User and maintenance manual for generating sets R66C2

User and maintenance manual
for generating sets
R66C2
33501782101NE_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
6.3.1.4.
Description of the pictograms in zone 2.....................................................................................................................49
6.3.1.5.
Description of the pictograms in zone 3.....................................................................................................................50
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 .......................................................................................................209
9.3.
Appendix C - Common spare parts ......................................................................................................................................241
9.4.
Appendix D - List of John Deere - Volvo and Perkins fault codes.........................................................................................243
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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 be
followed.
You are likely to encounter several warning symbols in this manual.
This symbol indicates an immediate danger to human health and life in case of exposure. Failure to
follow the corresponding advice entails serious consequences for human health and life in case of
exposure.
Danger
This symbol draws attention to the potential risks to human health and life in case of exposure. Failure to follow
the corresponding advice entails serious consequences for human health and life in case of exposure.
Warning
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 other
object in case of exposure.
Important
In order to obtain optimum efficiency and the longest possible life for the electrical generating sets, maintenance operations must be
carried out according to the periods indicated in the attached preventative maintenance tables. If the electrical generating set is used
under 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 this
qualification, 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 parts
thereby 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 offer
properly 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 in
implementation and maintenance.
Important
Some user and maintenance manuals for the engines fitted to generating sets cover control units and include
the 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 information
that 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 with
specific electrical wiring different to that described in the engine documentation.
3/256
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 potential
dangers and explain the action to be taken in the interest of safety. These notices are reproduced in this publication for ease of
identification by the operator.
Replace any notice that is missing or illegible.
Caution: danger
Publications delivered
with the generating set
must be referred to
Caution: risk of explosion
Caution: risk of
electric shock
Protective clothing
must be worn
Naked flames and
unprotected lights
prohibited.
No smoking
Caution: toxic
materials
Eyes and ears must be
protected
Entry prohibited to nonauthorised persons
Caution:
pressurised fluids
Periodic maintenance
must be carried out
Jet washing prohibited
Caution: high
temperature, risk
of burns
Battery level must be
checked
Earth
Caution: rotating
or moving parts
(risk of getting
caught in the
machinery)
Lifting point must be
used
Caution: corrosive product
Fork pockets for
lifting
Retention tank level
high
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 risk
of injury.
Observe the safety instructions and precautions for use.
Important:
Carefully read the instructions supplied with the generating set before using or
servicing the equipment.
WARNING: DANGER
Risk of electrocution
ƒ Do not touch the cables or connections when the generating set is in operation.
ƒ Switch off the generating set for maintenance operations.
DANGER
Use diesel fuel only.
ƒ The fuel is highly flammable, handle with care. Do not smoke near the
generating set or expose it to a naked flame or sparks.
ƒ Shut down the generating set engine before filling the fuel tank. Fill with fuel
outside.
ƒ To prevent fire risks, clean the generating set regularly. Wipe away any dirt and
traces of grease or fuel.
WARNING: DANGER
ƒ
ƒ
The exhaust gases from the engine are toxic and can affect health or even
cause death.
Use the generating set outdoors only, in well ventilated areas, or fit an exhaust
extension to discharge the exhaust gases outside.
Figure 1.2: Pictograms and their meanings
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WARNING: DANGER
ƒ
ƒ
ƒ
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
ƒ
ƒ
ƒ
ƒ
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
ƒ
ƒ
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
ƒ
ƒ
The gas from the battery electrolyte is explosive. Keep the batteries away
from 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
ƒ
ƒ
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
7/256
1.3. Instructions and safety regulations
THESE SAFETY GUIDELINES ARE IMPORTANT
If 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 you
a demonstration. A list of risks and precautionary measures to take follows. You should also refer to any local and national regulations
that 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 or
batteries.
1.3.1 General advice
Use
9 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 the
service 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.
Consumables
9 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.
Environment
9 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 and
dust.
9 The presence of dangerous or combustible materials inside premises housing combustion devices shall be limited to the operating
requirements.
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9
9
9
9
9
9
9
9
9
Facilities must be operated under the constant supervision of a qualified person, who must regularly check that the safety devices
are operating correctly and ensure that the combustion devices have the correct fuel supply.
Apart from the combustion devices, it is prohibited to use fire in any form. This restriction must be clearly displayed.
Spreading of waste water, sludge and waste is prohibited.
The fuels to be used must correspond to those featured in the declaration file and the specifications recommended by the
combustion device manufacturer.
The fuel is considered to remain in the same physical state as when it is introduced into the combustion chamber.
Burning of waste in the open air is prohibited.
Always protect your hands when checking for leaks. Pressurised liquids may penetrate body tissue and cause serious damage.
Risk of blood contamination.
Drain and dispose of engine oil in a specially provided container (fuel distributors can collect your used oil).
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.
Always use generating sets, pump units or lighting towers in a well-ventilated place where gases cannot
accumulate.
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
Glycol is a toxic product and dangerous if absorbed.
The corrosion inhibitor contains alkali.
Avoid all contact with the skin and eyes. Read the
Do not swallow it.
instructions on the packaging.
This substance should not come into contact with the
eyes. In the event of contact with the eyes, rinse
immediately with plenty of water for at least 15
minutes.
Avoid prolonged or repeated contact with the skin. In
the event of contact with the skin, wash thoroughly
with water and soap. CONSULT A DOCTOR
IMMEDIATELY. KEEP THE PRODUCT OUT OF
THE 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.
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.
9/256
1.3.4 Risk of fire, burns and explosion
The engine should not be operated in environments containing explosive products. As not all of the
electrical and mechanical components are shielded, there is a risk of sparks forming.
Danger
9
9
9
9
9
9
9
9
9
9
9
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.
Never cover the generating set, pump unit or lighting tower with any material during operation or just after shutdown (wait for the
engine to cool).
Do not touch hot parts such as the exhaust pipe, or put combustible materials on it.
Keep all flammable or explosive materials (e.g. petrol, oil, cloth, etc.) out of the way when the set is running.
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 to
surrounding property.
Do not remove the radiator cap if the engine is hot and the coolant is pressurised, due to risks of burns.
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 find
pressure leaks by hand. Oil at high pressure can cause bodily damage.
Some preservative oils are flammable. Also, some are dangerous to inhale. Ensure proper ventilation. Use a protective mask.
Hot oil causes burns. Avoid contact with hot oil. Check that the system is no longer pressurised before carrying out any
procedures. Never start or run the engine with the oil filler cap off (oil may splash out).
Never coat the generating set, pump unit or lighting column with a thin layer of oil to protect it from rust.
Never top up the oil or coolant if the generating set, pump unit or lighting column is running, or if the engine is hot.
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 the
countries in question.
9 The earth connection must be installed in accordance with the standards in force in each country in question, and with the neutral
system sold.
9 Read the manufacturer's identification plate carefully. The values for voltage, power, current and frequency are shown. Check that
these values match the supply use.
9 Never 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 and
damage 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 should
take the operating differences of the equipment into account, according to whether the mains supply network or generating set is
being used.
9 Protection against electric shocks is ensured by an assembly of specific equipment. If this needs to be replaced, it should be by
components with identical nominal values and specifications.
10/256
9 If the protective plates (blanking covers) need to be removed to route cables, the protector (blanking cover) must be refitted when
the operations are finished.
9 Due to high mechanical stresses, use only strong flexible wiring with rubber sheathing, compliant with IEC 245-4, or equivalent
wiring.
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 activate
the emergency stop on the generating set or lighting column. If the voltage
has not yet been cut off, move the victim out of contact with the live conductor
as quickly as possible. Avoid direct contact both with the live conductor and
the victim's body. Use a dry plank of wood, dry clothes or other nonconductive materials to move the victim away. The live wire may be cut with
an 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 life
could 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 and
efficiency 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 or
lighting column, the generating set, pump unit or lighting column must be lifted up with an adjustable boom. All the chains and
cables 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 be
necessary 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 without
stress (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 with
free access.
9 Never perform work on a generating set, pump unit or lighting tower just hanging from a lifting device.
11/256
1.4. Identifying 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 documentation
contained in the appendices of this manual.
1 - Generating set
2 - Manufacturer name
3 - Model
4 - Serial number
5 - Year of manufacture
6 - Rated output (kVA and kW) according to the ISO
8528-1 standard
PRP: main power
ESP: emergency power
7 - Rated power factor
8 - 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 marking
16
Non
CE
standard
marking
(e.g.: GOSSTANDART)
17 - Sound pressure
18 - Sound power
Figure 1.3: Example of generating set identification plate
Figure 1.4: Examples of engine identification plates
12/256
Figure 1.5: Examples of alternator identification plates
Control box
Figure 1.6: Example of control box identification plate
13/256
2. General description
2.1. Description
Overview
3
5
4
2
6
1
7
8
10
9
11
1
2
3
4
5
6
Electric sockets
Connection termination box
Circuit breakers
External emergency stop
Protective grilles
Battery charge alternator
7
8
9
10
11
Circuit breaker
Starter battery
Control unit
Chassis
Filling with fuel
Figure 2.1: General description of the generating set
14/256
Fittings
Socket control panels and terminals by enclosure type:
TYPE 2 - HI05
TO CIRCUIT BREAKERS
N1
R1
S1
T1
1
2
1
2
MAX CONNECTION CABLE CROSS-SECTION 185MM²
Ø M12 BOLT; Ø M12 NUT
15/256
TYPE 2 TT EDF OPTION HI05
TO CIRCUIT BREAKERS
N1
NF C15-100 EARTHING
SYSTEM
1
2
S1
EDF EARTHING
SYSTEM
1
Connect to the earthing rod
R1
EDF earth
MAX CONNECTION CABLE CROSS-SECTION 185MM²
Ø M12 BOLT; Ø M12 NUT
16/256
2
T1
M128/M129 50Hz FR
MERLIN GERIN
multi 9
ID
63A
23201
multi 9
C 60N
C 16
multi 9
C 60N
C 32
24485
24231
55
66
11
2
BALS
77
400V
32A
3P+N+
12801
IP44
1
2
3
4
5
6
7
8
9
33
88
44
99
DIFFERENTIAL SWITCH (Q10) 4x63A 30 mA
X03 16A 400V SOCKET
16A CIRCUIT BREAKER (Q08)
X08 16A 230V SOCKET
4x32A CIRCUIT BREAKER (Q02)
4x16A CIRCUIT BREAKER (Q03)
X02 32A 400V SOCKET
16A DIRUPTOR CIRCUIT BREAKER (Q05)
X05 16A 230V SOCKET
17/256
M128/M129 50Hz EU
MERLIN GERIN
multi 9
ID
40A
23196
multi 9
C 60N
C 16
multi 9
C 60N
C 63
24485
24234
55
11
66
22
BALS
77
400V
63A
3P+N+
12567
IP44
1
2
3
4
5
6
7
8
9
33
88
44
99
DIFFERENTIAL SWITCH (Q10) 4x40A 30 mA
X03 16A 400V SOCKET
16A CIRCUIT BREAKER (Q09)
X09 16A 230V SOCKET
4x63A CIRCUIT BREAKER (Q01)
4x16A CIRCUIT BREAKER (Q03)
X01 63A 400V SOCKET
16A DIRUPTOR CIRCUIT BREAKER (Q05)
X05 16A 230V SOCKET
18/256
M128/M129 50Hz UK
4
1
2
5
3
6
1
2
3
4
5
6
DIFFERENTIAL SWITCH (Q03) 4x40A 30 mA
X01 125A 400V 3P+N+T SOCKET
1X32A DIRUPTOR CIRCUIT BREAKER (Q04, Q05, Q06)
4x63A CIRCUIT BREAKER (Q02)
X02 63A 400V 3P+N+T SOCKET
X04, X05, X06 32A 220V SOCKET
19/256
2.2. Technical specifications
RENTAL POWER / R66C2
Range / Generating set type
Weights and Dimensions
Dimensions with standard tank
Dimensions l x w x h:
2300mm x 1080mm x 1680mm
Weight:
1470kg dry weight 1670kg in operating configuration
Hood:
M128C
Noise level:
63 dB @ 7 m
88 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:
M128C-DW
Noise level:
63 dB @ 7 m
88 Lwa
Output
Voltage
Hz
Phase
Load factor
400/230
50
3
0.8
Max current (A)
Emergency/Prime
95 / 85.5
Emergency power 1
kW / kVA
53 / 66
Prime power 2
kW / kVA
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 overload
available 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
Type
Cylinder configuration
Cubic capacity
Rotation speed
Max emergency/prime power at nominal speed
Adjustment type
JOHN DEERE 4045TFS70
4 Turbo Cycles
4 XL
4.5L
1500 Rpm
60.5 / 55 kW
Electrical
Fuel consumption
110 % (emergency power)
100 % main power
75 % main power
50 % main power
16.09L/h
14.75 L/h
11.26 L/h
7.41 L/h
Fuel
Fuel type
Standard fuel tank
High autonomy fuel tank
Diesel
180 L
390 L
20/256
Lubrication
Oil capacity with filter
Min. Oil pressure
Nominal oil pressure
Oil consumption (100 % load)
Oil sump capacity
Type of lubricant
6.5 L
1 bar
5 bar
0.04 L/h
5.5 L
Genlub
Cooling
Engine capacity with radiator
Fan power
Refrigerant type
Thermostat
8.1L
3.33 kW
Gencool
82-94 °C
Emissions
HC
CO
NoX
PM
0.47 g/kW-hr
1.04 g/kW-hr
5.41 g/kW-hr
0.03 g/kW-hr
Alternator data
● Compliant with NEMA MG21 standards, UTE NF C51 111,
VDE 0530, BS 4999, IEC 34.1, CSA
Type
Number of phases
Power factor (cos Phi)
Number of poles
Excitation type
Voltage regulator
Short-circuit current
Number of bearings
Coupling
● The alternator is protected against short circuits
● Vacuum impregnation, epoxy winding, IP23 protection rating
LEROY SOMER LSA432M45
3
0.8
4
AREP
R438
3 IN
1
Direct
Control unit(s)
NEXYS
Standard specifications:
Frequency meter, Voltmeter, Ammeter
Alarms and faults:
Oil pressure, Coolant temperature, Fail to start, Overspeed,
Alternator min/max, Fuel level low, Emergency shutdown
Engine parameters:
Working hours counter, Engine speed, Battery voltage, Fuel
Level, Air Preheating
TELYS
Standard specifications:
Voltmeter, Ammeter, Frequency meter
Alarms and faults:
Oil pressure, Water temperature, Start failure, Overspeed,
Alternator min/max, Battery voltage min/max, Emergency stop
Engine parameters:
Timer, Oil pressure, Water temperature, Fuel level, Engine
speed, Battery voltage
21/256
2.3. Fuel and consumables
All specifications (product features) are given in the motor and alternator maintenance manuals attached to this manual.
