U R G P 1 1 , 0 0 0 0 0 B 2 - 1 9 - 0 3 S E P 0 3 - 1 0 / 1 4

O U R G P 1 1 , 0 0 0 0 0 B 2 - 1 9 - 0 3 S E P 0 3 - 1 1 / 1 4


9 . T h e p a r a m e t e r t h a t i s h i g h l i g h t e d i s t h e s e l e c t e d p a r a m e t e r f o r t h e s c r e e n . U s e t h e " a r r o w " k e y s t o h i g h l i g h t t h e n e w p a r a m e t e r t o b e p l a c e d i n t h e " 4 - U p D i s p l a y " .

R G

1 3 2 3 0

— U N

— 2 6 S E P 0 3

S e l e c t D e s i r e d E n g i n e P a r a m e t e r

1 0 . P r e s s t h e " E n t e r " k e y t o c h a n g e t h e s e l e c t e d p a r a m e t e r i n t h e q u a d r a n t t o t h e n e w p a r a m e t e r .

R G 1 3 2 3 1

— U N

— 2 6 S E P 0 3

E n t e r S e l e c t e d P a r a m e t e r

1 1 . U s e t h e " M e n u " k e y s t o r e t u r n t o t h e " 4 - U p C u s t o m S e t u p " s c r e e n .

R G 1 3 2 3 2

— U N

— 2

6 S E P 0 3

R e t u r n T o 4 - U p C u s t o m S e t u p

1 2 . T h e s e l e c t e d q u a d r a n t h a s n o w c h a n g e d t o t h e n e w s e l e c t e d p a r a m e t e r .

R G 1 3 1 5 3

— U N

— 2 4 S E P 0 3

4 - U p D i s p l a y

1 5 - 2 4 0 7 2 2 0 9

P N = 6 1

131/258




O U R G P 1 1 , 0 0 0 0 0 B 2 - 1 9 - 0 3 S E P 0 3 - 1 3 / 1 4

O U R G P 1 1 , 0 0 0 0 0 B 2 - 1 9 - 0 3 S E P 0 3 - 1 4 / 1 4

D P S G , C D 0 3 5 2 3 , 1 7 - 1 9 - 2 2 J A N 0 7 - 1 / 1

D P S G , C D 0 3 5 2 3 , 1 8 - 1 9 - 2 2 J A N 0 7 - 1 / 1

1 3 . R e p e a t t h e p a r a m e t e r s e l e c t i o n p r o c e s s u n t i l a l l s p a c e s a r e a s d e s i r e d .

1 4 . P r e s s t h e " M e n u " k e y t o r e t u r n t o t h e m a i n m e n u .

R G 1 3 1 5 4

— U N —

2 4 S E P 0 3


1 5 . P r e s s t h e " M e n u " k e y t o e x i t t h e m a i n m e n u a n d r e t u r n t o t h e e n g i n e p a r a m e t e r d i s p l a y .

R G 1 3 1 5 5

— U

N —

0 7 O C T 0 3

S e l e c t R e m a i n i n g P a r a m e t e r s

B r e a k - i n p e r i o d

W i t h i n f i r s t 1 0 0 h o u r s o f o p e r a t i o n : D u r i n g t h e f i r s t 1 0 0 h o u r s o f o p e r a t i o n , a v o i d o v e r l o a d i n g , e x c e s s i v e i d l i n g a n d n o - l o a d o p e r a t i o n .

I f o i l h a s t o b e a d d e d d u r i n g t h i s t i m e , s e e E N G I N E B R E A K - I N O I L .

N O T E : D u r i n g t h e b r e a k - i n p e r i o d a h i g h e r - t h a n - u s u a l o i l c o n s u m p t i o n s h o u l d b e c o n s i d e r e d a s n o r m a l .

A f t e r f i r s t 1 0 0 h o u r s o f o p e r a t i o n :

A f t e r t h e f i r s t 1 0 0 h o u r s , d r a i n t h e c r a n k c a s e a n d c h a n g e t h e o i l f i l t e r ( s e e C H A N G I N G E N G I N E O I L A N D F I L T E R ) . F i l l c r a n k c a s e w i t h s e a s o n a l v i s c o s i t y g r a d e o i l ( s e e

D I E S E L E N G I N E O I L ) . C h e c k t e n s i o n o f a l t e r n a t o r b e l t .

C h e c k c o n n e c t i o n s o f a i r i n t a k e h o s e s .

C h e c k f o r p r o p e r t i g h t e n i n g o f c a p s c r e w s a l l a r o u n d t h e e n g i n e .

S t a r t i n g t h e e n g i n e

C A U T I O N : B e f o r e s t a r t i n g e n g i n e i n a c o n f i n e d

b u i l d i n g , i n s t a l l p r o p e r o u t l e t e x h a u s t v e n t i l a t i o n e q u i p m e n t . A l w a y s u s e s a f e t y a p p r o v e d f u e l s t o r a g e a n d p i p i n g .

N O T E : I f t e m p e r a t u r e i s b e l o w 0 ° C ( 3 2 ° F ) , i t m a y b e n e c e s s a r y t o u s e c o l d w e a t h e r s t a r t i n g a i d s ( S e e C O L D W E A T H E R O P E R A T I O N ) .

1 . P e r f o r m a l l p r e s t a r t i n g c h e c k s o u t l i n e d i n M a i n t e n a n c e / D a i l y S e c t i o n .

2 . O p e n t h e f u e l s u p p l y s h u t - o f f v a l v e , i f e q u i p p e d .

3 . A c t i v a t e t h e s t a r t e r m o t o r s w i t c h t o c r a n k t h e e n g i n e a n d r e l e a s e i t a s s o o n a s e n g i n e s t a r t s .

N O T E : D o n o t o p e r a t e t h e s t a r t e r m o t o r m o r e t h a n 2 0 s e c o n d s a t a t i m e .

1 5 - 2 5 0 7 2 2 0 9

P N = 6 2

132/258




C o n t i n u e d o n n e x t p a g e D P S G , C D 0 3 5 2 3 , 1 9 - 1 9 - 0 6 F E B 0 7 - 1 / 3

C o l d w e a t h e r o p e r a t i o n

D e p e n d i n g o n e q u i p m e n t , v a r i o u s c o l d w e a t h e r s t a r t i n g a i d s a r e a v a i l a b l e t o a s s i s t i n s t a r t i n g t h e e n g i n e a t t e m p e r a t u r e b e l o w 0 ° C ( 3 2 ° F ) .

A i r i n t a k e h e a t e r

C A U T I O N : D O N O T u s e s t a r t i n g f l u i d o n e n g i n e s

e q u i p p e d w i t h g r i d - t y p e a i r i n t a k e h e a t e r o r g l o w p l u g ( s ) . E t h e r s t a r t i n g f l u i d i s h i g h l y f l a m m a b l e a n d m a y e x p l o d e , c a u s i n g s e r i o u s i n j u r y .

N O T E : O n e n g i n e s w i t h e l e c t r o n i c a l l y c o n t r o l l e d f u e l s y s t e m ( D E 1 0 , H P C R ) , t h e a i r i n t a k e h e a t e r o p e r a t e s a u t o m a t i c a l l y , c o n t r o l l e d b y t h e E C U . A n e n g i n e p r e h e a t e r i n d i c a t o r l i g h t c o m e s o n w h e n t h e k e y s w i t c h i s t u r n e d O N . I n w a r m w e a t h e r , t h e l i g h t c o m e s o n b r i e f l y f o r a l i g h t c h e c k . I n c o l d w e a t h e r , t h e l i g h t r e m a i n s O N d u r i n g t h e a u t o m a t i c o p e r a t i o n o f t h e a i r i n t a k e h e a t e r o r g l o w p l u g ( s ) . O p e r a t i n g t i m e d e p e n d s o n t e m p e r a t u r e . D o n o t c r a n k e n g i n e u n t i l l i g h t g o e s O F F .

• 3 0 2 9 a n d 4 0 3 9 e n g i n e s a r e o p t i o n a l l y e q u i p p e d w i t h t h e s i n g l e g l o w p l u g ( B ) s c r e w e d i n c y l i n d e r h e a d i n t a k e m a n i f o l d . A c t i v a t e t h e g l o w p l u g ( p r e h e a t e r p o s i t i o n ) f o r 3 0 s e c o n d s m a x i m u m t h e n s t a r t t h e e n g i n e .

• 4 0 4 5 a n d 6 0 6 8 e n g i n e s ( e x c e p t H P C R , 4 - v a l v e h e a d ) a r e o p t i o n a l l y e q u i p p e d w i t h t h e g r i d - t y p e a i r h e a t e r ( A ) i n s t a l l e d b e t w e e n c y l i n d e r h e a d a n d a i r i n t a k e p i p e . - F o r m e c h a n i c a l f u e l s y s t e m , a c t i v a t e t h e h e a t i n g e l e m e n t ( p r e h e a t e r p o s i t i o n ) f o r 3 0 s e c o n d s m a x i m u m t h e n s t a r t t h e e n g i n e . - F o r e l e c t r o n i c a l l y c o n t r o l l e d e n g i n e s ( D E 1 0 , H P C R 2 - v a l v e h e a d ) , t u r n k e y s w i t c h O N , b u t D O N O T c r a n k e n g i n e u n t i l e n g i n e p r e h e a t e r i n d i c a t o r l i g h t t u r n s O F F .

• H P C R , 4 - v a l v e h e a d e n g i n e s a r e e q u i p p e d w i t h g l o w p l u g s ( o n e p e r c y l i n d e r ) ( C ) . T u r n k e y s w i t c h O N , b u t D O N O T c r a n k e n g i n e u n t i l p r e h e a t e r i n d i c a t o r l i g h t t u r n s O F F .

A — G r i d - T y p e h e a t e r ( 4 0 4 5 a n d 6 0 6 8 n o n H P C R 4 - v a l v e h e a d e n g i n e s )

B — S i n g l e G l o w P l u g ( 3 0 2 9 a n d 4 0 3 9 e n g i n e s )

C — M u l t i p l e G l o w P l u g s ( H P C R 4 - v a l v e h e a d e n g i n e s )

T S 1 3 5 6

— U N —

1 8 M A R 9 2

H a n d l e s t a r t i n g f l u i d w i t h c a r e

C D 3 0 7 5 0

— U N

— 0 3 S E P 9 9

G l o w P l u g o r G r i d - T y p e a i r h e a t e r

C D 3 0 9 2 5

— U N

— 2 3 J A N 0 7

G l o w P l u g s o n H P C R , 4 - v a l v e h e a d e n g i n e

1 5 - 2 6 0 7 2 2 0 9

P N = 6 3

133/258




D P S G , C D 0 3 5 2 3 , 1 9 - 1 9 - 0 6 F E B 0 7 - 2 / 3

D P S G , C D 0 3 5 2 3 , 1 9 - 1 9 - 0 6 F E B 0 7 - 3 / 3

C o o l a n t h e a t e r

C o n n e c t p l u g o f c o o l a n t h e a t e r ( A ) t o a p r o p e r p o w e r s o u r c e ( 1 1 0 o r 2 2 0 V ) .

A t a n a m b i e n t t e m p e r a t u r e o f - 1 5 ° C ( 5 ° F ) , t h e h e a t i n g p r o c e s s t a k e s a p p r o x i m a t i v e l y 2 h o u r s . E x t e n d h e a t i n g p e r i o d i f a m b i e n t t e m p e r a t u r e i s l o w e r .

L X 1 0 1 7 7 6 8

— U N

— 2 4 O C T 9 7

F u e l p r e h e a t e r

F u e l p r e h e a t e r ( A ) s w i t c h e s O N a n d O F F a u t o m a t i c a l l y i n r e l a t i o n w i t h t h e a m b i e n t t e m p e r a t u r e .

L X 1 0 1 7 7 0 8

— U N

— 0 9 O C T 9 7

1 5 - 2 7 0 7 2 2 0 9

P N = 6 4

134/258




D P S G , C D 0 3 5 2 3 , 2 0 - 1 9 - 2 2 J A N 0 7 - 1 / 1

U s i n g a b o o s t e r b a t t e r y o r c h a r g e r

A 1 2 - v o l t b o o s t e r b a t t e r y c a n b e c o n n e c t e d i n p a r a l l e l w i t h b a t t e r y ( i e s ) o n t h e u n i t t o a i d i n c o l d w e a t h e r s t a r t i n g .

A L W A Y S u s e h e a v y d u t y j u m p e r c a b l e s .

C A U T I O N : G a s g i v e n o f f b y b a t t e r y i s e x p l o s i v e . K e e p s p a r k s a n d f l a m e s a w a y f r o m b a t t e r y .

B e f o r e c o n n e c t i n g o r d i s c o n n e c t i n g a b a t t e r y c h a r g e r , t u r n c h a r g e r o f f . M a k e l a s t c o n n e c t i o n a n d f i r s t d i s c o n n e c t i o n a t a p o i n t a w a y f r o m b a t t e r y . A l w a y s c o n n e c t N E G A T I V E ( – ) c a b l e l a s t a n d d i s c o n n e c t t h i s c a b l e f i r s t .

I M P O R T A N T : B e s u r e p o l a r i t y i s c o r r e c t b e f o r e m a k i n g c o n n e c t i o n s . R e v e r s e d p o l a r i t y w i l l d a m a g e e l e c t r i c a l s y s t e m . A l w a y s c o n n e c t p o s i t i v e t o p o s i t i v e a n d n e g a t i v e t o g r o u n d . A l w a y s u s e 1 2 - v o l t b o o s t e r b a t t e r y f o r 1 2 - v o l t e l e c t r i c a l s y s t e m s a n d 2 4 - v o l t b o o s t e r b a t t e r y ( i e s ) f o r 2 4 - v o l t e l e c t r i c a l s y s t e m s .

1 . C o n n e c t b o o s t e r b a t t e r y o r b a t t e r i e s t o p r o d u c e t h e r e q u i r e d s y s t e m v o l t a g e f o r y o u r e n g i n e a p p l i c a t i o n .

N O T E : T o a v o i d s p a r k s , D O N O T a l l o w t h e f r e e e n d s o f j u m p e r c a b l e s t o t o u c h t h e e n g i n e .

2 . C o n n e c t o n e e n d o f j u m p e r c a b l e t o t h e P O S I T I V E ( + ) p o s t o f t h e b o o s t e r b a t t e r y .

3 . C o n n e c t t h e o t h e r e n d o f t h e j u m p e r c a b l e t o t h e P O S I T I V E ( + ) p o s t o f b a t t e r y c o n n e c t e d t o s t a r t e r .

4 . C o n n e c t o n e e n d o f t h e o t h e r j u m p e r c a b l e t o t h e N E G A T I V E ( – ) p o s t o f t h e b o o s t e r b a t t e r y .

5 . A L W A Y S c o m p l e t e t h e h o o k u p b y m a k i n g t h e l a s t c o n n e c t i o n o f t h e N E G A T I V E ( – ) c a b l e t o a g o o d g r o u n d o n t h e e n g i n e f r a m e a n d a w a y f r o m t h e b a t t e r y ( i e s ) .

6 . S t a r t t h e e n g i n e . D i s c o n n e c t j u m p e r c a b l e s i m m e d i a t e l y a f t e r e n g i n e s t a r t s . D i s c o n n e c t N E G A T I V E ( – ) c a b l e f i r s t .

T S 2 0 4

— U N

— 2

3 A U G 8 8

R G 4 6 7 8

— U N

— 1 4 D E C 8 8

1 2 - V o l t S y s t e m

R G 4 6 9 8 —

U N

— 1 4 D E C 8 8

2 4 - V o l t s S y s t e m

A — 1 2 - V o l t M a c h i n e b a t t e r y ( i e s )

B — 1 2 - V o l t B o o s t e r b a t t e r y ( i e s )

C — B o o s t e r c a b l e D — C a b l e t o s t a r t e r m o t o r

1 5 - 2 8 0 7 2 2 0 9

P N = 6 5

135/258




D P S G , C D 0 3 5 2 3 , 2 1 - 1 9 - 2 2 J A N 0 7 - 1 / 1

D P S G , C D 0 3 5 2 3 , 2 2 - 1 9 - 2 2 J A N 0 7 - 1 / 1

D P S G , C D 0 3 5 2 3 , 2 3 - 1 9 - 2 2 J A N 0 7 - 1 / 1

C D 0 3 5 2 3 , 0 0 0 0 1 8 C - 1 9 - 2 6 J A N 0 7 - 1 / 1

E n g i n e o p e r a t i o n

W a r m i n g e n g i n e O p e r a t e e n g i n e a t h i g h i d l e f o r 1 t o 2 m i n u t e s b e f o r e a p p l y i n g t h e l o a d .

N O T E : T h i s p r o c e d u r e d o e s n o t a p p l y t o s t a n d b y g e n e r a t o r s e t s w h e r e t h e e n g i n e i s l o a d e d

i m m e d i a t e l y u p o n r e a c h i n g r a t e d s p e e d .

N o r m a l e n g i n e o p e r a t i o n C o m p a r e e n g i n e c o o l a n t t e m p e r a t u r e a n d e n g i n e o i l p r e s s u r e w i t h s p e c i f i c a t i o n s b e l o w :

S p e c i f i c a t i o n

M i n i m u m o i l p r e s s u r e

a t f u l l l o a d r a t e d

s p e e d 1

— P r e s s u r e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 7 5 k P a ( 2 . 7 5 b a r ) ( 4 0 p s i )

C o o l a n t t e m p e r a t u r e

r a n g e — T e m p e r a t u r e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 2 ° — 9 4 ° C ( 1 8 0 ° — 2 0 2 ° F )

S t o p e n g i n e i m m e d i a t e l y i f c o o l a n t t e m p e r a t u r e i s a b o v e

o r o i l p r e s s u r e b e l o w s p e c i f i c a t i o n s o r i f t h e r e a r e a n y s i g n s o f p a r t f a i l u r e . S y m p t o m s t h a t m a y b e e a r l y s i g n s o f e n g i n e p r o b l e m s c o u l d b e :

• S u d d e n l o s s o f p o w e r

• U n u s u a l n o i s e o r v i b r a t i o n

• E x c e s s i v e b l a c k e x h a u s t

• E x c e s s i v e f u e l c o n s u m p t i o n

• E x c e s s i v e o i l c o n s u m p t i o n

• F l u i d l e a k s

R e c o m m e n d a t i o n f o r t u r b o c h a r g e r e n g i n e s S h o u l d t h e e n g i n e s t a l l w h e n o p e r a t i n g u n d e r l o a d , I M M E D I A T E L Y r e s t a r t i t t o p r e v e n t o v e r h e a t i n g o f t u r b o c h a r g e r c o m p o n e n t s .

I d l i n g e n g i n e A v o i d e x c e s s i v e e n g i n e i d l i n g . P r o l o n g e d i d l i n g m a y c a u s e t h e e n g i n e c o o l a n t t e m p e r a t u r e t o f a l l b e l o w i t s n o r m a l r a n g e . T h i s , i n t u r n , c a u s e s c r a n k c a s e o i l d i l u t i o n , d u e t o i n c o m p l e t e f u e l c o m b u s t i o n , a n d p e r m i t s f o r m a t i o n o f g u m m y d e p o s i t s o n v a l v e s , p i s t o n s , a n d p i s t o n r i n g s . I t a l s o p r o m o t e s r a p i d a c c u m u l a t i o n o f e n g i n e s l u d g e a n d u n b u r n e d f u e l i n t h e e x h a u s t s y s t e m . I f a n e n g i n e w i l l b e i d l i n g f o r m o r e t h a n 5 m i n u t e s , s t o p a n d r e s t a r t l a t e r .

N O T E : G e n e r a t o r s e t a p p l i c a t i o n s h a v e t h e g o v e r n o r l o c k e d a t a s p e c i f i e d s p e e d a n d d o n o t h a v e a s l o w i d l e f u n c t i o n . T h e s e e n g i n e s i d l e a t n o l o a d g o v e r n e d s p e e d ( f a s t i d l e ) .

1 O i l a t n o r m a l o p e r a t i n g t e m p e r a t u r e o f 1 1 5 ° C ( 2 4 0 ° F ) .

S t a n d b y p o w e r u n i t s

T o a s s u r e t h a t y o u r e n g i n e w i l l d e l i v e r e f f i c i e n t s t a n d b y o p e r a t i o n w h e n n e e d e d , s t a r t e n g i n e a n d r u n a t r a t e d

s p e e d ( w i t h 5 0 % — 7 0 % l o a d ) f o r 3 0 m i n u t e s e v e r y 2

w e e k s . D O N O T a l l o w e n g i n e t o r u n e x t e n d e d p e r i o d o f t i m e w i t h n o l o a d .

S t o p p i n g t h e e n g i n e

1 . B e f o r e s t o p p i n g , r u n e n g i n e f o r a t l e a s t 2 m i n u t e s a t f a s t i d l e a n d n o l o a d .

2 . S t o p t h e e n g i n e .

C h a n g i n g G e n e r a t o r F r e q u e n c y

G e n e r a t o r s e t s p o w e r e d b y 6 0 6 8 H F U 7 4 e n g i n e a r e d u a l - f r e q u e n c y ; 5 0 H z ( 1 5 0 0 r p m ) o r 6 0 H z ( 1 8 0 0 r p m ) .

R e f e r t o t h e g e n e r a t o r s e t d o c u m e n t a t i o n f o r m o r e i n f o r m a t i o n .

1 5 - 2 9 0 7 2 2 0 9

P N = 6 6

136/258



M a i n t e n a n c e

D P S G , C D 0 3 5 2 3 , 2 4 - 1 9 - 2 2 J A N 0 7 - 1 / 1

D P S G , C D 0 3 5 2 3 , 2 5 - 1 9 - 2 2 J A N 0 7 - 1 / 1

D P S G , C D 0 3 5 2 3 , 2 6 - 1 9 - 2 5 J A N 0 7 - 1 / 1

O b s e r v e s e r v i c e i n t e r v a l s

U s i n g h o u r m e t e r a s a g u i d e , p e r f o r m a l l s e r v i c e s a t t h e h o u r l y i n t e r v a l s i n d i c a t e d o n f o l l o w i n g p a g e s . A t e a c h s c h e d u l e d m a i n t e n a n c e i n t e r v a l , p e r f o r m a l l p r e v i o u s m a i n t e n a n c e o p e r a t i o n s i n a d d i t i o n t o t h e o n e s s p e c i f i e d . K e e p a r e c o r d o f h o u r l y i n t e r v a l s a n d s e r v i c e s p e r f o r m e d u s i n g c h a r t s p r o v i d e d i n M a i n t e n a n c e R e c o r d s S e c t i o n .

I M P O R T A N T : R e c o m m e n d e d s e r v i c e i n t e r v a l s a r e f o r n o r m a l o p e r a t i n g c o n d i t i o n s . S e r v i c e M O R E O F T E N i f e n g i n e i s o p e r a t e d u n d e r a d v e r s e c o n d i t i o n s . N e g l e c t i n g m a i n t e n a n c e c a n r e s u l t i n f a i l u r e s o r p e r m a n e n t d a m a g e t o t h e e n g i n e .

U s e c o r r e c t f u e l s , l u b r i c a n t s a n d c o o l a n t

I M P O R T A N T : U s e o n l y f u e l s , l u b r i c a n t s , a n d c o o l a n t s m e e t i n g s p e c i f i c a t i o n s o u t l i n e d i n F u e l s , L u b r i c a n t s , a n d C o o l a n t S e c t i o n w h e n s e r v i c i n g y o u r J o h n D e e r e E n g i n e .

C o n s u l t y o u r J o h n D e e r e e n g i n e d i s t r i b u t o r , s e r v i c i n g d e a l e r o r y o u r n e a r e s t J o h n D e e r e P a r t s N e t w o r k f o r r e c o m m e n d e d f u e l s , l u b r i c a n t s , a n d c o o l a n t . A l s o a v a i l a b l e a r e n e c e s s a r y a d d i t i v e s f o r u s e w h e n o p e r a t i n g

e n g i n e s i n t r o p i c a l , a r c t i c , o r a n y o t h e r a d v e r s e c o n d i t i o n s . T S 1 0 0

— U N

— 2 3 A U G 8 8

M a i n t e n a n c e i n t e r v a l c h a r t

I t e m 1 0 H / d a i l y 5 0 0 H 1 0 0 0 H / 1 y e a r

2 0 0 0 H / 2 y e a r s

2 5 0 0 H / 3 y e a r s

A s r e q u i r e d

C h e c k e n g i n e o i l a n d c o o l a n t l e v e l •

C h e c k a i r f i l t e r r e s t r i c t i o n i n d i c a t o r a •

C h a n g e e n g i n e o i l a n d f i l t e r b •

R e p l a c e f u e l f i l t e r e l e m e n t ( s ) •

C h e c k b e l t t e n s i o n a n d a u t o m a t i c t e n s i o n e r

c • •

C h e c k a n d a d j u s t v a l v e c l e a r a n c e d • •

C l e a n c r a n k c a s e v e n t t u b e •

C h e c k a i r i n t a k e h o s e s , c o n n e c t i o n s a n d s y s t e m •

P r e s s u r e t e s t c o o l i n g s y s t e m •

C h e c k v i b r a t i o n d a m p e r ( 6 c y l . ) e •

C h e c k e n g i n e s p e e d a n d s p e e d d r o p g o v e r n o r •

D r a i n a n d f l u s h c o o l i n g s y s t e m f • •

D r a i n w a t e r a n d s e d i m e n t f r o m f u e l f i l t e r •

C l e a n f i l t e r e l e m e n t ( s e e n o t e a ) •

T e s t t h e r m o s t a t a n d i n j e c t i o n n o z z l e s ( s e e y o u r d e a l e r ) g •

T e s t g l o w p l u g s ( H P C R , 4 - v a l v e h e a d ) •

a C l e a n a i r f i l t e r e l e m e n t w h e n r e s t r i c t i o n i n d i c a t o r i s r e d . R e p l a c e f i l t e r e l e m e n t a f t e r 6 c l e a n i n g s o r o n c e a y e a r .

b C h a n g e o i l a n d fi l t e r a f t e r t h e f i r s t 1 0 0 h o u r s o f o p e r a t i o n , t h e n e v e r y 5 0 0 h o u r s m a x i m u m t h e r e a f t e r ( s e e D I E S E L

E N G I N E O I L i n f o r m a t i o n ) . C h a n g e o i l a n d fi l t e r a t l e a s t o n c e a y e a r . c C h e c k b e l t t e n s i o n e v e r y 5 0 0 h o u r s o n 3 0 2 9 a n d 4 0 3 9 e n g i n e s a n d o n 4 0 4 5 a n d 6 0 6 8 e n g i n e s w i t h m a n u a l t e n s i o n e r . C h e c k

a u t o m a t i c b e l t t e n s i o n e r e v e r y 1 0 0 0 h o u r s / 1 y e a r o n 4 0 4 5 a n d 6 0 6 8 e n g i n e s w h e n e q u i p p e d . d H a v e y o u r a u t h o r i z e d s e r v i c i n g d e a l e r o r e n g i n e d i s t r i b u t o r a d j u s t v a l v e c l e a r a n c e a s f o l l o w s . A f t e r t h e f i r s t 5 0 0 h o u r s o f o p e r a t i o n t h e n

e v e r y 1 0 0 0 h o u r s t h e r e a f t e r o n 3 0 2 9 a n d 4 0 3 9 e n g i n e s . E v e r y 2 0 0 0 h o u r s o n 4 0 4 5 a n d 6 0 6 8 e n g i n e s . e H a v e y o u r a u t h o r i z e d d e a l e r o r e n g i n e d i s t r i b u t o r r e p l a c e t h e v i b r a t i o n d a m p e r e v e r y 4 5 0 0 h o u r s / 5 y e a r s .

f D r a i n a n d f l u s h c o o l i n g s y s t e m e v e r y 2 5 0 0 h o u r s / 3 y e a r s w h e n J o h n D e e r e C O O L - G A R D c o o l a n t i s u s e d . O t h e r w i s e e v e r y 2 0 0 0 h o u r s / 2 y e a r s .

g C o n t a c t y o u r d e a l e r w h e n t h e r m o s t a t o r i n j e c t i o n n o z z l e s a r e s u s p e c t e d t o b e d e f e c t i v e . R e p l a c e i n j e c t i o n n o z z l e s

e v e r y 5 0 0 0 h o u r s a n d t h e r m o s t a t e v e r y 1 0 0 0 0 h o u r s .

2 0 - 1 0 7 2 2 0 9

P N = 6 7

137/258



M a i n t e n a n c e / D a i l y o r e v e r y 1 0 h o u r s


D a i l y p r e s t a r t i n g c h e c k s

C D 3 0 7 5 3

— U N

— 2 6 A U G 9 9

4 0 4 5 a n d 6 0 6 8 e n g i n e s

C D 3 0 7 5 4

— U N

— 2 6 A U G 9 9

3 0 2 9 a n d 4 0 3 9 e n g i n e s

C D 3 0 7 5 5

— U N

— 2 4 S E P 9 9

F D 0 0 0 0 4 7

— U N

— 1 3 M A R 9 6

D o t h e f o l l o w i n g B E F O R E S T A R T I N G T H E E N G I N E f o r t h e f i r s t t i m e e a c h d a y :

I M P O R T A N T : D O N O T a d d m a k e u p o i l u n t i l t h e o i l l e v e l i s B E L O W t h e a d d m a r k .

1 . C h e c k e n g i n e o i l l e v e l o n d i p s t i c k ( A ) . A d d a s r e q u i r e d , u s i n g s e a s o n a l v i s c o s i t y g r a d e o i l . ( S e e D I E S E L E N G I N E O I L ) . A d d o i l a t r o c k e r a r m c o v e r f i l l e r c a p ( B ) .

I M P O R T A N T : D O N O T f i l l a b o v e t h e c r o s s h a t c h a r e a . O i l l e v e l s a n y w h e r e w i t h i n c r o s s h a t c h a r e c o n s i d e r e d i n t h e a c c e p t a b l e o p e r a t i n g r a n g e .

2 5 - 1 0 7 2 2 0 9

P N = 6 8

138/258




D P S G , C D 0 3 5 2 3 , 2 7 - 1 9 - 0 7 F E B 0 7 - 2 / 4


T S 2 8 1

— U N

— 2 3 A U

G 8 8

C D 3 0 7 5 6

— U N

— 2

6 A U G 9 9

2 .

C A U T I O N : E x p l o s i v e r e l e a s e o f f l u i d s f r o m p r e s s u r i z e d c o o l i n g s y s t e m c a n c a u s e s e r i o u s b u r n s .

O n l y r e m o v e f i l l e r c a p w h e n e n g i n e i s c o l d o r w h e n c o o l e n o u g h t o t o u c h w i t h b a r e h a n d s .

S l o w l y l o o s e n c a p t o f i r s t s t o p t o r e l i e v e p r e s s u r e b e f o r e r e m o v i n g c o m p l e t e l y .

R e m o v e r a d i a t o r c a p ( E ) a n d c h e c k c o o l a n t l e v e l w h i c h s h o u l d b e a t b o t t o m o f f i l l e r n e c k . F i l l r a d i a t o r w i t h p r o p e r c o o l a n t s o l u t i o n i f l e v e l i s l o w . ( S e e D I E S E L E N G I N E C O O L A N T ) . C h e c k e n t i r e c o o l i n g s y s t e m f o r l e a k s .

3 . I f a i r f i l t e r h a s a d u s t u n l o a d e r v a l v e ( C ) , s q u e e z e v a l v e t i p t o r e l e a s e a n y t r a p p e d d i r t p a r t i c l e s .

4 . C h e c k a i r i n t a k e r e s t r i c t i o n i n d i c a t o r ( D ) . W h e n i n d i c a t o r i s r e d , a i r f i l t e r n e e d s t o b e c l e a n e d .

I M P O R T A N T : M a x i m u m a i r i n t a k e r e s t r i c t i o n i s 6 . 2 5 k P a ( 0 . 0 6 b a r ) ( 1 . 0 p s i ) ( 2 5 i n . H 2 O ) . A c l o g g e d a i r c l e a n e r e l e m e n t w i l l c a u s e

e x c e s s i v e i n t a k e r e s t r i c t i o n a n d a r e d u c e d a i r s u p p l y t o t h e e n g i n e .

5 . M a k e a t h o r o u g h i n s p e c t i o n o f t h e e n g i n e c o m p a r t m e n t .

N O T E : W i p e a l l f i t t i n g s , c a p s , a n d p l u g s b e f o r e p e r f o r m i n g a n y m a i n t e n a n c e t o r e d u c e t h e c h a n c e o f s y s t e m c o n t a m i n a t i o n .

R G 4 6 8 7

— U N —

2 0 D E C 8 8

C D 3 0 7 5 7

— U N

— 2 6 A U G 9 9

2 5 - 2 0 7 2 2 0 9

P N = 6 9

139/258




D P S G , C D 0 3 5 2 3 , 2 7 - 1 9 - 0 7 F E B 0 7 - 4 / 4

6 .

N O T E : E n g i n e s w i t h m e c h a n i c a l f u e l s y s t e m h a v e a s i n g l e f u e l f i l t e r w h i l e e l e c t r o n i c a l l y c o n t r o l l e d e n g i n e s ( D E 1 0 a n d H P C R f u e l s y s t e m s ) h a v e t w o f u e l f i l t e r s ( p r i m a r y a n d f i n a l ) . M o r e o v e r t h e s e e l e c t r o n i c a l l y c o n t r o l l e d e n g i n e s m a y b e e q u i p p e d w i t h a w a t e r s e n s o r a t t h e f u e l f i l t e r s . A n i n d i c a t o r

l i g h t o n t h e i n s t r u m e n t p a n e l w i l l s i g n a l t h e o p e r a t o r t h a t w a t e r s h o u l d b e d r a i n e d f r o m f i l t e r b o w l s .

C h e c k f u e l f i l t e r s ( C ) a n d ( D ) f o r w a t e r a n d d e b r i s a s f o l l o w s :

a . L o o s e n d r a i n p l u g ( s ) ( A ) a t b o t t o m o f f u e l f i l t e r ( s ) o r b o w l ( s ) t w o o r t h r e e t u r n s .

b . L o o s e n a i r b l e e d p l u g ( s ) ( B ) t w o f u l l t u r n s a n d d r a i n w a t e r i n t o a s u i t a b l e c o n t a i n e r .

c . W h e n f u e l s t a r t s t o d r a i n o u t , t i g h t e n d r a i n p l u g ( s ) s e c u r e l y .

d . B l e e d f u e l s y s t e m .

C D 3 0 9 2 9

— U N

— 0 7 F E B

0 7

D r a i n f u e l fi l t e r ( s )

A — D r a i n p l u g B — A i r b l e e d p l u g

C — P r i m a r y f u e l f i l t e r D — F i n a l f u e l f i l t e r

2 5 - 3 0 7 2 2 0 9

P N = 7 0

140/258



M a i n t e n a n c e / 5 0 0 h o u r s

C o n t i n u e d o n n e x t p a g e D P S G , C D 0 3 5 2 3 , 2 9 - 1 9 - 0 1 J U L 0 9 - 1 / 3

C h a n g i n g e n g i n e o i l a n d f i l t e r

I M P O R T A N T : F i l t r a t i o n o f o i l s i s c r i t i c a l t o p r o p e r l u b r i c a t i o n . A l w a y s c h a n g e f i l t e r r e g u l a r l y . U s e f i l t e r m e e t i n g J o h n D e e r e p e r f o r m a n c e s p e c i f i c a t i o n s .

N O T E : C h a n g e e n g i n e o i l a n d f i l t e r f o r t h e f i r s t

t i m e a f t e r 1 0 0 h o u r s m a x i m u m o f o p e r a t i o n , t h e n e v e r y 5 0 0 h o u r s t h e r e a f t e r . C h a n g e o i l a n d f i l t e r a t l e a t o n c e a y e a r .

1 . R u n e n g i n e a p p r o x i m a t e l y 5 m i n u t e s t o w a r m u p o i l . S h u t e n g i n e o f f .

2 . O p e n o i l p a n d r a i n v a l v e ( A ) .

3 . D r a i n c r a n k c a s e o i l f r o m e n g i n e w h i l e w a r m .

C D 3 0 7 5 8

— U N

— 2 6 A U G 9

9

3 0 - 1 0 7 2 2 0 9

P N = 7 1

141/258





C D 3 0 7 6 0

— U N

— 2 6

A U G 9 9

O i l f i l t e r o n 3 0 2 9 a n d 4 0 3 9 e n g i n e s

C D 3 0 9 2 6

— U N

— 3 0 J A N 0 7

O i l n e w f i l t e r e l e m e n t p a c k i n g

C D 3 0 7 5 9 A

— U N

— 2 9 J A N 0 7

O i l f i l t e r o n 4 0 4 5 a n d 6 0 6 8 e n g i n e s

R G 1 1 6 1 7

— U N —

2 4 O C T 0 1

O i l fi l t e r s e a l s

4 . R e p l a c e o i l f i l t e r

• 3 0 2 9 a n d 4 0 3 9 e n g i n e s a . R e m o v e a n d d i s c a r d o i l f i l t e r e l e m e n t ( B ) u s i n g a

s u i t a b l e f i l t e r w r e n c h . b . O i l n e w p a c k i n g ( C ) a n d i n s t a l l n e w f i l t e r e l e m e n t .

H a n d t i g h t e n e l e m e n t a c c o r d i n g t o v a l u e s p r i n t e d o n f i l t e r e l e m e n t . I f v a l u e s a r e n o t p r o v i d e d , t i g h t e n e l e m e n t a p p r o x i m a t e l y 3 / 4 — 1 - 1 / 4 t u r n a f t e r p a c k i n g c o n t a c t s f i l t e r h o u s i n g . D O N O T o v e r t i g h t e n f i l t e r e l e m e n t .

• 4 0 4 5 a n d 6 0 6 8 e n g i n e s a . R e m o v e a n d d i s c a r d o i l f i l t e r e l e m e n t ( A ) u s i n g a

s u i t a b l e f i l t e r w r e n c h . b . A p p l y c l e a n e n g i n e o i l t o i n n e r ( B ) a n d o u t e r ( C )

s e a l s a n d t o f i l t e r t h r e a d s . c . W i p e b o t h s e a l i n g s u r f a c e s o f t h e h e a d e r ( D , E )

w i t h a c l e a n r a g . E n s u r e n o t c h e s i n d u s t s e a l ( F ) a r e p r o p e r l y i n s t a l l e d i n t h e s l o t s i n t h e h o u s i n g .

R e p l a c e d u s t s e a l i f d a m a g e d . d . I n s t a l l a n d t i g h t e n o i l f i l t e r b y h a n d u n t i l f i r m l y

a g a i n s t d u s t s e a l ( F ) . D O N O T o v e r t i g h t e n .

R G 1 1 6 1 8

— U N

— 2 4 O C T 0 1

F i l t e r a n d m o u n t i n g h e a d e r

A — O i l f i l t e r e l e m e n t B — I n n e r s e a l C — O u t e r s e a l

D — S e a l i n g s u r f a c e E — S e a l i n g s u r f a c e F — D u s t s e a l

5 . C l o s e o i l p a n d r a i n v a l v e .

3 0 - 2 0 7 2 2 0 9

P N = 7 2

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D P S G , C D 0 3 5 2 3 , 2 9 - 1 9 - 0 1 J U L 0 9 - 3 / 3

C D 3 0 7 6 1

— U N

— 2

4 S E P 9 9

O i l f i l l e r c a p o n r o c k e r a r m c o v e r

C D 3 0 9 2 7

— U N

— 0 1 F E B 0 7

O i l f i l l e r n e c k o n e n g i n e s i d e

6 . F i l l e n g i n e c r a n k c a s e w i t h c o r r e c t J o h n D e e r e e n g i n e o i l t h r o u g h o p e n i n g o n r o c k e r a r m c o v e r ( C ) o r o n t h e s i d e o f t h e e n g i n e ( D ) . S e e D I E S E L E N G I N E O I L S e c t i o n f o r d e t e r m i n i n g c o r r e c t e n g i n e o i l .

T o d e t e r m i n e t h e c o r r e c t o i l f i l l q u a n t i t y f o r y o u r e n g i n e , s e e t h e S p e c i f i c a t i o n s S e c t i o n .

N O T E : C r a n k c a s e o i l c a p a c i t y m a y v a r y s l i g h t l y . A L W A Y S f i l l c r a n k c a s e t o f u l l m a r k o r w i t h i n c r o s s h a t c h o n d i p s t i c k , w h i c h e v e r i s p r e s e n t . D O N O T o v e r f i l l .

7 . S t a r t e n g i n e a n d r u n t o c h e c k f o r p o s s i b l e l e a k s .

8 . S t o p e n g i n e a n d c h e c k o i l l e v e l a f t e r 1 0 m i n u t e s . I f n e c e s s a r y , t o p u p .

F D 0 0 0 0 4 7

— U N

— 1 3

M A R 9 6

O i l d i p s t i c k

3 0 - 3 0 7 2 2 0 9

P N = 7 3

143/258




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R e p l a c i n g f u e l f i l t e r e l e m e n t ( s )

X 9 8 1 1

— U N

— 2 3 A U G 8 8

C D 3 0 9 3 0

— U N

— 0 7 F E B 0 7

F u e l fi l t e r s

A — R e t a i n i n g r i n g B — F i n a l f u e l f i l t e r e l e m e n t

C — D r a i n p l u g D — B l e e d p l u g

E — W a t e r s e p a r a t o r b o w l F — P r i m a r y f u e l f i l t e r e l e m e n t

C A U T I O N : E s c a p i n g f l u i d u n d e r p r e s s u r e c a n

p e n e t r a t e t h e s k i n c a u s i n g s e r i o u s i n j u r y . R e l i e v e p r e s s u r e b e f o r e d i s c o n n e c t i n g f u e l o r o t h e r l i n e s . T i g h t e n a l l c o n n e c t i o n s b e f o r e a p p l y i n g p r e s s u r e . K e e p h a n d s a n d b o d y a w a y f r o m p i n h o l e s a n d n o z z l e s w h i c h e j e c t f l u i d s u n d e r h i g h p r e s s u r e . U s e a p i e c e o f c a r d b o a r d o r p a p e r t o s e a r c h f o r l e a k s . D o n o t u s e y o u r h a n d .

I f a n y f l u i d i s i n j e c t e d i n t o t h e s k i n , i t m u s t b e s u r g i c a l l y r e m o v e d w i t h i n a f e w h o u r s b y a d o c t o r f a m i l i a r w i t h t h i s t y p e i n j u r y o r g a n g r e n e m a y r e s u l t . D o c t o r s u n f a m i l i a r w i t h t h i s t y p e o f i n j u r y m a y c a l l t h e D e e r e & C o m p a n y M e d i c a l D e p a r t m e n t i n M o l i n e , I l l i n o i s , o r o t h e r

k n o w l e d g e a b l e m e d i c a l s o u r c e .

N O T E : E n g i n e s w i t h m e c h a n i c a l f u e l s y s t e m h a v e a s i n g l e f u e l f i l t e r w h i l e e l e c t r o n i c a l l y c o n t r o l l e d e n g i n e s ( D E 1 0 , H P C R ) h a v e t w o f u e l f i l t e r s ( p r i m a r y a n d f i n a l ) . B o t h t h e p r i m a r y a n d t h e f i n a l f i l t e r s h a v e t o b e r e p l a c e d t o g e t h e r a t t h e s a m e t i m e .

1 . T h o r o u g h l y c l e a n f u e l f i l t e r a s s e m b l y a n d s u r r o u n d i n g a r e a .

2 . L o o s e n d r a i n p l u g ( C ) a n d d r a i n f u e l i n t o a s u i t a b l e c o n t a i n e r .

N O T E : L i f t i n g u p o n r e t a i n i n g r i n g a s i t i s r o t a t e d

h e l p s t o g e t i t p a s t r a i s e d l o c a t o r s .

3 . F i r m l y g r a s p t h e r e t a i n i n g r i n g ( A ) a n d r o t a t e i t

c l o c k w i s e 1 / 4 t u r n . R e m o v e r i n g w i t h f i l t e r e l e m e n t ( B ) .

I M P O R T A N T : D o n o t d u m p t h e o l d f u e l i n t o t h e n e w f i l t e r e l e m e n t . T h i s c o u l d c a u s e f u e l i n j e c t i o n p r o b l e m .

A p l u g i s p r o v i d e d w i t h t h e n e w e l e m e n t f o r p l u g g i n g t h e u s e d e l e m e n t .

4 . I n s p e c t f i l t e r m o u n t i n g b a s e f o r c l e a n l i n e s s . C l e a n a s r e q u i r e d .

N O T E : R a i s e d l o c a t o r s o n f u e l f i l t e r c a n i s t e r m u s t b e i n d e x e d p r o p e r l y w i t h s l o t s i n m o u n t i n g b a s e f o r c o r r e c t i n s t a l l a t i o n .

5 . I n s t a l l n e w f i l t e r e l e m e n t d r y o n t o m o u n t i n g b a s e . B e s u r e e l e m e n t i s p r o p e r l y i n d e x e d a n d f i r m l y s e a t e d o n b a s e . I t m a y b e n e c e s s a r y t o r o t a t e f i l t e r f o r c o r r e c t a l i g n m e n t .

6 . I n s t a l l r e t a i n i n g r i n g o n t o m o u n t i n g b a s e m a k i n g c e r t a i n d u s t s e a l i s i n p l a c e o n f i l t e r b a s e . H a n d t i g h t e n r i n g ( a b o u t 1 / 3 t u r n ) u n t i l i t ” s n a p s ” i n t o t h e d e t e n t . D O N O T o v e r t i g h t e n r e t a i n i n g r i n g .

N O T E : T h e p r o p e r i n s t a l l a t i o n i s i n d i c a t e d w h e n a " c l i c k " i s h e a r d a n d a r e l e a s e o f t h e r e t a i n i n g r i n g i s f e l t .

7 . B l e e d t h e f u e l s y s t e m .

3 0 - 4 0 7 2 2 0 9

P N = 7 4

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C h e c k i n g b e l t ( 3 0 2 9 a n d 4 0 3 9 E n g i n e s )

1 . I n s p e c t b e l t f o r c r a c k s , f r a y i n g , o r s t r e t c h e d o u t a r e a s . R e p l a c e a s n e c e s s a r y .

2 . C h e c k b e l t t e n s i o n u s i n g o n e o f f o l l o w i n g m e t h o d s :

a ) U s e o f J D G 5 2 9 T e n s i o n G a u g e ( A )


B e l t t e n s i o n — N e w b e l t . . . . . . . . . . . . . . . . . . . . . . . . . . 5 7 8 — 6 2 2 N ( 1 3 0 — 1 4 0 l b - f o r c e )

U s e d b e l t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 7 8 — 4 2 3 N ( 8 5 — 9 4 l b - f o r c e )

N O T E : B e l t i s c o n s i d e r e d u s e d a f t e r 1 0 m i n u t e s o f o p e r a t i o n .

b ) U s e o f t e n s i o n t e s t e r ( B ) a n d s t r a i g h t e d g e ( C ) A 8 9 N ( 2 0 l b ) f o r c e a p p l i e d h a l f w a y b e t w e e n p u l l e y s s h o u l d d e f l e c t b e l t b y 1 9 m m ( 0 . 7 5 i n . ) .

3 . I f a d j u s t m e n t i s n e c e s s a r y , l o o s e n a l t e r n a t o r n u t s ( D ) a n d ( E ) . P u l l a l t e r n a t o r f r a m e o u t w a r d u n t i l b e l t i s c o r r e c t l y t e n s i o n e d .

I M P O R T A N T : D o n o t p r y a g a i n s t t h e a l t e r n a t o r

r e a r f r a m e . D o n o t t i g h t e n o r l o o s e n b e l t s w h i l e t h e y a r e h o t .

4 . T i g h t e n a l t e r n a t o r b r a c k e t n u t s f i r m l y .

5 . R u n e n g i n e f o r 1 0 m i n u t e s t h e n r e c h e c k b e l t t e n s i o n .

A — J D G 5 2 9 T e n s i o n G a u g e B — T e n s i o n t e s t e r C — S t r a i g h t e d g e

D — U p p e r n u t E — L o w e r n u t

C D 3 0 6 4 4

— U N

— 0 4 M A Y 9 8

C D 3 0 6 4 5

— U N

— 0 4 M A Y 9 8

C D 3 0 6 4 6

— U N

— 0 4 M A Y 9 8

3 0 - 5 0 7 2 2 0 9

P N = 7 5

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C h e c k i n g b e l t ( 4 0 4 5 a n d 6 0 6 8 E n g i n e s w i t h m a n u a l t e n s i o n e r )

I n s p e c t b e l t s f o r c r a c k s , f r a y i n g , o r s t r e t c h e d o u t a r e a s . R e p l a c e i f n e c e s s a r y .

N O T E : B e l t a d j u s t m e n t i s m e a s u r e d u s i n g a g a u g e s t a m p e d o n t h e t o p e d g e o f t h e a l t e r n a t o r b r a c k e t .

1 . L o o s e n c a p s c r e w s ( B ) a n d ( C ) .

2 . S l i d e a l t e r n a t o r i n s l o t b y h a n d t o r e m o v e a l l e x c e s s s l a c k i n b e l t . S c r i b e a r e f e r e n c e m a r k ( D ) o n l i n e w i t h n o t c h ( E ) o n u p p e r a l t e r n a t o r b r a c k e t .

I M P O R T A N T : D o n o t p r y a g a i n s t a l t e r n a t o r r e a r f r a m e .

3 . U s i n g t h e g a u g e ( A ) o n t h e a l t e r n a t o r b r a c k e t , s t r e t c h b e l t b y p r y i n g o u t w a r d o n a l t e r n a t o r f r o n t f r a m e . S t r e t c h t h e b e l t 1 g a u g e u n i t f o r a u s e d b e l t a n d 1 . 5 g a u g e u n i t s f o r a n e w b e l t .

4 . T i g h t e n c a p s c r e w s ( B ) a n d ( C ) .

A — B e l t g a u g e B — C a p s c r e w C — C a p s c r e w

D — R e f e r e n c e m a r k E — A l t e r n a t o r u p p e r b r a c k e t

n o t c h

R G 9 1 3 2

— U N

— 0 4 O C T 9 9

M a n u a l b e l t t e n s i o n e r o n 4 0 4 5 a n d 6 0 6 8 e n g i n e s

C D 3 0 8 4 3

— U N

— 1 0 J A N 0 3

R e f e r e n c e m a r k s

3 0 - 6 0 7 2 2 0 9

P N = 7 6

146/258



M a i n t e n a n c e / 1 0 0 0 h o u r s / 1 y e a r

D P S G , C D 0 3 5 2 3 , 3 2 - 1 9 - 2 2 J A N 0 7 - 1 / 1


C l e a n i n g c r a n k c a s e v e n t t u b e

I f y o u o p e r a t e t h e e n g i n e i n d u s t y c o n d i t i o n s , c l e a n t h e t u b e a t s h o r t e r i n t e r v a l s .

1 . R e m o v e a n d c l e a n c r a n k c a s e v e n t t u b e ( A ) .

2 . I n s t a l l t h e v e n t t u b e . B e s u r e t h e O - r i n g f i t s c o r r e c t l y i n t h e r o c k e r a r m c o v e r f o r e l b o w a d a p t e r . T i g h t e n

h o s e c l a m p s e c u r e l y .

C D 3 0 7 7 3

— U N —

2 7 A U G 9 9

C h e c k i n g a i r i n t a k e s y s t e m

C D 3 0 7 6 2

— U N

— 2 7 A U G 9 9

I M P O R T A N T : T h e a i r i n t a k e s y s t e m m u s t n o t l e a k . A n y l e a k , n o m a t t e r h o w s m a l l , m a y r e s u l t i n e n g i n e f a i l u r e d u e t o a b r a s i v e d i r t a n d d u s t e n t e r i n g t h e i n t a k e s y s t e m .

1 . I n s p e c t a l l i n t a k e h o s e s ( p i p i n g ) f o r c r a c k s . R e p l a c e a s n e c e s s a r y .

2 . C h e c k c l a m p s o n p i p i n g ( A ) w h i c h c o n n e c t t h e a i r f i l t e r , e n g i n e a n d , i f p r e s e n t , t u r b o c h a r g e r a n d a i r - t o - a i r r a d i a t o r . T i g h t e n c l a m p s a s n e c e s s a r y .

3 . T e s t a i r r e s t r i c t i o n i n d i c a t o r ( B ) f o r p r o p e r o p e r a t i o n . R e p l a c e i n d i c a t o r a s n e c e s s a r y .

3 5 - 1 0 7 2 2 0 9

P N = 7 7

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4 .

I f e n g i n e h a s a r u b b e r d u s t u n l o a d e r v a l v e ( C ) , i n s p e c t t h e v a l v e o n b o t t o m o f a i r f i l t e r f o r c r a c k s o r p l u g g i n g . R e p l a c e a s n e c e s s a r y .

5 . S e r v i c e a i r f i l t e r a s n e c e s s a r y .

R G 4 6 8 7

— U N

— 2 0 D E C 8 8

C h e c k i n g a u t o m a t i c b e l t t e n s i o n e r ( 4 0 4 5 a n d 6 0 6 8 E n g i n e s )

B e l t d r i v e s y s t e m s e q u i p p e d w i t h a u t o m a t i c ( s p r i n g ) b e l t t e n s i o n e r s c a n n o t b e a d j u s t e d o r r e p a i r e d . T h e a u t o m a t i c

b e l t t e n s i o n e r i s d e s i g n e d t o m a i n t a i n p r o p e r b e l t t e n s i o n o v e r t h e l i f e o f t h e b e l t . I f t e n s i o n e r s p r i n g t e n s i o n i s n o t w i t h i n s p e c i f i c a t i o n , r e p l a c e t e n s i o n e r a s s e m b l y .

• C h e c k i n g b e l t w e a r T h e b e l t t e n s i o n e r i s d e s i g n e d t o o p e r a t e w i t h i n t h e l i m i t o f a r m m o v e m e n t p r o v i d e d b y t h e c a s t s t o p s ( A a n d B ) w h e n c o r r e c t b e l t l e n g t h a n d g e o m e t r y i s u s e d . I f t h e t e n s i o n e r s t o p o n s w i n g a r m ( A ) i s h i t t i n g t h e f i x e d s t o p ( B ) , c h e c k m o u n t i n g b r a c k e t s ( a l t e r n a t o r , b e l t t e n s i o n e r , i d l e r p u l l e y , e t c . ) a n d t h e b e l t l e n g t h . R e p l a c e b e l t a s n e e d e d ( s e e R E P L A C I N G F A N A N D A L T E R N A T O R B E L T S ) .

A — S w i n g a r m s t o p B — F i x e d c a s t s t o p

R G 8 0 9 8

— U N

— 1 8 N O V 9 7

E a r l i e r d e s i g n t e n s i o n e r

R G 1 3 7 4 4

— U N

— 1 1 N O V 0 4

L a t e r d e s i g n t e n s i o n e r

3 5 - 2 0 7 2 2 0 9

P N = 7 8

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• C h e c k i n g t e n s i o n e r s p r i n g t e n s i o n A b e l t t e n s i o n g a u g e w i l l n o t g i v e a n a c c u r a t e m e a s u r e o f t h e b e l t t e n s i o n w h e n a u t o m a t i c s p r i n g t e n s i o n e r i s u s e d . M e a s u r e t e n s i o n e r s p r i n g t e n s i o n u s i n g a t o r q u e w r e n c h a n d p r o c e d u r e o u t l i n e d b e l o w :

a . R e l e a s e t e n s i o n o n b e l t u s i n g a b r e a k e r b a r a n d s o c k e t o n t e n s i o n a r m . R e m o v e b e l t f r o m p u l l e y s .

b . R e l e a s e t e n s i o n o n t e n s i o n a r m a n d r e m o v e b r e a k e r

b a r . c . P u t a m a r k ( A ) o n s w i n g a r m o f t e n s i o n e r a s s h o w n . d . M e a s u r e 2 1 m m ( 0 . 8 3 i n . ) f r o m ( A ) a n d p u t a m a r k ( B )

o n t e n s i o n e r m o u n t i n g b a s e .

N O T E : E a r l i e r e n g i n e s h a v e a L E F T - H A N D t h r e a d r o l l e r c a p s c r e w w h i l e l a t e r e n g i n e s h a v e a 1 2 . 7 m m ( 1 / 2 i n . ) s q u a r e h o l e i n t e n s i o n e r .

e . I n s t a l l t o r q u e w r e n c h o n r o l l e r c a p s c r e w o r i n s q u a r e h o l e s o t h a t i t i s a l i g n e d w i t h c e n t e r o f r o l l e r a n d t e n s i o n e r a s s h o w n . R o t a t e t h e s w i n g a r m u s i n g a t o r q u e w r e n c h u n t i l m a r k s ( A a n d B ) a r e a l i g n e d .

f . R e c o r d t o r q u e w r e n c h m e a s u r e m e n t a n d c o m p a r e

w i t h s p e c i f i c a t i o n b e l o w . R e p l a c e t e n s i o n e r a s s e m b l y a s r e q u i r e d .


S p r i n g — F o r c e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8 — 2 2 N ∙ m ( 1 3 — 1 6 l b - f t )

A — M a r k o n s w i n g a r m B — M a r k o n t e n s i o n e r m o u n t i n g b a s e

R G 7 9 7 7

— U N

— 1 4 N O V 9 7

M a r k s o n t e n s i o n e r

R G 1 2 0 5 4

— U N —

0 8 J A N 0 2

A l i g n m a r k s

C h e c k a n d a d j u s t e n g i n e v a l v e c l e a r a n c e ( 3 0 2 9 a n d 4 0 3 9 E n g i n e s )

N O T E : V a l v e c l e a r a n c e m u s t b e a d j u s t e d a f t e r t h e f i r s t 5 0 0 h o u r s o f o p e r a t i o n , t h e n e v e r y 1 0 0 0 h o u r s t h e r e a f t e r .

A d j u s t e n g i n e v a l v e c l e a r a n c e a s f o l l o w s o r h a v e y o u r a u t h o r i z e d s e r v i c i n g d e a l e r o r e n g i n e d i s t r i b u t o r a d j u s t t h e e n g i n e v a l v e c l e a r a n c e .

1 . R e m o v e r o c k e r a r m c o v e r a n d c r a n k c a s e v e n t t u b e .

2 . U s i n g J D E 8 3 o r J D G 8 2 0 F l y w h e e l T u r n i n g T o o l ( A ) , r o t a t e e n g i n e f l y w h e e l i n r u n n i n g d i r e c t i o n ( c l o c k w i s e v i e w e d f r o m w a t e r p u m p ) u n t i l N o . 1 p i s t o n ( f r o n t ) h a s r e a c h e d t o p d e a d c e n t e r ( T D C ) o n c o m p r e s s i o n s t r o k e . I n s e r t t i m i n g p i n J D E 8 1 - 4 o r J D G 1 5 7 1 ( B ) i n t o f l y w h e e l b o r e .

C D 3 0 5 4 4

— U N

— 1 9 M A Y 9 8

3 5 - 3 0 7 2 2 0 9

P N = 7 9

149/258




D P S G , C D 0 3 5 2 3 , 3 5 - 1 9 - 3 1 J A N 0 7 - 2 / 2

3 . C h e c k a n d a d j u s t v a l v e c l e a r a n c e t o s p e c i f i c a t i o n s a c c o r d i n g t o f o l l o w i n g p r o c e d u r e s .


V a l v e c l e a r a n c e ( e n g i n e

c o l d ) — I n t a k e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 . 3 5 m m ( 0 . 0 1 4 i n . )

E x h a u s t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 . 4 5 m m ( 0 . 0 1 8 i n . )

N O T E : I f r o c k e r a r m i s e q u i p p e d w i t h a d j u s t i n g s c r e w a n d j a m n u t ( A ) , t i g h t e n j a m n u t t o 2 7 N ∙ m ( 2 0 l b - f t ) a f t e r a d j u s t i n g v a l v e c l e a r a n c e .

4 . R e i n s t a l l r o c k e r a r m c o v e r a n d c r a n k c a s e v e n t t u b e .

• 3 - C y l i n d e r E n g i n e :

N O T E : F i r i n g o r d e r i s 1 - 2 - 3

a . L o c k N o . 1 p i s t o n a t T D C c o m p r e s s i o n s t r o k e ( D ) . b . A d j u s t v a l v e c l e a r a n c e o n N o . 1 a n d 2 e x h a u s t

v a l v e s a n d N o . 1 a n d 3 i n t a k e v a l v e s . c . R o t a t e f l y w h e e l 3 6 0 ° . L o c k N o . 1 p i s t o n a t T D C

e x h a u s t s t r o k e ( E ) . d . A d j u s t v a l v e c l e a r a n c e o n N o . 3 e x h a u s t v a l v e a n d

N o . 2 i n t a k e v a l v e .


N O T E : F i r i n g o r d e r i s 1 - 3 - 4 - 2

a . L o c k N o . 1 p i s t o n a t T D C c o m p r e s s i o n s t r o k e ( B ) . b . A d j u s t v a l v e c l e a r a n c e o n N o . 1 a n d 3 e x h a u s t

v a l v e s a n d N o . 1 a n d 2 i n t a k e v a l v e s . c . R o t a t e f l y w h e e l 3 6 0 ° . L o c k N o . 4 p i s t o n a t T D C

c o m p r e s s i o n s t r o k e ( C ) . d . A d j u s t v a l v e c l e a r a n c e o n N o . 2 a n d 4 e x h a u s t

v a l v e s a n d N o . 3 a n d 4 i n t a k e v a l v e s .

A — F r o n t o f e n g i n e B — E x h a u s t v a l v e C — I n t a k e v a l v e

D — N o . 1 P i s t o n a t T D C c o m p r e s s i o n s t r o k e

E — N o . 1 P i s t o n a t T D C e x h a u s t s t r o k e

A — F r o n t o f e n g i n e B — N o . 1 P i s t o n a t T D C

c o m p r e s s i o n s t r o k e C — N o . 4 P i s t o n a t T D C

c o m p r e s s i o n s t r o k e

E — E x h a u s t v a l v e I — I n t a k e v a l v e

C D 3 0 5 4 5

— U N

— 1 9 M A Y 9 8

R G 6 3 0 7

— U N —

0 3 A U G 9 2

C D 3 0 5 4 9

— U N

— 1 6 J U N 9 8

R G 4 7 7 6

— U N

— 3 1 O C T 9 7

3 5 - 4 0 7 2 2 0 9

P N = 8 0

150/258




C D 0 3 5 2 3 , 0 0 0 0 0 E C - 1 9 - 2 2 J A N 0 7 - 1 / 1

P r e s s u r e t e s t i n g c o o l i n g s y s t e m

R G 6 5 5 7

— U N

— 2 0 J A N 9 3

T e s t r a d i a d o r c a p

R G 6 5 5 8

— U N

— 2 0 J A

N 9 3

T e s t c o o l i n g s y s t e m

C A U T I O N : E x p l o s i v e r e l e a s e o f f l u i d s f r o m p r e s s u r i z e d c o o l i n g s y s t e m c a n c a u s e s e r i o u s b u r n s .

S h u t o f f e n g i n e s . O n l y r e m o v e f i l l e r c a p w h e n c o o l e n o u g h t o t o u c h w i t h b a r e h a n d s . S l o w l y

l o o s e n c a p t o f i r s t s t o p t o r e l i e v e p r e s s u r e b e f o r e r e m o v i n g c o m p l e t e l y .

T e s t R a d i a t o r C a p

1 . R e m o v e r a d i a t o r c a p a n d a t t a c h t o D 0 5 1 0 4 S T t e s t e r a s s h o w n .

2 . P r e s s u r i z e c a p t o s p e c i f i c a t i o n l i s t e d . G a u g e s h o u l d h o l d p r e s s u r e f o r 1 0 s e c o n d s w i t h i n t h e n o r m a l r a n g e i f c a p i s a c c e p t a b l e .

I f g a u g e d o e s n o t h o l d p r e s s u r e , r e p l a c e r a d i a t o r c a p .


R a d i a t o r C a p C a l i b r a t i o n — P r e s s u r e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 0 k P a ( 0 . 7 b a r )

( 1 0 p s i ) f o r 1 0 s e c o n d s m i n i m u m

3 . R e m o v e t h e c a p f r o m g a u g e , t u r n i t 1 8 0 ° , a n d r e t e s t c a p t o c o n f i r m m e a s u r e m e n t .

T e s t C o o l i n g S y s t e m

N O T E : E n g i n e s h o u l d b e w a r m e d u p t o t e s t o v e r a l l c o o l i n g s y s t e m .

1 . A l l o w e n g i n e s t o c o o l , t h e n c a r e f u l l y r e m o v e r a d i a t o r c a p .

2 . F i l l r a d i a t o r w i t h c o o l a n t t o t h e n o r m a l o p e r a t i n g l e v e l .

I M P O R T A N T : D O N O T a p p l y e x c e s s i v e p r e s s u r e

t o c o o l i n g s y s t e m , d o i n g s o m a y d a m a g e r a d i a t o r a n d h o s e s .

3 . C o n n e c t g a u g e a n d a d a p t e r t o r a d i a t o r f i l l e r n e c k . P r e s s u r i z e c o o l i n g s y s t e m t o s p e c i f i c a t i o n l i s t e d f o r r a d i a t o r c a p .

4 . W i t h p r e s s u r e a p p l i e d , c h e c k a l l c o o l i n g s y s t e m h o s e c o n n e c t i o n s , r a d i a t o r , a n d o v e r a l l e n g i n e f o r l e a k s .

I f l e a k a g e i s d e t e c t e d , c o r r e c t a s n e c e s s a r y a n d p r e s s u r e t e s t s y s t e m a g a i n .

I f n o l e a k a g e i s d e t e c t e d , b u t t h e g a u g e i n d i c a t e d a d r o p i n p r e s s u r e , c o o l a n t m a y b e l e a k i n g i n t e r n a l l y

w i t h i n t h e s y s t e m o r a t t h e b l o c k - t o - h e a d g a s k e t . H a v e y o u r e n g i n e d i s t r i b u t o r o r s e r v i c i n g d e a l e r c o r r e c t t h i s p r o b l e m i m m e d i a t e l y .

3 5 - 5 0 7 2 2 0 9

P N = 8 1

151/258



M a i n t e n a n c e / 2 0 0 0 h o u r s / 2 y e a r s


C h e c k a n d a d j u s t e n g i n e v a l v e c l e a r a n c e ( 4 0 4 5 a n d 6 0 6 8 E n g i n e s )

A d j u s t e n g i n e v a l v e c l e a r a n c e a s f o l l o w s o r h a v e y o u r a u t h o r i z e d s e r v i c i n g d e a l e r o r e n g i n e d i s t r i b u t o r a d j u s t t h e e n g i n e v a l v e c l e a r a n c e .

1 . R e m o v e r o c k e r a r m c o v e r a n d c r a n k c a s e v e n t t u b e .

2 . U s i n g J D E 8 3 o r J D G 8 2 0 F l y w h e e l T u r n i n g T o o l ( A ) , r o t a t e e n g i n e f l y w h e e l i n r u n n i n g d i r e c t i o n ( c l o c k w i s e v i e w e d f r o m w a t e r p u m p ) u n t i l N o . 1 p i s t o n ( f r o n t ) h a s r e a c h e d t o p d e a d c e n t e r ( T D C ) o n c o m p r e s s i o n s t r o k e . I n s e r t t i m i n g p i n J D E 8 1 - 4 ( B ) i n t o f l y w h e e l b o r e .

C D 3 0 5 4 4

— U N

— 1 9 M A Y 9 8

4 0 - 1 0 7 2 2 0 9

P N = 8 2

152/258




D P S G , C D 0 3 5 2 3 , 3 6 - 1 9 - 3 1 J A N 0 7 - 2 / 2

3 . C h e c k a n d a d j u s t v a l v e c l e a r a n c e t o s p e c i f i c a t i o n s a c c o r d i n g t o f o l l o w i n g p r o c e d u r e s .


V a l v e c l e a r a n c e ( e n g i n e

c o l d ) — I n t a k e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 . 3 5 m m ( 0 . 0 1 4 i n . )

E x h a u s t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 . 4 5 m m ( 0 . 0 1 8 i n . )

4 . I f v a l v e s n e e d a d j u s t i n g , l o o s e n t h e l o c k n u t o n r o c k e r a r m a d j u s t i n g s c r e w . T u r n a d j u s t i n g s c r e w u n t i l f e e l e r g a u g e s l i p s w i t h a s l i g h t d r a g . H o l d t h e a d j u s t i n g s c r e w f r o m t u r n i n g w i t h s c r e w d r i v e r a n d t i g h t e n l o c k n u t t o 2 7 N ∙ m ( 2 0 l b - f t ) . R e c h e c k c l e a r a n c e a f t e r t i g h t e n i n g l o c k n u t . R e a d j u s t c l e a r a n c e a s n e c e s s a r y

5 . R e i n s t a l l r o c k e r a r m c o v e r a n d c r a n k c a s e v e n t t u b e .


N O T E : F i r i n g o r d e r i s 1 - 3 - 4 - 2

a . L o c k N o . 1 p i s t o n a t T D C c o m p r e s s i o n s t r o k e ( B ) .

b . A d j u s t v a l v e c l e a r a n c e o n N o . 1 a n d 3 e x h a u s t v a l v e s a n d N o . 1 a n d 2 i n t a k e v a l v e s . c . R o t a t e f l y w h e e l 3 6 0 ° . L o c k N o . 4 p i s t o n a t T D C

c o m p r e s s i o n s t r o k e ( C ) . d . A d j u s t v a l v e c l e a r a n c e o n N o . 2 a n d 4 e x h a u s t

v a l v e s a n d N o . 3 a n d 4 i n t a k e v a l v e s .


N O T E : F i r i n g o r d e r i s 1 - 5 - 3 - 6 - 2 - 4 .

a . L o c k N o . 1 p i s t o n a t T D C c o m p r e s s i o n s t r o k e ( B ) . b . A d j u s t v a l v e c l e a r a n c e o n N o . 1 , 3 , a n d 5 e x h a u s t

v a l v e s a n d N o . 1 , 2 , a n d 4 i n t a k e v a l v e s . c . R o t a t e f l y w h e e l 3 6 0 ° . L o c k N o . 6 p i s t o n a t T D C

c o m p r e s s i o n s t r o k e ( C ) . d . A d j u s t v a l v e c l e a r a n c e o n N o . 2 , 4 , a n d 6 e x h a u s t

v a l v e s a n d N o . 3 , 5 , a n d 6 i n t a k e v a l v e s .





R G 7 4 0 9

— U N

— 0 6 A U G 9 6

R G 4 7 7 6

— U N

— 3 1 O C T 9 7





R G 4 7 7 7

— U N

— 3 1 O C T 9 7

4 0 - 2 0 7 2 2 0 9

P N = 8 3

153/258




D P S G , C D 0 3 5 2 3 , 3 8 - 1 9 - 3 1 J A N 0 7 - 1 / 1

D P S G , C D 0 3 5 2 3 , 3 9 - 1 9 - 3 1 J A N 0 7 - 1 / 1

C h e c k i n g e n g i n e s p e e d ( M e c h a n i c a l f u e l s y s t e m )

N O T E : M o s t e n g i n e s f o r g e n e r a t o r s e t a p p l i c a t i o n ( 1 5 0 0 r p m f o r 5 0 H z o r 1 8 0 0 r p m f o r 6 0 H z ) r u n o n l y a t f a s t i d l e a n d t h e r e f o r e t h e y d o n o t h a v e s l o w i d l e .


F a s t i d l e — 5 0 H z

G e n e r a t o r s e t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 5 0 — 1 5 8 0 r p m

6 0 H z G e n e r a t o r s e t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8 6 5 — 1 8 9 0 r p m

N O T E : F a s t i d l e i s s e t t l e d b y t h e f a c t o r y t h e n t h e i d l e a d j u s t i n g s c r e w ( A ) i s s e a l e d t o p r e v e n t f r o m t a m p e r i n g . F a s t i d l e a d j u s t m e n t c a n o n l y b e d o n e b y a n a u t h o r i z e d f u e l s y s t e m a g e n t .

C D 3 0 7 6 3

— U N

— 2 4 S E P 9 9

A — F a s t i d l e a d j u s t i n g s c r e w

A d j u s t s p e e d d r o o p g o v e r n o r ( M e c h a n i c a l f u e l s y s t e m )

1 . W a r m e n g i n e t o n o r m a l o p e r a t i n g t e m p e r a t u r e .

2 . R u n e n g i n e a t f a s t i d l e .

3 . A p p l y f u l l l o a d .

4 . I f s p e c i f i e d p o w e r c a n n o t b e o b t a i n e d , t u r n s c r e w ( B ) t o a d j u s t d r o o p u n t i l t h e r e q u e s t e d p o w e r i s r e a c h e d .

N O T E : I f s u r g i n g e x i t s u p o n r e m o v i n g t h e l o a d , t u r n s c r e w ( B ) c l o c k w i s e t o e l i m i n a t e .

B — S p e e d d r o o p g o v e r n o r a d j u s t i n g s c r e w

C D 3 0 7 6 4

— U N

— 2 4 S E P 9 9

4 0 - 3 0 7 2 2 0 9

P N = 8 4

154/258




D P S G , C D 0 3 5 2 3 , 4 0 - 1 9 - 2 2 J A N 0 7 - 1 / 1

C h e c k i n g c r a n k s h a f t v i b r a t i o n d a m p e r ( 6 - C Y L I N D E R E N G I N E O N L Y )

1 . R e m o v e b e l t s ( s h o w n r e m o v e d ) .

2 . G r a s p v i b r a t i o n d a m p e r w i t h b o t h h a n d s a n d a t t e m p t t o t u r n i t i n b o t h d i r e c t i o n s . I f r o t a t i o n i s f e l t , d a m p e r i s d e f e c t i v e a n d s h o u l d b e r e p l a c e d .

I M P O R T A N T : T h e v i b r a t i o n d a m p e r a s s e m b l y i s n o t r e p a i r a b l e a n d s h o u l d b e r e p l a c e d e v e r y 4 5 0 0 h o u r s o r 5 y e a r s , w h i c h e v e r o c c u r s f i r s t .

3 . C h e c k v i b r a t i o n d a m p e r r a d i a l r u n o u t b y p o s i t i o n i n g a d i a l i n d i c a t o r s o p r o b e c o n t a c t s d a m p e r o u t e r c i r c u m f e r e n c e .

4 . W i t h e n g i n e a t o p e r a t i n g t e m p e r a t u r e , r o t a t e c r a n k s h a f t u s i n g J D G 8 2 0 o r J D E 8 3 F l y w h e e l T u r n i n g T o o l .

5 . N o t e d i a l i n d i c a t o r r e a d i n g . I f r u n o u t e x c e e d s s p e c i f i c a t i o n s g i v e n b e l o w , r e p l a c e v i b r a t i o n d a m p e r .

S p e c i f i c a t i o n D a m p e r — M a x i m u m

r a d i a l r u n o u t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . 5 0 m m ( 0 . 0 6 0 i n . )

R G 8 0 1 8

— U N —

1 5 J A N 9 9

R G 7 5 0 8

— U N

— 2 3 N O V 9 7

4 0 - 4 0 7 2 2 0 9

P N = 8 5

155/258




D P S G , C D 0 3 5 2 3 , 4 1 - 1 9 - 1 5 J U L 0 9 - 1 / 5

D P S G , C D 0 3 5 2 3 , 4 1 - 1 9 - 1 5 J U L 0 9 - 2 / 5


D r a i n a n d f l u s h c o o l i n g s y s t e m

N O T E : D r a i n a n d f l u s h c o o l i n g s y s t e m e v e r y 2 5 0 0 h o u r s / 3 y e a r s w h e n J o h n D e e r e C O O L - G A R D c o o l a n t i s u s e d . O t h e r w i s e e v e r y 2 0 0 0 h o u r s / 2 y e a r s

C A U T I O N : E x p l o s i v e r e l e a s e o f f l u i d s

f r o m p r e s s u r i z e d c o o l i n g s y s t e m c a n c a u s e s e r i o u s b u r n s .

S h u t o f f e n g i n e . O n l y r e m o v e f i l l e r c a p w h e n c o o l e n o u g h t o t o u c h w i t h b a r e h a n d s . S l o w l y l o o s e n c a p t o f i r s t s t o p t o r e l i e v e p r e s s u r e b e f o r e r e m o v i n g c o m p l e t e l y .

T S 2 8 1

— U N

— 2 3 A U G 8 8

1 . S l o w l y o p e n t h e r a d i a t o r c a p .

2 . R e m o v e e n g i n e b l o c k d r a i n p l u g ( A ) .

R G 4 8 9 4

— U N

— 1 4 D E C 8 8

3 . O n P O W E R T e c h e n g i n e s , r e m o v e o i l c o o l e r h o u s i n g d r a i n p l u g ( B ) .

Z X 0 1 6 1 9 2

— U N

— 1 1 J A N 9 9

4 5 - 1 0 7 2 2 0 9

P N = 8 6

156/258




D P S G , C D 0 3 5 2 3 , 4 1 - 1 9 - 1 5 J U L 0 9 - 4 / 5

D P S G , C D 0 3 5 2 3 , 4 1 - 1 9 - 1 5 J U L 0 9 - 5 / 5

4 . O p e n r a d i a t o r d r a i n v a l v e ( C ) . D r a i n a l l c o o l a n t f r o m r a d i a t o r .

5 . C l o s e a l l d r a i n o r i f i c e s a f t e r c o o l a n t h a s d r a i n e d .

6 . F i l l t h e c o o l i n g s y s t e m w i t h c l e a n w a t e r . R u n e n g i n e u n t i l w a t e r p a s s e s t h r o u g h t h e t h e r m o s t a t t o s t i r u p p o s s i b l e r u s t o r s e d i m e n t .

7 . S t o p e n g i n e a n d i m m e d i a t e l y d r a i n t h e w a t e r f r o m s y s t e m b e f o r e r u s t a n d s e d i m e n t s e t t l e .

8 . A f t e r d r a i n i n g w a t e r , c l o s e a l l d r a i n o r i f i c e s a n d f i l l t h e c o o l i n g s y s t e m w i t h c l e a n i n g p r o d u c t s u c h a s P M C C 2 6 1 0 o r P M C C 2 6 3 8 C o o l i n g S y s t e m C l e a n e r s a v a i l a b l e f r o m y o u r J o h n D e e r e D e a l e r . F o l l o w m a n u f a c t u r e r ’ s d i r e c t i o n s o n l a b e l .