In addition, we recommend the consumables to be used in the "specifications" section.
2.3.1 Specifications
2.3.1.1. Oil grades
Engine
Oil
Make
Type
John Deere
All
MITSUBISHI
Volvo
All
All
Make
John Deere
GenPARTS
GenPARTS
GenPARTS
Type
John Deere PLUS-50
GENLUB TDX 15W40
GENLUB TDX 15W40
GENLUB TDX 15W40
GENLUB TDX 15W-40
Top-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 All types of use: can cope with the most demanding applications
9 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 E3
API 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 varying
conditions, demonstrating its high quality.
9 Conformity with new environmental legislation: adherence to new anti-pollution standards required for new EURO 2 and
EURO 3 engines.
SPECIFICATIONS:
SAE Grade
15W-40
Density at 15°C
Cinematic viscosity at 40 °C Cinematic
viscosity at 100 °C
Viscosity index
Dynamic viscosity at -15 °C
Pour point
Flash point
Sulphated ash content
(Values given as examples only)
0.883
105
14.1
mm2/s (cSt)
mm2/s (cSt)
140
3000
- 30
220
1.4
mPa.s(cP)
°C
°C
% weight
22/256
2.3.1.2. Specifications of coolants
Engine
Coolants
Make
John Deere
Type
All
MITSUBISHI
All
Volvo
All
Make
GenPARTS
Mitsubishi
GenPARTS
GenPARTS
Type
GENCOOL PC -26°C
LLC
GENCOOL PC -26°C
GENCOOL PC -26°C
GenCOOL PC -26
High-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 antifreeze):
HEAVY GOODS VEHICLE
LIGHTER VEHICLES
Approved by MTU, MERCEDES BENZ, MAN, KHD, GENERAL Approved by BMW, VOLKSWAGEN, MERCEDES, PORSCHE
MOTORS
Conforms with VOLVO, OPEL, SEAT and SKODA specifications
Conforms with VOLVO, IVECO, VAN HOOL and STAYR TRUCK
specifications
Conforms with the NF R 15.601 standard
REINFORCED ANTI-CORROSION FEATURES:
y
y
y
y
y
Protects against high-temperature corrosion by oxidisation of ethylene (cylinder head protection).
Protects against high-temperature cavitation (top of cylinder and coolant pump protection)
Non-corrosive for seals and hoses.
Improves the efficiency and longevity of the cooling system.
GenCOOL PC -26 is especially recommended for engines fitted with aluminium or light alloy radiators.
HIGH TEMPERATURE SUITABILITY:
y
y
y
Provides good conditions for thermal exchange.
Perfect stability at high temperatures.
GenCOOL PC -26 is specially adapted for engines with high power densities.
LONG LASTING PROTECTION:
y
y
y
y
High alkaline reserve/stability and longevity of corrosion inhibitors
Maintains its technical properties during prolonged use at high temperatures (neutralisation of acids).
Ensures maximum heat transfer without the build up of deposits in the cooling system
GenCOOL PC -26 ensures optimum protection against overheating and corrosion in extreme conditions of vehicle use.
23/256
PACKAGING/STORAGE:
y
y
y
GenCOOL PC -26 is supplied in 210 l metallic barrels with smooth interior linings.
It can be stored for 2 years in its original container and packaging.
Avoid zinc coated containers.
RECOMMENDATIONS FOR USE:
y
y
Compatible with the original fluid.
It is recommended that the cooling system is completely drained when replacing the fluid.
UNITS
SPECIFIED VALUES
TRIAL
METHODS
kg/m3
1,059 +/- 3
R 15-602-1
pH
pH
7.5 to 8.5
NF T 78-103
Alkalinity reserve
ml
>=10
NF T 78-101
Boiling point
°C
105 +/- 2
R 15-602-4
°C
-26 +/- 2
NF T 78-102
SPECIFICATIONS
Density at 20°C
Freezing point:
Glassware
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
Corrosion on warm
(test with antifreeze)
+/- 1.0
plate
mg/(cm²week)
24/256
+/- 0.17
R 15-602-8
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 ensure
that 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
o
p
q
r
s
Attach the lifting vehicle slings to the rings on the generating set designed for this procedure. Hang the slings carefully.
Check that the slings are correctly attached and the equipment is solid.
Lift the generating set carefully.
Direct and stabilise the set towards the chosen position.
Carefully set down the equipment while continuing to position it.
Release the slings, then detach and remove the lifting rings.
3.1.2.2. Fork lift truck
n
Position the forklift arms under the base frame (except with generating sets fitted with "forklift pockets", in which case position the
forklift arms in these pockets), making sure that only its cross-members are resting on the arms.
o
p
Lift the equipment, handling it gently.
Set down the generating set in its unloading position.
Figure 3.1: Transporting a generating set using a forklift truck
25/256
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 a
retention 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.
26/256
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 or
condensation). If necessary, drain the containers either via the drain port or by using the drain pump (for containers fitted with this
pump).
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 the
electric distribution panel and disturbances caused by the noise. However, fuel supply, burnt gas evacuation, and the direction of these
gases 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
Fuel filling impossible
Reduced access
Opening cover doors impossible
Diagram 3.5: Examples of problems that may be encountered
27/256
3.4. Electricity
a) Connections - general information
As with low voltage electrical installations, use and maintenance is governed by standard NFC 15.100 (France) or by the standards in the relevant
country, 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 be
observed in the country of installation. The choice of conductors must comply with international standard IEC 30364-5-52.
Three phase - Calculation hypothesis
Fitting 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
Circuit breaker
calibre
(A)
10
16
20
25
32
40
50
63
80
100
125
160
250
400
630
(1)
(1)
(1)
(1)
(1)
0 - 50m
mm²/AWG
1.5 / 14
2.5 / 12
2.5 / 12
4 / 10
6/9
10 / 7
10 / 7
16 / 5
25 / 3
35 / 2
4X(1X50) / 0
4X(1X70) / 2/0
4X(1X95) / 4/0
4X(1X185) / 0400MCM
4X(2X1X150) / 2x 2350MCM
51 - 100m
mm²/AWG
2.5 / 12
4 / 10
4 / 10
6/9
6/9
10 / 7
10 / 7
16 / 5
25 / 3
35 / 2
4X(1X50) / 0
4X(1X70) / 2/0
4X(1X150) / 2350MCM
4X(1X185) / 0400MCM
4X(2X1X150) / 2x 2350MCM
101 - 150m
mm²/AWG
4 / 10
6/9
6/9
10 / 7
10 / 7
16 / 5
16 / 5
25 / 3
35 / 2
4X(1X50) / 0
4X(1X70) / 2/0
4X(1X95) / 4/0
4X(1X150) / 2350MCM
4X(1X185) / 0400MCM
4X(2X1X150) / 2x 2350MCM
Single phase - Calculation hypothesis
Fitting 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.
Circuit breaker
rating (A)
10
16
20
25
32
40
50
63
80
100
125
Cable sizes
0 - 50m
51 - 100m
101 - 150m
mm²/AWG
4 / 10
6/9
10 / 7
10 / 7
10 / 7
16 / 5
16 / 5
25 / 3
35 / 2
35 / 2
50 / 0
mm²/AWG
10 / 7
10 / 7
16 / 5
16 / 5
25 / 3
35 / 2
35 / 2
50 / 0
50 / 0
70 / 2/0
95 / 4/0
mm²/AWG
10 / 7
16 / 5
25 / 3
25 / 3
35 / 2
50 / 0
50 / 0
70 / 2/0
95 / 4/0
95 / 4/0
120 / 2250MCM
c) Battery cables
Install the battery or batteries in the immediate vicinity of the electric starter motor. The cables will be connected directly from the
battery 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.
2
The minimum cross-section of the cables will be 70 mm . 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).
28/256
d) Safety guidelines
References: 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 be
returned 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 minimum
2
2
cross-section of 25 mm for a stripped cable and 16 mm for 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:
R = Ul
I Δn
Maximum resistance value of the earth socket R (Ω) according to the differential unit operational
current (operation time should not be longer than 1 second).