9 . A f t e r c l e a n i n g t h e c o o l i n g s y s t e m , d r a i n c l e a n e r a n d f i l l w i t h w a t e r t o f l u s h t h e s y s t e m . R u n e n g i n e u n t i l w a t e r p a s s e s t h r o u g h t h e t h e r m o s t a t , t h e n d r a i n o u t f l u s h i n g w a t e r .

1 0 . C h e c k c o o l i n g s y s t e m h o s e s f o r p r o p e r c o n d i t i o n .

R e p l a c e a s n e c e s s a r y .

1 1 . C l o s e a l l d r a i n o r i f i c e s a n d f i l l t h e c o o l i n g s y s t e m w i t h s p e c i f i e d c o o l a n t ( s e e D I E S E L E N G I N E C O O L A N T ) .

C D 3 0 7 6 5

— U N

— 2 7 A U G 9 9

C o o l i n g s y s t e m c a p a c i t y

E n g i n e M o d e l C o o l i n g s y s t e m c a p a c i t y

3 0 2 9 D F 1 2 8 , 3 0 2 9 T F 1 2 0 , 3 0 2 9 T F 1 5 8 , 3 0 2 9 H F S 7 0 , 3 0 2 9 T F 2 7 0 , 3 0 2 9 T F S 7 0 , 3 0 2 9 H F U 7 0 , 3 0 2 9 T F U 7 0

1 4 . 5 L ( 1 5 . 5 q t )

4 0 3 9 D F 0 0 8 , 4 0 3 9 T F 0 0 8 , 1 6 . 5 L ( 1 7 . 5 q t )

4 0 4 5 D F 1 5 8 2 0 L ( 2 1 q t )

4 0 4 5 T F 1 2 0 , 4 0 4 5 T F 1 5 8 , 4 0 4 5 T F 2 2 0 , 4 0 4 5 T F 2 5 8 , 4 0 4 5 H F S 8 0 , 4 0 4 5 T F 2 7 0 , 4 0 4 5 T F S 7 0 , 4 0 4 5 T F U 7 0

2 5 L ( 2 6 . 5 q t )

4 0 4 5 H F 1 5 8 , 4 0 4 5 H F U 7 2 , 6 0 6 8 T F 1 5 8 , 6 0 6 8 T F 2 5 8

2 8 L ( 2 9 . 5 q t )

4 0 4 5 H F S 7 3 , 4 0 4 5 H F S 8 2 , 4 0 4 5 H F S 8 3 , 4 0 4 5 H F U 7 9 , 6 0 6 8 H F 1 2 0 , 6 0 6 8 H F 1 5 8 , 6 0 6 8 H F 2 2 0 , 6 0 6 8 H F 2 5 8 , 6 0 6 8 H F 2 7 5 , 6 0 6 8 H F S 7 2 , 6 0 6 8 H F S 7 3 , 6 0 6 8 H F S 8 2 , 6 0 6 8 H F S 8 3 , 6 0 6 8 H F U 7 2 , 6 0 6 8 H F U 7 9

3 2 L ( 3 4 q t )

6 0 6 8 H F 4 7 5 , 6 0 6 8 H F S 7 6 , 6 0 6 8 H F S 7 7 , 6 0 6 8 H F S 8 9 , 6 0 6 8 H F U 7 4

3 5 L ( 3 7 q t )

1 2 . W h e n r e f i l l i n g c o o l i n g s y s t e m , l o o s e n t e m p e r a t u r e s e n s o r ( B ) o r p l u g a t t h e r e a r o f c y l i n d e r h e a d t o a l l o w a i r t o e s c a p e .

1 3 . R u n e n g i n e u n t i l i t r e a c h e s o p e r a t i n g t e m p e r a t u r e t h e n c h e c k c o o l a n t l e v e l a n d e n t i r e c o o l i n g s y s t e m f o r l e a k s .

C D 3 0 6 4 3

— U N

— 0 4 M A Y 9 8

4 5 - 2 0 7 2 2 0 9

P N = 8 7

157/258



M a i n t e n a n c e / A s r e q u i r e d

D P S G , C D 0 3 5 2 3 , 4 2 - 1 9 - 3 1 J A N 0 7 - 1 / 1

D P S G , C D 0 3 5 2 3 , 4 3 - 1 9 - 2 2 J A N 0 7 - 1 / 1

A d d i t i o n a l s e r v i c e i n f o r m a t i o n

T h i s m a n u a l d o e s n o t a l l o w a c o m p l e t e r e p a i r o f y o u r e n g i n e . I f y o u w a n t w a n t m o r e d e t a i l e d s e r v i c e i n f o r m a t i o n t h e f o l l o w i n g p u b l i c a t i o n s a r e a v a i l a b l e f r o m y o u r r e g u l a r p a r t s c h a n n e l .

• P C 2 4 5 1 — P a r t s C a t a l o g f o r N o n - E m i s s i o n C e r t i f i e d e n g i n e s

• P C 3 2 3 5 — P a r t s C a t a l o g f o r S t a g e I I E m i s s i o n C e r t i f i e d e n g i n e s

• C T M 3 2 7 4 — C o m p o n e n t T e c h n i c a l M a n u a l f o r 3 0 2 9 a n d 4 0 3 9 e n g i n e s ( E n g l i s h )

• C T M 1 0 4 — C o m p o n e n t T e c h n i c a l M a n u a l f o r 4 0 4 5 a n d 6 0 6 8 b a s e e n g i n e s ( E n g l i s h )

• C T M 2 0 7 — C o m p o n e n t T e c h n i c a l M a n u a l f o r M e c h a n i c a l F u e l S y s t e m s o n 4 0 4 5 a n d 6 0 6 8 e n g i n e s ( E n g l i s h )

• C T M 3 2 0 — C o m p o n e n t T e c h n i c a l M a n u a l f o r H P C R F u e l S y s t e m o n 4 0 4 5 a n d 6 0 6 8 w i t h 4 - V a l v e H e a d E n g i n e s ( E n g l i s h )

• C T M 3 3 1 — C o m p o n e n t T e c h n i c a l M a n u a l f o r D E 1 0 F u e l S y s t e m s o n 4 0 4 5 a n d 6 0 6 8 e n g i n e s ( E n g l i s h )

R G 4 6 2 4

— U N —

1 5 D E C 8 8

• C T M 5 0 2 — C o m p o n e n t T e c h n i c a l M a n u a l f o r H P C R F u e l S y s t e m o n 4 0 4 5 a n d 6 0 6 8 w i t h 2 - V a l v e H e a d E n g i n e s ( E n g l i s h )

• C T M 6 7 — C o m p o n e n t T e c h n i c a l M a n u a l f o r O E M E n g i n e a c c e s s o r i e s ( E n g l i s h o n l y )

• C T M 7 7 — C o m p o n e n t T e c h n i c a l M a n u a l f o r A l t e r n a t o r s a n d S t a r t e r M o t o r s ( E n g l i s h o n l y )

D o n o t m o d i f y f u e l s y s t e m

I M P O R T A N T : M o d i f i c a t i o n o r a l t e r a t i o n o f t h e i n j e c t i o n p u m p , t h e i n j e c t i o n p u m p t i m i n g , o r t h e f u e l i n j e c t o r s i n w a y s n o t r e c o m m e n d e d b y t h e m a n u f a c t u r e r w i l l t e r m i n a t e t h e w a r r a n t y o b l i g a t i o n t o t h e p u r c h a s e r .

D o n o t a t t e m p t t o s e r v i c e i n j e c t i o n p u m p o r f u e l i n j e c t o r s y o u r s e l f . S p e c i a l t r a i n i n g a n d s p e c i a l t o o l s a r e r e q u i r e d . ( S e e y o u r a u t h o r i z e d s e r v i c i n g d e a l e r o r e n g i n e d i s t r i b u t o r . )

C D 3 0 7 6 8

— U N

— 2

4 S E P 9 9

5 0 - 1 0 7 2 2 0 9

P N = 8 8

158/258




D X , W W , E C U 0 2 - 1 9 - 1 1 J U N 0 9 - 1 / 1

D X , W W , E C U 0 4 - 1 9 - 1 1 J U N 0 9 - 1 / 1

W e l d i n g N e a r E l e c t r o n i c C o n t r o l U n i t s

I M P O R T A N T : D o n o t j u m p - s t a r t e n g i n e s w i t h a r c w e l d i n g e q u i p m e n t . C u r r e n t s a n d v o l t a g e s a r e t o o h i g h a n d m a y c a u s e p e r m a n e n t d a m a g e .

1 . D i s c o n n e c t t h e n e g a t i v e ( - ) b a t t e r y c a b l e .

2 . D i s c o n n e c t t h e p o s i t i v e ( + ) b a t t e r y c a b l e .

3 . S h o r t t h e p o s i t i v e a n d n e g a t i v e t e r m i n a l s t o g e t h e r . D o n o t a t t a c h t o v e h i c l e f r a m e .

4 . C l e a r o r m o v e a n y w i r i n g h a r n e s s s e c t i o n s a w a y f r o m w e l d i n g a r e a .

5 . C o n n e c t w e l d e r g r o u n d c l o s e t o w e l d i n g p o i n t a n d a w a y f r o m c o n t r o l u n i t s .

T S 9 5 3

— U N

— 1

5 M A Y 9 0

6 . A f t e r w e l d i n g , r e v e r s e S t e p s 1 — 5 .

K e e p E l e c t r o n i c C o n t r o l U n i t C o n n e c t o r s C l e a n

I M P O R T A N T : D o n o t o p e n c o n t r o l u n i t a n d d o n o t c l e a n w i t h a h i g h - p r e s s u r e s p r a y . M o i s t u r e , d i r t , a n d o t h e r c o n t a m i n a n t s m a y c a u s e p e r m a n e n t d a m a g e .

1 . K e e p t e r m i n a l s c l e a n a n d f r e e o f f o r e i g n d e b r i s . M o i s t u r e , d i r t , a n d o t h e r c o n t a m i n a n t s m a y c a u s e t h e t e r m i n a l s t o e r o d e o v e r t i m e a n d n o t m a k e a g o o d e l e c t r i c a l c o n n e c t i o n .

2 . I f a c o n n e c t o r i s n o t i n u s e , p u t o n t h e p r o p e r d u s t c a p o r a n a p p r o p r i a t e s e a l t o p r o t e c t i t f r o m f o r e i g n d e b r i s a n d m o i s t u r e .

3 . C o n t r o l u n i t s a r e n o t r e p a i r a b l e .

4 . S i n c e c o n t r o l u n i t s a r e t h e c o m p o n e n t s L E A S T l i k e l y t o f a i l , i s o l a t e f a i l u r e b e f o r e r e p l a c i n g b y c o m p l e t i n g a d i a g n o s t i c p r o c e d u r e . ( S e e y o u r J o h n D e e r e d e a l e r . )

R G 1 6 9 4 6

— U N

— 3 1 M A R 0 9

5 . T h e w i r i n g h a r n e s s t e r m i n a l s a n d c o n n e c t o r s f o r e l e c t r o n i c c o n t r o l u n i t s a r e r e p a i r a b l e .

5 0 - 2 0 7 2 2 0 9

P N = 8 9

159/258




D P S G , C D 0 3 5 2 3 , 4 4 - 1 9 - 2 2 J A N 0 7 - 1 / 1

C l e a n o r r e p l a c e a i r f i l t e r ( o n e - p i e c e )

C l e a n a i r f i l t e r w h e n r e s t r i c t i o n i n d i c a t o r ( A ) i s r e d . A i r f i l t e r c a n b e c l e a n e d u p t o s i x t i m e s . T h e r e a f t e r , o r a t l e a s t o n c e a y e a r , i t m u s t b e r e p l a c e d .

P r o c e e d a s f o l l o w s :

1 . T h o r o u g h l y c l e a n a l l d i r t a r o u n d a i r f i l t e r a r e a .

2 . L o o s e n c l a m p ( B ) t h e n r e m o v e a i r f i l t e r .

I M P O R T A N T : N e v e r r e i n s t a l l a n a i r f i l t e r w h i c h s h o w s e v i d e n c e o f b a d c o n d i t i o n ( p u n c h e d , d e n t e d . . . ) a l l o w i n g n o f i l t e r e d a i r t o e n t e r t h e e n g i n e .

3 . C l e a n a i r f i l t e r w i t h c o m p r e s s e d a i r w o r k i n g f r o m ” c l e a n ” t o ” d i r t y ” s i d e .

N O T E : C o m p r e s s e d a i r p r e s s u r e m u s t n o t e x c e e d 6 0 0 k P a ( 6 b a r ; 8 8 p s i ) .

4 . M a r k a i r f i l t e r t o k e e p t r a c k o f e a c h c l e a n i n g o p e r a t i o n .

5 . F u l l y d e p r e s s a i r r e s t r i c t i o n i n d i c a t o r r e s e t b u t t o n a n d

r e l e a s e t o r e s e t i n d i c a t o r .

6 . C h e c k a i r s y s t e m e n t i r e l y f o r p r o p e r c o n d i t i o n ( s e e C H E C K I N G A I R I N T A K E S Y S T E M ) .

C D 3 0 7 6 6

— U N

— 0 6 S E P 9 9

R G 9 9 1 2

— U N —

2 5 F E B 9 9

5 0 - 3 0 7 2 2 0 9

P N = 9 0

160/258




D P S G , C D 0 3 5 2 3 , 5 8 - 1 9 - 2 2 J A N 0 7 - 1 / 1

C l e a n o r r e p l a c e a i r f i l t e r e l e m e n t

C D 3 0 7 7 2

— U N

— 2 7 A U G 9 9

A — P r i m a r y e l e m e n t B — S e c o n d a r y ( s a f e t y ) e l e m e n t C — A i r r e s t r i c t i o n i n d i c a t o r D — W i n g n u t

C l e a n a i r f i l t e r w h e n r e s t r i c t i o n i n d i c a t o r ( C ) i s r e d . R e p l a c e b o t h p r i m a r y ( A ) a n d s e c o n d a r y ( B ) f i l t e r e l e m e n t s a f t e r p r i m a r y e l e m e n t h a s b e e n c l e a n e d s i x t i m e s o r a t l e a s t o n c e a y e a r .

P r o c e e d a s f o l l o w s :

1 . T h o r o u g h l y c l e a n a l l d i r t a r o u n d a i r f i l t e r a r e a .

2 . R e m o v e w i n g n u t ( D ) a n d r e m o v e p r i m a r y e l e m e n t ( A ) f r o m c a n i s t e r .

I M P O R T A N T : D o n o t a t t e m p t t o c l e a n t h e s e c o n d a r y ( s a f e t y ) e l e m e n t ( B ) . I t m u s t b e o n l y r e p l a c e d a s r e c o m m e n d e d .

3 . T h o r o u g h l y c l e a n a l l d i r t f r o m i n s i d e c a n i s t e r .

I M P O R T A N T : I f p r i m a r y e l e m e n t s h o w s e v i d e n c e o f b a d c o n d i t i o n ( p u n c h e d , d e n t e d . . . ) , r e p l a c e b o t h t h e p r i m a r y a n d t h e s e c o n d a r y e l e m e n t s .

4 . C l e a n p r i m a r y e l e m e n t w i t h c o m p r e s s e d a i r w o r k i n g f r o m ” c l e a n ” t o ” d i r t y ” s i d e .

N O T E : C o m p r e s s e d a i r p r e s s u r e m u s t n o t e x c e e d 6 0 0 k P a ( 6 b a r ; 8 8 p s i ) .

5 . M a r k a i r f i l t e r t o k e e p t r a c k o f e a c h c l e a n i n g o p e r a t i o n .

6 . F u l l y d e p r e s s a i r r e s t r i c t i o n i n d i c a t o r r e s e t b u t t o n a n d r e l e a s e t o r e s e t i n d i c a t o r .

7 . C h e c k a i r s y s t e m e n t i r e l y f o r p r o p e r c o n d i t i o n ( s e e C H E C K I N G A I R I N T A K E S Y S T E M ) .

5 0 - 4 0 7 2 2 0 9

P N = 9 1

161/258




D P S G , C D 0 3 5 2 3 , 4 5 - 1 9 - 3 1 J A N 0 7 - 1 / 1


R e p l a c i n g f a n a n d a l t e r n a t o r b e l t ( 4 0 4 5 a n d 6 0 6 8 E n g i n e s )

N O T E : R e f e r t o C H E C K I N G B E L T T E N S I O N E R S P R I N G T E N S I O N A N D B E L T W E A R f o r a d d i t i o n a l i n f o r m a t i o n o n t h e b e l t t e n s i o n e r .

1 . I n s p e c t b e l t s f o r c r a c k s , f r a y i n g , o r s t r e t c h e d o u t

a r e a s . R e p l a c e i f n e c e s s a r y . 2 . O n e n g i n e s w i t h a u t o m a t i c b e l t t e n s i o n e r , r e l e a s e

t e n s i o n o n b e l t u s i n g a b r e a k e r b a r a n d s o c k e t o n t e n s i o n a r m .

O n e n g i n e s w i t h m a n u a l t e n s i o n e r , l o o s e n c a p s c r e w s h o l d i n g t h e a l t e r n a t o r .

3 . R e m o v e p o l y V - b e l t f r o m p u l l e y s a n d d i s c a r d b e l t .

4 . I n s t a l l n e w b e l t , m a k i n g s u r e b e l t i s c o r r e c t l y s e a t e d i n a l l p u l l e y g r o o v e s . R e f e r t o b e l t r o u t i n g a t r i g h t f o r y o u r a p p l i c a t i o n .

5 . A p p l y t e n s i o n t o b e l t ( S e e C H E C K I N G B E L T ) .

6 . S t a r t e n g i n e a n d c h e c k b e l t a l i g n m e n t .

A L T — A l t e r n a t o r C P — C r a n k P u l l e y F D — F a n D r i v e

I — I d l e r P u l l e y T — T e n s i o n e r W P — W a t e r P u m p

C D 3 0 7 6 9

— U N

— 0 1 S E P 9

9

I n s t a l l a t i o n o n 4 0 4 5 e n g i n e s

C D 3 0 7 7 0

— U N

— 0 1 S E P 9 9

I n s t a l l a t i o n o n 6 0 6 8 e n g i n e s

B l e e d i n g t h e f u e l s y s t e m

C A U T I O N : E s c a p i n g f l u i d u n d e r p r e s s u r e c a n p e n e t r a t e t h e s k i n c a u s i n g s e r i o u s i n j u r y . R e l i e v e p r e s s u r e b e f o r e d i s c o n n e c t i n g f u e l o r o t h e r l i n e s . T i g h t e n a l l c o n n e c t i o n s b e f o r e a p p l y i n g p r e s s u r e . K e e p h a n d s a n d b o d y a w a y f r o m p i n h o l e s a n d n o z z l e s w h i c h e j e c t f l u i d s u n d e r h i g h p r e s s u r e . U s e a p i e c e o f c a r d b o a r d o r p a p e r t o s e a r c h f o r l e a k s . D o n o t u s e y o u r h a n d .

I f A N Y f l u i d i s i n j e c t e d i n t o t h e s k i n , i t m u s t b e s u r g i c a l l y r e m o v e d w i t h i n a f e w h o u r s b y a d o c t o r f a m i l i a r w i t h t h i s t y p e i n j u r y o r g a n g r e n e m a y r e s u l t . D o c t o r s u n f a m i l i a r w i t h t h i s t y p e o f i n j u r y m a y c a l l t h e D e e r e & C o m p a n y M e d i c a l D e p a r t m e n t i n M o l i n e , I l l i n o i s , o r o t h e r k n o w l e d g e a b l e m e d i c a l s o u r c e .

N O T E : E n g i n e s w i t h m e c h a n i c a l f u e l s y s t e m h a v e a s i n g l e f u e l f i l t e r w h i l e e l e c t r o n i c a l l y c o n t r o l l e d e n g i n e s ( D E 1 0 a n d H P C R f u e l s y s t e m s ) h a v e

X 9 8 1 1

— U N

— 2 3 A U G 8 8

t w o f u e l f i l t e r s ( p r i m a r y a n d f i n a l ) . W h e n e v e r t h e f u e l s y s t e m h a s b e e n o p e n e d u p f o r s e r v i c e ( l i n e s d i s c o n n e c t e d o r f i l t e r s r e m o v e d ) , i t w i l l b e n e c e s s a r y t o b l e e d a i r f r o m t h e s y s t e m . O n d u a l f u e l f i l t e r s y s t e m , b l e e d a i r o n l y f r o m f i n a l f i l t e r .

5 0 - 5 0 7 2 2 0 9

P N = 9 2

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A . ) M e c h a n i c a l a n d D E 1 0 f u e l s y s t e m s

1 . L o o s e n t h e a i r b l e e d s c r e w ( A ) t w o f u l l t u r n s . O n D E 1 0 f u e l s y s t e m , l o o s e n o n l y a i r b l e e d s c r e w o n f i n a l f u e l f i l t e r .

2 . O p e r a t e s u p p l y p u m p p r i m e r l e v e r ( B ) u n t i l f u e l f l o w i s f r e e f r o m a i r b u b b l e s .

3 . T i g h t e n b l e e d s c r e w s e c u r e l y , c o n t i n u e o p e r a t i n g h a n d p r i m e r u n t i l p u m p i n g a c t i o n i s n o t f e l t .

4 . S t a r t e n g i n e a n d c h e c k f o r l e a k s .

I f e n g i n e d o e s n o t s t a r t , i t w i l l b e n e c e s s a r y t o b l e e d a i r f r o m f u e l s y s t e m a t f u e l i n j e c t i o n p u m p o r i n j e c t i o n n o z z l e s a s e x p l a i n e d n e x t .

R G 7 9 4 7

— U N

— 1 3 N O V 9 7

F u e l fi l t e r b l e e d s c r e w

R G 8 0 1 3 A

— U N

— 1

5 J A N 9 9

F u e l p u m p p r i m e r l e v e r

C D 3 0 7 7 1

— U N

— 2 4 S E P 9 9

M e c h a n i c a l i n j e c t i o n p u m p r e t u r n l i n e

C D 3 0 9 2 8

— U N

— 0 2 F E B 0

7

D E 1 0 F u e l r e t u r n l i n e

• A t F u e l I n j e c t i o n P u m p : a . S l i g h t l y l o o s e n f u e l r e t u r n l i n e c o n n e c t o r ( C ) a t f u e l

i n j e c t i o n p u m p . b . O p e r a t e f u e l s u p p l y p u m p p r i m e r l e v e r u n t i l f u e l ,

w i t h o u t a i r b u b b l e s , f l o w s f r o m f u e l r e t u r n l i n e

c o n n e c t i o n .

c . S e c u r e l y t i g h t e n r e t u r n l i n e c o n n e c t o r .

5 0 - 6 0 7 2 2 0 9

P N = 9 3

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D P S G , C D 0 3 5 2 3 , 4 6 - 1 9 - 0 9 F E B 0 7 - 3 / 3

• A t F u e l I n j e c t i o n N o z z l e s : a . U s i n g t w o o p e n - e n d w r e n c h e s , l o o s e n f u e l l i n e

c o n n e c t i o n a t i n j e c t i o n n o z z l e . b . C r a n k e n g i n e o v e r w i t h s t a r t i n g m o t o r , ( b u t d o n o t

s t a r t e n g i n e ) , u n t i l f u e l f r e e f r o m b u b b l e s f l o w s o u t o f l o o s e n e d c o n n e c t i o n . R e t i g h t e n c o n n e c t i o n t o 2 7 N ∙ m ( 2 0 l b - f t ) .

c . R e p e a t p r o c e d u r e f o r r e m a i n i n g i n j e c t i o n n o z z l e s ( i f

n e c e s s a r y ) u n t i l a l l a i r h a s b e e n r e m o v e d f r o m f u e l s y s t e m .

I f e n g i n e s t i l l w i l l n o t s t a r t , s e e y o u r a u t h o r i z e d s e r v i c i n g d e a l e r o r e n g i n e d i s t r i b u t o r .

R G 7 7 2 5

— U N

— 0 8 J A N 9 7

B l e e d f u e l s y s t e m a t f u e l i n j e c t i o n n o z z l e s

T S 1 3 4 3

— U N

— 1 8 M A R 9

2

R G 1 2 2 2 0

— U N

— 2 4 M A Y

0 2

F i n a l f u e l f i l t e r b l e e d s c r e w

B . ) H P C R f u e l s y s t e m ( 2 o r 4 - v a l v e h e a d )

C A U T I O N : H i g h - p r e s s u r e f l u i d r e m a i n i n g i n f u e l l i n e s c a n c a u s e s e r i o u s i n j u r y . D o n o t d i s c o n n e c t f u e l l i n e s b e t w e e n t h e h i g h p r e s s u r e

f u e l p u m p a n d n o z z l e s . O n l y b l e e d t h e f u e l s y s t e m a t t h e f u e l f i l t e r b l e e d s c r e w ( A ) .

1 . L o o s e n t h e a i r b l e e d s c r e w ( A ) t w o f u l l t u r n s o n f i n a l f i l t e r b a s e o n l y .

2 . O p e r a t e f u e l s u p p l y p u m p p r i m e r l e v e r ( B ) u n t i l f u e l f l o w i s f r e e f r o m a i r b u b b l e s .

3 . T i g h t e n b l e e d s c r e w s e c u r e l y . C o n t i n u e o p e r a t i n g p r i m e r u n t i l p u m p i n g a c t i o n i s n o t f e l t .

4 . S t a r t e n g i n e a n d c h e c k f o r l e a k s .

I f e n g i n e w i l l n o t s t a r t , r e p e a t s t e p s 1 - 4 .

R G 1 2 2 2 1

— U N

— 2 4 M A Y 0 2

F u e l s u p p l y p u m p p r i m e r l e v e r

5 0 - 7 0 7 2 2 0 9

P N = 9 4

164/258



T r o u b l e s h o o t i n g

C D 0 3 5 2 3 , 0 0 0 0 1 8 D - 1 9 - 0 8 F E B 0 7 - 1 / 1

G e n e r a l t r o u b l e s h o o t i n g i n f o r m a t i o n

T r o u b l e s h o o t i n g e l e c t r o n i c a l l y c o n t r o l l e d e n g i n e p r o b l e m s c a n b e d i f f i c u l t . T h e f i r s t t h i n g t o d o i s t o i d e n t i f y t h e t y p e o f p r o b l e m w h i c h c a n b e m e c h a n i c a l o r e l e c t r i c a l .

A n e n g i n e w i r i n g l a y o u t i s p r o v i d e d i n t h i s s e c t i o n t o i d e n t i f y e l e c t r i c a l c o m p o n e n t s ( e n g i n e c o n t r o l l e r , s e n s o r s ,

c o n n e c t o r s . . . ) . L a t e r i n t h i s s e c t i o n i s a l i s t o f p o s s i b l e e n g i n e p r o b l e m s a n d d i a g n o s t i c t r o u b l e c o d e s t h a t m a y b e e n c o u n t e r e d a c c o m p a n i e d b y p o s s i b l e c a u s e s a n d c o r r e c t i o n s . T h i s t r o u b l e s h o o t i n g i n f o r m a t i o n i s o f a g e n e r a l n a t u r e . S e e a l s o t h e g e n e r a t o r d o c u m e n t a t i o n f o r a c o m p l e t e i n f o r m a t i o n o f y o u r a p p l i c a t i o n .

A r e l i a b l e p r o g r a m f o r t r o u b l e s h o o t i n g e n g i n e p r o b l e m s s h o u l d i n c l u d e t h e f o l l o w i n g b a s i c d i a g n o s t i c t h o u g h t p r o c e s s :

• K n o w t h e e n g i n e a n d a l l r e l a t e d s y s t e m s .

• S t u d y t h e p r o b l e m t h o r o u g h l y .

• R e l a t e t h e s y m p t o m s t o y o u r k n o w l e d g e o f e n g i n e a n d s y s t e m s .

• D i a g n o s e t h e p r o b l e m s t a r t i n g w i t h t h e e a s i e s t t h i n g s f i r s t .

• D o u b l e - c h e c k b e f o r e b e g i n n i n g t h e d i s a s s e m b l y .

• D e t e r m i n e c a u s e a n d m a k e a t h o r o u g h r e p a i r .

• A f t e r m a k i n g r e p a i r s , o p e r a t e t h e e n g i n e u n d e r n o r m a l c o n d i t i o n s t o v e r i f y t h a t t h e p r o b l e m a n d c a u s e w a s c o r r e c t e d .

5 5 - 1 0 7 2 2 0 9

P N = 9 5

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C D 0 3 5 2 3 , 0 0 0 0 1 8 E - 1 9 - 0 2 F E B 0 7 - 1 / 1

E n g i n e W i r i n g L a y o u t ( E l e c t r o n i c F u e l S y s t e m W i t h S t a n a d y n e D E 1 0 I n j e c t i o n P u m p )

R G 1 2 2 0 1

— U N

— 2 4 M A Y 0 2

A — C o o l a n t T e m p e r a t u r e S e n s o r C o n n e c t o r

B — F u e l T e m p e r a t u r e S e n s o r C o n n e c t o r

C — I n j e c t i o n P u m p S o l e n o i d C o n n e c t o r

D — S A E 1 9 3 9 C A N C o n n e c t o r E — C r a n k s h a f t P o s i t i o n S e n s o r

C o n n e c t o r F — E C U C o n n e c t o r

G — S t a r t e r R e l a y C o n n e c t o r H — O i l P r e s s u r e S e n s o r

C o n n e c t o r I — M a i n S y s t e m F u s e ( 1 0 a m p ) J — P o w e r a n d G r o u n d B a t t e r y

C o n n e c t i o n s K — F u s e H o l d e r L — T r a n s i e n t V o l t a g e P r o t e c t i o n

( T V P ) M o d u l e C o n n e c t o r

M — R e m o t e O N / O F F C o n n e c t o r N — C A N N e t w o r k D i a g n o s t i c

C o n n e c t o r O — I n s t r u m e n t P a n e l C o n n e c t o r

H a r n e s s P — 2 3 - p i n O p t i o n a l F e a t u r e

C o n n e c t o r ( E x t e n d e d - f e a t u r e E C U o n l y )

Q — 2 1 - p i n I n s t r u m e n t P a n e l C o n n e c t o r

R — E n g i n e W i r i n g H a r n e s s

S — F u e l H e a t e r C o n n e c t o r T — M a n i f o l d A i r T e m p e r a t u r e

( M A T ) S e n s o r C o n n e c t o r U — A l t e r n a t o r I g n i t i o n C o n n e c t o r V — O p t i o n a l I n s t r u m e n t P a n e l o r

G e n e r a t o r I n s t r u m e n t P a n e l

5 5 - 2 0 7 2 2 0 9

P N = 9 6

166/258




C D 0 3 5 2 3 , 0 0 0 0 1 8 F - 1 9 - 0 2 F E B 0 7 - 1 / 1

E n g i n e W i r i n g L a y o u t ( E l e c t r o n i c F u e l S y s t e m W i t h D e n s o H i g h P r e s s u r e C o m m o n R a i l )

R G 1 2 2 2 4

— U N

— 1 9 J U N 0 2

6 0 6 8 H F U 7 4 E n g i n e s h o w n A — E n g i n e C o o l a n t T e m p e r a t u r e

( E C T ) S e n s o r B — E l e c t r o n i c I n j e c t o r C o n n e c t o r C — M a n i f o l d A i r T e m p e r a t u r e

( M A T ) S e n s o r D — E C U C o n n e c t o r

E — O p t i o n a l I n s t r u m e n t P a n e l o r G e n e r a t o r I n s t r u m e n t P a n e l

F — E n g i n e W i r i n g H a r n e s s G — E n g i n e O i l P r e s s u r e S e n s o r

C o n n e c t o r H — P o w e r a n d G r o u n d B a t t e r y

C o n n e c t i o n s

I — F u e l R a i l P r e s s u r e S e n s o r J — C r a n k s h a f t P o s i t i o n S e n s o r K — P u m p P o s i t i o n S e n s o r L — P u m p C o n t r o l V a l v e S o l e n o i d

M — F u e l T e m p e r a t u r e S e n s o r

5 5 - 3 0 7 2 2 0 9

P N = 9 7

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E n g i n e t r o u b l e s h o o t i n g

S y m p t o m P r o b l e m S o l u t i o n

E n g i n e c r a n k s b u t w i l l n o t s t a r t I n c o r r e c t s t a r t i n g p r o c e d u r e . V e r i f y c o r r e c t s t a r t i n g p r o c e d u r e .

N o f u e l . C h e c k f u e l i n t a n k a n d m a n u a l s h u t - o f f v a l v e .

E x h a u s t r e s t r i c t e d . C h e c k a n d c o r r e c t e x h a u s t r e s t r i c t i o n .

F u e l f i l t e r p l u g g e d o r f u l l o f w a t e r . R e p l a c e f u e l f i l t e r o r d r a i n w a t e r f r o m f i l t e r .

I n j e c t i o n p u m p n o t g e t t i n g f u e l o r a i r i n f u e l s y s t e m .

C h e c k f u e l f l o w a t s u p p l y p u m p o r b l e e d f u e l s y s t e m .

F a u l t y i n j e c t i o n p u m p o r n o z z l e s . C o n s u l t a u t h o r i z e d d i e s e l r e p a i r s t a t i o n f o r r e p a i r o r r e p l a c e m e n t .

E n g i n e h a r d t o s t a r t o r w i l l n o t s t a r t E n g i n e s t a r t i n g u n d e r l o a d . R e m o v e l o a d .

I m p r o p e r s t a r t i n g p r o c e d u r e . R e v i e w s t a r t i n g p r o c e d u r e .

N o f u e l . C h e c k f u e l t a n k .

A i r i n f u e l l i n e . B l e e d f u e l l i n e .

C o l d w e a t h e r . U s e c o l d w e a t h e r s t a r t i n g a i d s .

S l o w s t a r t e r s p e e d . S e e ” S t a r t e r C r a n k s S l o w l y ” .

C r a n k c a s e o i l t o o h e a v y . U s e o i l o f p r o p e r v i s c o s i t y .

I m p r o p e r t y p e o f f u e l . C o n s u l t f u e l s u p p l i e r ; u s e p r o p e r t y p e f u e l f o r o p e r a t i n g c o n d i t i o n s .

W a t e r , d i r t , o r a i r i n f u e l s y s t e m . D r a i n , f l u s h , f i l l , a n d b l e e d s y s t e m .

C l o g g e d f u e l f i l t e r . R e p l a c e f i l t e r e l e m e n t .

D i r t y o r f a u l t y i n j e c t i o n n o z z l e s . H a v e a u t h o r i z e d s e r v i c i n g d e a l e r o r e n g i n e d i s t r i b u t o r c h e c k i n j e c t o r s .

I n j e c t i o n p u m p s h u t - o f f n o t r e s e t . T u r n k e y s w i t c h t o ” O F F ” t h e n t o ” O N ” .

E n g i n e k n o c k s L o w e n g i n e o i l l e v e l . A d d o i l t o e n g i n e c r a n k c a s e .

I n j e c t i o n p u m p o u t o f t i m e . S e e y o u r a u t h o r i z e d s e r v i c i n g d e a l e r o r e n g i n e d i s t r i b u t o r .

L o w c o o l a n t t e m p e r a t u r e . R e m o v e a n d c h e c k t h e r m o s t a t .

E n g i n e o v e r h e a t i n g . S e e ” E n g i n e O v e r h e a t s ” .

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P N = 9 8

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E n g i n e r u n s i r r e g u l a r l y o r s t a l l s f r e q u e n t l y

L o w c o o l a n t t e m p e r a t u r e . R e m o v e a n d c h e c k t h e r m o s t a t .

C l o g g e d f u e l f i l t e r . R e p l a c e f u e l f i l t e r e l e m e n t .

W a t e r , d i r t , o r a i r i n f u e l s y s t e m . D r a i n , f l u s h , f i l l , a n d b l e e d s y s t e m .

D i r t y o r f a u l t y i n j e c t i o n n o z z l e s . H a v e a u t h o r i z e d s e r v i c i n g d e a l e r o r e n g i n e d i s t r i b u t o r c h e c k i n j e c t o r s .

B e l o w n o r m a l e n g i n e t e m p e r a t u r e D e f e c t i v e t h e r m o s t a t . R e m o v e a n d c h e c k t h e r m o s t a t .

D e f e c t i v e t e m p e r a t u r e g a u g e o r s e n d e r .

C h e c k g a u g e , s e n d e r , a n d c o n n e c t i o n s .

L a c k o f p o w e r E n g i n e o v e r l o a d e d . R e d u c e l o a d .

I n t a k e a i r r e s t r i c t i o n . S e r v i c e a i r c l e a n e r .

C l o g g e d f u e l f i l t e r . R e p l a c e f i l t e r e l e m e n t s .

I m p r o p e r t y p e o f f u e l . U s e p r o p e r f u e l .

O v e r h e a t e d e n g i n e . S e e ” E n g i n e O v e r h e a t s ” .

B e l o w n o r m a l e n g i n e t e m p e r a t u r e . R e m o v e a n d c h e c k t h e r m o s t a t .

I m p r o p e r v a l v e c l e a r a n c e . S e e y o u r a u t h o r i z e d s e r v i c i n g d e a l e r o r e n g i n e d i s t r i b u t o r .

D i r t y o r f a u l t y i n j e c t i o n n o z z l e s . H a v e a u t h o r i z e d s e r v i c i n g d e a l e r o r

e n g i n e d i s t r i b u t o r c h e c k i n j e c t o r s .

I n j e c t i o n p u m p o u t o f t i m e . S e e y o u r a u t h o r i z e d s e r v i c i n g d e a l e r o r e n g i n e d i s t r i b u t o r .

T u r b o c h a r g e r n o t f u n c t i o n i n g . S e e y o u r a u t h o r i z e d s e r v i c i n g d e a l e r o r e n g i n e d i s t r i b u t o r .

L e a k i n g e x h a u s t m a n i f o l d g a s k e t . S e e y o u r a u t h o r i z e d s e r v i c i n g d e a l e r o r e n g i n e d i s t r i b u t o r .

D e f e c t i v e a n e r o i d c o n t r o l l i n e . S e e y o u r a u t h o r i z e d s e r v i c i n g d e a l e r o r e n g i n e d i s t r i b u t o r .

R e s t r i c t e d f u e l h o s e . C l e a n o r r e p l a c e f u e l h o s e .

L o w f a s t i d l e s p e e d . S e e y o u r a u t h o r i z e d s e r v i c i n g d e a l e r o r e n g i n e d i s t r i b u t o r .

L o w o i l p r e s s u r e L o w o i l l e v e l . A d d o i l .

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P N = 9 9

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I m p r o p e r t y p e o f o i l . D r a i n , f i l l c r a n k c a s e w i t h o i l o f p r o p e r v i s c o s i t y a n d q u a l i t y .

H i g h o i l c o n s u m p t i o n C r a n k c a s e o i l t o o l i g h t . U s e p r o p e r v i s c o s i t y o i l .

O i l l e a k s . C h e c k f o r l e a k s i n l i n e s , g a s k e t s , a n d

d r a i n p l u g .

R e s t r i c t e d c r a n k c a s e v e n t t u b e . C l e a n v e n t t u b e .

D e f e c t i v e t u r b o c h a r g e r . S e e y o u r a u t h o r i z e d s e r v i c i n g d e a l e r o r e n g i n e d i s t r i b u t o r .

E n g i n e e m i t s w h i t e s m o k e I m p r o p e r t y p e o f f u e l . U s e p r o p e r f u e l .

L o w e n g i n e t e m p e r a t u r e . W a r m u p e n g i n e t o n o r m a l o p e r a t i n g t e m p e r a t u r e .

D e f e c t i v e t h e r m o s t a t . R e m o v e a n d c h e c k t h e r m o s t a t .

D e f e c t i v e i n j e c t i o n n o z z l e s . S e e y o u r a u t h o r i z e d s e r v i c i n g d e a l e r o r e n g i n e d i s t r i b u t o r .

E n g i n e o u t o f t i m e . S e e y o u r a u t h o r i z e d s e r v i c i n g d e a l e r o r e n g i n e d i s t r i b u t o r .

E n g i n e e m i t s b l a c k o r g r a y e x h a u s t s m o k e

I m p r o p e r t y p e o f f u e l . U s e p r o p e r f u e l .

C l o g g e d o r d i r t y a i r c l e a n e r . S e r v i c e a i r c l e a n e r .

E n g i n e o v e r l o a d e d . R e d u c e l o a d .

I n j e c t i o n n o z z l e s d i r t y . S e e y o u r a u t h o r i z e d s e r v i c i n g d e a l e r o r e n g i n e d i s t r i b u t o r .


T u r b o c h a r g e r n o t f u n c t i o n i n g . S e e y o u r a u t h o r i z e d s e r v i c i n g d e a l e r o r e n g i n e d i s t r i b u t o r .

E n g i n e o v e r h e a t s E n g i n e o v e r l o a d e d . R e d u c e l o a d .

L o w c o o l a n t l e v e l . F i l l r a d i a t o r t o p r o p e r l e v e l , c h e c k r a d i a t o r a n d h o s e s f o r l o o s e c o n n e c t i o n s o r l e a k s .

F a u l t y r a d i a t o r c a p . H a v e s e r v i c e m a n c h e c k .

S t r e t c h e d p o l y V - b e l t o r d e f e c t i v e b e l t t e n s i o n e r .

C h e c k a u t o m a t i c b e l t t e n s i o n e r a n d c h e c k b e l t s f o r s t r e t c h i n g . R e p l a c e a s r e q u i r e d .

5 5 - 6 0 7 2 2 0 9

P N = 1 0 0

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D P S G , C D 0 3 5 2 3 , 4 9 - 1 9 - 2 2 J A N 0 7 - 4 / 4


L o w e n g i n e o i l l e v e l . C h e c k o i l l e v e l . A d d o i l a s r e q u i r e d .

C o o l i n g s y s t e m n e e d s f l u s h i n g . F l u s h c o o l i n g s y s t e m .

D e f e c t i v e t h e r m o s t a t . R e m o v e a n d c h e c k t h e r m o s t a t .

D e f e c t i v e t e m p e r a t u r e g a u g e o r s e n d e r .

C h e c k w a t e r t e m p e r a t u r e w i t h t h e r m o m e t e r a n d r e p l a c e , i f n e c e s s a r y .

I n c o r r e c t g r a d e o f f u e l . U s e c o r r e c t g r a d e o f f u e l .

H i g h f u e l c o n s u m p t i o n I m p r o p e r t y p e o f f u e l . U s e p r o p e r t y p e o f f u e l .

C l o g g e d o r d i r t y a i r c l e a n e r . S e r v i c e a i r c l e a n e r .

E n g i n e o v e r l o a d e d . R e d u c e l o a d .

I m p r o p e r v a l v e c l e a r a n c e . S e e y o u r a u t h o r i z e d s e r v i c i n g d e a l e r o r e n g i n e d i s t r i b u t o r .

I n j e c t i o n n o z z l e s d i r t y . S e e y o u r a u t h o r i z e d s e r v i c i n g d e a l e r o r e n g i n e d i s t r i b u t o r .


D e f e c t i v e t u r b o c h a r g e r . S e e y o u r a u t h o r i z e d s e r v i c i n g d e a l e r o r e n g i n e d i s t r i b u t o r .

L o w e n g i n e t e m p e r a t u r e . C h e c k t h e r m o s t a t .

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P N = 1 0 1

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E l e c t r i c a l t r o u b l e s h o o t i n g


U n d e r c h a r g e d s y s t e m E x c e s s i v e e l e c t r i c a l l o a d f r o m a d d e d a c c e s s o r i e s .

R e m o v e a c c e s s o r i e s o r i n s t a l l h i g h e r o u t p u t a l t e r n a t o r .

E x c e s s i v e e n g i n e i d l i n g . I n c r e a s e e n g i n e r p m w h e n h e a v y

e l e c t r i c a l l o a d i s u s e d .

P o o r e l e c t r i c a l c o n n e c t i o n s o n b a t t e r y , g r o u n d s t r a p , s t a r t e r , o r a l t e r n a t o r .

I n s p e c t a n d c l e a n a s n e c e s s a r y .

D e f e c t i v e b a t t e r y . T e s t b a t t e r y .

D e f e c t i v e a l t e r n a t o r . T e s t c h a r g i n g s y s t e m .

B a t t e r y u s e s t o o m u c h w a t e r C r a c k e d b a t t e r y c a s e . C h e c k f o r m o i s t u r e a n d r e p l a c e a s n e c e s s a r y .

D e f e c t i v e b a t t e r y . T e s t b a t t e r y .

B a t t e r y c h a r g i n g r a t e t o o h i g h . T e s t c h a r g i n g s y s t e m .

B a t t e r i e s w i l l n o t c h a r g e L o o s e o r c o r r o d e d c o n n e c t i o n s . C l e a n a n d t i g h t e n c o n n e c t i o n s .

S u l f a t e d o r w o r n - o u t b a t t e r i e s . S e e y o u r a u t h o r i z e d s e r v i c i n g d e a l e r o r e n g i n e d i s t r i b u t o r .

S t r e t c h e d p o l y V - b e l t o r d e f e c t i v e b e l t t e n s i o n e r .

A d j u s t b e l t t e n s i o n o r r e p l a c e b e l t s .

S t a r t e r w i l l n o t c r a n k E n g i n e u n d e r l o a d R e m o v e l o a d

L o o s e o r c o r r o d e d c o n n e c t i o n s . C l e a n a n d t i g h t e n l o o s e c o n n e c t i o n s .

L o w b a t t e r y o u t p u t v o l t a g e . S e e y o u r a u t h o r i z e d s e r v i c i n g d e a l e r o r e n g i n e d i s t r i b u t o r .

F a u l t y s t a r t c i r c u i t r e l a y . S e e y o u r a u t h o r i z e d s e r v i c i n g d e a l e r o r e n g i n e d i s t r i b u t o r .

B l o w n f u s e . R e p l a c e f u s e .

S t a r t e r c r a n k s s l o w l y L o w b a t t e r y o u t p u t . S e e y o u r a u t h o r i z e d s e r v i c i n g d e a l e r o r e n g i n e d i s t r i b u t o r .

C r a n k c a s e o i l t o o h e a v y . U s e p r o p e r v i s c o s i t y o i l .

L o o s e o r c o r r o d e d c o n n e c t i o n s . C l e a n a n d t i g h t e n l o o s e c o n n e c t i o n s .

E n t i r e e l e c t r i c a l s y s t e m F a u l t y b a t t e r y c o n n e c t i o n . C l e a n a n d t i g h t e n c o n n e c t i o n s .

5 5 - 8 0 7 2 2 0 9

P N = 1 0 2

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D P S G , C D 0 3 5 2 3 , 5 0 - 1 9 - 2 2 J A N 0 7 - 2 / 2

C D 0 3 5 2 3 , 0 0 0 0 1 9 0 - 1 9 - 0 2 F E B 0 7 - 1 / 1

C D 0 3 5 2 3 , 0 0 0 0 1 9 1 - 1 9 - 0 2 F E B 0 7 - 1 / 1


S u l f a t e d o r w o r n - o u t b a t t e r i e s . S e e y o u r a u t h o r i z e d s e r v i c i n g d e a l e r o r e n g i n e d i s t r i b u t o r .

B l o w n f u s e . R e p l a c e f u s e .

D i s p l a y i n g O f D i a g n o s t i c T r o u b l e C o d e s ( D T C s )

T h e r e a r e s e v e r a l d i f f e r e n t m e t h o d s f o r d i s p l a y i n g b o t h s t o r e d a n d a c t i v e D T C s f r o m t h e E C U v i a a f a u l t l a m p o r a d i a g n o s t i c g a u g e o n t h e e l e c t r o n i c i n s t r u m e n t p a n e l .

2 - D I G I T C O D E S

S o m e e n g i n e s d i s p l a y S e r v i c e C o d e s o r D T C s a s 2 - d i g i t c o d e s r e a d f r o m a f a u l t l a m p w h i c h g i v e s b l i n k c o d e s .

S P N / F M I C O D E S

S t o r e d a n d a c t i v e d i a g n o s t i c t r o u b l e c o d e s a r e o u t p u t o n t h e d i a g n o s t i c g a u g e o n t h e D e e r e e l e c t r o n i c i n s t r u m e n t p a n e l a c c o r d i n g t o t h e J 1 9 3 9 s t a n d a r d a s a t w o - p a r t c o d e a s s h o w n o n t h e t a b l e s o n t h e f o l l o w i n g p a g e s .

T h e f i r s t p a r t i s a s i x - d i g i t S u s p e c t P a r a m e t e r N u m b e r ( S P N ) f o l l o w e d b y a t w o - d i g i t F a i l u r e M o d e I d e n t i f i e r ( F M I ) c o d e . I n o r d e r t o d e t e r m i n e t h e e x a c t f a i l u r e , b o t h p a r t s ( S P N a n d F M I ) o f t h e c o d e a r e n e e d e d .

T h e S P N i d e n t i f i e s t h e s y s t e m o r t h e c o m p o n e n t t h a t h a s t h e f a i l u r e ; f o r e x a m p l e S P N 0 0 0 1 1 0 i n d i c a t e s a f a i l u r e i n t h e e n g i n e c o o l a n t t e m p e r a t u r e c i r c u i t .

T h e F M I i d e n t i f i e s t h e t y p e o f f a i l u r e t h a t h a s o c c u r r e d ; f o r e x a m p l e F M I 0 3 i n d i c a t e s v a l u e a b o v e n o r m a l . C o m b i n i n g S P N 0 0 0 1 1 0 w i t h F M I 0 3 y i e l d s e n g i n e c o o l a n t t e m p e r a t u r e i n p u t v o l t a g e t o o h i g h , o r t h e e q u i v a l e n t o f 2 - d i g i t f a u l t c o d e 1 8 .

I f d i a g n o s i n g a n a p p l i c a t i o n t h a t s h o w s D T C s a s S P N s a n d F M I s , u s i n g t h e f o l l o w i n g l i s t , d e t e r m i n e t h e e q u i v a l e n t 2 - d i g i t c o d e a n d h a v e y o u r d e a l e r u s e t h e d i a g n o s t i c p r o c e d u r e i n t h e c o m p o n e n t t e c h n i c a l m a n u a l f o r t h a t 2 - d i g i t c o d e .

A l w a y s c o n t a c t y o u r s e r v i c i n g d e a l e r f o r h e l p i n c o r r e c t i n g d i a g n o s t i c t r o u b l e c o d e s w h i c h a r e d i s p l a y e d f o r y o u r e n g i n e .

U s i n g b l i n k c o d e m e t h o d f o r r e t r i e v i n g D i a g n o s t i c T r o u b l e C o d e s ( D T C ’ s )

N O T E : T h e m e t h o d b e l o w a p p l i e s t o a p p l i c a t i o n s h a v i n g a f a u l t l a m p o n i n s t r u m e n t p a n e l ( r e f e r t o t h e g e n e r a t o r d o c u m e n t a t i o n f o r m o r e i n f o r m a t i o n ) .

T h e E l e c t r o n i c C o n t r o l U n i t ( E C U ) h a s t h e a b i l i t y t o d i s p l a y D T C s u s i n g b l i n k i n g s e q u e n c e o f t h e f a u l t l a m p .

N O T E : T h e E C U b l i n k s t h e c o d e s i n 2 - d i g i t c o d e s o n l y . S e e L I S T I N G O F D I A G N O S T I C T R O U B L E C O D E S ( D T C S ) l a t e r i n t h i s G r o u p .

1 . P r e s s d o w n O v e r r i d e S h u t d o w n S w i t c h w h i l e t u r n i n g t h e i g n i t i o n s w i t c h ” O N ” .

2 . T h e F a u l t L a m p w i l l b e g i n t o f l a s h a c o d e n u m b e r . F o r e x a m p l e , f l a s h t h r e e t i m e s . . . s h o r t p a u s e . . . f l a s h t w o t i m e s . . . l o n g p a u s e . T h i s e x a m p l e i s c o d e 3 2 .

3 . T h e E C U b e g i n s t h e f l a s h i n g s e q u e n c e b y f l a s h i n g a c o d e 3 2 , t h i s i n d i c a t e s t h e s t a r t o f b l i n k i n g a c t i v e c o d e s . I f t h e r e a r e a n y a c t i v e D T C s , t h e E C U w i l l f l a s h i t s 2 – d i g i t n u m b e r . I f t h e r e i s m o r e t h a n o n e a c t i v e D T C , t h e E C U w i l l f l a s h e a c h c o d e i n n u m e r i c a l o r d e r .

I f t h e r e a r e n o a c t i v e D T C s , t h e F a u l t L a m p w i l l f l a s h a c o d e 8 8 .

4 . F o l l o w i n g t h e a c t i v e c o d e s , t h e F a u l t L a m p w i l l f l a s h a c o d e 3 3 . T h i s i n d i c a t e s t h e s t a r t o f b l i n k i n g s t o r e d c o d e s . I f t h e r e a r e a n y s t o r e d D T C s , t h e F a u l t L a m p w i l l f l a s h i t s 2 – d i g i t n u m b e r . I f t h e r e i s m o r e t h a n o n e s t o r e d D T C , t h e E C U w i l l f l a s h e a c h c o d e i n n u m e r i c a l o r d e r . I f t h e r e a r e n o s t o r e d D T C s , t h e F a u l t L a m p w i l l f l a s h a c o d e 8 8 .

5 . O n c e c o m p l e t e , t h i s s e q u e n c e w i l l r e p e a t .

6 . W h e n c o m p l e t e , t u r n i g n i t i o n ” O F F ” .

A s a n e x a m p l e , i f a n e n g i n e h a d a n a c t i v e D T C 1 8 a n d s t o r e d D T C 5 3 , t h e f l a s h i n g s e q u e n c e w o u l d b e : f l a s h t h r e e t i m e s . . . s h o r t p a u s e . . . f l a s h t w o t i m e s . . . l o n g p a u s e . . . f l a s h o n e t i m e . . . s h o r t p a u s e . . . f l a s h e i g h t t i m e s . . . l o n g p a u s e . . . f l a s h t h r e e t i m e s . . . s h o r t p a u s e . . . f l a s h t h r e e t i m e s . . . l o n g p a u s e . . . f l a s h f i v e t i m e s . . . s h o r t p a u s e . . . f l a s h t h r e e t i m e s .

5 5 - 9 0 7 2 2 0 9

P N = 1 0 3

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C D 0 3 5 2 3 , 0 0 0 0 1 9 2 - 1 9 - 0 2 F E B 0 7 - 1 / 1

U s i n g d i a g n o s t i c g a u g e f o r r e t r i e v i n g D i a g n o s t i c T r o u b l e C o d e s ( D T C ’ s )

N O T E : T h e m e t h o d b e l o w a p p l i e s o n a p p l i c a t i o n s h a v i n g t h e o p t i o n a l d i a g n o s t i c g a u g e s h o w n ( r e f e r t o t h e g e n e r a t o r d o c u m e n t a t i o n f o r m o r e i n f o r m a t i o n ) .

1 . M a k e s u r e a l l e n g i n e m e c h a n i c a l a n d o t h e r s y s t e m s

n o t r e l a t e d t o t h e e l e c t r o n i c c o n t r o l s y s t e m a r e o p e r a t i n g p r o p e r l y . ( S e e E N G I N E T R O U B L E S H O O T I N G i n t h i s s e c t i o n ) .

N O T E : D i a g n o s t i c g a u g e ( A ) u s e s t h e m e n u k e y ( B ) t o a c c e s s v a r i o u s e n g i n e f u n c t i o n s , t w o a r r o w k e y s ( C ) t o s c r o l l t h r o u g h t h e e n g i n e p a r a m e t e r l i s t a n d v i e w t h e m e n u l i s t , a n d a n e n t e r k e y ( D ) f o r s e l e c t i n g h i g h l i g h t e d i t e m s .

2 . R e a d a n d r e c o r d D T C ( s ) d i s p l a y e d o n L C D o f d i a g n o s t i c g a u g e ( A ) . F o r p r o c e d u r e t o a c c e s s d i a g n o s t i c t r o u b l e c o d e s , r e f e r t o ” U s i n g D i a g n o s t i c G a u g e t o A c c e s s E n g i n e I n f o r m a t i o n ” , e a r l i e r i n t h i s m a n u a l .

3 . G o t o t h e L I S T I N G O F D I A G N O S T I C T R O U B L E C O D E S ( D T C s ) l a t e r i n t h i s s e c t i o n , t o i n t e r p r e t t h e D T C ( s ) p r e s e n t .

R G 1 3 7 4 0

— U N

— 1 1 N O V 0 4

T r o u b l e C o d e D i s p l a y O n I n s t r u m e n t P a n e l

A — D i a g n o s t i c G a u g e B — M e n u K e y

C — A r r o w K e y s D — E n t e r K e y

4 . C o n t a c t y o u r n e a r e s t e n g i n e d i s t r i b u t o r o r s e r v i c i n g d e a l e r w i t h a l i s t o f D T C ( s ) s o t h a t n e c e s s a r y r e p a i r s c a n b e m a d e .

5 5 - 1 0 0 7 2 2 0 9

P N = 1 0 4

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C o n t i n u e d o n n e x t p a g e O U R G P 1 2 , 0 0 0 0 1 E 2 - 1 9 - 1 5 M A R 0 6 - 1 / 2

L i s t i n g o f D i a g n o s t i c T r o u b l e C o d e s ( D T C s )

N O T E : N o t a l l o f t h e s e c o d e s a r e u s e d o n a l l O E M e n g i n e a p p l i c a t i o n s

T r o u b l e C o d e s

S P N F M I D e s c r i p t i o n o f F a u l t C o r r e c t i v e A c t i o n

0 0 0 0 2 8 0 3 T h r o t t l e # 3 S i g n a l O u t o f R a n g e H i g h C h e c k S e n s o r a n d W i r i n g

0 4 T h r o t t l e # 3 S i g n a l O u t o f R a n g e L o w C h e c k S e n s o r a n d W i r i n g

0 0 0 0 2 9 0 3 T h r o t t l e # 2 S i g n a l O u t o f R a n g e H i g h C h e c k S e n s o r a n d W i r i n g

0 4 T h r o t t l e # 2 S i g n a l O u t o f R a n g e L o w C h e c k S e n s o r a n d W i r i n g

0 0 0 0 8 4 3 1 V e h i c l e S p e e d S i g n a l U n r e l i a b l e C o n t a c t S e r v i c i n g D e a l e r

0 0 0 0 9 1 0 3 T h r o t t l e # 1 S i g n a l O u t o f R a n g e H i g h C h e c k S w i t c h a n d W i r i n g

0 4 T h r o t t l e # 1 S i g n a l O u t o f R a n g e L o w C h e c k S w i t c h a n d W i r i n g

0 9 T h r o t t l e # 1 C o m m u n i c a t i o n S i g n a l E r r a t i c C h e c k S e n s o r a n d W i r i n g

0 0 0 0 9 4 0 3 L o w P r e s s u r e F u e l S i g n a l O u t o f R a n g e H i g h C h e c k S e n s o r a n d W i r i n g

0 4 L o w P r e s s u r e F u e l S i g n a l O u t o f R a n g e L o w C h e c k S e n s o r a n d W i r i n g

1 0 L o w P r e s s u r e F u e l R a t e o f C h a n g e A b n o r m a l C o n t a c t S e r v i c i n g D e a l e r

1 3 L o w P r e s s u r e F u e l O u t o f C a l i b r a t i o n C o n t a c t S e r v i c i n g D e a l e r

1 7 H i g h P r e s s u r e F u e l S y s t e m - P r e s s u r e S l i g h t l y L o w C o n t a c t S e r v i c i n g D e a l e r

0 0 0 0 9 7 0 0 W a t e r i n F u e l C o n t i n u o u s l y D e t e c t e d C o n t a c t S e r v i c i n g D e a l e r

0 3 W a t e r - i n - F u e l S i g n a l O u t o f R a n g e H i g h C h e c k S e n s o r a n d W i r i n g

0 4 W a t e r - i n - F u e l S i g n a l O u t o f R a n g e L o w C h e c k S e n s o r a n d W i r i n g

1 6 W a t e r i n F u e l D e t e c t e d S t o p a n d D r a i n W a t e r S e p a r a t o r

0 0 0 1 0 0 0 1 E n g i n e O i l P r e s s u r e S i g n a l E x t r e m e l y L o w C h e c k O i l L e v e l

0 3 E n g i n e O i l P r e s s u r e S i g n a l O u t o f R a n g e H i g h C h e c k S e n s o r a n d W i r i n g

0 4 E n g i n e O i l P r e s s u r e S i g n a l O u t o f R a n g e L o w C h e c k S e n s o r a n d W i r i n g

1 8 E n g i n e O i l P r e s s u r e S i g n a l M o d e r a t e l y L o w C h e c k O i l L e v e l

0 0 0 1 0 5 0 0 I n t a k e M a n i f o l d A i r T e m p e r a t u r e S i g n a l E x t r e m e l y H i g h C h e c k A i r C l e a n e r , A f t e r c o o l e r , o r R o o m T e m p e r a t u r e

0 3 I n t a k e M a n i f o l d A i r T e m p e r a t u r e S i g n a l O u t o f R a n g e H i g h C h e c k S e n s o r a n d W i r i n g

0 4 I n t a k e M a n i f o l d A i r T e m p e r a t u r e S i g n a l O u t o f R a n g e L o w C h e c k S e n s o r a n d W i r i n g

1 6 I n t a k e M a n i f o l d A i r T e m p e r a t u r e S i g n a l M o d e r a t e l y H i g h

C h e c k A i r C l e a n e r , A f t e r c o o l e r , o r R o o m T e m p e r a t u r e 0 0 0 1 0 7 0 0 A i r F i l t e r P r e s s u r e D i f f e r e n t i a l E x t r e m e l y H i g h C h e c k f o r p l u g g e d a i r f i l t e r

0 0 0 1 1 0 0 0 E n g i n e C o o l a n t T e m p e r a t u r e S i g n a l E x t r e m e l y H i g h C h e c k C o o l i n g S y s t e m , R e d u c e P o w e r

0 3 E n g i n e C o o l a n t T e m p e r a t u r e S i g n a l O u t o f R a n g e H i g h C h e c k S e n s o r a n d W i r i n g

0 4 E n g i n e C o o l a n t T e m p e r a t u r e S i g n a l O u t o f R a n g e L o w C h e c k S e n s o r a n d W i r i n g

1 5 E n g i n e C o o l a n t T e m p e r a t u r e S i g n a l S l i g h t l y H i g h C h e c k C o o l i n g S y s t e m , R e d u c e P o w e r

1 6 E n g i n e C o o l a n t T e m p e r a t u r e S i g n a l M o d e r a t e l y H i g h C h e c k C o o l i n g S y s t e m , R e d u c e P o w e r

0 0 0 1 1 1 0 1 E n g i n e C o o l a n t L e v e l L o w C h e c k O p e r a t o r ’ s M a n u a l , “ A d d i n g C o o l a n t ”

0 0 0 1 5 8 1 7 E C U P o w e r D o w n E r r o r ( I n t e r n a l E C U P r o b l e m ) C o n t a c t S e r v i c i n g D e a l e r

0 0 0 1 6 0 0 2 A x l e S p e e d S i g n a l U n r e l i a b l e C o n t a c t S e r v i c i n g D e a l e r

0 0 0 1 7 4 0 0 F u e l T e m p e r a t u r e S i g n a l E x t r e m e l y H i g h A d d F u e l o r S w i t c h F u e l T a n k s

0 0 0 1 7 4 0 3 F u e l T e m p e r a t u r e S i g n a l O u t o f R a n g e H i g h C h e c k S e n s o r a n d W i r i n g 0 4 F u e l T e m p e r a t u r e S i g n a l O u t o f R a n g e L o w C h e c k S e n s o r a n d W i r i n g

1 6 F u e l T e m p e r a t u r e S i g n a l M o d e r a t e l y H i g h A d d F u e l o r S w i t c h F u e l T a n k s

0 0 0 1 8 9 0 0 E n g i n e S p e e d D e r a t e C o n d i t i o n E x i s t s C h e c k F a u l t C o d e s o r C o n t a c t S e r v i c i n g D e a l e r

0 0 0 1 9 0 0 0 E n g i n e S p e e d E x t r e m e l y H i g h R e d u c e E n g i n e S p e e d

1 6 E n g i n e S p e e d M o d e r a t e l y H i g h R e d u c e E n g i n e S p e e d

0 0 0 6 1 1 0 3 I n j e c t o r S h o r t e d t o P o w e r C h e c k W i r i n g

0 4 I n j e c t o r S h o r t e d t o G r o u n d C h e c k W i r i n g

0 0 0 6 2 0 0 3 S e n s o r S u p p l y 2 V o l t a g e H i g h C h e c k W i r i n g

0 4 S e n s o r S u p p l y 2 V o l t a g e L o w C h e c k W i r i n g

5 5 - 1 1 0 7 2 2 0 9

P N = 1 0 5

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O U R G P 1 2 , 0 0 0 0 1 E 2 - 1 9 - 1 5 M A R 0 6 - 2 / 2

S P N F M I D e s c r i p t i o n o f F a u l t C o r r e c t i v e A c t i o n

0 0 0 6 2 7 0 1 A l l I n j e c t o r C u r r e n t s A r e L o w C h e c k B a t t e r y V o l t a g e a n d W i r i n g

0 0 0 6 2 9 1 3 E C U P r o g r a m m i n g E r r o r C o n t a c t S e r v i c e D e a l e r

0 0 0 6 3 6 0 2 E n g i n e P o s i t i o n S e n s o r S i g n a l U n r e l i a b l e C h e c k S e n s o r a n d W i r i n g

0 8 E n g i n e P o s i t i o n S e n s o r S i g n a l M i s s i n g C h e c k S e n s o r a n d W i r i n g

1 0 E n g i n e P o s i t i o n S e n s o r S i g n a l R a t e o f C h a n g e A b n o r m a l C h e c k S e n s o r a n d W i r i n g

0 0 0 6 3 7 0 2 E n g i n e T i m i n g S e n s o r S i g n a l U n r e l i a b l e C h e c k S e n s o r a n d W i r i n g

0 7 E n g i n e T i m i n g a n d P o s i t i o n S e n s o r s O u t o f S y n c C h e c k S e n s o r a n d W i r i n g

0 8 E n g i n e T i m i n g S e n s o r S i g n a l M i s s i n g C h e c k S e n s o r a n d W i r i n g

1 0 E n g i n e T i m i n g S i g n a l R a t e o f C h a n g e A b n o r m a l C h e c k S e n s o r a n d W i r i n g

0 0 0 6 3 9 1 3 C A N B u s E r r o r ( C o m m u n i c a t i o n n e t w o r k p r o b l e m ) C o n t a c t S e r v i c i n g D e a l e r

0 0 0 6 5 1 0 5 I n j e c t o r N u m b e r 1 C i r c u i t H a s H i g h R e s i s t a n c e C h e c k I n j e c t o r W i r i n g o r I n j e c t o r S o l e n o i d

0 6 I n j e c t o r N u m b e r 1 C i r c u i t H a s L o w R e s i s t a n c e C h e c k I n j e c t o r W i r i n g o r I n j e c t o r S o l e n o i d

0 7 I n j e c t o r N u m b e r 1 N o t R e s p o n d i n g I n j e c t o r F a i l e d o r F l o w L i m i t e r C l o s e d
















0 0 0 8 9 8 0 9 V e h i c l e S p e e d o r T o r q u e M e s s a g e U n r e l i a b l e C o n t a c t S e r v i c i n g D e a l e r

0 0 0 9 7 0 3 1 E x t e r n a l S h u t d o w n C o m m a n d e d N o t E n g i n e F a u l t . C h e c k O t h e r S h u t d o w n D e v i c e s

0 0 0 9 7 1 3 1 E x t e r n a l F u e l D e r a t e S w i t c h A c t i v e N o t E n g i n e F a u l t . C h e c k O t h e r S h u t d o w n D e v i c e s

0 0 1 0 6 9 0 9 T i r e S i z e I n v a l i d C o n t a c t S e r v i c i n g D e a l e r

3 1 T i r e S i z e E r r o r C o n t a c t S e r v i c i n g D e a l e r

0 0 1 0 7 9 0 3 S e n s o r S u p p l y 1 V o l t a g e H i g h C h e c k W i r i n g

0 4 S e n s o r S u p p l y 1 V o l t a g e L o w C h e c k W i r i n g

0 0 1 0 8 0 0 3 F u e l R a i l P r e s s u r e S e n s o r S u p p l y V o l t a g e H i g h C h e c k W i r i n g

0 4 F u e l R a i l P r e s s u r e S e n s o r S u p p l y V o l t a g e L o w C h e c k W i r i n g

0 0 1 1 0 9 3 1 E n g i n e P r o t e c t i o n S h u t d o w n W a r n i n g S h u t D o w n E n g i n e , C h e c k F a u l t C o d e s

0 0 1 1 1 0 3 1 E n g i n e P r o t e c t i o n S h u t d o w n S h u t D o w n E n g i n e , C h e c k F a u l t C o d e s

0 0 1 3 4 7 0 3 H i g h P r e s s u r e F u e l P u m p C o n t r o l V a l v e S i g n a l O u t o f R a n g e H i g h C o n t a c t S e r v i c i n g D e a l e r

0 5 H i g h P r e s s u r e F u e l P u m p S o l e n o i d N u m b e r 1 C i r c u i t H a s H i g h

R e s i s t a n c e C h e c k P u m p W i r i n g 0 7 H i g h P r e s s u r e F u e l P u m p N o t A b l e t o M e e t R e q u i r e d R a i l

P r e s s u r e C h e c k F u e l F i l t e r a n d L i n e s

0 0 1 5 6 8 0 2 R e q u e s t e d T o r q u e C u r v e S i g n a l U n r e l i a b l e C o n t a c t S e r v i c i n g D e a l e r

0 0 1 5 6 9 3 1 E n g i n e i n D e r a t e C o n d i t i o n C h e c k F a u l t C o d e s

0 0 2 0 0 0 1 3 S e c u r i t y V i o l a t i o n C o n t a c t S e r v i c i n g D e a l e r

5 5 - 1 2 0 7 2 2 0 9

P N = 1 0 6

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C D 0 3 5 2 3 , 0 0 0 0 1 9 3 - 1 9 - 0 5 F E B 0 7 - 1 / 1

I n t e r m i t t e n t F a u l t D i a g n o s t i c s ( W i t h E l e c t r o n i c C o n t r o l s )

I n t e r m i t t e n t f a u l t s a r e p r o b l e m s t h a t p e r i o d i c a l l y ” g o a w a y ” . A p r o b l e m s u c h a s a t e r m i n a l t h a t i n t e r m i t t e n t l y d o e s n ’ t m a k e c o n t a c t c a n c a u s e a n i n t e r m i t t e n t f a u l t . O t h e r i n t e r m i t t e n t f a u l t s m a y b e s e t o n l y u n d e r c e r t a i n o p e r a t i n g c o n d i t i o n s s u c h a s h e a v y l o a d , e x t e n d e d i d l e , e t c . W h e n d i a g n o s i n g i n t e r m i t t e n t f a u l t s , t a k e s p e c i a l

n o t e o f t h e c o n d i t i o n o f w i r i n g a n d c o n n e c t o r s , s i n c e a h i g h p e r c e n t a g e o f i n t e r m i t t e n t p r o b l e m s o r i g i n a t e h e r e . C h e c k f o r l o o s e , d i r t y o r d i s c o n n e c t e d c o n n e c t o r s . I n s p e c t t h e w i r i n g r o u t i n g , l o o k i n g f o r p o s s i b l e s h o r t s c a u s e d b y c o n t a c t w i t h e x t e r n a l p a r t s ( f o r e x a m p l e , r u b b i n g a g a i n s t s h a r p s h e e t m e t a l e d g e s ) . I n s p e c t t h e c o n n e c t o r v i c i n i t y , l o o k i n g f o r w i r e s t h a t h a v e p u l l e d o u t o f c o n n e c t o r s , p o o r l y p o s i t i o n e d t e r m i n a l s , d a m a g e d c o n n e c t o r s a n d c o r r o d e d o r d a m a g e d s p l i c e s a n d t e r m i n a l s . L o o k f o r b r o k e n w i r e s , d a m a g e d s p l i c e s , a n d w i r e - t o - w i r e s h o r t s . U s e g o o d

j u d g e m e n t i f c o m p o n e n t r e p l a c e m e n t i s t h o u g h t t o b e r e q u i r e d .

N O T E : T h e e n g i n e c o n t r o l u n i t ( E C U ) i s t h e c o m p o n e n t

L E A S T l i k e l y t o f a i l .

S u g g e s t i o n s f o r d i a g n o s i n g i n t e r m i t t e n t f a u l t s :

• I f t h e p r o b l e m i s i n t e r m i t t e n t , t r y t o r e p r o d u c e t h e o p e r a t i n g c o n d i t i o n s t h a t w e r e p r e s e n t w h e n t h e d i a g n o s t i c t r o u b l e c o d e ( D T C ) s e t .

• I f a f a u l t y c o n n e c t i o n o r w i r e i s s u s p e c t e d t o b e t h e

c a u s e o f t h e i n t e r m i t t e n t p r o b l e m : c l e a r D T C s , t h e n c h e c k t h e c o n n e c t i o n o r w i r e b y w i g g l i n g i t w h i l e w a t c h i n g t h e d i a g n o s t i c g a u g e t o s e e i f t h e f a u l t r e s e t s .

P o s s i b l e c a u s e s o f i n t e r m i t t e n t f a u l t s :

• F a u l t y c o n n e c t i o n b e t w e e n s e n s o r o r a c t u a t o r h a r n e s s .

• F a u l t y c o n t a c t b e t w e e n t e r m i n a l s i n c o n n e c t o r .

• F a u l t y t e r m i n a l / w i r e c o n n e c t i o n .

• E l e c t r o m a g n e t i c i n t e r f e r e n c e ( E M I ) f r o m a n i m p r o p e r l y i n s t a l l e d 2 - w a y r a d i o , e t c . , c a n c a u s e f a u l t y s i g n a l s t o b e s e n t t o t h e E C U .

N O T E : R e f e r a l s o t o g e n e r a t o r d o c u m e n t s f o r m o r e i n f o r m a t i o n a b o u t c o n n e c t i o n s a n d w i r i n g s .

5 5 - 1 3 0 7 2 2 0 9

P N = 1 0 7

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S t o r a g e

D P S G , C D 0 3 5 2 3 , 5 1 - 1 9 - 2 2 J A N 0 7 - 1 / 1

D P S G , C D 0 3 5 2 3 , 5 3 - 1 9 - 2 2 J A N 0 7 - 1 / 1

D P S G , C D 0 3 5 2 3 , 5 4 - 1 9 - 2 2 J A N 0 7 - 1 / 1

E n g i n e s t o r a g e g u i d e l i n e s

1 . J o h n D e e r e e n g i n e s c a n b e s t o r e d o u t s i d e f o r u p t o t h r e e ( 3 ) m o n t h s w i t h n o l o n g t e r m p r e p a r a t i o n I F C O V E R E D B Y W A T E R P R O O F C O V E R I N G .

2 . J o h n D e e r e e n g i n e s c a n b e s t o r e d i n a s t a n d a r d o v e r s e a s s h i p p i n g c o n t a i n e r f o r u p t o t h r e e ( 3 ) m o n t h s

w i t h n o l o n g t e r m p r e p a r a t i o n . 3 . J o h n D e e r e e n g i n e s c a n b e s t o r e d i n s i d e , w a r e h o u s e d ,

f o r u p t o s i x ( 6 ) m o n t h s w i t h n o l o n g t e r m p r e p a r a t i o n .

4 . J o h n D e e r e e n g i n e s e x p e c t e d t o b e s t o r e d m o r e t h a n s i x ( 6 ) m o n t h s , l o n g t e r m s t o r a g e p r e p a r a t i o n M U S T B E t a k e n . ( S e e P R E P A R I N G E N G I N E F O R L O N G T E R M S T O R A G E ) .

P r e p a r i n g e n g i n e f o r l o n g t e r m s t o r a g e

T h e f o l l o w i n g s t o r a g e p r e p a r a t i o n s a r e g o o d f o r l o n g t e r m e n g i n e s t o r a g e u p t o o n e y e a r . A f t e r t h a t , t h e e n g i n e s h o u l d b e s t a r t e d , w a r m e d u p , a n d r e t r e a t e d f o r a n e x t e n d e d s t o r a g e p e r i o d .

I M P O R T A N T : A n y t i m e y o u r e n g i n e w i l l n o t b e

u s e d f o r o v e r s i x ( 6 ) m o n t h s , t h e f o l l o w i n g r e c o m m e n d a t i o n s f o r s t o r i n g i t a n d r e m o v i n g i t f r o m s t o r a g e w i l l h e l p t o m i n i m i z e c o r r o s i o n a n d d e t e r i o r a t i o n .

1 . C h a n g e e n g i n e o i l a n d r e p l a c e f i l t e r . U s e d o i l w i l l n o t g i v e a d e q u a t e p r o t e c t i o n . ( S e e C H A N G I N G E N G I N E O I L A N D F I L T E R ) .

2 . S e r v i c e a i r c l e a n e r . ( S e e C L E A N O R R E P L A C E A I R F I L T E R ) .

3 . D r a i n i n g a n d f l u s h i n g o f c o o l i n g s y s t e m i s n o t n e c e s s a r y i f e n g i n e i s t o b e s t o r e d o n l y f o r s e v e r a l m o n t h s . H o w e v e r , f o r e x t e n d e d s t o r a g e p e r i o d s o f a y e a r o r l o n g e r , i t i s r e c o m m e n d e d t h a t t h e c o o l i n g s y s t e m b e d r a i n e d , f l u s h e d , a n d r e f i l l e d . R e f i l l

w i t h a p p r o p r i a t e c o o l a n t . ( S e e D I E S E L E N G I N E C O O L A N T ) .

4 . F i l l t h e f u e l t a n k .

5 . R e m o v e f a n / a l t e r n a t o r b e l t , i f d e s i r e d .

6 . R e m o v e a n d c l e a n b a t t e r i e s . S t o r e t h e m i n a c o o l , d r y p l a c e a n d k e e p t h e m f u l l y c h a r g e d .