I Δn
differential
Earth R
(Ω)
Ul: 50 V
500
500
167
100
50
17
10
5
≤ 30 mA
100 mA
300 mA
500 mA
1A
3A
5A
10A
Earth R
(Ω)
Ul: 25 V
> 500
250
83
50
25
8
5
2.5
The Ul value: 25 V is required for work site installations, and livestock buildings, etc.
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 ground
Thick arable land,
moist compact ballast
Lean arable land,
Gravel, coarse ballast
Bare stony soils, dry sand,
impermeable rock
Length of
rod in
metres
1
1
3.6
To obtain an equivalent length, you can use several earthing rods
connected 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.
29/256
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 with 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
o
p
q
r
s
t
Lock the wheels to stop the trailer from moving.
Lift up the rear trailer supports and lock them.
Release the parking brake.
Release the locking levers for the draw bar arms and adjust the ring to the same height as the vehicle hook.
Hitch the trailer, remove the locks on each side of the wheels then lift up the front wheel fully using its handle.
Connect the electrical circuit of the trailer to that of the tow vehicle.
Hook the handbrake safety wire onto the hook on the tow vehicle.
CORRECT
CORRECT
Tow vehicle
Tow vehicle
Trailer
Trailer
INCORRECT
INCORRECT
Tow vehicle
Tow vehicle
Trailer
Trailer
Diagram 4.1 : Coupling a trailer
4.2. Check before towing
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.
30/256
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. So
it 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 may
cause 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. It
is 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.
Red rear lights
+ direction indicators
+ stop lights
Front reflective devices (white)
Rear reflective devices (red
triangle)
Side reflective devices (orange)
Figure 4.2: Example of French signalling
4.4. Unhitching the trailer
This operation should be carried out on horizontal, flat, stable ground.
n
o
p
q
r
s
Lock the wheels.
Lower the front wheel.
Disconnect the road signals wire.
Refit the hitch using the wheel to release the hook ring from the tow vehicle.
Engage the handbrake.
Release the tow vehicle.
31/256
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
- The handbrake is used only as a parking brake.
- Setting is carried out starting with the brakes moving to the brake control.
Important
n
After fitting the wheels on the axle, turn the wheels in the FORWARD direction (on all RA 2 type brakes, check that the adjustment
screw 8 reaches the “FORWARD” stop on the brake backing plate).
o
p
Adjust the brake setting using screw 8, with the cables not connected to the cross bar(s). The shoes should rub the drum slightly.
Connect the brake cables to the cross bars(s) and tighten the nuts and lock nuts, leaving the end of the threaded end protruding
by 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 (unscrew
the nuts 5 fully).
r
s
Check that the hook slide 2 is not compressed and the yoke 3 is in the pulled out position.
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 (J2)
max between the spring and nuts 5.
u
Tighten all the lock nuts.
Fit the transmission and adjust the assembly using the tensioner 6 until a gap (J1) of 1 mm max is obtained between the linkage 9
and slide 2.
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 (J1) using the
tensioner.
Parking
¾
¾
The lever must be fully pulled up, so that the compensating spring is fully compressed.
Every 900 miles (1500 km), check the braking settings and distribution on all the wheels.
Important
¾
¾
¾
The brake controls are designed to draw trailers behind flexible suspension touring vehicles. If used behind an HGV, be sure
to provide the fitted ball joint with a shock absorber to prevent premature wear.
During any manoeuvres with the trailer coupled, do not turn more than 90° or force reverse.
The specifications of our brake controls are indicated on a manufacturer's plate, and the items on this should be supplied to us
when requesting replacement parts, in particular for the shock absorber, of a special type, approved by the Service des Mines
to correspond to European standards (it is advisable to have a spare shock absorber to enable instant repairs).
32/256
Figure 4.3: Braking transmission
Figure 4.4: Cross bar fitting
Figure 4.5: Tandem bearing fitting
33/256
4.7. Faults and repairs
Fault observed
Erratic braking of trailer
Braking too weak
Drum temperature abnormally high
Jerky braking
Origin
- Faulty shock absorber
- Jaws worn
- Jaws not run in
- Incorrect linkage setting
- Significant friction on the slide
- Slide corrosion
- Coupling height does not match that of the
towing vehicle
- Incorrect linkage setting
- Incorrect brake setting
- High levels of dust in the drums
- Jaws, springs, drums damaged
- Brake cables or link rod damaged
- Incorrect linkage setting
- Interfering parts on the slide
- Corroded slide
- Damage to slide guide rings
- Faulty shock absorber
- Cross-bar(s) not balanced
- Different brake setting on the two sides
Trailer tending to swerve upon braking
When starting the trailer holds back the
towing vehicle
Play in the coupling head
Parking braking too weak
- Cables damaged or incorrectly fitted
- Poor load distribution
- Damage to slide or to guide rings
- Slide corrosion
- Tie rod damaged
- Linkage damaged or incorrectly set
- Brake on
- Head worn (see wear indicator)
- Ball joint worn
- Compensating spring incorrectly set
- Braking system incorrectly set
- Notched sector damaged
- Lever ratchet worn
- Cable ruptured
34/256
Solutions
Replace the shock absorber
Replace the jaws
Fault will disappear only after running in
Adjust the setting
Grease the sliding parts
Remove the corrosion and grease
Adjust the height so that the two parts are
in the same horizontal plane
Adjust the settings
Adjust the settings
Remove the dust
Replace the damaged parts
Replace the damaged parts
Adjust the settings
Remove, clean and grease
Remove the corrosion and grease
Replace the rings (and possibly the slide)
and grease
Replace the shock absorber
Adjust the cross-bar(s)
Adjust the brake settings
Replace the damaged parts
Refit the cables
Check the load distribution
Replace the faulty parts and grease
Remove the corrosion and grease
Replace the tie rod and adjust the settings
Replace the damaged parts and adjust the
settings
Loosen the brake
Replace the head
Replace the ball joint
Adjust the setting
Adjust the setting
Replace the sector and adjust the setting
Replace the lever and adjust the setting
Replace the cable and adjust the setting
4.8. Electrical connection diagram
Figure 4.6: Electrical connection diagram
4.9. Complete wheels technical information
TYRES
550
566
578
534
548
594
622
Cross section
(mm)
134
145
150
150
147
185
172
Radius under load
(mm)
265
272
277
259
263
285
284
100 N
525
155
244
185 R 14 C
102 P
650
188
316
195 R 14 C
195/50 x 10
106 P
98 N
666
450
198
190
32
-
Dimensions
Indices
Diameter (mm)
135 R 13
145 R 13
155 R 13
145/70 R 13
155/70 R 13
185/70 R 13
165 R 14 C
70 T
75 T
79 T
71 T
75 T
86 T
98 N
155/70 R12
35/256
Load
(Kg)
335
387
437
345
387
530
650
650
800
675
850
950
750
COMPLETE
WHEELS
Pressure
(bar)
2.4
2.4
2.4
2.5
2.5
2.5
3.8
6.25
4.5
4.5
6.0
5. Preparation before operating the set
The inspections referred to in this section enable the electrical generator set to operate.
Specific skills are required to carry out these operations.
They must only be entrusted to personnel with the necessary skills.
Failure to follow these instructions in any way could result in malfunction or very serious accidents.
Danger
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
Inspecting the engine compartment
Inspect 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 area
The oil level is correct if it is within the hatched area.
n
o
Check the oil level using the dipstick (A).
p
Pour the oil through the rocker cover filling port (B).
Top up the oil as required.
Use an oil whose viscosity is suited to the seasonal conditions.
36/256
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 bare
hands. 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
p
Fill the radiator with the appropriate coolant if the level is too low.
Check for leaks in the cooling circuit.
Checking the air filter
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.
Important
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.
37/256
Checking the fuel filters
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.
Danger
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 fitted
with a water presence sensor. An indicator on the instrument panel warns the operator that the water must be drained from the filter
cup.
Inspect fuel filters (C) and (D) as follows, in order to detect any traces of water or debris:
n
o
p
q
Undo the drain plug(s) (A) at the bottom of the fuel filter(s) or cup(s) by two or three turns.
Loosen the air drain plugs(s) (B) by two full turns and drain the water into a suitable container.
When the fuel begins to flow out, tighten the drain plugs.
Bleed the supply circuit.
A – Drain plug
B – Air bleed plug
C – Main fuel filter
D – Final fuel filter
38/256
6.2. Generator set with NEXYS control panel
6.2.1 Control panel presentation
9
1
7
9
10
2
3
9
9
4
5
6
8
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
e
f
g
h
i
j
k
l
Key switch for starting up/shutting down the module and RESET function
Electronic card protection fuse
Screen-scroll button, press successively to access the various screens which are available
STOP button, press to switch off the generating set
START button, press to switch on the generating set
Normal operation LEDs and alarm and fault warning LEDs
Slot reserved for panel fascia options
Mounting bolt.
LCD for displaying alarms and faults, operating states, electrical and mechanical quantities
39/256
1
2
3
4
5
Diagram 6.2 – Description of the LEDs
A lit LED indicates:
c
d
e
Module being supplied (green, lights up and remains lit)
f
g
General alarm (orange, flashing)
Emergency stop activated (control panel or external emergency stop) (red, lights up and remains lit)
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)
General fault (red, flashing)
6.2.1.1. Introduction to pictograms
The pictograms are as follows:
Fuel
Operating temperature
Symbols for electric and
mechanical sizes
Overspeed
Battery
Non-starting fault
Starting on external command
Preheating
Air intake
Oil pressure
Delay
Diagram 6.3: View of pictograms
¾
¾
¾
¾
The "fuel level" pictogram is used to display the fault, the alarm and the fuel level.
The "operating temperature" and "oil pressure" pictograms are used to display the fault and analog value.
The "overspeed" and "non-starting fault" pictograms are used to display the fault.
The "battery" pictogram is used to display the "alternator charge" fault and to indicate the battery voltage.
40/256
6.2.2 Manual starting
Check that the generating set circuit breaker has triggered.
Danger
n
o
Connect the generating set battery.
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 in
volts (V).
9
p
Check the battery voltage (min. 12 V)
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 (preheating
activation period).
9 The following screen appears.
The third line displays the air preheating time
remaining (with pictograms representing a
resistor and an hourglass).
9
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).
The following screen appears.
The number of successive and automatic starting attempts is limited to 3.
Warning
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 been
inserted.
Following stabilisation, the LED light comes on
continuously.
41/256
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 screen
to be displayed (one or more pictograms or a fault code along with
the 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).
If one or more faults have appeared after the first fault, they can only be displayed after the first fault has been reset (press "Reset" as
many 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 of faults which will cause the generating set to stop and generate a pictogram
Associated message
Low coolant level fault: indicates that the level of coolant is low in
the radiator (linked to a two second time delay).
Or
Overload or short-circuit fault (optional): with the circuit breaker SD
contact closing (overload or short-circuit), the generating set
switches off immediately also causing the main circuit breaker to
be triggered.
Additional fault linked to message opposite: is displayed in the
following two cases:
¾ Differential fault (1)
¾ insulation fault (2)
(1) Differential fault (optional): with a differential fault causing the
activation of the differential relay, the generating set stops
immediately also causing the main circuit breaker to be
tripped.
(2) Insulation fault (optional): with an insulation fault causing the
activation of the control unit performing insulation, the
generating set stops immediately.
42/256
Associated message
Associated message
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 whilst
the "AUT" LED is flashing to indicate that the generating set
is operating in automatic mode.
List of faults which will cause the generating set to stop and generate a fault code
Associated pictogram
Oil pressure fault: Indicates that the oil pressure is incorrect.
Associated pictogram
Engine temperature fault:
temperature is too high.
Indicates
that
the
engine
Associated pictogram
Non-starting fault: Indicates that there have been three
consecutive unsuccessful starting attempts.
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Associated pictogram
Overspeed fault: Indicates an excessive generating set running
speed.
Associated pictogram
Low fuel level fault: Indicates the need to top up the fuel.
List of alarms associated with a pictogram
Associated pictogram
Low fuel level alarm: Indicates the need to fill up with fuel.
Associated pictogram
"Alternator charging fault" alarm indicates a problem affecting the
alternator charging rate.
44/256
6.3. Generator set with TELYS control panel
6.3.1 Control panel presentation
6.3.1.1. View of the front panel
9
13
6
7
9
1
5
2
12
3
9
9
8
10
11
4
Diagram 6.4 - View of the front panel
1
2
3
4
5
6
7
8
9
10
11
12
13
Emergency stop button (AU) for switching off the generating set in the event of a fault which could endanger personnel or damage
equipment.
Key switch for switching the module on/off.
Electronic board protection fuse.
Scrolling and selection wheel for scrolling through the menus and screens and selecting items simply by pressing the wheel.
STOP button, press to switch off the generating set.
START button, press to switch on the generating set.
Power ON LEDs and alarm/fault warning LEDs.
Location of USB ports.
Mounting bolt.
LCD for displaying alarms and faults, operating statuses, electrical and mechanical quantities.
ESC button: for returning to the previous selection and for default RESET function.4
MENU button for accessing the menus.
Lighting for the emergency stop button.
45/256
1
2
3
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).
1
2
3
Diagram 6.6 – Close-up of USB ports
1
2
3
USB key connection (HOST): file transfer between USB key and TELYS and vice versa.
Connection for microcomputer (DEVICE):
¾ file transfer between PC and TELYS and vice versa,
¾ main module power supply.
Protective cover.
46/256
6.3.1.2. Description of the screen
The screen is backlit and requires no contrast adjustments. This screen is divided into 4 zones.
n
p
o
SERIAL No.: 08030010000
SOFTWARE: 5.3.5
NOMINAL VOLTAGE: 400V
FREQUENCY: 50Hz
NOMINAL KW: 320kW
EARTH 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 the
generating set will depend on the equipment level of each generating set. Certain screens may therefore not be present.
47/256
6.3.1.3. Description of the pictograms in zone 1
Pictograms in zone 1
Pictograms
Display
Activation conditions
TELYS in manual mode (MANU)
Fixed
"MANU" Mode
Flashing
For 5 seconds when switching from AUTO mode
to MANU mode
Fixed
TELYS in automatic mode (AUTO)
Flashing
For 5 seconds when switching from MANU
mode to AUTO mode
Flashing
Generating set in start-up phase
Fixed
Generating set started
Fixed
Generating
frequency)
Flashing (appearance of constant movement
from left to right)
The generating set is powering the installation
Fixed
The installation is supplied
"AUTO" Mode
Not used
Not used
48/256
set
stabilised
(voltage
and
6.3.1.4. Description of the pictograms in zone 2
Alarm and fault pictograms in zone 2
All the pictograms in this zone are activated when TELYS is initialised.
Data displayed
Fuel level indicator
Alarm / Fault
low fuel level
Alarm
Low level
fault
Min battery
voltage
(flashing)
Alarm / Fault
high fuel level
High level
fault alarm
Coolant level / temperature indicator
Alarm
High
temperature
fault
Battery
Max
battery
voltage (flashing)
No preheating
fault
alarm
Battery charge indicator
(flashing bars)
Oil pressure / temperature indicator
Oil pressure
Alarm / Fault
High or low oil level
Alarm /
Fault
High or low oil
temperature
Alarm / Fault
Emergency stop
Emergency stop fault
Overload or short circuit
Tripping of circuit breaker following an overload
or short circuit
Engine speed
Underspeed fault
Overspeed fault
49/256
Non-starting fault
6.3.1.5. Description of the pictograms in zone 3
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
Screen
no.
Pictograms
Data displayed
Fuel Level Indicator
Indication of Temperature of High Temperature
coolant (HT) (units according to settings menu)
P1
Indication of Battery Voltage
Indication of Oil Temperature (units according to
settings menu)
Generating set start-up or generating set started or generating set switching off in progress
Screen
no.
Pictograms
Data displayed
Engine Speed Indication
Indication of Temperature of High Temperature
coolant (units according to settings menu)
P2
Indication of Oil Pressure (units according to settings)
Indication of Oil Temperature (units according to
settings menu)
Generating set started
Screen
no.
Pictograms
Data displayed
Fuel Level Indicator
P3
Default
screen in
operation
Alternator composite Voltage Indicator
Total Active Power Indicator
Alternator Frequency Indicator
U12 Alternator composite Voltage Indicator
U23 Alternator composite Voltage Indicator
P4
U31 Alternator composite Voltage Indicator
Alternator Frequency Indicator
50/256
Screen
no.
Pictograms
Data displayed
V1 Alternator single Voltage Indicator
V2 Alternator single Voltage Indicator
P5
V3 Alternator single Voltage Indicator
Alternator Frequency Indicator
U12 Alternator composite Voltage Indicator
V2 Alternator single Voltage Indicator
P6
V1 Alternator single Voltage Indicator
Alternator Frequency Indicator
V1 Alternator single Voltage Indicator
P7
Single phase Alternator current indicator
Alternator Frequency Indicator
Single phase Alternator current indicator
Two phase Alternator current indicator
P8
Three phase Alternator current indicator
Neutral Alternator current indicator
Total Active Power Indicator
Total Reactive Power Indicator
P9
Total Effective Power Indicator
Total Power Factor Indicator (lagging or leading)
Fuel Level Indicator
P10
Indication of Battery Voltage
Indication of Battery Amps
51/256
Screen order of appearance according to network type with the generating set on.
Type of network
Order of appearance
1
2
3
4
5
6
7
3P+N
P3
P4
P5
P8
P9
P2
P10
3P
P3
P4
P8
P9
P2
P10
2P+N
P3
P6
P8
P9
P2
P10
1P+N
P3
P7
P9
P2
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:
Initialisation of TELYS
Screen no.
Screen
Data displayed
Initialisation of TELYS when the power is switched
on and/or when loading a configuration
G1
G2
SERIAL No.: 08030010000
SOFTWARE: 6.1.0
NOMINAL VOLTAGE: 400V
FREQUENCY: 50Hz
NOMINAL KW: 320kW
EARTH SYSTEM: TNS
Generating set serial no.
Software version of TELYS
Alternator Nominal Voltage
Alternator Nominal Frequency
Nominal Active Output
Neutral Point
Bar graph indicating the display delay of the screen
Generating set stopped
Screen
no.
Screen
Data displayed
OPERATION
MANUAL
G3
Operating mode - generating set in Manual Mode
ready to start
Date and time (depending on settings)
Press START
to start
24/08/2005
13:12
52/256
Screen
no.
Screen
Data displayed
OPERATION
AUTO
G4
Operating mode - generating set in Auto Mode
ready to start
Date and time (depending on settings)
WARNING
START-UP POSSIBLE
IMMEDIATELY
24/08/2005
13:12
WARNING
G5
Operating mode - generating set in Auto Mode with
programmed start
Countdown to micro disconnection delay or EJP
notice delay (for France only)
Date and time (depending on settings)
AUTOMATIC Start
19 min 30 sec
24/08/2005
13:12
Generating set start-up
Screen
no.
G6
Screen
Data displayed
START-UP
IN PROGRESS
24/08/2005
Operating phase - generating set in starting phase
Date and time (depending on settings)
13:12
AIR PREHEATING
Operating phase - air preheating prior to starting
generating set
Countdown for air preheating delay
Date and time (depending on settings)
G7
10 seconds
24/08/2005
13:12
53/256
Generating set started
Screen
no.
Screen
Data displayed
AVAILABLE POWER
G8
Default
screen
Operating phase – generating set in operation –
stable voltage and frequency
Available power
Date and time (depending on settings)
75%
24/08/2005
13:12
AUTOMATIC STOP
IN PROGRESS
G9
LOAD SUPPRESSION
1 min 30 sec
24/08/2005
13:12
AUTOMATIC STOP
IN PROGRESS
G 10
COOLING DOWN
1 min 30 sec
24/08/2005
13:14
Operating mode - operation in Auto Mode
Opening of power supply device (motorised circuit
breaker or source changeover switch controlled by
TELYS)
Countdown for the mains return delay OR the load
test delay
Date and time (depending on settings)
Operating mode - operation in Auto Mode
Generation set cooling in progress
Countdown for Engine Stop delay (cooling) OR
Gradual Stop delay (Coolant temperature) OR
Overload Gradual Stop delay OR OFF load test
delay
Date and time (depending on settings)
Generating setstop
Screen
no.
G 11
Screen
Data displayed
OFF
IN PROGRESS
24/08/2005
Generating set stop in progress
Date and time (depending on settings)
13:16
54/256
Operating mode changeover (switching from Manual Mode to Auto Mode following auto start demand)
Screen
no.
G 12
Screen
Data displayed
Start Demand
AUTO
Do you wish to change
to Auto Mode?
WARNING
Immediate start
OK
Operating mode - operation in Manual Mode
AUTOMATIC start demand
Esc
Generating set stop request due to fault or by pressing STOP in Auto Mode
Screen
no.
Screen
Data displayed
Manual Mode
activated
G 13
Operating mode - operation in Auto Mode
(generating set in operation)
Warning message for switching to Manual Mode
after the STOP button has been pressed or a fault
has appeared
Do you wish to change
to AUTO mode?
OK
Esc
55/256
6.3.2 Starting
Check that the generating set circuit breaker has triggered.
Danger
n Connect 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 <> AUTO
12 CONTROL LOAD
13 TEST GENERATING SET
14 PROGRAMS
15 TEST LAMPS
12
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 voltage
s Press START:
AVAILABLE POWER
AIR PREHEATING
START-UP
IN PROGRESS
100.0%
10 seconds
13:12
ƒ If the engine is equipped with an
air preheating system, there is a
delay (adjustable) before the
engine
starts
(preheating
activation period).
ƒ 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).
24/08/2005
13:12
Warning: the number of successive
and automatic starting attempts is
limited to 3.
The following pictogram will flash
24/08/2005
13:12
The following pictogram is displayed
The following information is displayed
Speed of rotation
Coolant temperature
Oil pressure
Oil Temperature
56/256
Options
24/08/2005
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 the
associated indicator, if present
(example)
¾ message
on
graphic
FAULT
ALARM
Low Fuel Level
25/12/05 15:30
OK=HELP
57/256
display
(example)
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".
In conjunction with this LED:
¾ a flashing pictogram appears on the LCD screen
representing the circuit affected by the fault and the
associated indicator, if present
(example)
¾ message
on
graphic
display
(example)
FAULT
FAULT
Oil 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. Activation of an alarm or fault
The appearance of an alarm or a fault causes the corresponding screen to be displayed (examples below)
FAULT
FAULT
ALARM
Low coolant Level
06/10/06 10:30
FAULT
Emergency Stop
06/10/06 15:30
OK=HELP
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 level
fuel
Esc=EXIT
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.
58/256
6.3.4.3. Activation of an alarm and a fault
The appearance of an alarm and a fault causes:
¾ The yellow and red LEDs to flash
¾ the related screen to be displayed (example below)
FAULTS 1/2
FAULT
Emergency Stop
25/12/05 15:30
Esc=RESET
If several faults are present, the number of faults is
displayed at the top of the screen.