7 . C l e a n t h e e x t e r i o r o f t h e e n g i n e w i t h s a l t - f r e e w a t e r a n d t o u c h u p a n y s c r a t c h e d o r c h i p p e d p a i n t e d s u r f a c e s w i t h a g o o d q u a l i t y p a i n t .

8 . C o a t a l l e x p o s e d ( m a c h i n e d ) m e t a l s u r f a c e s w i t h g r e a s e o r c o r r o s i o n i n h i b i t o r i f n o t f e a s i b l e t o p a i n t .

9 . S e a l a l l o p e n i n g s o n e n g i n e w i t h p l a s t i c b a g s a n d t a p e .

1 0 . S t o r e t h e e n g i n e i n a d r y p r o t e c t e d p l a c e . I f e n g i n e m u s t b e s t o r e d o u t s i d e , c o v e r i t w i t h a w a t e r p r o o f c a n v a s o r o t h e r s u i t a b l e p r o t e c t i v e m a t e r i a l a n d u s e

a s t r o n g w a t e r p r o o f t a p e .

R e m o v i n g e n g i n e f r o m l o n g t e r m s t o r a g e

R e f e r t o t h e a p p r o p r i a t e s e c t i o n f o r d e t a i l e d s e r v i c e s l i s t e d b e l o w o r h a v e y o u r a u t h o r i z e d s e r v i c i n g d e a l e r o r e n g i n e d i s t r i b u t o r p e r f o r m s e r v i c e s t h a t y o u m a y n o t b e f a m i l i a r w i t h .

1 . R e m o v e a l l p r o t e c t i v e c o v e r i n g s f r o m e n g i n e . U n s e a l a l l o p e n i n g s i n e n g i n e a n d r e m o v e c o v e r i n g f r o m

e l e c t r i c a l s y s t e m s .

2 . R e m o v e t h e b a t t e r i e s f r o m s t o r a g e . I n s t a l l b a t t e r i e s ( f u l l y c h a r g e d ) a n d c o n n e c t t h e t e r m i n a l s .

3 . I n s t a l l f a n / a l t e r n a t o r b e l t i f r e m o v e d .

4 . C h e c k f o r f i l l e d f u e l t a n k .

5 . P e r f o r m a l l a p p r o p r i a t e p r e s t a r t i n g c h e c k s . ( S e e D A I L Y P R E S T A R T I N G C H E C K S ) .

I M P O R T A N T : D O N O T o p e r a t e s t a r t e r m o r e t h a n 3 0 s e c o n d s a t a t i m e . W a i t a t l e a s t 2 m i n u t e s f o r s t a r t e r t o c o o l b e f o r e t r y i n g a g a i n .

6 . C r a n k e n g i n e f o r 2 0 s e c o n d s w i t h s t a r t e r ( d o n o t a l l o w t h e e n g i n e t o s t a r t ) . W a i t 2 m i n u t e s a n d c r a n k e n g i n e

a n a d d i t i o n a l 2 0 s e c o n d s t o a s s u r e b e a r i n g s u r f a c e s a r e a d e q u a t e l y l u b r i c a t e d .

7 . S t a r t e n g i n e a n d r u n a t n o l o a d f o r s e v e r a l m i n u t e s . W a r m u p c a r e f u l l y a n d c h e c k a l l g a u g e s b e f o r e p l a c i n g e n g i n e u n d e r l o a d .

8 . O n t h e f i r s t d a y o f o p e r a t i o n a f t e r s t o r a g e , c h e c k o v e r a l l e n g i n e f o r l e a k s a n d c h e c k a l l g a u g e s f o r c o r r e c t o p e r a t i o n .

6 0 - 1 0 7 2 2 0 9

P N = 1 0 8

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S p e c i f i c a t i o n s


G e n e r a l e n g i n e p a c k s p e c i f i c a t i o n s ( N o n - E m i s s i o n C e r t i f i e d E n g i n e s )

I T E M U N I T O F M E A S U R E

3 0 2 9 D F 1 2 0 3 0 2 9 D F 1 2 8 3 0 2 9 T F 1 2 0 3 0 2 9 T F 1 5 8

N u m b e r o f C y l i n d e r s

3 3 3 3

F u e l D i e s e l D i e s e l D i e s e l D i e s e l

B o r e m m 1 0 6 . 5 1 0 6 . 5 1 0 6 . 5 1 0 6 . 5 S t r o k e m m 1 1 0 1 1 0 1 1 0 1 1 0

D i s p l a c e m e n t L 2 . 9 2 . 9 2 . 9 2 . 9

C o m p r e s s i o n R a t i o 1 7 . 2 : 1 1 7 . 2 : 1 1 7 . 2 : 1 1 7 . 2 : 1

P O W E R a @ 1 5 0 0 r p m ( P r i m e )

k W ( h p ) 2 7 ( 3 6 ) 2 6 ( 3 5 ) 3 8 ( 5 1 ) 3 6 ( 4 9 )

P O W E R a @ 1 5 0 0 r p m ( S t a n d b y )

k W ( h p ) 3 0 ( 4 1 ) 3 0 ( 4 1 ) 4 2 ( 5 6 ) 4 0 ( 5 4 )

P O W E R a @ 1 8 0 0 r p m ( P r i m e )

k W ( h p ) 3 0 ( 4 1 ) 3 0 ( 4 1 ) 4 3 ( 5 8 ) 4 0 ( 5 4 )


k W ( h p ) 3 5 ( 4 7 ) 3 4 ( 4 6 ) 4 8 ( 6 4 ) 4 5 ( 6 1 )

W i d t h ( o v e r a l l ) m m 5 1 9 5 8 2 5 1 9 5 8 2

L e n g t h ( o v e r a l l ) m m 7 1 6 8 8 8 7 1 6 8 8 8

H e i g h t ( o v e r a l l ) m m 8 1 9 9 3 1 8 1 9 9 7 9

W e i g h t ( d r y ) b k g 3 1 6 3 4 5 3 1 6 3 5 0

E n g i n e o i l q u a n t i t y L 6 6 8 8

E n g i n e c o o l a n t q u a n t i t y

L 1 4 . 5 1 4 . 5 1 4 . 5 1 4 . 5

a W i t h F a n

b A p p r o x i m a t e


4 0 3 9 D F 0 0 8 4 0 3 9 T F 0 0 8 4 0 4 5 D F 1 5 8 4 0 4 5 H F 1 2 0 4 0 4 5 H F 1 5 8

N u m b e r o f

C y l i n d e r s

4 4 4 4 4

F u e l D i e s e l D i e s e l D i e s e l D i e s e l D i e s e l

B o r e m m 1 0 6 . 5 1 0 6 . 5 1 0 6 . 5 1 0 6 . 5 1 0 6 . 5

S t r o k e m m 1 1 0 1 1 0 1 2 7 1 2 7 1 2 7

D i s p l a c e m e n t L 3 . 9 3 . 9 4 . 5 4 . 5 4 . 5

C o m p r e s s i o n R a t i o 1 7 . 8 : 1 1 7 . 8 : 1 1 7 . 6 : 1 1 7 . 0 : 1 1 7 . 0 : 1

P O W E R a @ 1 5 0 0 r p m ( P r i m e )

k W ( h p ) 3 5 ( 4 8 ) 5 5 ( 7 5 ) 4 1 ( 5 6 ) 9 1 ( 1 2 2 ) 8 8 ( 1 2 0 )


k W ( h p ) 3 8 ( 5 2 ) 6 1 ( 8 3 ) 4 2 ( 5 7 ) 1 0 2 ( 1 3 7 ) 9 6 ( 1 3 1 )

P O W E R a @ 1 8 0 0 r p m ( P r i m e )

k W ( h p ) 4 1 ( 5 6 ) 6 7 ( 9 1 ) 4 8 ( 6 5 ) 1 0 8 ( 1 4 7 )


k W ( h p ) 4 7 ( 6 4 ) 7 3 ( 9 9 ) 5 1 ( 6 9 ) 1 2 0 ( 1 6 3 )

W i d t h ( o v e r a l l ) m m 5 8 8 5 8 8 6 0 6 5 9 8 7 9 8

L e n g t h ( o v e r a l l ) m m 1 0 1 6 1 0 1 6 1 0 3 8 8 6 1 1 2 0 9

H e i g h t ( o v e r a l l ) m m 9 6 0 9 7 9 9 5 9 9 8 0 1 1 9 7

W e i g h t ( d r y ) b k g 4 7 5 4 8 7 4 9 3 3 9 6 5 9 9

E n g i n e o i l q u a n t i t y L 1 2 1 2 8 1 2 1 2


L 1 6 . 5 1 6 . 5 2 0 2 8 2 8

a W i t h F a n

6 5 - 1 0 7 2 2 0 9

P N = 1 0 9

179/258






I T E M U N I T O F M E A S U R E 4 0 4 5 T F 1 2 0 4 0 4 5 T F 1 5 8 4 0 4 5 T F 2 2 0 4 0 4 5 T F 2 5 8

N u m b e r o f C y l i n d e r s 4 4 4 4


B o r e m m 1 0 6 . 5 1 0 6 . 5 1 0 6 . 5 1 0 6 . 5

S t r o k e m m 1 2 7 1 2 7 1 2 7 1 2 7

D i s p l a c e m e n t L 4 . 5 4 . 5 4 . 5 4 . 5


P O W E R a @ 1 5 0 0 r p m ( P r i m e )

k W ( h p ) 6 3 ( 8 4 ) 6 1 ( 8 3 ) 7 5 ( 1 0 1 ) 7 2 ( 9 8 )


k W ( h p ) 7 0 ( 9 4 ) 6 8 ( 9 2 ) 8 3 ( 1 1 1 ) 8 0 ( 1 0 9 )

P O W E R a @ 1 8 0 0 r p m ( P r i m e )

k W ( h p ) 7 2 ( 9 8 ) 9 0 ( 1 2 1 ) 8 0 ( 1 0 9 )


k W ( h p ) 7 9 ( 1 0 7 ) 1 0 0 ( 1 3 4 ) 8 8 ( 1 2 0 )

W i d t h ( o v e r a l l ) m m 5 9 8 6 0 6 5 9 8 6 5 2

L e n g t h ( o v e r a l l ) m m 8 6 1 1 1 9 1 8 6 1 1 2 2 5

H e i g h t ( o v e r a l l ) m m 9 8 0 1 0 2 7 9 8 0 1 0 2 7

W e i g h t ( d r y ) b k g 3 9 6 5 0 5 3 9 6 5 2 0

E n g i n e o i l q u a n t i t y L 1 2 1 2 1 2 1 2


L 2 5 2 5 2 5 2 5

a W i t h F a n



6 0 6 8 H F 1 2 0 - 1 1 5 6 0 6 8 H F 1 2 0 - 1 8 3 6 0 6 8 H F 1 5 8 6 0 6 8 H F 2 5 8



B o r e m m 1 0 6 . 5 1 0 6 . 5 1 0 6 . 5 1 0 6 . 5

S t r o k e m m

1 2 7 1 2 7 1 2 7 1 2 7 D i s p l a c e m e n t L 6 . 8 6 . 8 6 . 8 6 . 8


P O W E R a @ 1 5 0 0 r p m ( P r i m e )

k W ( h p ) 1 4 0 ( 1 8 8 ) 1 6 6 ( 2 2 3 ) 1 3 4 ( 1 8 2 ) 1 6 0 ( 2 1 8 )


k W ( h p ) 1 5 5 ( 2 0 8 ) 1 8 3 ( 2 4 5 ) 1 4 8 ( 2 0 1 ) 1 7 7 ( 2 4 1 )

P O W E R a @ 1 8 0 0 r p m ( P r i m e )

k W ( h p ) 1 6 4 ( 2 2 3 ) 1 7 9 ( 2 4 3 )


k W ( h p ) 1 8 7 ( 2 5 4 ) 2 0 0 ( 2 7 2 )

W i d t h ( o v e r a l l ) m m 6 2 3 6 2 3 7 9 8 7 9 8

L e n g t h ( o v e r a l l ) m m 1 1 4 1 1 1 4 1 1 5 0 0 1 5 0 0


W e i g h t ( d r y ) b k g 5 6 9 5 6 9 7 0 5 7 6 4



L 3 2 3 2 3 2 3 2

a W i t h F a n


I T E M U N I T O F M E A S U R E 6 0 6 8 T F 1 5 8 6 0 6 8 T F 2 2 0 6 0 6 8 T F 2 5 8

N u m b e r o f C y l i n d e r s 6 6 6

6 5 - 2 0 7 2 2 0 9

P N = 1 1 0

180/258




D P S G , C D 0 3 5 2 3 , 5 5 - 1 9 - 0 8 J U L 0 9 - 3 / 3

I T E M U N I T O F M E A S U R E 6 0 6 8 T F 1 5 8 6 0 6 8 T F 2 2 0 6 0 6 8 T F 2 5 8

F u e l D i e s e l D i e s e l D i e s e l

B o r e m m 1 0 6 . 5 1 0 6 . 5 1 0 6 . 5

S t r o k e m m 1 2 7 1 2 7 1 2 7

D i s p l a c e m e n t L 6 . 8 6 . 8 6 . 8

C o m p r e s s i o n R a t i o 1 7 . 0 : 1 1 7 . 0 : 1 1 7 . 0 : 1

P O W E R a @ 1 5 0 0 r p m

( P r i m e )

k W ( h p ) 9 2 ( 1 2 5 ) 1 0 9 ( 1 4 6 ) 1 0 5 ( 1 4 3 )


k W ( h p ) 1 0 1 ( 1 3 7 ) 1 2 1 ( 1 6 2 ) 1 1 6 ( 1 5 8 )

P O W E R a @ 1 8 0 0 r p m ( P r i m e )

k W ( h p ) 1 0 8 ( 1 4 7 ) 1 2 4 ( 1 6 9 )


k W ( h p ) 1 1 9 ( 1 6 2 ) 1 3 7 ( 1 8 6 )

W i d t h ( o v e r a l l ) m m 6 5 2 5 9 8 6 5 2


H e i g h t ( o v e r a l l ) m m 1 0 7 0 9 8 4 1 0 7 0

W e i g h t ( d r y ) b k g 6 5 1 5 3 3 6 5 1

E n g i n e o i l q u a n t i t y L 2 0 2 0 2 0

E n g i n e c o o l a n t q u a n t i t y L 2 8 2 8 2 8

a W i t h F a n


6 5 - 3 0 7 2 2 0 9

P N = 1 1 1

181/258




C o n t i n u e d o n n e x t p a g e C D 0 3 5 2 3 , 0 0 0 0 1 9 4 - 1 9 - 0 8 J U L 0 9 - 1 / 3

G e n e r a l e n g i n e p a c k s p e c i f i c a t i o n s ( S t a g e I I E m i s s i o n C e r t i f i e d E n g i n e s )


3 0 2 9 H F S 7 0 3 0 2 9 H F U 7 0 3 0 2 9 T F S 7 0 3 0 2 9 T F U 7 0



B o r e m m 1 0 6 . 5 1 0 6 . 5 1 0 6 . 5 1 0 6 . 5

S t r o k e m m 1 1 0 1 1 0 1 1 0 1 1 0

D i s p l a c e m e n t L 2 . 9 2 . 9 2 . 9 2 . 9


P O W E R a @ 1 5 0 0 r p m ( P r i m e )

k W ( h p ) 3 7 ( 5 0 ) 3 7 ( 5 0 ) 2 8 ( 3 7 ) 2 8 ( 3 7 )


k W ( h p ) 4 1 ( 5 6 ) 4 1 ( 5 6 ) 3 1 ( 4 1 ) 3 1 ( 4 1 )

P O W E R a @ 1 8 0 0 r p m ( P r i m e )

k W ( h p )


k W ( h p )

W i d t h ( o v e r a l l ) m m 5 8 2 5 8 2 5 8 2 5 8 2

L e n g t h ( o v e r a l l ) m m

8 8 8 8 8 8 8 8 8 8 8 8 H e i g h t ( o v e r a l l ) m m 9 7 4 9 7 4 9 7 4 9 7 4

W e i g h t ( d r y ) b k g 3 5 0 3 5 0 3 5 0 3 5 0

E n g i n e o i l q u a n t i t y L 8 8 8 8


L 1 4 . 5 1 4 . 5 1 4 . 5 1 4 . 5

a W i t h F a n



4 0 4 5 H F S 7 2 4 0 4 5 H F S 7 3 4 0 4 5 H F U 7 2 4 0 4 5 H F U 7 9



B o r e m m 1 0 6 . 5 1 0 6 . 5 1 0 6 . 5 1 0 6 . 5

S t r o k e m m 1 1 0 1 1 0 1 2 7 1 2 7

D i s p l a c e m e n t L 4 . 5 4 . 5 4 . 5 4 . 5


P O W E R a @ 1 5 0 0 r p m ( P r i m e )

k W ( h p ) 7 5 ( 1 0 0 ) 9 4 ( 1 2 6 ) 7 5 ( 1 0 0 ) 9 4 ( 1 2 6 )


k W ( h p ) 8 3 ( 1 1 1 ) 1 0 3 ( 1 3 8 ) 8 3 ( 1 1 1 ) 1 0 3 ( 1 3 8 )

P O W E R a @ 1 8 0 0 r p m ( P r i m e )

k W ( h p )


k W ( h p )

W i d t h ( o v e r a l l ) m m 7 5 1 7 6 5 7 5 1 7 6 5



W e i g h t ( d r y ) b k g 5 0 5 5 0 5 5 0 5 5 0 5



L 2 8 3 2 2 8 3 2

a W i t h F a n


6 5 - 4 0 7 2 2 0 9

P N = 1 1 2

182/258




C o n t i n u e d o n n e x t p a g e C D 0 3 5 2 3 , 0 0 0 0 1 9 4 - 1 9 - 0 8 J U L 0 9 - 2 / 3

I T E M U N I T O F M E A S U R E 4 0 4 5 T F S 7 0 4 0 4 5 T F U 7 0

N u m b e r o f C y l i n d e r s 4 4

F u e l D i e s e l D i e s e l

B o r e m m 1 0 6 . 5 1 0 6 . 5

S t r o k e m m 1 1 0 1 2 7

D i s p l a c e m e n t L 4 . 5 4 . 5

C o m p r e s s i o n R a t i o 1 7 . 0 : 1 1 7 . 0 : 1

P O W E R a @ 1 5 0 0 r p m ( P r i m e )

k W ( h p ) 5 5 ( 7 4 ) 5 5 ( 7 4 )


k W ( h p ) 6 1 ( 8 1 ) 6 1 ( 8 1 )

P O W E R a @ 1 8 0 0 r p m ( P r i m e )

k W ( h p )


k W ( h p )

W i d t h ( o v e r a l l ) m m 6 3 7 6 0 0

L e n g t h ( o v e r a l l ) m m 8 6 7 1 2 3 0

H e i g h t ( o v e r a l l ) m m 9 7 9 1 0 1 0

W e i g h t ( d r y ) b k g 4 5 1 5 0 5

E n g i n e o i l q u a n t i t y L 1 2 1 2 E n g i n e c o o l a n t q u a n t i t y L 2 5 2 5

a W i t h F a n


I T E M U N I T O F M E A S U R E 6 0 6 8 H F S 7 2 6 0 6 8 H F S 7 3 6 0 6 8 H F S 7 6 6 0 6 8 H F S 7 7



B o r e m m 1 0 6 . 5 1 0 6 . 5 1 0 6 . 5 1 0 6 . 5

S t r o k e m m 1 2 7 1 2 7 1 2 7 1 2 7

D i s p l a c e m e n t L 6 . 8 6 . 8 6 . 8 6 . 8


P O W E R a @ 1 5 0 0 r p m ( P r i m e )

k W ( h p ) 1 1 2 ( 1 5 0 ) 1 3 9 ( 1 8 6 ) 1 6 7 ( 2 2 4 ) 1 8 9 ( 2 5 3 )


k W ( h p ) 1 2 3 ( 1 6 5 ) 1 5 3 ( 2 0 5 ) 1 8 4 ( 2 4 7 ) 2 0 7 ( 2 7 7 ) )

P O W E R a @ 1 8 0 0 r p m ( P r i m e )

k W ( h p )


k W ( h p )

W i d t h ( o v e r a l l ) m m 7 8 4 7 8 4 9 6 0 9 6 0



W e i g h t ( d r y ) b k g 7 6 4 7 6 4 7 6 4 7 6 4

E n g i n e o i l q u a n t i t y L 3 2 3 2 3 2 3 2 E n g i n e c o o l a n t q u a n t i t y L 3 2 3 2 3 5 3 5

a W i t h F a n


I T E M U N I T O F M E A S U R E 6 0 6 8 H F U 7 2 6 0 6 8 H F U 7 4 6 0 6 8 H F U 7 9



B o r e m m 1 0 6 . 5 1 0 6 . 5 1 0 6 . 5

S t r o k e m m 1 2 7 1 2 7 1 2 7

6 5 - 5 0 7 2 2 0 9

P N = 1 1 3

183/258




C D 0 3 5 2 3 , 0 0 0 0 1 9 4 - 1 9 - 0 8 J U L 0 9 - 3 / 3

C D 0 3 5 2 3 , 0 0 0 0 1 D 3 - 1 9 - 0 8 J U L 0 9 - 1 / 1

I T E M U N I T O F M E A S U R E 6 0 6 8 H F U 7 2 6 0 6 8 H F U 7 4 6 0 6 8 H F U 7 9

D i s p l a c e m e n t L 6 . 8 6 . 8 6 . 8


P O W E R a @ 1 5 0 0 r p m ( P r i m e )

k W ( h p ) 1 1 1 ( 1 4 9 ) 1 6 6 ( 2 2 3 ) / 1 8 8 ( 2 5 2 ) 1 3 9 ( 1 8 6 )


k W ( h p ) 1 2 3 ( 1 6 5 ) 1 8 4 ( 2 4 7 ) / 2 0 7 ( 2 7 7 ) ) 1 5 3 ( 2 0 5 )

P O W E R a @ 1 8 0 0 r p m

( P r i m e )

k W ( h p ) 1 9 1 ( 2 5 6 )


k W ( h p ) 2 0 1 ( 2 6 9 )

W i d t h ( o v e r a l l ) m m 7 8 4 9 6 0 8 1 2



W e i g h t ( d r y ) b k g 7 6 4 7 6 4 7 6 4



a W i t h F a n


G e n e r a l e n g i n e p a c k s p e c i f i c a t i o n s ( E P A T i e r 2 E m i s s i o n C e r t i f i e d E n g i n e s )

I T E M U N I T O F M E A S U R E 3 0 2 9 T F 2 7 0 4 0 4 5 T F 2 7 0 6 0 6 8 H F 4 7 5



B o r e m m 1 0 6 . 5 1 0 6 . 5 1 0 6 . 5

S t r o k e m m 1 1 0 1 2 7 1 2 7

D i s p l a c e m e n t L 2 . 9 4 . 5 6 . 8


P O W E R a @ 1 5 0 0 r p m ( P r i m e )

k W ( h p )


k W ( h p )

P O W E R a @ 1 8 0 0 r p m ( P r i m e )

k W ( h p ) 4 4 ( 5 9 ) 6 7 ( 9 0 ) 2 1 3 ( 2 8 6 )


k W ( h p ) 4 8 ( 6 4 ) 7 4 ( 9 9 ) 2 3 4 ( 3 1 4 )

W i d t h ( o v e r a l l ) m m 5 1 9 6 1 2 6 2 7

L e n g t h ( o v e r a l l ) m m 7 1 6 8 6 0 1 1 6 1

H e i g h t ( o v e r a l l ) m m 8 1 9 9 9 4 1 0 4 4

W e i g h t ( d r y ) b k g 3 1 6 3 9 6 5 8 7

E n g i n e o i l q u a n t i t y L 8 1 2 3 2 E n g i n e c o o l a n t q u a n t i t y L 1 4 . 5 2 5 3 5

a W i t h F a n


6 5 - 6 0 7 2 2 0 9

P N = 1 1 4

184/258




C D 0 3 5 2 3 , 0 0 0 0 1 D 4 - 1 9 - 0 8 J U L 0 9 - 1 / 1

G e n e r a l e n g i n e p a c k s p e c i f i c a t i o n s ( E P A T i e r 3 E m i s s i o n C e r t i f i e d E n g i n e s )

I T E M U N I T O F M E A S U R E 4 0 4 5 H F S 8 0 4 0 4 5 H F S 8 2 4 0 4 5 H F S 8 3



B o r e m m 1 0 6 . 5 1 0 6 . 5 1 0 6 . 5

S t r o k e m m 1 2 7 1 2 7 1 1 0

D i s p l a c e m e n t L 4 . 5 4 . 5 4 . 5


P O W E R a @ 1 5 0 0 r p m ( P r i m e )

k W ( h p )


k W ( h p )

P O W E R a @ 1 8 0 0 r p m ( P r i m e )

k W ( h p ) 6 7 ( 9 0 ) 8 5 ( 1 1 4 ) 1 0 7 ( 1 4 3 )


k W ( h p ) 7 4 ( 9 9 ) 9 4 ( 1 2 6 ) 1 1 8 ( 1 5 8 )

W i d t h ( o v e r a l l ) m m 6 0 0 7 6 5 7 6 5



W e i g h t ( d r y ) b k g 5 0 5 5 0 5 5 0 5



a W i t h F a n


I T E M U N I T O F M E A S U R E 6 0 6 8 H F S 8 2 6 0 6 8 H F S 8 3 6 0 6 8 H F S 8 9



B o r e m m 1 0 6 . 5 1 0 6 . 5 1 0 6 . 5

S t r o k e m m 1 2 7 1 2 7 1 2 7

D i s p l a c e m e n t L 6 . 8 6 . 8 6 . 8


P O W E R a @ 1 5 0 0 r p m ( P r i m e )

k W ( h p )


k W ( h p )

P O W E R a @ 1 8 0 0 r p m ( P r i m e )

k W ( h p ) 1 3 4 ( 1 8 0 ) 1 6 1 ( 2 1 6 ) 2 1 4 ( 2 8 7 )


k W ( h p ) 1 4 7 ( 1 9 7 ) 1 7 7 ( 2 3 7 ) 2 3 5 ( 3 1 5 )

W i d t h ( o v e r a l l ) m m 7 8 4 7 8 4 9 6 0



W e i g h t ( d r y ) b k g 7 6 4 7 6 4 7 6 4



a W i t h F a n


6 5 - 7 0 7 2 2 0 9

P N = 1 1 5

185/258




D X , T O R Q 1 - 1 9 - 2 4 M A R 0 9 - 1 / 1

U n i f i e d I n c h B o l t a n d S c r e w T o r q u e V a l u e s T S 1 6 7 1 — U N — 0 1 M A Y 0 3

B o l t o r S A E G r a d e 1 S A E G r a d e 2 a S A E G r a d e 5 , 5 . 1 o r 5 . 2 S A E G r a d e 8 o r 8 . 2

S c r e w L u b r i c a t e d b D r y c L u b r i c a t e d b D r y c L u b r i c a t e d b D r y c L u b r i c a t e d b D r y c

S i z e N ∙ m l b - i n N ∙ m l b - i n N ∙ m l b - i n N ∙ m l b - i n N ∙ m l b - i n N ∙ m l b - i n N ∙ m l b - i n N ∙ m l b - i n

1 / 4 3 . 7 3 3 4 . 7 4 2 6 5 3 7 . 5 6 6 9 . 5 8 4 1 2 1 0 6 1 3 . 5 1 2 0 1 7 1 5 0

N ∙ m l b - f t N ∙ m l b - f t

5 / 1 6 7 . 7 6 8 9 . 8 8 6 1 2 1 0 6 1 5 . 5 1 3 7 1 9 . 5 1 7 2 2 5 2 2 1 2 8 2 0 . 5 3 5 2 6

N ∙ m l b - f t N ∙ m l b - f t

3 / 8 1 3 . 5 1 2 0 1 7 . 5 1 5 5 2 2 1 9 4 2 7 2 4 0 3 5 2 6 4 4 3 2 . 5 4 9 3 6 6 3 4 6

N ∙ m l b - f t N ∙ m l b - f t N ∙ m l b - f t

7 / 1 6 2 2 1 9 4 2 8 2 0 . 5 3 5 2 6 4 4 3 2 . 5 5 6 4 1 7 0 5 2 8 0 5 9 1 0 0 7 4

N ∙ m l b - f t

1 / 2 3 4 2 5 4 2 3 1 5 3 3 9 6 7 4 9 8 5 6 3 1 1 0 8 0 1 2 0 8 8 1 5 5 1 1 5

9 / 1 6 4 8 3 5 . 5 6 0 4 5 7 6 5 6 9 5 7 0 1 2 5 9 2 1 5 5 1 1 5 1 7 5 1 3 0 2 2 0 1 6 5

5 / 8 6 7 4 9 8 5 6 3 1 0 5 7 7 1 3 5 1 0 0 1 7 0 1 2 5 2 1 5 1 6 0 2 4 0 1 7 5 3 0 5 2 2 5

3 / 4 1 2 0 8 8 1 5 0 1 1 0 1 9 0 1 4 0 2 4 0 1 7 5 3 0 0 2 2 0 3 8 0 2 8 0 4 2 5 3 1 5 5 4 0 4 0 0

7 / 8 1 9 0 1 4 0 2 4 0 1 7 5 1 9 0 1 4 0 2 4 0 1 7 5 4 9 0 3 6 0 6 1 5 4 5 5 6 9 0 5 1 0 8 7 0 6 4 0

1 2 8 5 2 1 0 3 6 0 2 6 5 2 8 5 2 1 0 3 6 0 2 6 5 7 3 0 5 4 0 9 2 0 6 8 0 1 0 3 0 7 6 0 1 3 0 0 9 6 0

1 - 1 / 8 4 0 0 3 0 0 5 1 0 3 7 5 4 0 0 3 0 0 5 1 0 3 7 5 9 1 0 6 7 0 1 1 5 0 8 5 0 1 4 5 0 1 0 7 5 1 8 5 0 1 3 5 0

1 - 1 / 4 5 7 0 4 2 0 7 2 5 5 3 5 5 7 0 4 2 0 7 2 5 5 3 5 1 2 8 0 9 4 5 1 6 3 0 1 2 0 0 2 0 5 0 1 5 0 0 2 6 0 0 1 9 2 0

1 - 3 / 8 7 5 0 5 5 0 9 5 0 7 0 0 7 5 0 5 5 0 9 5 0 7 0 0 1 7 0 0 1 2 5 0 2 1 4 0 1 5 8 0 2 7 0 0 2 0 0 0 3 4 0 0 2 5 0 0

1 - 1 / 2 9 9 0 7 3 0 1 2 5 0 9 3 0 9 9 0 7 3 0 1 2 5 0 9 3 0 2 2 5 0 1 6 5 0 2 8 5 0 2 1 0 0 3 6 0 0 2 6 5 0 4 5 5 0 3 3 5 0

T o r q u e v a l u e s l i s t e d a r e f o r g e n e r a l u s e o n l y , b a s e d o n t h e s t r e n g t h o f t h e b o l t o r s c r e w . D O N O T u s e t h e s e v a l u e s i f a d i f f e r e n t t o r q u e v a l u e o r t i g h t e n i n g p r o c e d u r e i s g i v e n f o r a s p e c i f i c a p p l i c a t i o n . F o r p l a s t i c i n s e r t o r c r i m p e d s t e e l t y p e l o c k n u t s , f o r s t a i n l e s s s t e e l f a s t e n e r s , o r f o r n u t s o n U - b o l t s , s e e t h e t i g h t e n i n g i n s t r u c t i o n s f o r t h e s p e c i f i c a p p l i c a t i o n . S h e a r b o l t s a r e d e s i g n e d t o f a i l

u n d e r p r e d e t e r m i n e d l o a d s . A l w a y s r e p l a c e s h e a r b o l t s w i t h i d e n t i c a l g r a d e .

R e p l a c e f a s t e n e r s w i t h t h e s a m e o r h i g h e r g r a d e . I f h i g h e r g r a d e f a s t e n e r s a r e u s e d , t i g h t e n t h e s e t o t h e s t r e n g t h o f t h e o r i g i n a l . M a k e s u r e f a s t e n e r t h r e a d s a r e c l e a n a n d t h a t y o u p r o p e r l y s t a r t t h r e a d e n g a g e m e n t . W h e n p o s s i b l e , l u b r i c a t e p l a i n o r z i n c p l a t e d f a s t e n e r s o t h e r t h a n l o c k n u t s , w h e e l b o l t s

o r w h e e l n u t s , u n l e s s d i f f e r e n t i n s t r u c t i o n s a r e g i v e n f o r t h e s p e c i f i c a p p l i c a t i o n .

a G r a d e 2 a p p l i e s f o r h e x c a p s c r e w s ( n o t h e x b o l t s ) u p t o 6 . i n ( 1 5 2 m m ) l o n g . G r a d e 1 a p p l i e s f o r h e x c a p s c r e w s o v e r 6

i n . ( 1 5 2 m m ) l o n g , a n d f o r a l l o t h e r t y p e s o f b o l t s a n d s c r e w s o f a n y l e n g t h . b “ L u b r i c a t e d ” m e a n s c o a t e d w i t h a l u b r i c a n t s u c h a s e n g i n e o i l , f a s t e n e r s w i t h p h o s p h a t e a n d o i l c o a t i n g s , o r 7 / 8

i n . a n d l a r g e r f a s t e n e r s w i t h J D M F 1 3 C z i n c f l a k e c o a t i n g . c “ D r y ” m e a n s p l a i n o r z i n c p l a t e d w i t h o u t a n y l u b r i c a t i o n , o r 1 / 4 t o 3 / 4 i n . f a s t e n e r s w i t h J D M F 1 3 B z i n c f l a k e c o a t i n g .

6 5 - 8 0 7 2 2 0 9

P N = 1 1 6

186/258




D X , T O R Q 2 - 1 9 - 2 4 M A R 0 9 - 1 / 1

M e t r i c B o l t a n d S c r e w T o r q u e V a l u e s T S 1 6 7 0 — U N — 0 1 M A Y 0 3

4.84.8 8.8 9.8 10.9 12.9 12.9

12.912.910.99.88.84.8

B o l t o r C l a s s 4 . 8 C l a s s 8 . 8 o r 9 . 8 C l a s s 1 0 . 9 C l a s s 1 2 . 9

S c r e w L u b r i c a t e d a D r y b L u b r i c a t e d a D r y b L u b r i c a t e d a D r y b L u b r i c a t e d a D r y b

S i z e N ∙ m l b - i n N ∙ m l b - i n N ∙ m l b - i n N ∙ m l b - i n N ∙ m l b - i n N ∙ m l b - i n N ∙ m l b - i n N ∙ m l b - i n

M 6 4 . 7 4 2 6 5 3 8 . 9 7 9 1 1 . 3 1 0 0 1 3 1 1 5 1 6 . 5 1 4 6 1 5 . 5 1 3 7 1 9 . 5 1 7 2

N ∙ m l b - f t N ∙ m l b - f t N ∙ m l b - f t N ∙ m l b - f t

M 8 1 1 . 5 1 0 2 1 4 . 5 1 2 8 2 2 1 9 4 2 7 . 5 2 4 3 3 2 2 3 . 5 4 0 2 9 . 5 3 7 2 7 . 5 4 7 3 5

N ∙ m l b - f t N ∙ m l b - f t N ∙ m l b - f t

M 1 0 2 3 2 0 4 2 9 2 1 4 3 3 2 5 5 4 0 6 3 4 6 8 0 5 9 7 5 5 5 9 5 7 0

N ∙ m l b - f t

M 1 2 4 0 2 9 . 5 5 0 3 7 7 5 5 5 9 5 7 0 1 1 0 8 0 1 4 0 1 0 5 1 3 0 9 5 1 6 5 1 2 0

M 1 4 6 3 4 6 8 0 5 9 1 2 0 8 8 1 5 0 1 1 0 1 7 5 1 3 0 2 2 0 1 6 5 2 0 5 1 5 0 2 6 0 1 9 0 M 1 6 1 0 0 7 4 1 2 5 9 2 1 9 0 1 4 0 2 4 0 1 7 5 2 7 5 2 0 0 3 5 0 2 5 5 3 2 0 2 3 5 4 0 0 3 0 0

M 1 8 1 3 5 1 0 0 1 7 0 1 2 5 2 6 5 1 9 5 3 3 0 2 4 5 3 7 5 2 7 5 4 7 5 3 5 0 4 4 0 3 2 5 5 6 0 4 1 0

M 2 0 1 9 0 1 4 0 2 4 5 1 8 0 3 7 5 2 7 5 4 7 5 3 5 0 5 3 0 3 9 0 6 7 5 5 0 0 6 2 5 4 6 0 7 9 0 5 8 0

M 2 2 2 6 5 1 9 5 3 3 0 2 4 5 5 1 0 3 7 5 6 5 0 4 8 0 7 2 5 5 3 5 9 2 0 6 8 0 8 5 0 6 2 5 1 0 8 0 8 0 0

M 2 4 3 3 0 2 4 5 4 2 5 3 1 5 6 5 0 4 8 0 8 2 0 6 0 0 9 2 0 6 8 0 1 1 5 0 8 5 0 1 0 8 0 8 0 0 1 3 5 0 1 0 0 0

M 2 7 4 9 0 3 6 0 6 2 5 4 6 0 9 5 0 7 0 0 1 2 0 0 8 8 5 1 3 5 0 1 0 0 0 1 7 0 0 1 2 5 0 1 5 8 0 1 1 6 0 2 0 0 0 1 4 7 5

M 3 0 6 6 0 4 9 0 8 5 0 6 2 5 1 2 9 0 9 5 0 1 6 3 0 1 2 0 0 1 8 5 0 1 3 5 0 2 3 0 0 1 7 0 0 2 1 4 0 1 5 8 0 2 7 0 0 2 0 0 0

M 3 3 9 0 0 6 6 5 1 1 5 0 8 5 0 1 7 5 0 1 3 0 0 2 2 0 0 1 6 2 5 2 5 0 0 1 8 5 0 3 1 5 0 2 3 2 5 2 9 0 0 2 1 5 0 3 7 0 0 2 7 3 0

M 3 6 1 1 5 0 8 5 0 1 4 5 0 1 0 7 5 2 2 5 0 1 6 5 0 2 8 5 0 2 1 0 0 3 2 0 0 2 3 5 0 4 0 5 0 3 0 0 0 3 7 5 0 2 7 7 0 4 7 5 0 3 5 0 0

T o r q u e v a l u e s l i s t e d a r e f o r g e n e r a l u s e o n l y , b a s e d o n t h e s t r e n g t h o f t h e b o l t o r s c r e w . D O N O T u s e t h e s e v a l u e s i f a d i f f e r e n t t o r q u e v a l u e o r t i g h t e n i n g p r o c e d u r e i s g i v e n f o r a s p e c i f i c a p p l i c a t i o n . F o r s t a i n l e s s s t e e l

f a s t e n e r s o r f o r n u t s o n U - b o l t s , s e e t h e t i g h t e n i n g i n s t r u c t i o n s f o r t h e s p e c i f i c a p p l i c a t i o n . T i g h t e n p l a s t i c i n s e r t o r c r i m p e d s t e e l t y p e l o c k n u t s b y t u r n i n g t h e n u t t o t h e d r y t o r q u e s h o w n i n t h e c h a r t , u n l e s s d i f f e r e n t i n s t r u c t i o n s a r e g i v e n f o r t h e s p e c i f i c a p p l i c a t i o n .