OK=LIST
The faults list can be accessed by pressing OK (of the scrolling and selection wheel) (examples below)
FAULTS
1/2
FAULT 25/12/05 15:30
Emergency Stop
ALARM 25/12/05 15:30
Low Fuel Level
12
OK=HELP
Press Esc to return to the previous screen.
Press OK to go to the HELP screen (help on the
highlighted fault)
Use the scrolling and selection wheel to scroll through
the list of faults.
Esc
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.
59/256
6.3.4.4. Engine fault codes display
Certain alarms and engine faults generate specific fault codes. These codes are standardised according to the J1939 and/or J1587
standards, except for MTU engines that have a specific transmission protocol (see appendix, if applicable).
Terminology used by the SAE CAN J1939 standard
SPN: Suspect Parameter
Number
This represents the system or component at fault, for example: SPN 100, indicates an oil pressure
problem 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 equipment
fault.
Terminology used by VOLVO
SID: System Identifier
PID: Parameter Identifier
This term, used in the J1587 standard, has an equivalent in the J1939 standard (SPN).
However, this term corresponds, more particularly, to an assembly of components, for example, the
injection system.
This term, used in the J1587 standard, has an equivalent in the J1939 standard (SPN).
However, this term corresponds, more particularly, to a specific component, for example, a sensor.
PPID: Parameter Identifier
This term, used in the J1587 standard, has an equivalent in the J1939 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 equipment
fault. 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 Parameter
Number
This represents the system or component at fault, for example: SPN 100, indicates an oil pressure
problem 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 equipment
fault.
60/256
Terminology used by MTU
The MDEC general system faults are indicated on the equipment in the following way: fault code
numbers (generated by the ECU - Engine control unit).
Displaying faults
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 the
code. The checking and maintenance operations to
carry out in order to solve the fault are included in the
user and maintenance manuals of the engines
supplied with the generating set documentation.
For JOHN DEERE (JD), PERKINS (PE) and VOLVO (VO) engines, the codes displayed are SPN and FMI codes.
6.3.4.5. Horn reset
Depending on the settings made (menu 363 - HORN), the activation of an alarm and/or a fault leads to the horn
sounding and the following screen appearing:
HORN STOP
PRESS OK
25/12/2005
This screen will display first any messages relating to
the alarms and faults that appear as soon as OK is
pressed.
15:30
61/256
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.
If the generating set is used in extreme conditions, shorter intervals between maintenance procedures should be observed
These 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
OPERATION
Inspect the engine compartment
Check the engine
oil/fuel/refrigerant levels
Check the air filter clogging
indicator (a)
Drain the water and sediment
from the fuel filter(s)
Drain the engine oil and replace
the filter (b)
Replace the fuel filter element(s)
Check the tension of the belts
and the automatic tensioner (c)
Check the valve clearances and
adjust if necessary (d)
Clean the breather
Check the air inlet circuit (with
hoses and unions)
Check
the
cooling
circuit
pressure
Check the damper (6 cyl.) (e)
Check the engine speed and the
regulator droop
Drain and flush the cooling
circuit (f)
Clean the air filter element (a)
Check the thermostat and the
injectors (g)
10 h /
1 day
500 hours
1000 hrs /
every year
2000 hrs /
every
2 years
2500 hrs /
every
3 years
As required
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
(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 John Deere COOL GARD coolant, drain and flush the cooling circuit every 2500 hours/every 3 years. In all other cases, carry
out this operation every 2000 hours/every 2 years
(g) Operation to be carried out by one of our agents. Replace the injectors every 5000 hours and the thermostat every 10000 hours. If
in 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.
62/256
8. Battery
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 explosion).
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 positive lead (+) first.
Charge the battery in a well-ventilated place, with all the filler 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 off 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.
Danger
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 to
use 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 servicing
9 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
1.27
1.25
1.20
1.19
1.13
Charge status
100%
80%
60%
40%
20%
Voltage when idle
Above 12.60 V
12.54 V
12.36 V
12.18 V
Under 11.88 V
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From 50 % recharge
Risk of sulphation
Unusable
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. This
deposit reduces the active surface of the plates and increases their internal resistance.
A discharged battery may become irreparably damaged. Recharge it immediately
Important
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 batteries
9 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 A
9 Charge status: 50% (acid density 1.21/voltage when idle 12.30V)
9 The battery should be recharged to 30Ah
9 Charge factor: 1.2
9 Ah x 1.2 = 36 Ah to be charged
9 Charging current: 6A approximately 6 hours charging required.
Recharging is complete when the battery voltage and the acid density stop increasing.
th
→ The charging current must always be 1/10 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 to
handle spontaneous battery discharge.
65/256
8.5. Faults and remedies
Fault observed
The acid heats up when a new battery is
filled
The acid escapes through the filler holes
Acid level too low
Acid level too low
Incorrect operation from start-up
Acid density too high
Starting problems
Starting test incorrect
Battery terminals melted
Probable origin
Incorrect composition
Incorrect storage
Prolonged storage in a damp place
Overfilled battery
Battery tray not leaktight
Excessive charge voltage leading to a
significant accumulation of gas
- Insufficient charge
- Short circuit in the power circuit
- Consumption fault
-
- The battery has been filled with acid
instead of battery fluid
-
Battery empty
Battery exhausted or faulty
Capacity too low
Battery sulphated
Incorrect electrical connection
Battery cabling incorrect
-
Measures or observations
Cool
Load
Check the acid density
Reduce the battery fluid level
Replace the battery
Check the charger and repair
necessary
if
- Recharge
- Check the electrical installation
- Reduce the acid level by filling with
distilled water. Repeat the operation if
necessary
- Recharge the battery
- Fit a new battery
- Tighten the ends of the battery cables,
or replace them if necessary
One or two cells release a lot of gas at
high 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. for
the recommended use
- It is recommended to charge the battery
using a regulator
High water consumption
The battery explodes
Overload
Charging voltage too high
Spark after battery charging
Short circuit
Connection or disconnection during
charging
- Internal fault and low electrolyte level
-
66/256
- Check the charger (voltage regulator)
- Replace the battery
- Ventilate well
9. Appendix
9.1. Appendix A – Engine user and maintenance manual
67/256
68/256
User guide and maintenance manual
JOHN DEERE
Engine
3029DF & TF120
3029TFS & HFS70 (TF & HF270)
4045TFS70 (TF270)
4045HFS72 (HF275)
4045HFS73 (HF279)
4045HFS80(HF280)
4045HFS82 & 83 (HF285)
6068HFS72 (HF275)
6068HFS73 (HF279)
6068HFS76 & 77 (HF475)
6068HFS82 & 83 (HF285)
6068HFS89 (HF485)
OMCD15564
01/02/2007
33522039401_2
OMCD15564
01/06/2008
33522039401_3_1
69/256
70/256
Power Units for
Generator Sets
Stage II and
Non-Certified Engines
(Saran-Built)
OPERATOR’S MANUAL
Power Units for Generator Sets
Stage II and Non-Certified Engines
(Saran-Built)
OMCD16564 Issue F8 (ANGLAIS)
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
If this product contains a gasoline engine:
WARNING
The engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth
defects or other reproductive harm.
The State of California requires the above two warnings.
John Deere Usine De Saran
(This manual replaces OMCD16564 B7)
European Version
Printed in Germany
71/256
Introduction
Foreword
THIS MANUAL COVERS the following engines for
generator sets:
Non Emission Certified Engines (Mechanical Fuel System)
CD3029DF128
CD3029TF158
CD4039DF008
CD4039TF008
CD4045DF158
CD4045HF158
CD4045TF158
CD4045TF258
CD6068HF158
CD6068HF258
CD6068TF158
CD6068TF258
Emission Certified Engines (Stage II according to Directive
97/68/EC)
CD3029HFS70 (Mechanical Fuel System)
CD3029HFU70 (Mechanical Fuel System)
CD3029TFS70 (Mechanical Fuel System)
CD3029TFU70 (Mechanical Fuel System)
CD4045HFS72 (DE10 Fuel System)
CD4045HFS73 (HPCR System, 2-Valve Head)
CD4045HFS80 (Mechanical Fuel System)
CD4045HFS82 (HPCR System, 2-Valve Head)
CD4045HFS83 (HPCR System, 2-Valve Head)
CD4045HFU72 (DE10 Fuel System)
CD4045HFU79 (HPCR System, 2-Valve Head)
CD4045TFU70 (Mechanical Fuel System)
CD6068HFS72 (DE10 Fuel System)
CD6068HFS73 (HPCR System, 2-Valve Head)
CD6068HFS76 (HPCR System, 4-Valve Head)
CD6068HFS77 (HPCR System, 4-Valve Head)
CD6068HFS82 (HPCR System, 2-Valve Head)
CD6068HFS83 (HPCR System, 2-Valve Head)
CD6068HFS89 (HPCR System, 4-Valve Head)
CD6068HFU72 (DE10 Fuel System)
CD6068HFU74 (HPCR System, 4-Valve Head)
CD6068HFU79 (HPCR System, 2-Valve Head)
READ THIS MANUAL carefully to learn how to operate
and service your engine correctly. Failure to do so
could result in personal injury or equipment damage.
THIS MANUAL SHOULD BE CONSIDERED a
permanent part of your engine and should remain with
the engine when you sell it.
MEASUREMENTS IN THIS MANUAL are given in
metric. Use only correct replacement parts and
fasteners. Metric and inch fasteners may require a
specific metric or inch wrench.
WRITE ENGINE SERIAL NUMBERS and option codes
in the spaces indicated in the Serial Number Section.
Accurately record all the numbers. Your dealer also
needs these numbers when you order parts. File the
identification numbers in a secure place off the engine
or machine.
RIGHT-HAND AND LEFT-HAND sides are determined
by standing at the drive or flywheel end (rear) of the
engine and facing toward the front of the engine.
SETTING FUEL DELIVERY beyond published factory
specifications or otherwise overpowering will result in
loss of warranty protection for this engine.
Information relative to emissions regulations
Depending on final destination, this engine can meet
the emissions regulations according to the US
Environmental Protection Agency (EPA), California Air
Resources Board (CARB) and for Europe, the
Directive 97/68/EC relating the measures against the
emissions of gaseous and particulates pollutants from
internal combustion engines. In this case an emission
label is stuck on the engine.
Emission regulations prohibit tampering with the
emission-related components listed below which would
render that component inoperative or to make any
adjustment on the engine beyond published
specifications. It is also illegal to install a part or
component where the principal effect of that
component is to bypass, defeat, or render inoperative
any engine component or device which would affect
the engine conformance to the emissions regulations.
To summarize, it is illegal to do anything except return
the engine to its original published specifications.
DPSG,CD03523,1 –19–05JUN08–1/2
061208
PN=2
72/256
Introduction
List of emission-related components:
- Fuel injection pump
- Intake manifold
- Turbocharger
- Charge air cooling system
- Piston
CALIFORNIA PROPOSITION 65 WARNING
Diesel engine exhaust and some of its constituents are known to
the State of California to cause cancer,
birth defects and other reproductive harm.
DPSG,CD03523,1 –19–05JUN08–2/2
061208
PN=3
73/256
Introduction
061208
PN=4
74/256
Contents
Page
Page
Identification Views
Identification views . . . . . . . . . . . . . . . . . . . . . . . 01-1
Diesel Engine Break-In Oil . . . . . . . . . . . . . . . . .
Diesel Engine Oil . . . . . . . . . . . . . . . . . . . . . . . .
Lubricant Storage . . . . . . . . . . . . . . . . . . . . . . . .
Mixing of Lubricants . . . . . . . . . . . . . . . . . . . . . .
Diesel Engine Coolant . . . . . . . . . . . . . . . . . . . .
Operating in Warm Temperature Climates . . . . .
Maintenance Records
Using maintenance records . . . . . . . . . . . . . . . . 02-1
100 Hours of operation. . . . . . . . . . . . . . . . . . . . 02-1
500 Hours of operation. . . . . . . . . . . . . . . . . . . . 02-2
1000 Hours of operation . . . . . . . . . . . . . . . . . . . 02-2
1500 Hours of operation . . . . . . . . . . . . . . . . . . . 02-3
2000 Hours of operation . . . . . . . . . . . . . . . . . . . 02-3
2500 Hours of operation . . . . . . . . . . . . . . . . . . . 02-4
3000 Hours of operation . . . . . . . . . . . . . . . . . . . 02-4
3500 Hours of operation . . . . . . . . . . . . . . . . . . . 02-5
4000 Hours of operation . . . . . . . . . . . . . . . . . . . 02-5
4500 Hours of operation . . . . . . . . . . . . . . . . . . . 02-6
5000 Hours of operation . . . . . . . . . . . . . . . . . . . 02-6
5500 Hours of operation . . . . . . . . . . . . . . . . . . . 02-7
6000 Hours of operation . . . . . . . . . . . . . . . . . . . 02-7
6500 Hours of operation . . . . . . . . . . . . . . . . . . . 02-8
7000 Hours of operation . . . . . . . . . . . . . . . . . . . 02-8
7500 Hours of operation . . . . . . . . . . . . . . . . . . . 02-9
8000 Hours of operation . . . . . . . . . . . . . . . . . . . 02-9
8500 Hours of operation . . . . . . . . . . . . . . . . . . 02-10
9000 Hours of operation . . . . . . . . . . . . . . . . . . 02-10
9500 Hours of operation . . . . . . . . . . . . . . . . . . 02-11
10000 Hours of operation . . . . . . . . . . . . . . . . . 02-11
Serial Numbers
POWERTech label . . . . . . . . . . . . . . . . . . . . . .
Engine serial number plate. . . . . . . . . . . . . . . . .
Record engine serial number . . . . . . . . . . . . . . .
Engine option codes . . . . . . . . . . . . . . . . . . . . . .
Record fuel injection pump model number . . . . .
Record Engine Control Unit (ECU) Serial
Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Record High-Pressure Fuel Pump Model
Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-3
10-4
10-5
10-5
10-6
10-6
Operating the Engine
Using Diagnostic Gauge to Access
Engine Information (Optional equipment) . . . . 15-1
Main Menu Navigation . . . . . . . . . . . . . . . . . . . . 15-2
Engine Configuration Data . . . . . . . . . . . . . . . . . 15-4
Accessing Stored Trouble Codes . . . . . . . . . . . . 15-6
Accessing Active Trouble Codes . . . . . . . . . . . . 15-8
Engine Shutdown Codes . . . . . . . . . . . . . . . . . 15-10
Adjusting Backlighting. . . . . . . . . . . . . . . . . . . . 15-11
Adjusting Contrast . . . . . . . . . . . . . . . . . . . . . . 15-13
Selecting Units Of Measurement . . . . . . . . . . . 15-15
Setup 1-Up Display . . . . . . . . . . . . . . . . . . . . . 15-18
Setup 4-Up Display . . . . . . . . . . . . . . . . . . . . . 15-24
Break-in period . . . . . . . . . . . . . . . . . . . . . . . . . 15-29
Starting the engine . . . . . . . . . . . . . . . . . . . . . . 15-30
Cold weather operation . . . . . . . . . . . . . . . . . . 15-30
Using a booster battery or charger . . . . . . . . . . 15-33
Engine operation . . . . . . . . . . . . . . . . . . . . . . . 15-34
Standby power units . . . . . . . . . . . . . . . . . . . . . 15-34
Stopping the engine . . . . . . . . . . . . . . . . . . . . . 15-35
Changing Generator Frequency . . . . . . . . . . . . 15-35
03-1
03-1
03-2
03-3
03-5
Maintenance
Observe service intervals . . . . . . . . . . . . . . . . . . 20-1
Use correct fuels, lubricants and coolant . . . . . . 20-1
Maintenance interval chart . . . . . . . . . . . . . . . . . 20-2
03-5
Maintenance/Daily or every 10 hours
Daily prestarting checks . . . . . . . . . . . . . . . . . . . 25-1
03-5
Maintenance/500 hours
Changing engine oil and filter . . . . . . . . . . . . . . . 30-1
Replacing fuel filter element(s) . . . . . . . . . . . . . . 30-4
Checking belt (3029 and 4039 Engines) . . . . . . . 30-6
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-1
Fuels, Lubricants and Coolant
Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Handling and Storing Diesel Fuel . . . . . . . . . . . . 10-2
Continued on next page
All information, illustrations and specifications in this manual are based on
the latest information available at the time of publication. The right is
reserved to make changes at any time without notice.
COPYRIGHT  2008
DEERE & COMPANY
European Office Mannheim
All rights reserved
A John Deere ILLUSTRUCTION Manual
Previous Editions
Copyright  2007
i
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PN=1
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Contents
Page
Page
Checking belt (4045 and 6068 Engines with
manual tensioner) . . . . . . . . . . . . . . . . . . . . . . 30-7
Storage
Engine storage guidelines . . . . . . . . . . . . . . . . . 60-1
Preparing engine for long term storage . . . . . . . 60-1
Removing engine from long term storage . . . . . . 60-2
Maintenance/1000 hours/1 year
Cleaning crankcase vent tube . . . . . . . . . . . . . .
Checking air intake system. . . . . . . . . . . . . . . . .
Checking automatic belt tensioner (4045
and 6068 Engines) . . . . . . . . . . . . . . . . . . . . .
Check and adjust engine valve
clearance (3029 and 4039 Engines) . . . . . . . .
Pressure testing cooling system . . . . . . . . . . . . .
Maintenance/2000 hours/2 years
Check and adjust engine valve
clearance (4045 and 6068 Engines) . . . . . . . .
Checking engine speed (Mechanical fuel
system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjust speed droop governor (Mechanical
fuel system) . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking crankshaft vibration damper
(6-CYLINDER ENGINE ONLY) . . . . . . . . . . . .
35-1
35-1
Specifications
General engine pack specifications
(Non-Emission Certified Engines) . . . . . . . . . . 65-1
General engine pack specifications
(Stage II Emission Certified Engines) . . . . . . . 65-4
Unified Inch Bolt and Screw Torque Values . . . . 65-9
Metric Bolt and Screw Torque Values. . . . . . . . 65-10
35-2
35-4
35-6
40-1
40-3
40-3
40-4
Maintenance/2500 hours/3 years
Drain and flush cooling system. . . . . . . . . . . . . . 45-1
Maintenance/As required
Additional service information . . . . . . . . . . . . . . .
Do not modify fuel system . . . . . . . . . . . . . . . . .
Clean or replace air filter (one-piece) . . . . . . . . .
Clean or replace air filter element. . . . . . . . . . . .
Replacing fan and alternator belt (4045 and
6068 Engines). . . . . . . . . . . . . . . . . . . . . . . . .
Bleeding the fuel system . . . . . . . . . . . . . . . . . .
50-1
50-2
50-3
50-4
50-5
50-6
Troubleshooting
General troubleshooting information . . . . . . . . . . 55-1
Engine Wiring Layout (Electronic Fuel
System With Stanadyne DE10 Injection
Pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-2
Engine Wiring Layout (Electronic Fuel
System With Denso High Pressure Common
Rail) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-3
Engine troubleshooting . . . . . . . . . . . . . . . . . . . . 55-4
Electrical troubleshooting . . . . . . . . . . . . . . . . . . 55-9
Displaying Of Diagnostic Trouble Codes
(DTCs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-10
Using blink code method for retrieving
Diagnostic Trouble Codes (DTC’s) . . . . . . . . 55-11
Using diagnostic gauge for retrieving
Diagnostic Trouble Codes (DTC’s) . . . . . . . . 55-12
Listing of Diagnostic Trouble Codes (DTCs) . . . 55-13
Intermittent Fault Diagnostics (With
Electronic Controls). . . . . . . . . . . . . . . . . . . . 55-15
ii
061208
PN=2
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Identification Views
CD30840
–UN–10JAN03
Identification views
3029DF128
Continued on next page
01-1
DPSG,CD03523,3 –19–22JAN07–1/3
061208
PN=7
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CD30841
–UN–10JAN03
Identification Views
4045HF158
Continued on next page
01-2
DPSG,CD03523,3 –19–22JAN07–2/3
061208
PN=8
78/256
CD30842
–UN–10JAN03
Identification Views
6068HF258
DPSG,CD03523,3 –19–22JAN07–3/3
01-3
061208
PN=9
79/256
Maintenance Records
Using maintenance records
To obtain the best performance, economy and service
life from your engine, ensure service is carried out
according to this present manual and recorded in the
following pages. It is recommended that your engine
Distributor or your Dealer carry out this service work
and stamp the appropriate case.
Keeping an accurate account of all service performed
on your engine will give more value to the machine
when resell it.
John Deere oils and coolants have been formulated to
give maximum protection and performance to your
engine. We recommend only genuine John Deere
service products and replacement parts.
To protect your rights under the warranty ensure all
scheduled services are carried out and recorded. If
your engine is covered by extended warranty, it is
important to maintain this record for the duration of the
warranty.