S h e a r b o l t s a r e d e s i g n e d t o f a i l u n d e r p r e d e t e r m i n e d l o a d s . A l w a y s r e p l a c e s h e a r b o l t s w i t h i d e n t i c a l p r o p e r t y c l a s s . R e p l a c e f a s t e n e r s w i t h t h e s a m e o r h i g h e r p r o p e r t y c l a s s . I f h i g h e r p r o p e r t y c l a s s f a s t e n e r s a r e

u s e d , t i g h t e n t h e s e t o t h e s t r e n g t h o f t h e o r i g i n a l . M a k e s u r e f a s t e n e r t h r e a d s a r e c l e a n a n d t h a t y o u p r o p e r l y s t a r t t h r e a d e n g a g e m e n t . W h e n p o s s i b l e , l u b r i c a t e p l a i n o r z i n c p l a t e d f a s t e n e r s o t h e r t h a n l o c k n u t s , w h e e l b o l t s o r w h e e l n u t s , u n l e s s d i f f e r e n t i n s t r u c t i o n s a r e g i v e n f o r t h e s p e c i f i c a p p l i c a t i o n .

a “ L u b r i c a t e d ” m e a n s c o a t e d w i t h a l u b r i c a n t s u c h a s e n g i n e o i l , f a s t e n e r s w i t h p h o s p h a t e a n d o i l c o a t i n g s , o r M 2 0

a n d l a r g e r f a s t e n e r s w i t h J D M F 1 3 C z i n c f l a k e c o a t i n g . b “ D r y ” m e a n s p l a i n o r z i n c p l a t e d w i t h o u t a n y l u b r i c a t i o n , o r M 6 t o M 1 8 f a s t e n e r s w i t h J D M F 1 3 B z i n c f l a k e c o a t i n g .

6 5 - 9 0 7 2 2 0 9

P N = 1 1 7

187/258




6 5 - 1 0 0 7 2 2 0 9

P N = 1 1 8

188/258



I n d e x

P a g e

A

A i r f i l t e r C l e a n o r r e p l a c e ( o n e - p i e c e ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 0 - 3 C l e a n o r r e p l a c e e l e m e n t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 0 - 4

A i r i n t a k e s y s t e m

C h e c k i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 5 - 1

B

B e l t C h e c k a u t o m a t i c t e n s i o n e r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 5 - 2 C h e c k t e n s i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 0 - 5 R e p l a c e ( 4 0 4 5 a n d 6 0 6 8 e n g i n e s ) . . . . . . . . . . . . . . . . . . . . . . . . 5 0 - 5

B o l t a n d s c r e w t o r q u e v a l u e s M e t r i c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 5 - 9 U n i f i e d i n c h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 5 - 8

B r e a k - i n e n g i n e o i l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 - 2

C

C o n f i g u r a t i o n d a t a , v i e w i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 - 3 C o o l a n t

D i e s e l e n g i n e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 - 3 D r a i n a n d f l u s h c o o l i n g s y s t e m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 5 - 1 P r e s s u r e t e s t i n g c o o l i n g s y s t e m . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 5 - 5 W a r m t e m p e r a t u r e c l i m a t e s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 - 4

C r a n k c a s e v e n t t u b e C l e a n i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 5 - 1

D

D a m p e r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 0 - 4

D i a g n o s t i c p r o c e d u r e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 5 - 1 0 U s i n g d i a g n o s t i c g a u g e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 - 1 D i a g n o s t i c t r o u b l e c o d e s ( D T C s )

A c t i v e e n g i n e s e r v i c e c o d e s , v i e w i n g . . . . . . . . . . . . . . . . . . . 1 5 - 7 S t o r e d s e r v i c e c o d e s , v i e w i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 - 5

D i a g n o s t i c T r o u b l e C o d e s ( D T C s ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 5 - 1 1 D i a g n o s t i c g a u g e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 5 - 1 0

D i e s e l e n g i n e o i l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 - 2 D i e s e l f u e l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 - 1 D T C s ( D i a g n o s t i c T r o u b l e C o d e s )

V i e w a c t i v e s e r v i c e c o d e s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 - 7 V i e w s t o r e d s e r v i c e c o d e s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 - 5

E

E n g i n e O p e r a t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 - 2 9

E n g i n e C o n t r o l U n i t ( E C U ) s e r i a l n u m b e r . . . . . . . . . . . . . . . . . 0 3 - 5 E n g i n e o i l

B r e a k - I n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 - 2 D i e s e l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 - 2 D r a i n i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 0 - 1

E n g i n e s p e e d ( M e c h a n i c a l f u e l s y s t e m ) . . . . . . . . . . . . . . . . . . . 4 0 - 3

P a g e

E n g i n e w i r i n g l a y o u t W i t h D e n s o H i g h P r e s s u r e C o m m o n R a i l . . . . . . . . . . . . . 5 5 - 3 W i t h S t a n a d y n e D E 1 0 p u m p . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 5 - 2

F

F u e l D i e s e l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 - 1 H a n d l i n g a n d s t o r i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 - 1

F u e l f i l t e r R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 0 - 4

F u e l p u m p m o d e l n u m b e r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 3 - 5 F u e l s y s t e m

B l e e d i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 0 - 5

H

H a r d w a r e t o r q u e v a l u e s M e t r i c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 5 - 9 U n i f i e d i n c h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 5 - 8

I

I n s t r u m e n t p a n e l A d j u s t b a c k l i g h t i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 - 1 0 A d j u s t c o n t r a s t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 - 1 2 C h a n g i n g u n i t s o f m e a s u r e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 - 1 3 M a i n m e n u n a v i g a t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 - 1 S e t u p 1 - u p d i s p l a y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 - 1 5 S e t u p 4 - u p d i s p l a y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 - 2 1 S h u t d o w n c o d e s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 - 9 U s i n g d i a g n o s t i c g a u g e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 - 1 V i e w i n g a c t i v e s e r v i c e c o d e s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 - 7 V i e w i n g c o n f i g u r a t i o n d a t a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 - 3 V i e w i n g s t o r e d s e r v i c e c o d e s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 - 5

I n t e r m i t t e n t f a u l t d i a g n o s t i c s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 5 - 1 3

L

L i s t i n g o f D T C s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 5 - 1 1 L u b r i c a n t

M i x i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 - 3 S t o r a g e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 - 3

M

M a i n t e n a n c e

1 0 0 0 h o u r s / 1 y e a r C h e c k a n d a d j u s t v a l v e c l e a r a n c e ( 3 0 2 9 a n d 4 0 3 9 e n g i n e s ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 5 - 3

C h e c k i n g a i r i n t a k e s y s t e m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 5 - 1 C h e c k i n g a u t o m a t i c b e l t t e n s i o n e r

( 4 0 4 5 a n d 6 0 6 8 E n g i n e s ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 5 - 2 C l e a n i n g c r a n k c a s e v e n t t u b e . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 5 - 1 P r e s s u r e t e s t i n g c o o l i n g s y s t e m . . . . . . . . . . . . . . . . . . . . . . . . 3 5 - 5

C o n t i n u e d o n n e x t p a g e

I n d e x - 1 0 7 2 2 0 9

P N = 1

189/258



I n d e x

P a g e

2 0 0 0 h o u r s / 2 y e a r s A d j u s t s p e e d d r o o p g o v e r n o r

( M e c h a n i c a l f u e l s y s t e m ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 0 - 3 A d j u s t v a l v e c l e a r a n c e ( 4 0 4 5 a n d 6 0 6 8

e n g i n e s ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 0 - 1 C h e c k e n g i n e s p e e d ( M e c h a n i c a l f u e l

s y s t e m ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 0 - 3

D a m p e r c h e c k . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 0 - 4 2 5 0 0 h o u r s / 3 y e a r s D r a i n a n d f l u s h c o o l i n g s y s t e m . . . . . . . . . . . . . . . . . . . . . . . . . 4 5 - 1

5 0 0 h o u r s C h a n g i n g e n g i n e o i l a n d f i l t e r . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 0 - 1 C h e c k i n g b e l t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 0 - 5 R e p l a c e f u e l f i l t e r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 0 - 4

A s r e q u i r e d A d d i t i o n a l s e r v i c e i n f o r m a t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 0 - 1 C l e a n o r r e p l a c e a i r f i l t e r ( o n e - p i e c e ) . . . . . . . . . . . . . . . . 5 0 - 3 C l e a n o r r e p l a c e a i r f i l t e r e l e m e n t . . . . . . . . . . . . . . . . . . . . . 5 0 - 4 D o n o t m o d i f y f u e l s y s t e m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 0 - 1 R e p l a c e f a n a n d a l t e r n a t o r b e l t s ( 4 0 4 5

a n d 6 0 6 8 e n g i n e s ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 0 - 5

D a i l y o r e v e r y 1 0 h o u r s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 5 - 1 O b s e r v e s e r v i c e i n t e r v a l s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 0 - 1 U s e c o r r e c t f u e l , l u b r i c a n t a n d c o o l a n t . . . . . . . . . . . . . . . . . . 2 0 - 1

M a i n t e n a n c e r e c o r d s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 2 - 1 M e t r i c b o l t a n d s c r e w t o r q u e v a l u e s . . . . . . . . . . . . . . . . . . . . . . . . . 6 5 - 9 M i x i n g l u b r i c a n t s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 - 3

O

O p e r a t i n g t h e e n g i n e B r e a k - i n p e r i o d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 - 2 5 C h a n g i n g G e n e r a t o r F r e q u e n c y . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 - 2 9 S t a n d b y p o w e r u n i t s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 - 2 9 S t a r t i n g t h e e n g i n e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 - 2 5

S t o p p i n g t h e e n g i n e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 - 2 9 U s i n g a b o o s t e r b a t t e r y o r c h a r g e r . . . . . . . . . . . . . . . . . . . . . . . 1 5 - 2 8

S

S e r i a l n u m b e r E n g i n e C o n t r o l U n i t ( E C U ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 3 - 5 H i g h - p r e s s u r e f u e l p u m p . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 3 - 5

S e r i a l n u m b e r s E n g i n e C o n t r o l U n i t ( E C U ) s e r i a l n u m b e r . . . . . . . . . . . . . 0 3 - 5

P a g e

E n g i n e o p t i o n c o d e s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 3 - 3 E n g i n e s e r i a l n u m b e r p l a t e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 3 - 1 F u e l p u m p m o d e l n u m b e r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 3 - 5 P O W E R T e c h l a b e l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 3 - 1 R e c o r d e n g i n e s e r i a l n u m b e r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 3 - 2 R e c o r d f u e l i n j e c t i o n p u m p m o d e l n u m b e r . . . . . . . . . . . 0 3 - 4


E n g i n e P a c k E P A T i e r 2 E m i s s i o n C e r t i f i e d E n g i n e s . . . . . . . . . . . . . 6 5 - 6 E P A T i e r 3 E m i s s i o n C e r t i f i e d E n g i n e s . . . . . . . . . . . . . 6 5 - 7 N o n - E m i s s i o n C e r t i f i e d E n g i n e s . . . . . . . . . . . . . . . . . . . . . . . . 6 5 - 1 S t a g e I I E m i s s i o n C e r t i f i e d E n g i n e s . . . . . . . . . . . . . . . . . . 6 5 - 4

S t o r a g e E n g i n e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 0 - 1

S t o r i n g f u e l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 - 1 S t o r i n g l u b r i c a n t s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 - 3

T

T o r q u e c h a r t s M e t r i c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 5 - 9

U n i f i e d i n c h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 5 - 8 T r o u b l e c o d e s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 5 - 1 1 T r o u b l e s h o o t i n g

E l e c t r i c a l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 5 - 8 E n g i n e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 5 - 4 G e n e r a l i n f o r m a t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 5 - 1

U

U n i f i e d i n c h b o l t a n d s c r e w t o r q u e v a l u e s . . . . . . . . . . . . . . . . 6 5 - 8 U n i t s o f m e a s u r e , c h a n g i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 - 1 3

V

V a l v e c l e a r a n c e A d j u s t ( 3 0 2 9 a n d 4 0 3 9 e n g i n e s ) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 5 - 3 A d j u s t ( 4 0 4 5 a n d 6 0 6 8 e n g i n e s ) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 0 - 1

W

W i r i n g h a r n e s s W i t h D e n s o H i g h P r e s s u r e C o m m o n R a i l . . . . . . . . . . . . . 5 5 - 3 W i t h S t a n a d y n e D E 1 0 p u m p . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 5 - 2

I n d e x - 2 0 7 2 2 0 9

P N = 2

190/258



9.2. Appendix B - Alternator user and maintenance manual

191/258



192/258



User guide and maintenance manual

LLEERROOYY SSOOMMEERR

A Alltteer r nnaattoor r

4433..22 && 4444..22

SSHHUUNNTT,, A ARREEPP && PPMMGG

3434 i

01/10/201033522059401_6_1

193/258



194/258



2010 .10 / i

1

124198

374

1530

33

322324

325

323

320

28

207120

3434 en -

T h i s m

a n u a l i s t

o b e g i v e

n

t o t h e e n d

u s e r

LSA 43.2/44.2 - 4 poLeALTeRNAToRS

Installation and maintenance195/258



2010.10 / iLeRoY-SoMeR

This manual concerns the alternator which youhave just purchased.

The latest addition to a whole new generation of alternators, this range benets from theexperience of the world’s leading manufacturer,using advanced technology and incorporatingstrict quality control.

SAFETY MEASURES

Before using your alternator for the rst time, it is important to

read the whole of this installation and maintenance manual.

All necessary operations and interventions on this alternator must be performed by a qualied technician.

Our technical support service will be pleased to provide any

additional information you may require.

The various operations described in this manual are

accompanied by recommendations or symbols to alert the

user to potential risk of accident. It is vital that you understand

and take notice of the different warning symbols used.

CAUTION

Warning symbol for an operation capable of damaging o r

destroying the alternator or surrounding equipment.

Warning symbol for general danger to personnel.

Warning symbo l for electrical danger to personnel.

Note: LEROY-SOMER reserves the right to modify the

characteristics of its products at any time in order to incorporate

the latest technological developments. The information

contained in this document may therefore be changed without

notice.

WARNING SYMBOLS

We would like to draw your attention to the following two safety

measures that must be complied with:

a) During operation, do not allow anyone to stand in front of the

air outlet guards, in case anything is ejected from them.

b) Do not allow children younger than 14 to go near the air

outlet guards.

A set of self-adhesive stickers depicting the various warning

symbols is included with this maintenance manual. They

should be positioned as shown in the drawing below once the

alternator has been fully installed.

WARNING

The alternators must not be put into service until the

machines in wh ich they are to be incorporated have been

declared compliant with Directives EC plus any other

directives that may be applicable.

Copyright 2004: MOTEURS LEROY-SOMER

This document is the property of:

MOTEURS LEROY-SOMER

It may not be reproduced in any form without prior

authorization.

All brands and models have been registered and patents

applied for.

INSTALLATION AND MAINTENANCE

LSA 43.2 / 44.2 - 4-poLeALTeRNAToRS

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1 - RECEIPT

1.1 - Standards and safety measures .................... 4

1.2 - Inspection ...................................................... 4

1.3 - Identication .................................................. 4

1.4 - Storage .......................................................... 4

1.5 - Applications ................................................... 4

1.6 - Contra-indications to use ..............................4

2 - TECHNICAL CHARACTERISTICS

2.1 - Electrical characteristics ................................5

2.2 - Mechanical characteristics.............................5

3 - INSTALLATION - COMMISSIONING

3.1 - Assembly ....................................................... 6

3.2 - Inspection prior to rst use .............................6

3.3 - Terminal connection diagrams .......................7

3.4 - Commissioning .............................................. 9

3.5 - Settings .......................................................... 9

4 - SERVICING - MAINTENANCE

4.1 - Safety measures.......................................... 10

4.2 - Regular maintenance................................... 10

4.3 - Fault detection ............................................. 10

4.4 - Mechanical defects .......................................11

4.5 - Electrical faults..............................................11

4.6 - Dismantling, reassembly.............................. 12

4.7 - Installation and maintenance of the PMG.....14

4.8 - Table of characteristics ................................ 14

4.9 - Table of weights ........................................... 15

5 - SPARE PARTS

5.1 - First maintenance parts ............................... 16

5.2 - Bearing designations ................................... 16

5.3 - Technical support service ............................. 16

5.4 - Exploded view, parts list ............................... 17

EC DECLARATION OF INCORPORATION......19



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ALTERNATEURS

Valeurs excit / Excit. values

en charge / full load

à vide / at no load

TensionVoltage

Secours

Std by

40C

27C

PUISSANCE / RATING

Connex.

kVA

kW

A

kVA

kW

A

V

Ph.

Continue

Continuous

LSA Date

N° Hz

Min-1/R.P.M. ProtectionCos Ø /P.F. Cl. ther. / Th. class

Régulateur/A.V.R.

Altit. m Masse / WeightRlt AV/D.E bearing

Rlt AR/N.D.E bearing

Graisse / Grease

ALTERNATORS

1 - RECEIPT

1.1 - Standards and safety measures

Our alternators comply with most international standards.

See the EC Declaration of Incorporation on the last page.

1.2 - Inspection

On receipt of your alternator, check that it has not suffered any

damage in transit. If there are obvious signs of knocks, contact the

transporter (you may able to claim on their insurance) and after a

visual check, turn the machine by hand to detect any

malfunction.

1.3 - Identication

The alternator is identied by means of a nameplate glued tothe frame.

Make sure that the nameplate on the alternator conforms to

your order.

The alternator name is dened according to various criteria

(see below).

Example of description: LSA 43.2 M45 J6/4

• LSA: Name used in the PARTNER range• M: Marine• C: Cogeneration• T: Telecommunications• 43.2: Machine type• M45: Model• J: Excitation system (C: AREP/J: SHUNT or PMG/

E: COMPOUND)

• 6/4: Winding number/number of poles

1.3.1 - Nameplate

So that you can identify your alternator quickly and accurately,

we suggest you ll in its specications on the non-contractual

nameplate below.

1.4 - Storage

Prior to commissioning, machines should not be stored in

humid conditions: at relative humidity levels greater than 90%,

the machine insulation can drop very rapidly, to just above zero

at around 100%. The state of the anti-rust protection on

unpainted parts should be monitored.

For storage over an extended period, the alternator can be

placed in a sealed enclosure (heatshrunk plastic for example)

with dehydrating sachets inside, away from signicant and

frequent variations in temperature to avoid the risk of

condensation during storage.

If the area is affected by vibration, try to reduce the effect of these vibrations by placing the generator on a damper support

(rubber disc or similar) and turn the rotor a fraction of a turn

once a fortnight to avoid marking the bearing rings.

1.5 - Applications

These alternators are designed mainly to produce electricity in

the context of applications involving the use of generators.

1.6 - Contra-indications to use

Use of the alternator is restricted to operating conditions(environment, speed, voltage, power, etc.) compatible with the

characteristics indicated on your genset.



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T1 T2 T3

T4 T5 T6

T7 T8 T9

T10 T11 T12

R 250

5 + 6 –

T1 T2 T3

T4 T5 T65 + 6 –

T7 T8 T9

T10 T11 T12

R 438

T1 T2 T3

T4 T5 T6

5 + 6 –

T7 T8 T9

T10 T11 T12

R 438

PMG

2 - TECHNICAL

CHARACTERISTICS

2.1 - Electrical characteristicsPARTNER LSA 43.2/44.2 alternators are generators without

sliprings or revolving eld brushes, wound as «2/3 pitch», 12-

wire; the insulation is class H and the eld excitation system is

available in either «SHUNT», «AREP» or «PMG» versions

(see AVR manual).

2.1.1 - Options

- Stator temperature detection probes.

- Space heaters.

Interference suppression conforms to standard EN 55011,

group 1, class B. (Europe).

2.1.2 - SHUNT system wi th R 250 AVR

Other version R 251 AVR for dedicated single-phase or R 448

for additional function.

2.1.3 - AREP system wi th R 438 AVR

2.1.4 - PMG system with R 438 AVR

2.2 - Mechanical characterist ics- Steel frame

- Cast iron end shields

- Protected ball bearings, greased for life

- Mounting arrangements:

IM 1201 (MD 35) foot and ange mounted, single-bearing with

SAE coupling disc.

IM 1001 (B 34) double-bearing with SAE ange and standard

cylindrical shaft extension.

- Drip-proof machine, self-cooled

- Degree of protection: IP 23

2.2.1 - Options

- Air inlet lter

- Regreasable bearings (only for LSA 44.2 and SHUNT or

AREP version)

- IP 44 protection

Exiter

Exiter

Exiter

Armature

Armature

Armature

Field

Field

Field

SERIESconnection

PARALLELconnection

PARALLELconnection

MAIN FIELD

MAIN FIELD

MAIN FIELD

STATOR : 12 wires (marked T1 to T12)



Auxiliary windings

Power supply and voltage reference

Voltage reference

Voltage reference

V a r i s t o r

V a r i s t o r

V a r i s t o r

R

e d

Y

e l l o w

G

r e e n

B

l a c k



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3 - INSTALLATION

Personnel undertaking the various operations discussed

in this section must wear the appropriate personal

protective equipment for mechanical and electricalhazards.

3.1 - Assembly

Al l mechanical handl ing operations must be under taken

using approved equipment and the machine must be

horizontal. Check how much the alternator weight (see

4.9) before choosing the lifting t ool. During this operation,

do not allow anyone to stand under the load.

3.1.1 - Handling

The generously-sized lifting rings are for handling the alternator

alone. They must not be used to lift the genset. The choice of

lifting hooks or handles should be determined by the shape of

these rings. Choose a lifting system that has regard for the

integrity and environment of the alternator.

3.1.2 - Coupling3.1.2.1 - Single-bearing alternator

Before coupling the alternator and the heat engine, check they

are compatible by:- undertaking a torsional analysis of the transmission on both

units

- checking the dimensions of the ywheel and its housing, the

ange, coupling discs and offset.

CAUTION

When coupling t he alternator to the prime mover, the holes

of the coupling discs should be aligned with the ywheel

holes by cranking the engine.

Do not use the alternator fan to turn the roto r.

Make sure the alternator is securely bedded in position

during coupling.

Tighten the coupling disc screws to the recommended torqueand check that there is lateral play on the crankshaft.

3.1.2.2 - Two-bearing alternator

- Semi-exible coupling

Careful alignment of the alternator and the heat engine is

recommended, checking that the differences in concentricity

and parallelism of the two parts of the coupling do not exceed0.1 mm.

CAUTION

This alternator has been balanced with a half-key.

3.1.3 - Location

Ensure that the ambient temperature in the room where the

alternator is placed cannot exceed 40 °C for standard power

ratings (for temperatures > 40 °C, apply a derating coefcient).

Fresh air, free from damp and dust, must be able to circulate

freely around the air intake grilles on the opposite side from the

coupling.

3.2 - Inspection prior to rst use

3.2.1 - Electrical checks

Under no circumstances should an alternator, new or

otherwise, be operated if the insulation is less than

1 megohm for the stator and 100,000 ohms for the other

windings.

There are three possible methods for restoring the above

minimum values.a) Dry out the machine for 24 hours in a drying oven at a

temperature of approximately 110 °C (without the AVR).

b) Blow hot air into the air inlet, having made sure that the

machine is rotating with the exciter eld disconnected.

c) Run in short-circuit mode (disconnect the AVR):

- Short-circuit the three output terminals (power) using

connections capable of supporting the rated current (try not to

exceed 6 A/ mm2)

- Insert a clamp ammeter to monitor the current passing through

the short-circuit connections

- Connect a 48 Volt battery in series with a rheostat of

approximately 10 ohms (50 W) to the exciter eld terminals,

respecting the polarity

- Open all the alternator openings fully

- Run the alternator at its rated speed, and adjust the exciter

eld current using the rheostat to obtain the rated output current

in the short-circuit connections

Note: Prolonged standstill: In order to avoid these problems,

we recommend the use of space heaters, as well as turning

over the machine from time to time. Space heaters are only

really effective if they are working continuously while the

machine is stopped.

CAUTION

Ensure that the alternator has the degree of protection

matching the dened environmental conditions.



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L1(U)

N

L3(W)

T1 T7

T12

T10 T4

T9

T3

T6

T11

T5

T2

T8 L2(V)

A 60 Hz50 Hz

190 - 208 190 - 240

220 - 230 -

- 190 - 208

6

7

8

N

T1

T7

T12

T10

T4

T9

T3 T6

T11 T5

T2 T8

L1(U)

L3(W) L2(V)

D

F L1(U)

M

L3(W)

T1

T7

T12

T10

T4 T9

T3

T6

T11 T5 T2 T8L2(V)

N

L1(U)

L2(V)

L3(W)T9

T8

T7

T12

T10

T11

T4

T3

T2

T1

T5 T6

60 Hz50 Hz

380 - 415 380 - 480

440 - 460 -

- 380 - 416

6

7

8

N

L1(U)

L2(V)

L3(W)

L1(U)

L2(V)

L3(W)

T9

T8

T7

T12

T10

T11

T4

T3

T2

T1

T5

T6

FF 60 Hz50 Hz

220 - 240 220 - 240

220 - 240200

250 - 260 -

6

7

8

M

L

L

L

L

T9

T8

T7

T12

T10

T11 T4

T3

T2

T1

T5

T6

60 Hz50 Hz

220 - 240 220 - 240

220 - 240200

250 - 260 -

6

7

8

T9

T8

T7 T12

T10

T11

T4

T3

T2

T1

T5

T6

L

L L

T1 T7

T12

T10 T4

T9

T3

T6

T11 T5

T2 T8

LM

3.2.2 - Mechanical checks

Before starting the machine for the rst time, check that:

- the xing bolts on the feet are tight,

- the cooling air is drawn in freely,

- the protective grilles and housing are correctly in place,

- the standard direction of rotation is clockwise as seen from

the shaft end (phase rotation in order 1-2-3). For anti-clockwise

rotation, swap 2 and 3.

- the winding connection corresponds to the site operating

voltage (see section 3.3).

3.3 - Terminal connection diagrams

To modify the connection, change the position of the terminal

cables. The winding code is specied on the nameplate.

Any in tervention on the alternator terminals during

reconnection or checks should be performed with the

machine stopped.

R 250 voltage sensing:

0 => (T8) / 110 V => (T11)


0 => (T3) / 220 V => (T2)

Connections codes L.L voltage

Winding

Winding

Winding

Winding

3 phases

3 phases

1 phase

1 phaseor

3 phases

Factory connection


0 => (T8) / 110 V => (T11)


0 => (T3) / 380 V => (T2)


0 => (T1) / 110 V => (T4)


0 => (T10) / 220 V => (T1)LM voltage = 1/2 LL voltage

LM voltage = 1/2 LL voltage


0 => (T8) / 110 V => (T11)


0 => (T3) / 220 V => (T2)

AR

AR

AR

AR



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T1 T4 T3 T2

L LM

L - L

220

230

240

110

115

120

T2 - T3 T2 - T3 T1 T4

L - M L L M

T1

T4 T3

T2

L L

L - L

-

-

-

110

115

120

T1 - T3

T2 - T4- T1-T3 T2 - T4

L - M L L M

M T1

T7 T12

T10

T4

T9

T3

T6

T11

T5

T2

T8L

L

G60 Hz50 Hz

220 - 240 220 - 240

250 - 260

200

-

220 - 240

6

7

8

M

L

L T9

T8

T7

T12

T10

T11

T4

T3

T2

T1

T5

T6

L1(U)

L2(V)

L3(W)L

L

60 Hz50 Hz

110 - 120 120

110 - 120-

120 - 130 -

6

7

8

T9

T8

T7

T12

T10

T11

T4

T3

T2

T1

T5

T6

LL

L3(W)

T1

T7

T10

T9 T3

T6

T11

T5 T2

T8

L2(V)

B

T12

T4

L1(V)

6-

5+

6–

+ +

– –

R 250 R 438

6-

5+

6–

+ +

– –

3.3.1 - Connexion de l’excitatr ice


0 => (T8) / 110 V => (T11)


0 => (T3) / 110 V => (T2)


0 => (T8) / 110 V => (T11)


0 => (T3) / 220 V => (T2)

Connection codes

Series connection (shunt excitation)

White

Blue Blue

Black Black

Red Red

Parallel connection (AREP or PMG excitation)

SERIAL CONNECTION

Voltage 50/60Hz

R 251 voltage sensing: 0 => (T1) / 110 V => (T2) R 251 voltage sensing: 0 => (T1) / 110 V => (T2)

Voltage 50/60HzOutput Output

Link Link

PARALLEL CONNECTION (Not possible with LSA 44.2)

Connection notrecommended

LM voltage = 1/2 LL voltage

L.L. voltage

FOR LSA 44.2, THE COUPLINGB IS NOT POSSIBLE

SINGLE-PHASE 4-WIRE - type M or M1 DEDICATED WINDING

Winding

Winding

1 phaseor 3 phases

Factory connection

White

AR

AR



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A D F B F/F G

T1 T1 T1 T1 T1 T2

T2 T2 T2 T2 T9 T4

T3 T3 T3 T3 T3 T3

N N

ST4

LSA 43.2, 44.2

Ph1

Ph2

Ph3

101

102

103

104

130°C

150°C

180°C

3.3.3 - Connection checks

Electrical installations must comply with the current

legislation in force in the country of use.

Check that:

- The residual circuit-breaker complies with legislation on

protection of personnel in force in the country of use, and has

been correctly installed on the alternator power output as close

as possible to the alternator. (In this case, disconnect the blue

wire of the R 791 interference suppression module linking the

neutral);

- Any protective devices in place have not tripped;

- If there is an external AVR, the connections between the

alternator and the cubicle are made in accordance with the

connection diagram;

- There is no short-circuit between phase or phase-neutral

between the alternator output terminals and the generator set

control cabinet (part of the circuit not protected by circuit-breakers or cubicle relays);

- The alternator has been connected with the busbar separating

the terminals as shown in the terminal connection diagram.

- The equipotential earth l inks have been implemented

correctly (cross-section and continuity of the earths).

3.4 - Commissioning

The alternator can only be started up and used if the

installation is in accordance with the regulations andinstructions dened in this manual.

The alternator is tested and set in the factory. When rst used

with no load, make sure that the drive speed is correct and

stable (see the genset nameplate). On application of the load,

the alternator should achieve its rated speed and voltage;

however, in the event of abnormal operation, the alternator

setting can be altered (follow the adjustment procedure: see

section 3.5). If the operation is still incorrect, the cause of the

malfunction must be located (see section 4.4 & 4.5).

3.5 - Setting up

The various adjustments during tests must be made by a

qualied engineer. The screwdriver for making

adjustments must be suitable for use with electrical

equipment. It is essential that the drive speed specied

on the genset nameplate is reached before commencing

adjustment. The AVR is used to make any adjustments to

the alternator. Access to the AVR adjustments is via the

panel provided for this purpose.

Af ter operat ional tes ting , rep lace all access panels or

covers.

R 791 T interference suppression ki t (standard for CE marking)

Connections

Voltage adjustmentby remote potentiometer

Voltage potentiometer

Anti condensat ion heater Thermistor (PTC) temperature

Blue

Black

Red/white

Black

Black

Black

Blue

White

3.3.2 - Schéma de connexion des options



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4 - SERVICING / MAINTENANCE

4.1 - Safety measures

Servicing or tr oubleshooting mus t be carried out strictly

in accordance with instructi ons so as to avoid the risk of

accidents and to maintain the alternator in its original

state.

Al l such operations performed on the alternator should be

undertaken by personnel trained in the commissioning,servicing and maintenance of electrical and mechanical

components, who must wear the appropriate personal

protective equipment for mechanical and electrical

hazards.

Before carrying out any work on the alternator, ensure that it

cannot be started by a manual or automatic system by isolating

the power in any cabinet or enclosure and make sure you have

understood the operating principles of the system.

4.2 - Regular maintenance

4.2.1 - Checks after start-up

After approximately 20 hours of operation, check that all xingscrews on the alternator are still tight, plus the general state of

the alternator and the various electrical connections in the

installation.

4.2.2 - Cool ing circuit

It is advisable to check that circulation of air is not reduced by

partial blocking of the air intake and outlet grilles: mud, bre,

grease, etc. and to check whether the ventilation guards are

corroded or scratched.

4.2.3 - Bearings

The bearings are permanently greased: approximate life of thegrease = 20,000 hours or 3 years.

As an option, they are regreasable for the LSA 44.2. It is

advisable to lubricate the alternator during operation. Time

intervals and quantity of grease are given in the table below.

NDE/DE bearing 6315 C3 6309 C3

Quantity of grease 30 g 15 g

Regreasing interval 6000 hrs 10,000 hrs

Lubrication intervals are given for grease type

LITHIUM - standard - NLGI 3.

In the factory, the grease used for lubrication is:

ESSO UNIREX N3.

Before using another grease, check for compatibility with theoriginal one. Monitor the temperature rise in the bearings,

which must not exceed 50°C above the ambient temperature.

Should this value be exceeded, the alternator must be

stopped and checks carried out.

4.2.4 - Electrical servicing

Cleaning product for the windings.

CAUTIONDo not use: trichlorethylene, perchlorethylene,

trichloroethane or any alkaline products.

Certain strictly dened pure volatile degreasing agents can be

used, such as:

- Normal petrol (without additives); inammable

- Toluene (slightly toxic); inammable

- Benzene (or benzine, toxic); inammable

- Ciclohexare (non toxic); inammable

The insulating components and the impregnation system are

not at risk of damage from solvents (see the list of authorized

products). Avoid letting the cleaning product run into the slots. Apply the

product with a brush, sponging frequently to avoid accumulation

in the housing. Dry the winding with a dry cloth. Let any traces

evaporate before reassembling the alternator.

These operations must be performed at a cleaning station,

equipped with a vacuum system that collects and ushes

out the products used.

4.2.5 - Mechanical servicing

CAUTION

Cleaning the machine using a water spray or ahigh-pressure washer is strict ly prohibi ted.

Any prob lems arising from such treatment are no t covered

by our warranty.

The machine should be cleaned with a degreasing agent,

applied using a brush. Check that the degreasing agent will not

affect the paint.

Compressed air should used to remove any dust.

If lters have been added to the machine after manufacture

and do not have thermal protection, the service personnel

should clean the air lters periodically and systematically, as

often as necessary (every day in very dusty atmospheres).

Cleaning can be performed using water for dry dust or in a bath

containing soap or detergent in the case of greasy dust. Petrolor chloroethylene can also be used.

After cleaning the alternator, it is essential to check the winding

insulation (see sections 3.2 and 4.8).

4.3 - Fault detection

If, when commissioned, the alternator does not work normally,

the source of the malfunction must be identied.

To do this, check that:

- the protective devices are tted correctly

- the connections comply with the diagrams in the manuals

supplied with the machine

- the speed of the unit is correct (see section 1.3)Repeat the operations dened in section 3



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4.4 - Mechanical defects

Fault Action

Bearing

Excessive overheating of one or both

bearings (temperature > 80 °C on thebearing retainers with or without abnormal

noise)

- If the bearing has turned blue or if the grease has turned black, change the

bearing.- Bearing not properly seated.

- End shields misaligned (anges not properly tted).

Temperature

abnormal

Excessive overheating of alternator frame

(more than 40 °C above the ambient

temperature)

- Air ow (intake-outlet) partially clogged or hot air is being recycled from

the alternator or engine- Alternator operating at too high a voltage (> 105% of Un on load)

- Alternator overloaded

Vibration

Excessive vibration

- Misalignment (coupling)

- Defective mounting or play in coupling

- Rotor balancing fault

Excessive vibration and humming noise

coming from the machine

- Alternator operating in single-phase mode (single-phase load or faulty

contactor or installation fault)

- Stator short-circuit

Abnormal noise

Alternator damaged by a signicant impact,

followed by humming and vibration

- System short-circuit- Mis-paralleling

Possible consequences

- Broken or damaged coupling

- Broken or bent shaft end

- Shifting and short-circuit of main eld

- Fan fractured or coming loose on shaft

- Irreparable damage to rotating diodes or AVR

4.5 - Electrical faults

Fault Action Effect Check/Cause

Novoltage at no loadon start-up

Connect between E- and

E+ a new battery of 4 to

12 volts, respecting the AVR polarities, for

2 to 3 seconds

The alternator builds up and its voltage is

still correct when the battery is removed.

- Lack of residual magnetism

The alternator builds up but its voltagedoes not reach the rated value when

the battery is removed.

- Check the connection of the voltage reference to the AVR

- Faulty diodes- Armature short-circuit

The alternator builds up but its voltage

disappears when the battery is removed

- Faulty AVR

- Field windings disconnected

- Main eld winding open circuit. Check the resistance

Voltage too low Check the drive speed

Correct speed

Check the AVR connections (AVR may be faulty)

- Field windings short-circuited

- Rotating diodes burnt out

- Main eld winding short-circuited - Check the

resistance

Speed too low

Increase the drive speed (Do not touch the AVR voltage pot. (P2) before running

at the correct speed.)

Voltage too high Adjust AVR voltage

potentiometer

Adjustment ineffective Faulty AVR

Voltage

oscillations

Adjust AVR stability

potentiometer

If no effect: try normal/rapid recovery

modes (ST2)

- Check the speed: possibility of cyclic irregularity

- Loose connections

- Faulty AVR

- Speed too low when on load (or LAM set too high)

Voltage correct

at no load andtoo low when onload (*)

Run at no load and check

the voltage between E+

and E- on the AVR

Voltage between E+ and E-

SHUNT < 20 V - AREP/PMG < 10 V - Check the speed (or LAM set too high)

Voltage between E+ and E-

SHUNT > 30 V - AREP/PMG > 15 V

- Faulty rotating diodes- Short-circuit in the main eld. Check the resistance - Faulty exciter armature

(*) Caution : For single-phase operation, check that the sensing wires coming from the AVR are correctly connected to the operating terminals

Voltagedisappears

during operation

(**)

Check the AVR, the surgesuppressor, the rotating

diodes, and replace any

defective components

The voltage does not return to the ratedvalue - Exciter winding open circuit- Faulty exciter armature

- Faulty AVR

- Main eld open circuit or short-circuited

(**) Caution: Internal protection may be activated (overload, open circuit, short-circuit)



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- -

C C C

A A A

+

C C C

A A A

+~ ~ ~ ~ ~ ~

C A

6- 5+

Rh. 50Ω - 300 W

-+

-

+

6 – 5 +Variac

AC

220 V

DC

12 V

50 6 0

7 0

8 0

9 0

1 0 0

4 0

3 0

2 0

1 0

0

4.5.1 - Checking the winding

You can check the winding insulation by performing a high

voltage test. In this case, you must disconnect all AVR wires.

CAUTION

Damage caused to the AVR in such conditions is not

covered by our warranty.

4.5.2 - Checking the diode bridge

4.5.3 - Checking the windings and rotatingdiodes using separate excitation

During this procedure, make sure that the alternator is

disconnected from any external load and inspect the

terminal box to check that the connections are fully

tightened.

1) Stop the unit, disconnect and isolate the AVR wires.

2) There are two ways of creating an assembly with separate

excitation.

Assembly A: Connect a 12 V battery in series with a rheostat

of approximately 50 ohms - 300 W and a diode on both exciter eld wires (5+) and (6-).