DPSG,CD03523,6 –19–22JAN07–1/1
100 Hours of operation
❒ Engine oil, drain
❒ Engine oil filter, replace
❒ Hose connections, check
Number of hours:
Observation:
Dealer or distributor stamp
Date:
Job done by:
DPSG,CD03523,7 –19–22JAN07–1/1
02-1
061208
PN=10
80/256
Maintenance Records
500 Hours of operation
❒ Engine oil, drain
❒ Engine oil filter, replace
❒ Fuel filter, replace
❒ Belt, check tension and wear (300-Series and POWERTech with
manual tensioner)
❒ Valve clearance, adjust (300-Series)
Number of hours:
Observation:
Dealer or distributor stamp
Date:
Job done by:
DPSG,CD03523,8 –19–22JAN07–1/1
1000 Hours of operation
❒ Engine oil, drain
❒ Air intake system, check
❒ Engine oil filter, replace
❒ Fuel filter, replace
❒ Check belt and tensioning system
❒ Crankcase vent tube, clean
Number of hours:
Observation:
Dealer or distributor stamp
Date:
Job done by:
DPSG,CD03523,9 –19–22JAN07–1/1
02-2
061208
PN=11
81/256
Maintenance Records
1500 Hours of operation
❒ Engine oil, drain
❒ Engine oil filter, replace
❒ Fuel filter, replace
❒ Belt, check tension and wear (300-Series and POWERTech with
manual tensioner)
❒ Valve clearance, adjust (300-Series)
Number of hours:
Observation:
Dealer or distributor stamp
Date:
Job done by:
DPSG,CD03523,10 –19–22JAN07–1/1
2000 Hours of operation
❒ Engine oil, drain
❒ Cooling system, drain and flush (if COOL-GARD is not used)
❒ Engine oil filter, replace
❒ Valve clearance, adjust (POWERTech)
❒ Fuel filter, replace
❒ Air intake system, check
❒ Check belt and tensioning system
❒ Vibration damper, check
❒ Crankcase vent tube, clean
Number of hours:
Observation:
Dealer or distributor stamp
Date:
Job done by:
DPSG,CD03523,59 –19–22JAN07–1/1
02-3
061208
PN=12
82/256
Maintenance Records
2500 Hours of operation
❒ Engine oil, drain
❒ Cooling system, drain and flush (if COOL-GARD is used)
❒ Engine oil filter, replace
❒ Fuel filter, replace
❒ Belt, check tension and wear (300-Series and POWERTech with
manual tensioner)
❒ Valve clearance, adjust (300-Series)
Number of hours:
Observation:
Dealer or distributor stamp
Date:
Job done by:
DPSG,CD03523,60 –19–22JAN07–1/1
3000 Hours of operation
❒ Engine oil, drain
❒ Air intake system, check
❒ Engine oil filter, replace
❒ Fuel filter, replace
❒ Check belt and tensioning system
❒ Crankcase vent tube, clean
Number of hours:
Observation:
Dealer or distributor stamp
Date:
Job done by:
DPSG,CD03523,61 –19–22JAN07–1/1
02-4
061208
PN=13
83/256
Maintenance Records
3500 Hours of operation
❒ Engine oil, drain
❒ Engine oil filter, replace
❒ Fuel filter, replace
❒ Belt, check tension and wear (300-Series and POWERTech with
manual tensioner)
❒ Valve clearance, adjust (300-Series)
Number of hours:
Observation:
Dealer or distributor stamp
Date:
Job done by:
DPSG,CD03523,62 –19–22JAN07–1/1
4000 Hours of operation
❒ Engine oil, drain
❒ Cooling system, drain and flush (if COOL-GARD is not used)
❒ Engine oil filter, replace
❒ Valve clearance, adjust (POWERTech)
❒ Fuel filter, replace
❒ Air intake system, check
❒ Check belt and tensioning system
❒ Vibration damper, check
❒ Crankcase vent tube, clean
Number of hours:
Observation:
Dealer or distributor stamp
Date:
Job done by:
DPSG,CD03523,63 –19–22JAN07–1/1
02-5
061208
PN=14
84/256
Maintenance Records
4500 Hours of operation
❒ Engine oil, drain
❒ Vibration damper, replace (6 cyl.)
❒ Fuel filter, replace
❒ Belt, check tension and wear (300-Series and POWERTech with
manual tensioner)
❒ Valve clearance, adjust (300-Series)
Number of hours:
Observation:
Dealer or distributor stamp
Date:
Job done by:
DPSG,CD03523,64 –19–22JAN07–1/1
5000 Hours of operation
❒ Engine oil, drain
❒ Injection nozzles, replace
❒ Engine oil filter, replace
❒ Air intake system, check
❒ Fuel filter, replace
❒ Cooling system, drain and flush (if COOL-GARD is used)
❒ Check belt and tensioning system
❒ Crankcase vent tube, clean
Number of hours:
Observation:
Dealer or distributor stamp
Date:
Job done by:
DPSG,CD03523,65 –19–22JAN07–1/1
02-6
061208
PN=15
85/256
Maintenance Records
5500 Hours of operation
❒ Engine oil, drain
❒ Engine oil filter, replace
❒ Fuel filter, replace
❒ Belt, check tension and wear (300-Series and POWERTech with
manual tensioner)
❒ Valve clearance, adjust (300-Series)
Number of hours:
Observation:
Dealer or distributor stamp
Date:
Job done by:
DPSG,CD03523,66 –19–22JAN07–1/1
6000 Hours of operation
❒ Engine oil, drain
❒ Cooling system, drain and flush (if COOL-GARD is not used)
❒ Engine oil filter, replace
❒ Valve clearance, adjust (POWERTech)
❒ Fuel filter, replace
❒ Air intake system, check
❒ Check belt and tensioning system
❒ Vibration damper, check
❒ Crankcase vent tube, clean
Number of hours:
Observation:
Dealer or distributor stamp
Date:
Job done by:
DPSG,CD03523,67 –19–22JAN07–1/1
02-7
061208
PN=16
86/256
Maintenance Records
6500 Hours of operation
❒ Engine oil, drain
❒ Engine oil filter, replace
❒ Fuel filter, replace
❒ Belt, check tension and wear (300-Series and POWERTech with
manual tensioner)
❒ Valve clearance, adjust (300-Series)
Number of hours:
Observation:
Dealer or distributor stamp
Date:
Job done by:
DPSG,CD03523,68 –19–22JAN07–1/1
7000 Hours of operation
❒ Engine oil, drain
❒ Air intake system, check
❒ Engine oil filter, replace
❒ Fuel filter, replace
❒ Check belt and tensioning system
❒ Crankcase vent tube, clean
Number of hours:
Observation:
Dealer or distributor stamp
Date:
Job done by:
DPSG,CD03523,69 –19–22JAN07–1/1
02-8
061208
PN=17
87/256
Maintenance Records
7500 Hours of operation
❒ Engine oil, drain
❒ Cooling system, drain and flush (if COOL-GARD is used)
❒ Engine oil filter, replace
❒ Fuel filter, replace
❒ Belt, check tension and wear (300-Series and POWERTech with
manual tensioner)
❒ Valve clearance, adjust (300-Series)
Number of hours:
Observation:
Dealer or distributor stamp
Date:
Job done by:
DPSG,CD03523,70 –19–22JAN07–1/1
8000 Hours of operation
❒ Engine oil, drain
❒ Cooling system, drain and flush (if COOL-GARD is not used)
❒ Engine oil filter, replace
❒ Valve clearance, adjust (POWERTech)
❒ Fuel filter, replace
❒ Air intake system, check
❒ Check belt and tensioning system
❒ Vibration damper, check
❒ Crankcase vent tube, clean
Number of hours:
Observation:
Dealer or distributor stamp
Date:
Job done by:
DPSG,CD03523,71 –19–22JAN07–1/1
02-9
061208
PN=18
88/256
Maintenance Records
8500 Hours of operation
❒ Engine oil, drain
❒ Engine oil filter, replace
❒ Fuel filter, replace
❒ Belt, check tension and wear (300-Series and POWERTech with
manual tensioner)
❒ Valve clearance, adjust (300-Series)
Number of hours:
Observation:
Dealer or distributor stamp
Date:
Job done by:
DPSG,CD03523,72 –19–22JAN07–1/1
9000 Hours of operation
❒ Engine oil, drain
❒ Air intake system, check
❒ Engine oil filter, replace
❒ Fuel filter, replace
❒ Check belt and tensioning system
❒ Crankcase vent tube, clean
Number of hours:
Observation:
Dealer or distributor stamp
Date:
Job done by:
DPSG,CD03523,73 –19–22JAN07–1/1
02-10
061208
PN=19
89/256
Maintenance Records
9500 Hours of operation
❒ Engine oil, drain
❒ Engine oil filter, replace
❒ Fuel filter, replace
❒ Belt, check tension and wear (300-Series and POWERTech with
manual tensioner)
❒ Valve clearance, adjust (300-Series)
Number of hours:
Observation:
Dealer or distributor stamp
Date:
Job done by:
DPSG,CD03523,74 –19–22JAN07–1/1
10000 Hours of operation
❒ Engine oil, drain
❒ Cooling system, drain and flush
❒ Engine oil filter, replace
❒ Valve clearance, adjust (POWERTech)
❒ Fuel filter, replace
❒ Thermostat, replace
❒ Check belt and tensioning system
❒ Vibration damper, check
❒ Crankcase vent tube, clean
❒ Injection nozzles, replace
❒ Air intake system, check
Number of hours:
Observation:
Dealer or distributor stamp
Date:
Job done by:
DPSG,CD03523,75 –19–22JAN07–1/1
02-11
061208
PN=20
90/256
Serial Numbers
POWERTech label
RG8041
–UN–15JAN99
A label is located on the rocker arm cover which identifies
each engine as a John Deere POWERTECH engine.
POWERTECH is a trademark of Deere & Company
DPSG,CD03523,11 –19–22JAN07–1/1
RG8007
CD30746
–UN–15JAN99
–UN–24SEP99
Engine serial number plate
4045 and 6068 Engines
Each engine has a 13–digit John Deere serial number.
The first two digits identify the factory that produced
the engine:
3029 and 4039 Engines
Your engine’s serial number plate (A) is located on the
right-hand side of cylinder block behind the fuel filter
for 4045 and 6068 engines and near the fuel supply
pump on 3029 and 4039 engines.
”CD” indicates the engine was built in Saran, France
DPSG,CD03523,12 –19–22JAN07–1/1
03-1
061208
PN=21
91/256
Serial Numbers
Record engine serial number
Record all of the numbers and letters found on your
engine serial number plate in the spaces provided below.
–UN–24AUG99
This information is very important for repair parts or
warranty information.
CD30705B
Engine Serial Number (B)
___________________
3029 and 4039 engine plate
Engine Model Number (C)
___________________
Coefficient of Absorption Value (D)
CD30747A
–UN–22JAN07
___________________
4045 and 6068 engine plate
DPSG,CD03523,13 –19–22JAN07–1/1
03-2
061208
PN=22
92/256
Serial Numbers
CD30748A
–UN–26AUG99
Engine option codes
Engine option code label
In addition to the serial number plate, OEM engines
have an engine option code label affixed to the rocker
arm cover. These codes indicate which of the engine
options were installed on your engine at the factory.
When in need of parts or service, furnish your
authorized servicing dealer or engine distributor with
these numbers.
code identify one specific option provided on your
engine, such as a 12-volt, 55-amp alternator.
An additional sticker may be also delivered (in a plastic
bag attached to the engine or inserted in the machine
documentation). It is recommended to stick this option
code list sticker either:
If an engine is ordered without a particular component,
the last two digits of that functional group option code
will be 99, 00, or XX. The list on the next page shows
only the first two digits of the code numbers. For future
reference such as ordering repair parts, it is important
to have these code numbers available. To ensure this
availability, enter the third and fourth digits shown on
your engine option code label in the spaces provided
on the following page.
• On this page of your Operator’s manual below this
section.
or
• On the ”Engine Owner’s Warranty” booklet under the
title OPTION CODES (Engine manufacturing
configuration).
NOTE: These option codes are based on the latest
information available at the time of publication.
The right is reserved to make changes at any
time without notice.
NOTE: The Machine Manufacturer may have already
stuck it at a specific accessible place (inside
the enclosure or close to a maintenance area).
The engine option code label includes an engine base
code (A). This base code must also be recorded along
with the option codes. At times it will be necessary to
furnish this base code to differentiate two identical
option codes for the same engine model.
The first two digits of each code identify a specific
group, such as alternators. The last two digits of each
Continued on next page
03-3
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061208
PN=23
93/256
Serial Numbers
NOTE: NOTE: Your engine option code label may not
contain all option codes if an option has been
added after the engine left the producing
factory.
Option
Codes
Description
If option code label is lost or destroyed,
consult your servicing dealer or engine
distributor selling the engine for a replacement.