Assembly B : Connect a «Variac» variable power supply and

a diode bridge on both exciter eld wires (5+) and (6-).

Both these systems should have characteristics which are

compatible with the eld excitation power of the machine (see

the genset nameplate).

3) Run the unit at its rated speed.

4) Gradually increase the exciter eld supply current by

adjusting the rheostat or the Variac and measure the output

voltages on L1 - L2 - L3, checking the excitation voltage at no

load (see machine nameplate or ask for the factory test

report).

When the output voltage is at its rated value and balanced

within 1% for the rated excitation level, the machine is in good

working order. The fault therefore comes from the AVR or its

associated wiring (ie. sensing, auxiliary windings).

4.6 - Dismant ling, reassembly

(see sect ions 5.4.1/5.4.2 & 5.4.3)

During the warranty period, this operation should onl y be

carried out in an LEROY-SOMER approved workshop or i n

our factory, otherwise the warranty may be invalidated.

Whilst being handled, the alternator should remain

horizontal (translational movement of rotor not locked).

Check how much the alternator weighs (see section 4.9)

before choosing the lifting method.

The choice of lifting hooks or handles should be

determined by the shape of the lifting rings .

Assembly A

Diode 1A

Exciter eld

12 V battery

Anode

LSA 43.2 / 44.2 diode bridge

A diode in good working condition allows the currentto ow in only one direction, from anode to cathode.

Cathode

Assembly B

Diode 1A

Exciter eld



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4.6.1 - Tools required

To fully dismantle the machine, we recommend using the tools

listed below:

- 1 ratchet spanner + extension

- 1 torque wrench

- 1 set of at spanners: 7 mm, 8 mm, 10 mm, 12 mm

- 1 socket set: 8 mm, 10 mm, 13 mm, 16 mm, 18 mm, 21 mm,

22 mm, 24 mm

- 1 size 5 Allen key (eg. Facom: ET5)




- 1 T20 and T30 TORX bit

- 1 puller (eg. Facom: U35)

- 1 puller (eg. Facom: U32/350).

4.6.2 - Screw tightening torque

IDENTIFICATION screw Ø Torque N.m

Field terminal block screw M4 4 N.m

Field screw M6 10 N.m

Diode bridge/RP M6 5 N.m

Diode nut M5 4 N.m

43.2 tie rod M12 57 N.m

44.2 tie rod M14 90 N.m

Earth screw M8 26 N.m

43.2 disc/shaft screw M12 110 N.m

44.2 disc/shaft screw M16 250 N.m

44.2 turbine screw M6 5 N.m

Grille screws M6 5 N.m

Cover screws M6 5 N.m

Terminal block nut M10 20 N.m

4.6.3 - Access to connections and theregulation system

The terminals are accessed directly by removing the terminal

box lid [48].

To access the AVR adjustment potentiometers, the side plate

[367] should be removed.

4.6.4 - Accessing, checking andreplacing diodes

4.6.4.1 - Dismantling

- Remove the air intake grille [51]

- Remove the surge suppressor [347]

- Disconnect the 6 diodes using an ohmmeter or a battery lamp

(see section 4.5.2)

4.6.4.2 - Reassembly

- Replace the bridges, respecting the polarity (see section 4.5.1)

- Replace the surge suppressor [347]

- Ret the air intake grille [51]

- Replace the terminal box lid [48]

4.6.5 - Replacing the NDE bearing on s ingle-bearing machines

4.6.5.1 - Dismantling- Remove the terminal box lid [48]

- Remove the air intake grille [51]

- Unscrew the xing clamps on the power output cables,

remove the connector from the exciter and the R 791 module.

- Remove the 4 nuts on the tie rods

- Remove the NDE shield [36] using a puller: eg. U.32 - 350

(FACOM)

- Remove the ball bearing [70] using a screw puller


- Heat the inner slipring of a new bearing by induction or in a

drying oven at 80 °C (do not use an oil-bath) and t it to the

machine.

- Place the preloading wavy washer [79] in the shield and t a

new O ring seal [349].

Ret the NDE shield and pass the bundle of wires between the

top bars of the shield.

- Ret the xing clamps on the cables, the R 791 module and

the exciter connector.

- Ret the air intake grille [51].

- Replace the terminal box lid [48].

NDE shieldRotor

Screw rod

4.6.6 - Replacing the bearings on two-bearingmachines

4.6.6.1 - Dismantling- Uncouple the alternator from the prime mover.

- Remove the 8 assembly screws.

- Remove the DE shield [30].

- Remove the NDE shield (see section 4.6.5.1)

- Remove both ball bearings [60] and [70] using a puller with a

central screw.


- Heat the new bearings by induction or in a drying oven at 80°C

(do not use an oil-bath) and t them to the machine.

- Check that both the preloading wavy washer [79] and the new

O ring seal [349] have been tted on the NDE shield [36].

Ret the NDE shield and pass the bundle of wires between the

top bars of the shield.- Ret the DE shield [30] and tighten the 4 xing screws.

- Check that the machine assembly is correctly mounted and

that all screws are tightened.



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4.4.6.7 - Accessing the main eld and stator

4.6.7.1 - Dismantling

Follow the procedure for dismantling the bearings (see

sections 4.6.5.1 and 4.6.6.1)

- Remove the coupling disc (single-bearing alternator) or the

DE shield (two-bearing alternator) and insert a tube of the

corresponding diameter on the shaft end.

- Rest the rotor on one of its poles, then slide it out. Use the tube

as a lever arm to assist dismantling.

- After extraction of the rotor, be careful not to damage the fan.

If the fan is dismantled, it is essential that it is replaced for the

43.2.

NOTE: If intervention is required on the main eld

(rewinding, replacement of components), the rotor

assembly must be rebalanced.

4.6.7.2 - Reassembling the main eld

- Follow the dismantling procedure in reverse order.Take care not to knock the windings when retting the rotor in

the stator.

- If the fan is being replaced on the 43.2, assemble the parts as

shown in the following diagram. Fit a tube and a threaded

screw. On the 44.2 the fan is xed by screws on the hub.

Follow the procedure for reassembling the bearings (see

sections 4.6.5.2 and 4.6.6.2).

Af ter operat ional tes ting, replace all access panels or

covers.

4.7 - Installation and maintenance

of the PMG

For the LSA 43.2 and LSA 44.2, the PMG reference is PMG 1.

See the PMG maintenance manual, ref: 4211.

CAUTION

Mounting is impossib le with the «regreasable bearings»

option with the LSA 44.2.

4.8 - Electrical characteristics

Table of average values:

Alternator - 2 and 4 poles - 50 Hz/60 Hz - Winding n° 6 and Mor M1 connected in dedicated single-phase. (400 V for the

excitation values).

The voltage and current values are given for no-load operation

and operation at rated load with separate eld excitation. All

values are given at ± 10% (for exact values, consult the test

report) and are subject to change without prior warning. For 60

Hz machines, the resistance values are the same and the

excitation current «i exc» is approximately 5 to 10% weaker.

4.8.1 - 3-phase LSA 43.2 4 P, SHUNT excitationResistances at 20 °C (Ω)

LSA 43.2 Stator L/N Rotor Field Armature

S1 0.155 1.35 18.4 0.23

S15 0.155 1.35 18.4 0.23

S25 0.155 1.35 18.4 0.23

S35 0.128 1.41 18.4 0.23

M45 0.105 1.57 18.4 0.23

L65 0.083 1.76 18.4 0.23

L8 0.063 1.96 18.4 0.23

Field excit ation current i exc (A) - 400 V - 50 Hz

«i exc»: excitation current of the exciter eld

LSA 43.2 no load on load

S1 0.5 1.3

S15 0.5 1.5

S25 0.5 1.6

S35 0.5 1.8

M45 0.4 1.6

L65 0.4 1.6L8 0.4 1.6

4.8.2 - 3-phase LSA 43.2 4 P, AREP exci tationResistances at 20 °C (Ω)

LSA 43.2Stator

L/NRotor

Wind.X1,X2

Widing.Z1,Z2

Field Armat.

S1 0.155 1.35 0.32 0.52 4.6 0.23

S15 0.155 1.35 0.32 0.52 4.6 0.23

S25 0.155 1.35 0.32 0.52 4.6 0.23

S35 0.128 1.41 0.29 0.5 4.6 0.23

M45 0.105 1.57 0.26 0.51 4.6 0.23

L65 0.083 1.76 0.26 0.44 4.6 0.23

L8 0.063 1.96 0.21 0.4 4.6 0.23

Field excit ation current i exc (A) -400 V -50 Hz



S1 1 2.6

S15 1 3

S25 1 3.2

S35 1 3.6

M45 0.8 3.2

L65 0.8 3.2

L8 0.8 3.2



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4.8.3 - Dedicated single-phase LSA 43.2:4-pole, SHUNT exci tation (60 Hz only)

Resistances at 20 °C (Ω)

LSA 43.2 Stator L/N Rotor Field ArmatureS1 0.058 1.35 13.9 0.23

S25 0.058 1.35 13.9 0.23

S35 0.046 1.41 13.9 0.23

M45 0.037 1.57 13.9 0.23

L65 0.027 1.76 13.9 0.23

L8 0.019 1.96 13.9 0.23




S1 0.59 1.44

S25 0.59 1.68S35 0.66 1.65

M45 0.61 1.48

L65 0.62 1.48

L8 0.74 1.46

4.8.4 - 3-phase LSA 44.2: 4-pole, SHUNTexcitation



VS3 0.046 2.51 18.4 0.5

VS45 0.046 2.51 18.4 0.5S7 0.036 2.91 18.4 0.5

S75 0.036 2.91 18.4 0.5

M95 0.024 3.32 18.4 0.5

L12 0.019 3.66 18.4 0.5

Field excitation current i exc (A) - 400 V - 50 Hz



VS3 0.5 1.8

VS45 0.5 2.1

S7 0.5 1.9

S75 0.5 2.1

M95 0.6 2L12 0.5 1.9

4.8.5 - 3-phase LSA 44.2: 4-pole, AREPexcitation


LSA 44.2Stator

L/NRotor

Wind.X1,X2

Wind.Z1,Z2

Field Armat.

VS3 0.046 2.51 0.3 0.5 4.9 0.5

VS45 0.046 2.51 0.3 0.5 4.9 0.5

S7 0.036 2.91 0.21 0.32 4.9 0.5

S75 0.036 2.91 0.21 0.32 4.9 0.5

M95 0.024 3.32 0.17 0.28 4.9 0.5L12 0.019 3.66 0.16 0.21 4.9 0.5

Field excitation current i exc (A) -400 V -50 Hz



VS3 1 3.6

VS45 1 4.2

S7 1 3.8

S75 1 4.2

M95 1.2 4

L12 1 3.8

4.8.6 - Dedicated single-phase LSA 44.2:4-pole, SHUNT excitation (60 Hz only)



VS3 0.0194 2.51 18.4 0.5

VS45 0.0194 2.51 18.4 0.5

S7 0.0140 2.91 18.4 0.5

M95 0.0088 3.32 18.4 0.5




VS3 0.44 1.18

VS45 0.44 1.25

S7 0.43 1.2

M95 0.55 1.28

4.9 - Table of weights

LSA 43.2 Total weight (kg) Rotor (kg)

S1 220 76

S15 220 76

S25 220 76

S35 240 80

M45 270 90

L65 290 102

L8 330 120

LSA 44.2 Total weight (kg) Rotor (kg)VS3 405 140

VS45 405 140

S7 460 165

S75 460 165

M95 515 185

L12 570 210



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5 - SPARE PARTS

5.1 - First maintenance parts

Emergency repair kits are available as an option.They contain the following items:

Ref. Designation Qty LSA 43.2/44.2 - SHUNT Code

198 AVR 1R 250 AEM 110 RE 019

R 251 AEM 110 RE 021

343 Diode bridge assembly 1 LSA 432 9 100 ALT 432 KD 001

347 Surge suppressor 1 LSA 432 1 13 AEM 000 RE 126

AVR fuse 1 250 V - 8 A/slow-blow

Ref. Designation Qty LSA 43.2/44.2 - AREP 4 P Code

198 AVR 1 R 438 AEM 110 RE 017

343 Diode bridge assembly 1 LSA 432 9 100 ALT 432 KD 001

347 Surge suppressor 1 LSA 432 1 13 AEM 000 RE 126

AVR fuse 2 250 V - 8 A/fast-blow

5.2 - Bearing designations

Ref. Designation Qty LSA 43.2 Code LSA 44.2 Code

60 Bearing on shaft extension end 1 6312 2RS/C3 RLT060ET007 6315 2RS/C3 RLT075ET004

70 Bearing on exciter end 1 6307 2RS/C3 RLT035ET030 6309 2RS/C3 RLT045ET030

5.3 - Technical support serviceOur technical support service will be pleased to provide any

additional information you may require.

When ordering spare parts, you should indicate the

complete machine type, its serial number and the

information given on the genset nameplate.

Address your enquiry to your usual contact.

CAUTION

Part numbers should be identied from the exploded

views and their description from the parts list.

Our extensive network o f service centres can dispatch the

necessary parts without delay.

To ensure correct operation and the safety of our machines,

we recommend the use of original manufacturer spare

parts.

In the event of failure to comply with this advice, the

manufacturer cannot be held responsible for any

damage.



3434 en -

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343

349

347

70

79

90

36

51

48 59

1

124

41

47

198

100107

91

374

1615

1530

33

322324

325

325

320

323

320

49

28

290291

292293

294295

296297

207120

217

5.4 - Exploded views, parts list

5.4.1 - Single-bearing LSA 43.2/44.2

N° Nbr Description N° Nbr Description

1 1 Stator assembly 120 1 Terminal block support (AREP)

4 1 Rotor assembly 124 1 Terminal block

15 1 Fan 198 1 Voltage regulator (AVR)

16 6 Fixing screws (44.2 only) 207 1 AVR damper seal

28 1 Earth terminal 217 1 Terminal block

30 1 DE shield 290 1 PMG housing

33 1 Air outlet grille 291 1 Adaptation shaft

36 1 Shield on exciter end 292 1 Magnetic rotor 37 4 Tie rod 293 1 Stator

41 1 Cover front panel 294 2 Fixing screws

47 1 Cover rear panel 295 1 Tie rod

48 1 Cover top panel 296 1 Cable gland washer + nut

49 34 Fixing screws 297 1 End plate

51 1 Air intake grille 320 1 Hub (43.2 L7 & 44.2 only)

59 3 Inspection door 322 1 Coupling disc

70 1 NDE bearing 323 - Fixing screws

79 1 Preloading wavy washer 324 1 Clamping washer (43.2 S1 to L6)

90 1 Exciter eld 325 - Spacer shim (43.2 L7 & 44.2 only)

91 4 Exciter eld xing screw 343 1 Diode bridge assembly

100 1 Exciter armature 347 1 Surge suppressor

107 1 Diode crescent support 349 1 «O» ring

44.2 coupling

PMG option



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343

349

347

70

79

90

36

51

59

1

124

41

48

49

47

100107

91

2837

4

15

3033

290291

292 293

294295

296297

217

410

60

6863

67

198207

120

LSA 44.2

320

1615

6862

5.4.2 - Two-bearing LSA 43.2/44.2

N° Nbr Description N° Nbr Description

1 1 Stator assembly 90 1 Exciter eld

4 1 Rotor assembly 91 4 Exciter eld xing screw

15 1 Fan 100 1 Exciter armature

16 6 Fixing screws (44.2 only) 107 1 Diode crescent support

28 1 Earth terminal 120 1 Terminal block support (AREP)

30 1 DE shield 124 1 Terminal block

33 1 Air outlet grille 198 1 Voltage regulator (AVR)

36 1 Shield on exciter end 207 1 AVR damper seal

37 4 Tie rod 217 1 Terminal block

41 1 Cover front panel 290 1 PMG housing

47 1 Cover rear panel 291 1 Adaptation shaft

48 1 Cover top panel 292 1 Magnetic rotor

49 34 Fixing screws 293 1 Stator

51 1 Air intake grille 294 2 Fixing screws

59 3 Inspection door 295 1 Tie rod

60 1 DE bearing 296 1 Cable gland washer + nut

62 2/4 Bearing retainer xing screw 297 1 End plate

63 1 Cable gland washer (43.2 only) 320 1 Hub (44.2 only)

67 1 Circlips 343 1 Diode bridge assembly

68 1 Inner bearing retainer 347 1 Surge suppressor

70 1 NDE bearing 349 1 «O» ring

79 1 Preloading wavy washer 410 1 End shield

PMG option



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2010.10 / iLeRoY-SoMeR INSTALLATION AND MAINTENANCE


3434 en -

Electric Power Generation

DECLARATION of COMPLIANCErelated to CE marking

This Declaration applies to the generators designed to be incorporated into machines complying with theMachine Directive Nr 2006/42/CE dated 17 May 2006.

MOTEURS LEROY-SOMERBoulevard Marcellin Leroy16015 ANGOULEME (France)

Declares hereby that the electric generators of the ranges " PARTNER", Industrial and Professional, as well astheir derivatives, manufactured by Leroy Somer or on Leroy Somer's behalf, comply with the followingInternational Standards and Directives :

- EN et CEI 60034 -1 et 60034 -5- ISO 8528 – 3 “ Reciprocating internal combustion engine driven alternating current generating sets.

Part 3. Alternating current generators for generating sets ”- The Low Voltage Directive Nr 2006/95/CE dated 12 December 2006.

Furthermore, these generators, designed in compliance with the Machine Directive Nr 2006/42, are thereforeable to be incorporated into Electrical Gen-Sets complying with the following International Standards andDirectives :

- The Machine Directive Nr 2006/42/CE dated 17 May 2006- The EMC Directive Nr 2004/108/CE dated 15 December 2004, as intrinsic levels of emissions andimmunity are concerned

WARNING :

The here above mentioned generators should not be commissioned until the corresponding Gen-Sets havebeen declared in compliance with the Directives Nr 2006/42/CE et 2004/108/CE, as well as with the otherrelevant Directives.

Technical Managers

P Betge – O Cadel

4152 en – 12.2009 / c

213/258



MOTEURS LEROY-SOMER 16015 ANGOULÊME CEDEX - FRANCE

RCS ANGOULÊME N° B 671 820 223S.A. au capital de 62 779 000 €

http://www.leroy-somer.com

214/258



This manua

l is to be g

i ven to

the end u

ser

4067 en - 2009.05 / b

R250

A.V.R.

Installation and maintenance

l

1 4 0 m m

75 mm

i l

i

i i

R 250

V O L T

F R E Q. & L .A .M. C ON F I G.

S T A B

F1 Slow fuse250V 8 A

P1 Voltage

P2 Stability

110 E+ E-0V

0 9

8 7

6 5 4 3

2 1

o

1

2

3

56

7

9

8

4

60Hz

65Hz

57Hz

47.5Hz50Hz

KNEE

SPECIAL

LAM

OFF

OFF

13%

13%

25%

25%

LAM

KNEE

KNEE

LAM OFF

LAM OFF

LAM OFF

External potentiometrerfor voltage adjusting

ST4 Option

Freq l/ 60 iand

215/258




R250A.V.R.

2

LEROY-SOMER 4067 en - 2009.05 / b

Before using your machine for the rst time,it is important to read the whole of this

installation and maintenance manual.All necessary operations and interventionson this machine must be performed by aqualied technician.

Our technical support service will be pleasedto provide any additional information youmay require.

The various operations described in this

manual are accompanied byrecommendations or symbols to alert theuser to potential risks of accidents. It is vitalthat you understand and take notice of thefollowing warning symbols.

Warning symbol for an operation capableof damaging or destroying the machineor surrounding equipment.

Warning symbol for general danger topersonnel.

Warning symbol for electrical danger topersonnel.

Note : LEROY-SOMER reserves the right tomodify the characteristics of its products atany time in order to incorporate the latesttechnological developments.

The information contained in this documentmay therefore be changed without notice.

WARNING

This manual concerns the alternator A.V.R. which you have just purchased.

We wish to draw your attention to the contents of this maintenance manual. By following

certain important points during installation, use and servicing of your A.V.R., you canlook forward to many years of trouble-free operation.

SAFETY MEASURES

216/258




R250A.V.R.

4067 en - 2009.05 / bLEROY-SOMER

3

SUMMARY

1 - SUPPLY ..............................................................................................................................4

1.1 - SHUNT excitation system ............................................................................................4

2 - R250 A.V.R. ........................................................................................................................5

2.1 - Characteristics .............................................................................................................52.2 - U/F fonction and LAM ...................................................................................................52.3 - R250 A.V.R. option .......................................................................................................52.4 - LAM Characteristics ....................................................................................................62.5 - Typical effects of the LAM .............................................................................................7

3 - INSTALLATION - COMMISIONING ...................................................................................83.1 - Electrical checks on the AVR ........................................................................................83.2 - Settings ........................................................................................................................83.3 - Electrical faults .............................................................................................................9

4 - SPARE PARTS .................................................................................................................10

4.1 - Designation.................................................................................................................104.2 - Technical support service. ..........................................................................................10

Any maintenance or breakdown operations on the A.V.R. are to be done by personneltrained on commisioning, servicing and maintenance for the electrical and mechanicalelements.

The R250 is an IP00 product. It must be installed inside a unit so that this unit’s cover can provideIP20 minimum total protection (it must only be installed on LS alternators in the appropriatelocation so that when viewed externally, it has a higher degree of protection than IP20).

Copyright 2005: MOTEURS LEROY-SOMERThis document is the property of:MOTEURS LEROY SOMER.It may not be reproduced in any form without prior authorizationAll brands and models have been registered and patents applied for.

217/258




R250A.V.R.

4

LEROY-SOMER 4067 en - 2009.05 / b

1 - SUPPLY

1.1 - SHUNT excitation system

The SHUNT excitation alternator is auto-excited with a R 250 voltage regulator.

The regulator controls the excitation currentaccording to the alternator’s output voltage.With a very simple conception, the SHUNT

excitation alternator does not have a shortcircuit capacity.

4 x holes Ø 5.8 x

50 x 115 mm

1 4 0 m m

75 mm

SHUNT SYSTEM

Field

Induced

T1 T2 T3

T4 T5 T6

V a r i s t o r

5+ 6-

T7 T8 T9

T10 T11 T12

STATOR : 12 wires (marking T1 to T12)MAIN FIELD

R 250

V O L T

F R E Q .

& L .A .M. C O N F I G .

S T A B

F1 Slow fuse250V 8 A

P1 Voltage

P2 Stability

110 E+ E-0V

0 9

8 7

6 5 4 3 2

1

o

1

2

3

56

7

9

8

4

60Hz

65Hz

57Hz

47.5Hz 50HzKNEE

SPECIAL

LAM

OFF

OFF

13%

13%

25%

25%

LAM

KNEE

KNEE

LAM OFF

LAM OFF

LAM OFF

External potentiometrerfor voltage adjusting

ST4 Option

Frequency selector 50 Hz/ 60 Hz for U/F fonctionand LAM adjustement

218/258




R250A.V.R.


5

2 - R250 A.V.R.

2.1 - Characteristics

- Storage: -55°C; +85°C- Operation: -40°C; +70°C- Voltage regulation: around ± 0,5 %.

- Supply range/voltage detection 85 to 139 V(50/60Hz).

- Rapid response time (500 ms) for atransient voltage variation amplitude of± 20 %.

- Voltage setting P1.

- Stability setting P2.- Power supply protected by 8 A fuse,replacement product: Ferraz-ShawmutT084013T fast-blow fuse, 8 A FA 250 V,breaking capacity 30 kA.

2.2 - U/F Fonction and LAM

The threshold position (50 Hz - 60 Hz) to

action the U/F fonction as well as the LAMsetting type is selected using thepotentionmeter.

WARNING: The jumper settings mustcorrespond to the rated operatingfrequency (see the nameplate on the

alternator).Risk of destruction for the alternator.

The threshhold position and LAM fonctionsettings are done with the jumper.

Operating at 50 Hz: (U/F gradient)

0: threshold at 48 Hz without LAM for impactsbetween 30 and 40% of the rated load.

1: threshold at 48 Hz with LAM 13% forimpacts between 40 and 70% of the ratedload.

2: threshold at 48 Hz with LAM 25% for

impacts > 70% of the rated load.

Operating at 60 Hz: (U/F gradient)

3: threshold at 58 Hz without LAM for impactsbetween 30 and 40% of the rated load.

4: threshold at 58Hz with LAM 13% forimpacts 40 and 70% of the rated load.

5: threshold at 58Hz with LAM 25% for

impacts > 70% of the rated load.

Specic operating

6: threshold at 57Hz without LAM for speedvariations at a steady state > 2 Hz

7: threshold at 65Hz without LAM for variablespeed and tractelec / gearlec (U/Fgradient).

8: special: the factory setting 48Hz 2U/Fgradient ; a special programme is possibleon request. This programme must bespecied before ordering, during the projectstudy.

9: threshold at 47.5 Hz without LAM forspeed variations at a steady state > 2 Hz.For hydraulic applications, it is advisable toselect:- position 0 for 50 Hz

- position 3 for 60 Hz

0 9 8 7 6 5

4 3 2

1

o

1

2

3

5

6

7

9

8

4

60Hz

65Hz

57Hz

47.5Hz50Hz

KNEE

SPECIAL

LAM

OFF

OFF

13%

13%

25%

25%

LAM

KNEE

KNEE

LAM OFF

LAM OFF

LAM OFF

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R250A.V.R.

6

LEROY-SOMER 4067 en - 2009.05 / b

2.3 - R250 A.V.R. option

Potentiometer for voltage setting, 1000 W /

0,5 W min: setting range ± 5 %.

- Remove the ST4 jumper.

For wiring up the external potentiometer;

the “earth” wires must be isolated as

well as the potentiometer terminals

(wires at the same voltage as the power).

2.4 - LAM characteristics (LoadAcceptance Module)

2.4.1 - Voltage drop

The LAM system is integrated in the A.V.R.It is active as standard. It can be adjusted to13% or 25%.

- Role of the «LAM» (Load AdjustmentModule):

On application of a load, the rotation speedof the generator set decreases. When itpasses below the preset frequencythreshold, the LAM causes the voltage todrop by approximately 13% or 25% andconsequently the amount of active loadapplied is reduced by approximately 25% to50%, until the speed reaches its rated value

again. Hence the “LAM” can be used either toreduce the speed variation (frequency) andits duration for a given applied load, or toincrease the applied load possible for onespeed variation (turbo-charged engines).To avoid voltage oscillations, the tripthreshold for the “LAM” function should beset approximately 2 Hz below the lowestfrequency in steady state.

It is advised to use the “LAM” at 25% for loadimpacts > at 70% of the genset rated power.

2.4.2 - Gradual voltage return function

During load impacts, the function helps the

genset to return to its rated speed fasterthanks to a gradual increase in voltageaccording to the following principles:

- if the speed drops between 46 Hz and 50 Hz,the rated voltage follows a fast gradient as itis restored.

- if the speed drops below 46 Hz, since theengine needs more help, the voltage followsa slow gradient as it returns to the referencevalue.

LAM

UN

048 or 58 Hz

0,85 UN

Voltage

U/f

50 or 60 Hz

fC fN

Voltage

ST3

0Time

Drop N < 46 Hz

U

Drop N > 46 Hz

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R250A.V.R.


7

2.5 - Typical effects of the LAM witha diesel engine or without a LAM(U/F only)

2.5.1 - Voltage

2.5.2 - Frequency

2.5.3 - Power

UN

0

0,9

0,8

(U/f)

with

LAMTime

without LAM

1 s 2 s 3 s

Transient voltage drop

0,9

0,8

fN

Max speed drop

0

with

LAM

Time

without

LAM

1 s 2 s 3 s

0 1 s 2 s 3 sTime

LAM

Load variation

L o a d o n

s h a f t ( k W )

Shedding due to "LAM"

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R250A.V.R.

8

LEROY-SOMER 4067 en - 2009.05 / b

3 - INSTALLATION -COMMISSIONING

3.1 - Electrical checks on the AVR

- Check that all connections have beenmade properly as shown in the attachedwiring diagram.- Check that the position of the jumpercorresponds to the operating frequency.- Check whether the ST4 jumper or theremote adjustment potentiometer havebeen connected.

3.2 - Settings

The different settings made during the

trial are to be done by qualied personnel.

Respecting the load speed specied on

the nameplate is vital in order to start a

settings procedure. After operationaltesting, replace all access panels or

covers.The only possible settings on themachine are to be done with the A.V.R.

3.2.1 - R250 settings (SHUNT system)

Initial potentiometer positions- voltage setting potentiometer P1 for the

A.V.R.: full left- remote voltage setting potentiometer: inthe middle.Operate the alternator at its rated speed: ifthe voltage does not rise it is necessary tore-magnatise the magnetic circuit.- slowly adjust the voltage potentiometer ofthe A.V.R.P1until the output voltage reachesits rated value.- Stability setting with P2.

3.2.2 - Special type of use

Excitation circuit E+, E- must not be left

open when the machine is running:

A.V.R. damage will occur.

3.2.2.1 - R250 eld weakening (SHUNT)

The exciter is switched off by disconnectingthe A.V.R. power supply (1 wire - 0 or 110V).Contact rating: 16A - 250V AC

Do not reclose the power supply until thevoltage has reached a value ≤15% of the

rated voltage (approximately 5 secondsafter opening)

3.2.2.2 - R250 eld forcing

The battery must be isolated from themass.

Exciter eld may be at line potential.

WARNING

E +

E -

0 V

1 1 0

Battery (B Volt)

+-t

(400V - 10A)

Excitation Inducer

Diode

E +

E -

0 V

1 1 0

222/258




R250A.V.R.


9


Warning: after setting-up or trouble-shooting, replace all access panels orcovers.

Fault Action Effect Check/cause

No voltage atno load onstart-up

Connect a new batteryof 4 to 12 volts toterminals E- and E+respecting the polarityfor 2 to 3 seconds

The alternator starts up and itsvoltage is still correct when thebattery is removed.


The alternator starts up but itsvoltage does not reach the ratedvalue when the battery isremoved.

- Check the connection of the voltagereference to the A.V.R.- Faulty diodes- Induced short circuit

The alternator starts up but itsvoltage disappears when thebattery is removed

- Faulty A.V.R.- Exciter eld short-circuited- Short-circuit in the main eld. Check theresistance

Voltage toolow Check the drive speed

Correct speed

Check the A.V.R. connections (A.V.R. may

be faulty)- Field windings short-circuited- Rotating diodes burnt out- Main eld winding short-circuited- Check the resistance

Speed too lowIncrease the drive speed(Do not touch the A.V.R. pot (P1) beforereturning to the correct speed.)

Voltage toohigh

Adjust A.V.R.potentiometer Adjustment ineffective - Faulty A.V.R.

- 1 faulty diode

Voltageoscillations Adjust A.V.R. stabilitypotentiometer

- Check the speed: possibility of cyclicirregularity

- Loose terminals- Faulty A.V.R.- Speed too low on load(or U/F gradient set too high)

Voltagecorrect at noload and toolow when onload (*)

Run at no load andcheck the voltagebetween E+ and E- onthe A.V.R.

- Check the speed (or U/F gradient set toohigh)

- Faulty rotating diodes- Short-circuit in the main eld. Check theresistance- Faulty induced excitaion

(*) Warning: For single-phase operation, check that the sensing wires coming from the A.V.R. are correctly connected tothe operating terminals (see the alternator manual).

Voltagedisappearsduringoperation

Check the A.V.R., thesurge suppressor, therotating diodes andreplace any defectivecomponents

The voltage does not return to therated value

- Exciter winding open circuit- Faulty induced excitation- Faulty A.V.R.- Main eld open circuit or short-circuited

223/258




R250A.V.R.

10

LEROY-SOMER 4067 en - 2009.05 / b

4 - SPARE PARTS

4.1 - Designation

Description Type CodeA.V.R. R 250 AEM 110 RE 019

4.2 - Technical support service

Our technical support service will be pleasedto help you with any information needed.

For replacement part orders, it is necessary

to indicate the type and the code number ofthe A.V.R.

Please contact your usual correspondant.

An extensive network of service centres isavailable to rapidly supply any necessaryparts.In order to ensure the correct operation and

safety of our machines, we stronglyrecommend that original manufacturer’sspare parts are used.Failure to do so, will discharge the

manufacturer from liabilty in the case ofdamage.

224/258




R250A.V.R.


11225/258




338 567 258 RCS ANGOULÊMES.A. au capital de 62 779 000 ¤

www.leroy-somer.com

226/258



2 0 0 m m

140 mm

X2 X1 Z2 E+ E- 0V 110 220 380Z1

T1 T2

T4 T5+ -

T7 T8

T10 T11

ST9

AREP

PP

.I.

.

P1

2010.11 / f 3971 en -

Th i s m an

u a l i s to b

e g i v en to

th e end u

s er

R438

A.V.R.

Installation and maintenance227/258



LEROY-SOMER 2010.11 / f Installation and maintenance

R438

A.V.R.

3971 en -

Before using your machine for the rst time,it is important to read the whole of this instal-

lation and maintenance manual.All necessary operations and interventionson this machine must be performed by aqualied technician.

Our technical support service will be pleasedto provide any additional infor-mation youmay require.

The various operations described in this

manual are accompanied by recommen-da-tions or symbols to alert the user to potentialrisks of accidents. It is vital that you unders-tand and take notice of the following warningsymbols.

This A.V.R. can be incorporated in a ma-chine marked C.E.

Warning symbol for an operation ca-pable of damaging or destroying the ma-

chine or surround-ing equipment.

Warning symbol for general danger to

personnel.

Warning symbol for electrical danger to

personnel.

Note: LEROY-SOMER reserves the right tomodify the characteristics of its products atany time in order to incorporate the latest tech-nological developments. The informationcontained in this document may therefore bechanged without notice.

WARNING

This manual concerns the alternator A.V.R. which you have just purchased.

We wish to draw your attention to the contents of this maintenance manual. By following

certain important points during installation, use and servicing of your A.V.R., you canlook forward to many years of trouble-free operation.

SAFETY MEASURES

228/258



LEROY-SOMER

3

2010.11 / f Installation and maintenance

R438

A.V.R.

3971 en -

CONTENTS

1 - SUPPLY ..............................................................................................................................4

1.1 - AREP excitation system ...............................................................................................41.2 - PMG excitation system.................................................................................................51.3 - SHUNT or separate excitation system ..........................................................................5

2 - R438 A.V.R. ........................................................................................................................6

2.1 - Characteristics .............................................................................................................62.2 - Frequency compared with voltage (without LAM) .........................................................62.3 - LAM (Load Acceptance Module) characteristics...........................................................62.4 - Typical effects of the LAM with a diesel engine with or without a LAM (U/F only) ..........7

2.5 - R438 A.V.R. options .....................................................................................................7

3 - INSTALLATION - COMMISSIONING .................................................................................8

3.1 - Electrical checks on the AVR ........................................................................................83.2 - Settings ........................................................................................................................83.3 - Electrical faults ...........................................................................................................11

4 - SPARE PARTS .................................................................................................................12

4.1 - Designation ................................................................................................................124.2 - Technical support service ...........................................................................................12

All such operations performed on the A.V.R. should be undertaken by personnel trainedin the commissioning, servicing and maintenance of electrical and mechanical

components.

The R438 is an IP00 product. It must be installed inside a unit so that this unit’s cover canprovide IP20 minimum total protection (it must only be installed on LS alternators in the ap-propriate location so that when viewed externally, it has a higher degree of protection thanIP20).

Copyright 2005 : MOTEURS LEROY-SOMERThis document is the property of :MOTEURS LEROY-SOMERIt may not be reproduced in any form without prior authorization. All brands and models have been registered and patents applied for.

229/258




R438

A.V.R.

1 - SUPPLY

1.1 - AREP excitation system

For both AREP & PMG excitation systems,the alternator voltage regulator is the R438.With AREP excitation, the R438 electronicAVR is powered by two auxiliary windingswhich are independent of the voltage matchcircuit.The rst winding has a voltage in proportion

to that of the alternator (characteristicShunt), the second has a voltage in propor-tion to the stator current (compound charac-

teristic: Booster effect).The power supply voltage is rectied andltered before being used by the AVR moni-toring transistor. This principle ensures thatregulation is not affected by distortions ge-nerated by the load.

4 x holes Ø 5.8 x

175 x 115 mm

2 0 0 m m

140 mm

X2 X1 Z2 E+ E- 0V 110 220 380Z1

T1 T2 T3

T4 T5 T6

V a r i s t o r

5+ 6-

T7 T8 T9

T10 T11 T12

R 438

F1

ST5

P5

ST11

ST2 ST1

P3

P2

P1

ST4

ST9

Option

AREP

PMGPMG

T.I.

Option

S1P1

Ph.1

P2S2

R731

Option

AREP SYSTEM

Field

Armature

10 Yellow

11 Red

9 Green

12 Black

MAIN FIELDAux. windings

Slow fuse250V 8 A

with LAM without LAM

Excitationceiling

knee-point: 65 Hz

open

Responsetime

normal

fast

StabilityVoltageSingle-

phasedetection

External potentiometerfor adjusting the voltage

Quaddroop

according voltage



in 3-ph. detection ST1 open

3-ph. detection

ST350Hz 60Hz

ST10

13 % LAM 25 %

Frequency

3971 en -

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LEROY-SOMER

5


R438

A.V.R.

1.2 - PMG excitation system

This excitation system consists of a «PMG»(permanent magnet generator). This is ttedat the rear of the machine and connected tothe R438 AVR.The PMG supplies the AVR with constantvoltage which is independent of the main

alternator winding. As a result the machinehas a short-circuit current capacity andgood immunity to distortions generated by

the load.The AVR monitors and corrects the alterna-tor output voltage by adjusting the excitationcurrent.- 50/60 Hz selection via the ST3 jumper.

4 x holes Ø 5.8 x

175 x 115 mm

2 0 0 m m

140 mm

X2 X1 Z2 E+ E- 0V 110 220 380Z1

T1 T2 T3

T4 T5 T6

V a

r i s t o r

5+ 6-

T7 T8 T9

T10 T11 T12

R 438

F1

ST5

P5

ST11

ST2 ST1

P3

P2

P1

ST4

ST9

Option

AREP

PMG

14 15 16

PMG

T.I.

Option

S1P1

Ph.1

P2S2

R731

Option

PMG SYSTEM

Field

Armature

MAIN FIELD

Slow fuse250V 8 A

with LAM without LAM

Excitationceiling

knee-point: 65 Hz

open

Responsetime

normal

fast

StabilityVoltageSingle-

phasedetection

External potentiometerfor adjusting the voltage

Quaddroop

according voltage



in 3-ph. detection ST1 open

3-ph. detection

ST350Hz 60Hz

ST10

13 % LAM 25 %

Frequency

1.3 - SHUNT or separate excitation system

A.V.R. can be operated with SHUNT supply (with a transformer / secondary 50V or a 48V battery).

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R438

A.V.R.

2 - R438 A.V.R.

2.1 - Characteristics

- Storage : -55°C ; +85°C- Operation : -40°C ; +70°C - Standard power supply: AREP or PMG.- Rated overload current: 8 A - 10 s- Electronic protection (overload, short-cir-cuit on opening of voltage sensing circuit):excitation overload current for 10 secondsthen return to approximately 1A. The alter-nator must be stopped (or the power switched off) in order to reset the protection.- Fuse : F1 on X1, X2. 8A ; slow - 250V

- Voltage sensing : 5 VA isolated via trans-former ;• 0-110 V terminals = 95 to 140 V,• 0-220 V terminals = 170 to 260 V,• 0-380 V terminals = 340 to 520 V.

- Voltage regulation ± 1%.- Normal or rapid response time via ST2 jumper (see below).- Voltage adjustment via potentiometer P2.

other voltages via adapter transformer - Current sensing (parallel operation): C.T.

2.5 VA cl1, secondary 1 A (optional).- Quadrature droop adjustment via potentio-meter P1.- Max. excitation current adjustment via P5 (see below).

2.1.1 - Conguration jumpers function

Pot.

Delivrerycong. Position Function

Open Closed

ST1 3-ph. MonoOpen for module

installation tri detectionST2 Fast Normal Response time

ST3 50 ou 60 Hz Frequency selection

ST4Externalpotentio-

meter Without Potentiometer

ST5 Without With LAM

ST9Others

(PMG...) AREP Supply

ST10 13% or 25%LAM voltage dropamplitude

ST11 65 Hz48 or 58 Hz

U/f function bendposition

2.1.2 - Setting potentiometersfunction

Delivreryposition

Pot. Function

0 P1 Quadrature droop ; // operation with C.T.

400V P2 Voltage

Centre P3 Stability

Maxi P5 Excitation current ceiling

2.2 - Frequency compared with

voltage (without LAM)

2.3 - LAM (Load Acceptance

Module) characteristics2.3.1 - Voltage drop

The LAM system is integrated in the R 438 AVR as standard.Role of the «LAM» (Load Adjustment Mo-dule) :On application of a load, the rotation speedof the generator set decreases. When itpasses below the preset frequency thres-hold, the LAM causes the voltage to drop by

approximately 13% or 25% and conse-quently the amount of active load applied isreduced by approximately 25% to 50%, untilthe speed reaches its rated value again.Hence the LAM can be used either to reducethe speed variation (frequency) and its dura-tion for a given applied load, or to increasethe applied load possible for one speed va-riation (turbo-charged engine).To avoid voltage oscillations, the trip thres-

hold for the LAM function should be set ap-proximately 2 Hz below the lowest frequen-cy in steady state.

100 %

50 Hz 60 Hz Hz

50 Hz

48 Hz

57.5 Hz

60 Hz

Voltage Bend

U/UN

Frequency

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LEROY-SOMER

7


R438

A.V.R.

- LAM : action eliminated by cutting the ST5 jumper.

2.3.2 - Gradual voltage return function

During load impacts, the function helps thegenset to return to its rated speed faster thanks to a gradual increase in voltage ac-cording to the principle:- If the speed drops between 46 and 50 Hz,the rated voltage follows a fast gradient as itis restored.

- If the speed drops below 46 Hz, since theengine needs more help, the voltage followsa slow gradient as it returns to the referencevalue.

2.4 - Typical effects of the LAM with

a diesel engine with or without a

LAM (U/F only)

2.4.1 - Voltage

2.4.2 - Frequency

2.4.3 - Power

LAM

UN

048 or 57.5 Hz

0.85 UN

Voltage

U/f

50 or 60 Hz

fC fN

VoltageST5 disconnected

ST3

P2

Underspeed and LAM

0

Time

Drop N ≤ 46 Hz

U

Drop N > 46 Hz

UN

0

0,9

0,8

(U/f)

withLAM

Time

without LAM

1 s 2 s 3 s

Transient voltage drop

0,9

0,8

fN

Max speed drop

0

with

LAM

Time

without

LAM

1 s 2 s 3 s

0 1 s 2 s 3 sTime

LAM

Variation in the load

L o a d o n t h e

s h a f t ( k W )

Load shedding due to "LAM"

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R438

A.V.R.

2.5 - R438 A.V.R. options

- Current transformer for parallel operation

of ....../1A. 5 VA CL 1.

- Remote voltage adjustment potentiometer : 470 Ω, 0.5 W min: adjustment range ± 5%(range limited by internal voltage potentio-meter P2). Remove ST4 to connect the po-ten-tiometer. (A 1 kΩ potentiometer can alsobe used to extend the adjustment range).

For wiring up the external potentiometer;

the “earth” wires must be isolated as

well as the potentiometer terminals

(wires at the same voltage as the power).

-R 731 external module: sensing of 3-phasevoltage 200 to 500 V, compatible with parallel

operation. Disconnect ST1 to connect themodule; set the voltage via the module po-tentiometer.

- R 734 module: detection of 3-phase currentand voltage for parallel operation on unba-lanced installations (imbalance > 15%).

- R 726 module: 3 functions (mounted exter-nally).P.F. regulation (2F) and voltage sensing cir-

cuit before paralleling (3 F).

- Control through DC voltage used monito-ring apply to the terminals for connection of apotentiometer DC voltage :• internal impedance 1,5 kΩ• ± 0,5V enable a voltage setting of 10%.

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9


R438

A.V.R.

3 - INSTALLATION - COMMISSIONING

3.1 - Electrical checks on the AVR

- Check that all connections have beenmade properly as shown in the attached wi-ring diagram.- Check that the ST3 frequency selection jumper is on the correct frequency setting.- Check whether the ST4 jumper or the re-mote adjustment potentiometer have beenconnected.- Optional operating modes.• ST1 jumper : open to connect the R 731or

R 734 3-phase

sensing module.• ST2 jumper : open if rapid response timeused

• ST5 jumper : open to suppress the LAMfunction.

3.2 - Settings

The machine is tested and set at the fac-tory. When rst used with no load, makesure that the drive speed is correct andstable (see the nameplate). After opera-tional testing, replace all access panelsor covers.The only possible adjustments to themachine should be made on the AVR.

3.2.1 - R438 settings (AREP or PMGsystem)

Before any intervention on the A.V.R.,make sure that the ST9 jumper is closedwith AREP excitation and disconnectedwith PMG or SHUNT or separate excita-tion.

a) Initial potentiometer settings (see tablebelow)- Remote voltage adjustment potentiometer :

centre (ST4 jumper removed).

Stability adjustments in standaloneoperation

b) Install a D.C. analogue voltmeter (needle

dial) cal. 50V on terminals E+, E- and an A.C. voltmeter cal 300 - 500 or 1000V on thealternator output terminals.

c) Make sure that the ST3 jumper is positio-ned on the desired frequency (50 or 60 Hz).

d) Voltage potentiometer P2 at minimum,fully anti-clockwise.

e) Stability potentiometer P3 to around 1/3of the anti-clockwise limit.

f ) Start the engine and set its speed to a fre-quency of 48 Hz for 50 Hz, or 58 for 60 Hz.

g) Set the output voltage to the desired va-lue using P2.- Rated voltage UN for solo operation (eg.400 V)- Or UN + 2 to 4% for parallel operation withC.T. (eg. 410 V)If the voltage oscillates, use P3 to make ad-

justments (try both directions) observing thevoltage between E+ and E- (approx. 10VD.C.).

WARNING

P2

P3

P1

P510 A

maximum

400V - 50 Hz

(Input

0 - 380 V)

Not set

(centre position)

Not set

(fully anti-

clockwise)

Excitation ceilingLimit of excitation and

short-circuit current,

minimum fully anti-clockwise.

Voltage quadrature droop(// operation with C.T.)

- 0 quadrature loop fullyanti-clockwise.

Voltageminimum fully anti-clockwise

Stability

Action Factory setting Pot.

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R438

A.V.R.

The best response times are obtained at thelimit of the instability. If no stable positioncan be obtained, try disconnecting or repla-

cing the ST2 jumper (normal/fast).h) Check LAM operation : ST5 closed.

i) Vary the frequency (speed) around 48 or 58 Hz according to the operating frequency,and check the change in voltage from thatobserved previously (~ 15%).

j) Readjust the speed of the unit to its ratedno-load value.

Adjustments in parallel operationBefore any intervention on the alterna-tor, make sure that the speed droop isidentical for all engines.

k) Preset for parallel operation (with C.T.connected to S1, S2)- Potentiometer P1 (quadrature droop) incentre position.Apply the rated load (cos ϕ = 0.8 inductive).

The voltage should drop by 2 to 3%. If it in-creases, check that V and W and also S1and S2 have not been reversed.

l) The no-load voltages should be identicalfor all the alternators intended to run in pa-rallel.- Couple the machines in parallel.- By adjusting the speed, try to obtain 0 KW power exchange.- By altering the voltage setting P2 on one of the machines, try to cancel (or minimise) thecurrent circulating between the machines.- From now on, do not touch the voltage set-tings.

m) Apply the available load (the setting is onlycorrect if a reactive load is available)- By altering the speed, match the kW (or di-vide the rated power of the units proportionally)- By altering the quadrature droop potentiome-ter P1, match or divide the currents.

3.2.2 - Max. excitation setting (excitation

ceiling)

Static adjustment of the current limit,potentiometer P5 (factory setting: 7.5 A,fuse rating: 8 A - 10 seconds).

The maximum factory setting correspondsto that of the excitation current required toobtain a 3-phase short-circuit current of approximately 3 IN at 50 Hz for industrial

power, unless otherwise specied(*). A static method can be used to reduce thisvalue or adapt the Isc to the actual operatingpower (derated machine), which is safer for the alternator and the installation.Disconnect power supply wires X1,X2 andZ1,Z2 and the voltage reference(0-110V-220V-380V) on the alternator.

Connect the mains power supply using a

transformer (200-240V) as indicated(X1,X2 : 48V). Install a 10A D.C. ammeter in series with the exciter eld. Turn P5 fullyanti-clockwise and activate the power supply. If there is no output current from the AVR, turn potentiometer P2 (voltage)clockwise until the ammeter indicates astable current. Switch the power supply off,then on again, turn P5 clockwise until therequired max. current is obtained (no morethan 8 A).

Depending on

the mains frequency Main(50/60 Hz supply)Max. excitation

Voltage

Field~ 5 ohms

X2

Z1

X1

Z2

E+

E-

0V

110 V

220 V

380 V

50Hz 60Hz

P2

P3

P5

ST3

10 A CC/DC

48 V

110/220/380 V

R 438

ST4

A+ –

A

D

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LEROY-SOMER

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R438

A.V.R.

Checking the internal protection :Open switch (D) : the excitation currentshould increase to its preset ceiling, remain

at that level for ≥ 10 seconds and then dropto < 1A.To reset, switch off the power supply by ope-ning switch (A).Note: After setting the excitation ceiling asdescribed, adjust the voltage again (seesection 2.1.1)(*) In some countries it is a legal requirementto have a short-circuit current of 3 In, so asto offer selective protection.

3.2.3 - Special type of use

Excitation circuit E+, E- must not be leftopen when the machine is running : AVRdamage will occur.

3.2.3.1 - R438 eld weakening (SHUNT)

The exciter is switched off by disconnectingthe AVR power supply (1 wire - X1 or X2).

Contact rating 16 A - 250V A.C.

3.2.3.2 - R438 eld weakening (AREP/

PMG)

The exciter is switched off by disconnectingthe AVR power supply (1 wire on each auxi-liary winding) - contact rating 16 A - 250V

A.C.Connection is identical for resetting the AVRinternal protection.

In case of using the de-excitation, pro-vide a forced excitation.

3.2.3.3 - R438 eld forcing

Applications B volts Time t

Guaranteed voltage build-up 12 (1A) 1 - 2 s

Parallel operation, de-energized 12 (1A) 1 - 2 s

Parallel operation, at standstill 12 (1A) 5 - 10 s

Frequency starting 12 (1A) 5 - 10 s

Sustained voltage on overload 12 (1A) 5 - 10 s

WARNING

X2

Z1

X1

Z2

E+

E-

X2

Z1

X1

Z2

E+E-

X2

Z1

X1

Z2

E+

E-

Battery (B Volt)

+-t

(400V - 10A)

Exciter field

Diode

t

B Volt

Forced excitation

Time

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R438

A.V.R.


Fault Action Effect Check/Cause

No voltage atno load onstart-up

Connect a new batteryof 4 to 12 volts toterminals E- and E+,respecting the polarity,for 2 to 3 seconds

The alternator builds up and itsvoltage is still correct when thebattery is removed.


The alternator builds up but itsvoltage does not reach the ratedvalue when the battery isremoved.

- Check the connection of the voltagereference to the AVR- Faulty diodes- Armature short-circuit

The alternator builds up but itsvoltage disappears when thebattery is removed

- Faulty AVR- Field windings disconnected- Main eld winding open circuit - check theresistance

Voltage toolow

Check the drive speed

Correct speed

Check the AVR connections (AVR may be

faulty)- Field windings short-circuited- Rotating diodes burnt out- Main eld winding short-circuited - Checkthe resistance

Speed too low

Increase the drive speed(Do not touch the AVR voltage pot. (P2)before running at the correct speed.)

Voltage toohigh

Adjust AVR voltagepotentiometer

Adjustment ineffective Faulty AVR

Voltageoscillations Adjust AVR stabilitypotentiometer If no effect : try normal / fastrecovery modes (ST2)

- Check the speed : possibility of cyclicirregularity

- Loose connections- Faulty AVR- Speed too low when on load (or U/F bendset too high)

Voltagecorrect at noload and toolow when onload (*)

Run at no load andcheck the voltagebetween E+ and E- onthe AVR

Voltage between E+ and E-SHUNT < 20 V AREP / PMG < 10V

- Check the speed (or U/F bend set toohigh)

Voltage between E+ and E-SHUNT > 30V AREP / PMG > 15V

- Faulty rotating diodes- Short-circuit in the main eld. Check theresistance- Faulty exciter armature.

(*) Caution : For single-phase operation, check that the sensing wires coming from the AVR are correctly connected to the

operating terminalsVoltagedisappearsduringoperation (**)

Check the AVR, thesurge suppressor, therotating diodes, andreplace any defectivecomponents

The voltage does not return to therated value.

- Exciter winding open circuit- Faulty exciter armature- Faulty AVR- Main eld open circuit or short-circuited

(**) Caution : Internal protection may be activated (overload, open circuit, short-circuit)

Warning : after operational testing,

replace all access panels or covers.

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LEROY-SOMER

13


R438

A.V.R.

4 - SPARE PARTS

4.1 - Designation

Description Type Code A.V.R. R 438 AEM 110 RE 017

4.2 - Technical support serviceOur technical support service will be happyto provide any information you require.

When ordering spare parts, you should in-dicate the complete machine type, its serialnumber and the information indicated on thenameplate.

Part numbers should be identied from theexploded views and their description inthe parts list.

Our extensive network of «service stations»can dispatch the necessary parts withoutdelay.To ensure correct operation and the safetyof our machines, we recommend the use of original manufacture spare parts.In the event of failure to comply with this ad-vice, the manufacturer cannot be held res-ponsible for any damage.

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R438

NOTES

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LEROY-SOMER

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R438

NOTES

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338 567 258 RCS ANGOULÊME

S.A. au capital de 62 779 000 €

www.leroy-somer.com

242/258



9.3. Appendix C - Common spare parts

R66

Rental Power

JOHN DEERE

4045TF120

Starter motor solenoid 330361644 X 1

Radiator cap 31802000304 X 1

Alternator diode 330360144 X 1

Fan belt 330361614 X 1

Thermostat 330360012 X 1

Thermostat seal 330361286 X 1

Alarm oil pressure sensor 330360059 X 1

Alarm water temperature sensor 330360060 X 1

E N G I N E

x 20 L 330910115

x 208 L 330910095

X 1

G E N L U B

x 20 L 330910098

x 60 L 330910099

x 210 L 330910100

X 1

G E N C O O L

243/258



330570118+330570092 X 1

330560552+330510015 x 1

330560613 x 1

LEROY-SOMER

LSA432M45

Diode bridge 330410713 x 1

Varistor 330410335 X 1 A L T E R N A T O R

Note For all technical assistance or spare part requests, contact your nearest SDMO agent.

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9.4. Appendix D - List o f John Deere - Volvo and Perkins fault codes

SPN CID SID PID PPID FMI

J o h n

D e e r e

V o l v o

P e r k i n s

Description Commentary

28 Thrott le #3 Position

3 Throttle Voltage high, short to V+ Short to V+

4 Throttle Voltage low, short to V- Short to V-

29 Thrott le #2 Position

3 Throttle Voltage high, short to V+ Short to V+

4 Throttle Voltage low, short to V- Short to V-

14 Throttle Voltage out of range

84 Vehicle speed

2 Vehicle invalid or missing

31 Vehicle speed mismatch

Not possible with gensetapplication

91 91 91 132 Accelerator pedal posi tion FMI non déterminé pour tous les VOLVO

3 Throttle Voltage high, short to V+

4 Throttle Voltage low, short to V-

7 Throttle calibration invalid

8 PWM throttle abnormal pulse width

9 Throttle invalid (CAN value)

10 Throttle voltage out of range low

13 Throttle calibration aborted

14 Throttle voltage out of range

Not possible with gensetapplication, codes declaredby the CAN J 1587 forVOLVO.

94 94 Fuel rail pressure sensor

1 Fuel supply pressure extremely low

3 Fuel rail pressure input voltage high Short to V+

4 Fuel rail pressure input voltage low Short to V-

5 Fuel rail pressure sensor open circuit

10 Fuel rail pressure lost detected

13 Fuel rail pressure higher than expected

16 Fuel supply pressure moderately high

17 Fuel rail pressure not developed

18 Fuel supply pressure moderately low

97 97 Water in fuel sensor

0 Water in fuel continuously detected

3 Water in fuel input voltage high Short to V+

4 Water in fuel input voltage low Short to V-

16 Water in fuel detected

31 Water in fuel detected

98 98 Oil level sensor

1 Oil level value below normal

3 Oil level sensor input voltage high Short to V+

4 Oil level sensor input voltage low Short to V-

5 Oil level sensor open circuit

99 99 Engine Oil fil ter Differential Pressure

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J o h n

D e e r e

V o l v o

P e r k i n s


100 100 100 Oil pressure sensor

1 Engine oil pressure extremely low

3 Oil pressure sensor input voltage high Short to V+

4 Oil pressure sensor input voltage low Short to V-

5 Oil pressure sensor open circuit

17 Engine oil pressure low

18 Engine oil pressure moderately low

102 273 102 Manifold air pressure sensor

0 Manifold air pressure above normal

1 Manifold air pressure below normal

3Manifold air pressure sensor input

voltage highShort to V+

4Manifold air pressure sensor inputvoltage low

Short to V-

15 Manifold air pressure moderately low

16 Manifold air pressure low

105 105 Manifold air temperature sensor

0 Manifold air temperature extremely high

3Manifold air temperature sensor inputvoltage high

4Manifold air temperature sensor inputvoltage low

5Manifold air temperature sensor opencircuit

16 Manifold air temperature moderately high

106 106 Air inlet pressure sensor

0 Air inlet pressure above normal

3Air inlet pressure sensor input voltagehigh

5 Air inlet pressure sensor open circuit

107 107 Air fil ter dif ferential pressure sensor

0 Air filter restriction high

3Air filter differential pressure sensor inputvoltage high

4Air filter differential pressure sensor input

voltage low5

Air filter differential pressure sensor opencircuit

31 Air filter restriction high

108 274 108 Barometric pressure sensor Not use with EDC III andEMS2

3High barometric pressure sensor short tohigh

4High barometric pressure sensor short tolow

17 High barometric pressureECM option, sensor notconnected

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J o h n

D e e r e

V o l v o

P e r k i n s


110 110 110 Coolant temperature sensor

0 Coolant temperature extremely high

3Coolant temperature sensor input voltagehigh

4Coolant temperature sensor input voltagelow

5 Coolant temperature sensor open circuit

15 Coolant temperature high least severe

16 Coolant temperature moderately high

31 Coolant temperature high

111 111 Coolant level sensor

0 Engine coolant level low

1 Engine coolant level low

3 Coolant level sensor input voltage high

4 Coolant level sensor input voltage low

153 153 Crankcase pressure sensor

0 Value above normal

3Crankcase pressure sensor input voltagehigh

5 Crankcase pressure sensor open circuit

158 158 Battery voltage sensor

1 Voltage above normal

17 ECU power down error

160 Wheel speed sensor

2 Wheel speed input noise

164 164 Injection Contro l Pressure

168 168 Electrical system voltage

2 Electrical system voltage low

172 172 172 Ambiant air temperature sensor Inlet air temperaturesensor for PERKINS

3Ambiant air temperature sensor inputvoltage high

Inlet air temperature sensorinput voltage high

4Ambiant air temperature sensor inputvoltage low

Inlet air temperature sensorinput voltage low

5 Ambiant air temperature sensor opencircuit

15High Inlet air temperaturealarm-warning

16High Inlet air temperaturealarm-action alert

174 174 Fuel temperature sensor

0 Fuel temperature high most severe

3Fuel temperature sensor input voltagehigh

4Fuel temperature sensor input voltagelow

15 Fuel temperature high

16 Fuel temperature high moderately high31 Fuel temperature sensor faulty

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J o h n

D e e r e

V o l v o

P e r k i n s


175 175 Oil temperature sensor

0 Oil temperature extremely high

3 Oil temperature sensor input voltage high

4 Oil temperature sensor input voltage low

5 Oil temperature sensor open circuit

177 Transmission oil temperature sensor

9 Transmission oil temperature invalidnot possible with Gensetapplication

189 Rated engine speed

0 Engine speed de rated

31 Engine speed de rated

190 190 190 Engine speed sensor 0 Overspeed extreme

2 Engine speed sensor data intermittent

9 Engine speed sensor abnormal update

11 Engine speed sensor signal lost

12 Engine speed sensor signal lost

15 Overspeed

16 Overspeed moderate

228 261 Speed sensor calibration

13 Engine timing abnormal calibration

252 252 Softw are11 Incorrect engine software

234 253 Check system parameters

2 Incorrect parameters

281 281 Action alert output status

3 Action alert output open/short to B+

4 Action alert output short to ground

5 Action alert output open circuit

282 282 Overspeed output status

3 Overspeed output open/short to B+

4 Overspeed output short to ground

285 285 Coolant temperature output status

3Coolant temperature lamp open/short toB+

4Coolant temperature lamp short toground

286 286 Oil pressure output status

3 Oil pressure output open/short to B+

4 Oil pressure output short to ground

5 Oil pressure output open circuit

323 323 Shutdown output status

3 Shutdown output open/short to B+

4 Shutdown output short to ground

5 Shutdown output open circuit

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J o h n

D e e r e

V o l v o

P e r k i n s


324 324 Warning output status

3 Warning output open/short to B+

4 Warning output short to ground

5 Warning output open circuit

443 443 ENGINE RUN output status

3 Engine run output open/short to B+

4 Engine run output short to B-

523 Gear select ion

9 Gear selection invalidNot possible with Gensetapplication

608 250 98Data link faulty J1587 Start/Stopredundancy / J1939 communication

bus

611 Injector wiring status

3 Injector wiring shorted to power source

4 Injector wiring shorted to ground

620 262 232 5 Volt sensor power supplyFMI not informed byVOLVO

3 Sensor power supply open/short to B+

4 Sensor power supply short to ground

626 45Start enable device (intake heater andether)

3 Start enable device output short to B+

4Start enable device output short toground

5 Start enable device output open circuit

Not use, the control panel is

in charge to manage thestart enable device

627 Power supply

1 Injector supply voltage problem For 6125HF070 only

4 ECU unswitched power missing For 6068HF275 VP44 only

628 240 Memory faul t in EMS2

629 254 ECU status/con trol ler error CIU module status

2 RAM cell test failure

8 CPU watchdog reset test failure

11 Main and fuelling ASIC test fail

12 RAM address test failure

13 Watchdog trip failure

19ECU to injection pump communicationerror

Possible only with6068HF475 VP44

630 253 Data set memory EEPROM

632 Injection status

2 Fuel shutoff error

5 Fuel shutoff non-functional

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J o h n

D e e r e

V o l v o

P e r k i n s


636 21

Pump position sensor/Cam position

sensor/Speed sensor CAM

2Pump position sensor/cam positionsensor input noise

Pump position or CAMposition in function of thetype of injection

3 Permanent loss of signal

8Pump position sensor/cam positionsensor input missing

9 Not informed by VOLVO

10Pump position sensor/cam positionsensor input pattern error

637 22Crank position sensor/Speed sensor flywheel

2 Crank position input noice

3 Permanent loss of signal

7Crank position/Cam position out of synchronisation

8 Crank position input missing

9 Not informed by VOLVO

10 Crank position sensor input pattern error

639 247 231 Communication status

2 Bus Off error

9 Passive bus error

11 Data registers read back failure

12 Loss of message error

13 Bus CAN error640 Engine shutdown vehicle status

11 Engine shutdown vehicle request invalid

31 Engine shutdown vehicle request

651 1 1 651 Cylinder #1 status injector

2 Short circuit high side to B+

3Short circuit high side to low side or lowside to B+

4 Short circuit high or low side to ground

5 Cylinder #1 circuit open

6 Cylinder #1 circuit shorted

7 Cylinder #1 balancing error/mechanicalfailure

11Cylinder #1 unknown error/mechanicalfailure







7

Cylinder #2 balancing error/mechanical

failure


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J o h n

D e e r e

V o l v o

P e r k i n s








7Cylinder #3 balancing error/mechanicalfailure












3

Short circuit high side to low side or low

side to B+












7 Cylinder #6 balancing error/mechanical failure

11 Cylinder #6 unknown error/mechanical failure

676 39 Glow plug relay status

3 Glow plug relay voltage high

5 Glow plug relay voltage low

677 3 Start relay status

3 Start relay control short circuit to high

4 Start relay control short circuit low

5 Start relay control open circuit

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SPN CID SID PID PPID FMI J o h n

D e e r e

V o l v o

P e r k i n s


678 41 8 Volt power supply

3 ACM 8 Volt DC supply open/short to B+

4 ACM 8 Volt DC supply open/short to ground

679 42Injection control pressureregulator/pressure release valve

723 342 Secondary speed sensor

2Secondary engine speed sensor dataintermittent

11 Secondary engine speed sensor loss of signal

12 Loss of signal/sensor failure

729 70 Inlet air heater signal/Preheat sense

3 Inlet air heater signal high

5 Inlet air heater signal low

810 Vehicle speed

2 Calculated vehicle speed input noiseNot possible with Gensetapplication

861 861 Diagnostic output status

3 Diagnostic output open/short to B+

4 Diagnostic output short to ground

898 CAN thro ttle status

9 Speed value invalid or missing

970 6 Auxiliary engine shutdown switch status EMS

2 Auxiliary engine shutdown switch signal invalid Not used

31 Auxiliary engine shutdown switch active

971 External engine de rate switch status

31 External engine de rate switch active Not used

1069 Tire size status

2 Tire size error

9 Tire size invalid

31 Tire size error

Not possible with Gensetapplication

1076 Fuel Injection pump status

0 Pump control valve closure too long Injection DE10

1 Pump control valve closure too short Injection DE10

2 Pump detected defect Injection VP44

3 Pump solenoid current high Injection DE10

5 Pump solenoid circuit open Injection DE10

6 Pump solenoid circuit severely shorted Injection DE10

7 Pump control valve closure not detected Injection DE10

10 Pump solenoid circuit moderately shorted Injection DE10

13 Pump current decay time invalid Injection DE10

1077 Fuel injection pump controller status

7 Attempting to fuel without command

11 Pump supply voltage out of range

12 Pump self test error

19 Pump detected communication error

31 Pump initiated engine protection

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J o h n

D e e r e

V o l v o

P e r k i n s


1078 ECU/Pump timing status

7 ECU/Pump timing moderately out of synchronisation

11ECU/Pump timing speed out of synchronisation

31ECU/Pump timing extremely out of synchronisation

1079 Sensor supply voltage (+5 Volt) Analog thro ttle reference

3 Sensor supply voltage high >5,5 Volt

4 Sensor supply voltage low <4,44 Volt

1080 211Sensor supply voltage (Oil pressure, Coolant temp, fuelpressure)/+5V sensor supply 2

3 Sensor supply voltage high >5,5 Volt

4 Sensor supply voltage low <4,40 Volt1109 Engine/ECU status

31 Engine shutdown warning

1110 Engine status

31 Engine shutdown

1111 268 Check parameters

2 Programmed parameter fault

1136 55 ECU Temperatu re

1184 173 Exhaust gas temperature sensor

1188 32 Wastegate

1231 CAN bus 21239 Rail pressure system

1266 1266 General fault output status

3 General fault output open/short to B+

4 General fault output short to ground

1347 Pump cont rol valve statusPump control valve #1status for 6081HF070

3 Pump control valve current high

5 Pump control valve error/mismatch

7 Fuel rail pressure control error

10 Pump control valve fuel flow not detected

1348 Pump cont rol valve #2 status Only for 6081HF070

5 Pump control valve #2 error/mismatch

10 Pump control valve #2 fuel flow not detected

1485 1485 5 Pump power relay statusECU main relay of VOLVOEMS/EDC

2 Pump power relay fault

3 ECU main relay short circuit high

1568 Torque curve selection

2 Torque curve selection invalid

4 Torque curve input voltage high

9 Torque curve selection missing

1569 Fuel supply status

31 Fuel de rate

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J o h n

D e e r e

V o l v o

P e r k i n s


1639 Fan speed sensor

1 Fan speed signal missing

2 Fan speed signal erratic

16 Fan speed higher than expected

18 Fan speed lower than expected

Not possible with Gensetapplication

1675 Engine starter motor relay

1690 1690 Analogue thro ttle status

Abnormal pulse signal

2000 ECU status

6 Vehicle ID missing

13 Security violation

2017 J1939 Communication bus

2791 19 Internal EGR status

520192 8 Piston cooling switch

520193 267 Sea water pressure

520194 4 Starter inpu t sensor (start request)

520195 6Key off input sensor (stop request)CIU

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SAE J1939-73 : March 2004FMI and Description

FMI=0—D ATA V ALID BUT ABOVE NORMAL OPERATIONAL R ANGE - MOST SEVERE LEVEL

The signal communicating information is within a defined acceptable and valid range, but the real world condition is abovewhat would be considered normal as determined by the predefined most severe level limits for that particular measure of the real world condition (Region e of the signal range definition) Broadcast of data values is continued as normal.

FMI=1—D ATA V ALID BUT BELOW NORMAL OPERATIONAL R ANGE - MOST SEVERE LEVEL

The signal communicating information is within a defined acceptable and valid range, but the real world condition is belowwhat would be considered normal as determined by the predefined least severe level limits for that particular measure of the real world condition (Region e of the signal range definition). Broadcast of data values is continued as normal.

FMI=2—D ATA ERRATIC, INTERMITTENT OR INCORRECT

Erratic or intermittent data includes all measurements that change at a rate that is not considered possible in the realworld condition and must be caused by improper operation of the measuring device or its connection to the module.Broadcast of data values is substituted with the “error indicator” value.Incorrect data includes any data not received and any data that is exclusive of the situations covered by FMIs 3, 4, 5and 6. Data may also be considered incorrect if it is inconsistent with other information collected or known about thesystem.

FMI=3—VOLTAGE ABOVE NORMAL, OR SHORTED TO HIGH SOURCE

a. A voltage signal, data or otherwise, is above the predefined limits that bound the range (Region e of the signal rangedefinition). Broadcast of data values is substituted with the “error indicator” value.

b. Any signal external to an electronic control module whose voltage remains at a high level when the ECM commands itto low. Broadcast of data value is substituted with the “error indicator” value.

FMI=4—VOLTAGE BELOW NORMAL, OR SHORTED TO LOW SOURCE

c. A voltage signal, data or otherwise, is below the predefined limits that bound the range (Region e of the signal rangedefinition). Broadcast of data values is substituted with the “error indicator” value.

d. Any signal external to an electronic control module whose voltage remains at a low level when the ECM commands itto high. Broadcast of data value is substituted with the “error indicator” value.

FMI=5—CURRENT BELOW NORMAL OR OPEN CIRCUIT

e. A current signal, data or otherwise, is below the predefined limits that bound the range (Region e of the signal rangedefinition). Broadcast of data values is substituted with the “error indicator” value.

f. Any signal external to an electronic control module whose current remains off when the ECM commands it on.Broadcast of data value is substituted with the “error indicator” value.

FMI=6—CURRENT ABOVE NORMAL OR GROUNDED CIRCUIT

g. A current signal, data or otherwise, is above the predefined limits that bound the range. (Region e of the signal rangedefinition). Broadcast of data values is substituted with the “error indicator” value.

h. Any signal external to an electronic control module whose current remains on when the ECM commands it off.Broadcast of data value is substituted with the “error indicator” value.

FMI=7—MECHANICAL SYSTEM NOT RESPONDING OR OUT OF ADJUSTMENT

Any fault that is detected as the result of an improper mechanical adjustment or an improper response or action of amechanical system that, with a reasonable confidence level, is not caused by an electronic or electrical system failure. This type of fault may or may not be directly associated with the value of general broadcast information.

FMI=8—ABNORMAL FREQUENCY OR PULSE WIDTH OR PERIOD

To be considered in cases of FMI 4 and 5. Any frequency or PWM signal that is outside the predefined limits which boundthe signal range for frequency or duty cycle (outside Region b or the signal definition). Also if the signal is an ECM output,any signal whose frequency or duty cycle is not consistent with the signal which is emitted. Broadcast of data value issubstituted with the “error indicator” value.

FMI=9—ABNORMAL UPDATE R ATE

Any failure that is detected when receipt of data via the data link or as input from a smart actuator or smart sensor is not

at the update rate expected or required by the ECM (outside Region c of the signal range definition). Also any error thatcauses the ECM not to send information at the rate required by the system. This type of fault may or may not be directlyassociated with the value of general broadcast information.

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FMI=10—ABNORMAL R ATE OF CHANGE

Any data, exclusive of the abnormalities covered by FMI 2, that is considered valid but whose data is changing at a ratethat is outside the predefined limits that bound the rate of change for a properly functioning system (outside Region c of the signal range definition). Broadcast of data values is continued as normal.

FMI=11—ROOT C AUSE NOT KNOWN

t has been detected that a failure has occurred in a particular subsystem but the exact nature of the fault is not known.Broadcast of data value is substituted with the “error indicator” value.

FMI=12—B AD INTELLIGENT DEVICE OR COMPONENT

nternal diagnostic procedures have determined that the failure is one which requires the replacement of the ECU, usedhere to mean the packaged unit that includes some microprocessor and its associated components and circuits. It can beassumed that the communications subsystem is not the part that has failed, and the manufacturer has determined thatthere is no serviceable component smaller than the ECU involved in the failure. Broadcast of data value is substitutedwith the “error indicator” value if appropriate, as there may or may not be any broadcast involved. This error is to includeall internal controller trouble codes that can not be caused by connections or systems external to the controller.

FMI=13—OUT OF C ALIBRATION

A failure that can be identified to be the result of not being properly calibrated. This may be the case for a subsystemwhich can identify that the calibration attempting to be used by the controller is out of date. Or it may be the case that themechanical subsystem is determined to be out of calibration. This failure mode does not relate to the signal rangedefinition as do many of the FMIs.

FMI=14—SPECIAL INSTRUCTIONS

“Special Instructions” is the FMI to be used when the on-board system can isolate the failure to a small number of choicesbut not to a single point of failure. When the FMI is used, there is clear necessity for the service technician to take someaction to complete the specific diagnosis, and the manufacturer has provided instructions for the completion of thatdiagnosis. There are two cases where this will be used: 1. for emission-related diagnostics where the particular failurecannot be separated between a sensor out of range and the case where the actual value is at the edge of a diagnosticregion, and 2. for the older SPN 611 to 615 where the problem is in determining which of two or more circuits (which maynteract) is the one that needs repair.SPNs 611 through 615 are defined as “System Diagnostic Codes” and are used to identify failures that cannot be tied to aspecific field replaceable component. Specific subsystem fault isolation is the goal of any diagnostic system, but forvarious reasons this cannot always be accomplished. These SPNs allow the manufacturer some flexibility tocommunicate non-“specific component” diagnostic information. Since SPNs 611-615 use the standard SPN/FMI format itallows the use of standard diagnostic tools, electronic dashboards, satellite systems and other advanced devices thatscan Parameter Groups containing the SPN/FMI formats. Because manufacturer defined codes are not desirable in termsof standardization, the use of these codes should only occur when diagnostic information cannot be communicated as aspecific component and failure mode.Possible reasons for using a System Diagnostic Code include:

1. Cost of specific component fault isolation is not justified, or2. New concepts in Total Vehicle Diagnostics are being developed, or3. New diagnostic strategies that are not component specific are being developed.

Due to the fact that SPNs 611-615 are manufacturer defined and are not component specific, FMIs 0-13 and 15-31 haveittle meaning. Therefore, FMI 14, “Special Instructions”, is usually used. The goal is to refer the service personnel to themanufacturer's troubleshooting manual for more information on the particular diagnostic code. This failure mode does notrelate to the signal range definition as do many of the FMIs. This type of fault may or may not be directly associated withthe value of general broadcast information.

FMI=15—D ATA V ALID BUT ABOVE NORMAL OPERATING R ANGE - LEAST SEVERE LEVEL

The signal communicating information is within a defined acceptable and valid range, but the real world condition is abovewhat would be considered normal as determined by the predefined least severe level limits for that particular measure of the real world condition (Region i of the signal range definition). Broadcast of data values is continued as normal.

FMI=16—D ATA V ALID BUT ABOVE NORMAL OPERATING R ANGE - MODERATELY SEVERE LEVEL

The signal communicating information is within a defined acceptable and valid range, but the real world condition is abovewhat would be considered normal as determined by the predefined moderately severe level limits for that particular

measure of the real world condition (Region k of the signal range definition). Broadcast of data values is continued asnormal.

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FMI=17—D ATA V ALID BUT BELOW NORMAL OPERATING R ANGE - LEAST SEVERE LEVEL

The signal communicating information is within a defined acceptable and valid range, but the real world condition is belowwhat would be considered normal as determined by the predefined least severe level limits for that particular measure of the real world condition (Region h of the signal range definition). Broadcast of data values is continued as normal.

FMI=18—D ATA V ALID BUT BELOW NORMAL OPERATING R ANGE - MODERATELY SEVERE LEVEL

The signal communicating information is within a defined acceptable and valid range, but the real world condition is below

what would be considered normal as determined by the predefined moderately severe level limits for that particularmeasure of the real world condition (Region j of the signal range definition). Broadcast of data values is continued asnormal.

FMI=19—RECEIVED NETWORK D ATA IN ERROR

Any failure that is detected when the data received via the network is found substituted with the “error indicator” value(i.e. FE16, see J 1939-71). This type of failure is associated with received network data. The component used to measurethe real world signal is wired directly to the module sourcing the data to the network and not to the module receiving thedata via the network. The FMI is applicable to Region f and g of the signal range definition. This type of fault may or maynot be directly associated with the value of general broadcast information.

FMI=20-30—RESERVED FOR SAE ASSIGNMENT

FMI=31—CONDITION EXISTS

Used to indicate that the condition that is identified by the SPN exists when no more applicable FMI exists or in caseswhen the reported SPN name spells out the component and a non-standard failure mode. This type of fault may or maybe directly associated with the value of general broadcast information. This FMI will mean “not available” when theassociated SPN is also “not available” as when the remainder of the packet is filled with binary ones after all data hasbeen transmitted.

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