Option
Codes
Description
50____
51____
52____
53____
54____
55____
56____
57____
59____
60____
62____
63____
64____
65____
66____
67____
68____
69____
72____
74____
75____
76____
81____
83____
84____
86____
87____
88____
91____
94____
95____
97____
98____
Oil Pump
Cylinder Head With Valves
Auxiliary Gear Drive
Fuel Heater
Oil heater
Shipping stand
Paint Option
Coolant Inlet
Oil Cooler
Add-on Auxiliary Drive Pulley
Alternator Mounting
Low Pressure Fuel Line
Exhaust Elbow
Turbocharger
Temperature Switch
Electronic Tachometer Sensor
Damper
Engine Serial Number Plate
ECU Electronic Software Option
Air conditioner Compressor Mounting
Air Restriction Indicator
Oil Pressure Switch
Primary Fuel Filter
Electronic Software
Electrical Wiring Harness
Fan Pulley
Automatic Belt Tensioner
Oil Filter
Special Equipment (Factory Installed)
Vehicle Timing
Identification label
Special Equipment (Field Installed)
Shipping
Engine Base Code:________
11____
12____
13____
14____
15____
16____
17____
18____
19____
20____
21____
22____
23____
24____
25____
26____
27____
28____
29____
30____
31____
32____
35____
36____
37____
39____
40____
41____
43____
44____
45____
46____
47____
48____
49____
Rocker Arm Cover
Oil Filler Neck
Crankshaft Pulley
Flywheel Housing
Flywheel
Fuel Injection Pump
Air inlet
Air cleaner
Oil pan
Coolant pump
Thermostat Cover
Thermostat
Fan Drive
Fan Belt
Fan
Engine Coolant Heater
Radiator
Exhaust Manifold
Ventilator System
Starting Motor
Alternator
Instrument Panel
Fuel Filter
Front Plate
Fuel Transfer Pump
Thermostat Housing
Oil Dipstick
Belt Driven Front Auxiliary Drive
Starting Aid
Timing Gear Cover with Gears
Balancer Shaft
Cylinder Block With Liners and Camshaft
Crankshaft and Bearings
Connecting Rods and Pistons
Valve Actuating Mechanisms
DPSG,CD03523,14 –19–22JAN07–2/2
03-4
061208
PN=24
94/256
Serial Numbers
Record fuel injection pump model number
Record the fuel injection pump model and serial
information found on the serial number plate (A).
–UN–24SEP99
Model No. _____________________ RPM _______
Manufacturer’s No. __________________________
CD30749
Serial No. _________________________________
DPSG,CD03523,15 –19–22JAN07–1/1
Record Engine Control Unit (ECU) Serial
Number
–UN–13APR06
Record the part number and serial number information
found on the serial number label (A) on the Engine
Control Unit (ECU) mounted on or near the engine.
RG14635
Part No.
Serial No.
Record Engine Control Unit (ECU) Serial Number
A—Serial Number Label
CD03523,0000189 –19–06FEB07–1/1
Record High-Pressure Fuel Pump Model
Number
Model No.
–UN–11NOV04
Record the high-pressure fuel pump model and serial
number information found on the serial number plate (A).
RPM
RG13718
Manufacturer’s No.
Serial No.
A—Serial Number Plate
Record High-Pressure Fuel Pump Serial Number
CD03523,000018A –19–06FEB07–1/1
03-5
061208
PN=25
95/256
Safety
Recognize Safety Information
–UN–07DEC88
This is a safety-alert symbol. When you see this symbol
on your machine or in this manual, be alert to the
potential for personal injury.
T81389
Follow recommended precautions and safe operating
practices.
DX,ALERT –19–29SEP98–1/1
Understand Signal Words
A signal word—DANGER, WARNING, or CAUTION—is
used with the safety-alert symbol. DANGER identifies the
most serious hazards.
TS187
–19–30SEP88
DANGER or WARNING safety signs are located near
specific hazards. General precautions are listed on
CAUTION safety signs. CAUTION also calls attention to
safety messages in this manual.
DX,SIGNAL –19–03MAR93–1/1
Do Not Open High-Pressure Fuel System
–UN–18MAR92
High-pressure fluid remaining in fuel lines can cause
serious injury. Do not disconnect or attempt repair of fuel
lines, sensors, or any other components between the
high-pressure fuel pump and nozzles on engines with
High Pressure Common Rail (HPCR) fuel system.
TS1343
Only technicians familiar with this type of system can
perform repairs. (See your John Deere dealer.)
DX,WW,HPCR1 –19–07JAN03–1/1
05-1
061208
PN=26
96/256
Safety
Engine lifting procedure
RG7784
–UN–11NOV97
CAUTION: The only recommended method for
lifting the engine is with JDG23 Engine Lifting
Sling (A) and safety approved lifting straps (B)
that come with engine. Use extreme caution
when lifting and NEVER permit any part of the
body to be positioned under an engine being
lifted or suspended.
Lift engine with longitudinal loading on lifting
sling and lifting straps only. Angular loading
greatly reduces lifting capacity of sling and
straps.
NOTE: If engine does not have lifting straps, universal
straps can be procured through service parts
under part numbers JD-244-1 and JD-244-2.
1. If not equipped, install lifting straps and torque to 200
N•m (145 lb-ft).
2. Attach JDG23 Engine Lifting Sling (A) to engine lifting
straps (B) and overhead hoist.
IMPORTANT: Lifting straps are designed to lift the
engine and accessories such as
radiator, air filter and other small
components. If larger components,
such as power take-off, transmission,
generator air compressor... etc, are
attached to engine, the lifting straps
provided with engine or through parts
channel are not intended for this
purpose. Technician is responsible for
providing adequate lifting devices under
these situations. See machine manuals
for additional information on removing
engine from machine.
3. Carefully move engine to desired location.
DPSG,CD03523,95 –19–22JAN07–1/1
05-2
061208
PN=27
97/256
Safety
Follow Safety Instructions
–UN–23AUG88
Carefully read all safety messages in this manual and on
your machine safety signs. Keep safety signs in good
condition. Replace missing or damaged safety signs. Be
sure new equipment components and repair parts include
the current safety signs. Replacement safety signs are
available from your John Deere dealer.
TS201
Learn how to operate the machine and how to use
controls properly. Do not let anyone operate without
instruction.
Keep your machine in proper working condition.
Unauthorized modifications to the machine may impair the
function and/or safety and affect machine life.
If you do not understand any part of this manual and need
assistance, contact your John Deere dealer.
DX,READ –19–03MAR93–1/1
Prevent Machine Runaway
Avoid possible injury or death from machinery runaway.
–UN–11JAN89
Do not start engine by shorting across starter terminals.
Machine will start in gear if normal circuitry is bypassed.
TS177
NEVER start engine while standing on ground. Start
engine only from operator’s seat, with transmission in
neutral or park.
DX,BYPAS1 –19–29SEP98–1/1
05-3
061208
PN=28
98/256
Safety
Handle Fuel Safely—Avoid Fires
Handle fuel with care: it is highly flammable. Do not refuel
the machine while smoking or when near open flame or
sparks.
–UN–23AUG88
Always stop engine before refueling machine. Fill fuel tank
outdoors.
TS202
Prevent fires by keeping machine clean of accumulated
trash, grease, and debris. Always clean up spilled fuel.
DX,FIRE1 –19–03MAR93–1/1
Prepare for Emergencies
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
TS291
–UN–23AUG88
Keep emergency numbers for doctors, ambulance service,
hospital, and fire department near your telephone.
DX,FIRE2 –19–03MAR93–1/1
Handle Starting Fluid Safely
Starting fluid is highly flammable.
–UN–18MAR92
Keep all sparks and flame away when using it. Keep
starting fluid away from batteries and cables.
TS1356
To prevent accidental discharge when storing the
pressurized can, keep the cap on the container, and store
in a cool, protected location.
Do not incinerate or puncture a starting fluid container.
DX,FIRE3 –19–16APR92–1/1
05-4
061208
PN=29
99/256
Safety
Wear Protective Clothing
Wear close fitting clothing and safety equipment
appropriate to the job.
–UN–23AUG88
Prolonged exposure to loud noise can cause impairment
or loss of hearing.
TS206
Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.
Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones
while operating machine.
DX,WEAR –19–10SEP90–1/1
Protect Against Noise
Prolonged exposure to loud noise can cause impairment
or loss of hearing.
TS207
–UN–23AUG88
Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.
DX,NOISE –19–03MAR93–1/1
05-5
061208
PN=30
100/256
Safety
Handle Chemical Products Safely
–UN–26NOV90
Direct exposure to hazardous chemicals can cause
serious injury. Potentially hazardous chemicals used with
John Deere equipment include such items as lubricants,
coolants, paints, and adhesives.
TS1132
A Material Safety Data Sheet (MSDS) provides specific
details on chemical products: physical and health hazards,
safety procedures, and emergency response techniques.
Check the MSDS before you start any job using a
hazardous chemical. That way you will know exactly what
the risks are and how to do the job safely. Then follow
procedures and recommended equipment.
(See your John Deere dealer for MSDS’s on chemical
products used with John Deere equipment.)
DX,MSDS,NA –19–03MAR93–1/1
Stay Clear of Rotating Drivelines
Entanglement in rotating driveline can cause serious injury
or death.
–UN–22AUG95
Keep master shield and driveline shields in place at all
times. Make sure rotating shields turn freely.
TS1644
Wear close fitting clothing. Stop the engine and be sure
the PTO driveline is stopped before making adjustments
or performing any type service on the engine or
PTO-driven equipment.
CD,PTO –19–22JAN07–1/1
05-6
061208
PN=31
101/256
Safety
Practice Safe Maintenance
Understand service procedure before doing work. Keep
area clean and dry.
Never lubricate, service, or adjust machine while it is
moving. Keep hands, feet , and clothing from
power-driven parts. Disengage all power and operate
controls to relieve pressure. Lower equipment to the
ground. Stop the engine. Remove the key. Allow machine
to cool.
Securely support any machine elements that must be
raised for service work.
Keep all parts in good condition and properly installed. Fix
damage immediately. Replace worn or broken parts.
Remove any buildup of grease, oil, or debris.
–UN–23AUG88
On self-propelled equipment, disconnect battery ground
cable (-) before making adjustments on electrical systems
or welding on machine.
TS218
On towed implements, disconnect wiring harnesses from
tractor before servicing electrical system components or
welding on machine.
DX,SERV –19–17FEB99–1/1
Work In Ventilated Area
–UN–23AUG88
Engine exhaust fumes can cause sickness or death. If it is
necessary to run an engine in an enclosed area, remove
the exhaust fumes from the area with an exhaust pipe
extension.
TS220
If you do not have an exhaust pipe extension, open the
doors and get outside air into the area.
DX,AIR –19–17FEB99–1/1
05-7
061208
PN=32
102/256
Safety
Avoid High-Pressure Fluids
Escaping fluid under pressure can penetrate the skin
causing serious injury.
–UN–23AUG88
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.
X9811
Search for leaks with a piece of cardboard. Protect hands
and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid
injected into the skin must be surgically removed within a
few hours or gangrene may result. Doctors unfamiliar with
this type of injury should reference a knowledgeable
medical source. Such information is available from Deere
& Company Medical Department in Moline, Illinois, U.S.A.
DX,FLUID –19–03MAR93–1/1
Avoid Heating Near Pressurized Fluid Lines
TS953
–UN–15MAY90
Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to
yourself and bystanders. Do not heat by welding,
soldering, or using a torch near pressurized fluid lines or
other flammable materials. Pressurized lines can
accidentally burst when heat goes beyond the immediate
flame area.
DX,TORCH –19–10DEC04–1/1
05-8
061208
PN=33
103/256
Safety
Remove Paint Before Welding or Heating
Avoid potentially toxic fumes and dust.
–UN–23AUG88
Hazardous fumes can be generated when paint is heated
by welding, soldering, or using a torch.
Remove paint before heating:
TS220
• Remove paint a minimum of 100 mm (4 in.) from area
to be affected by heating. If paint cannot be removed,
wear an approved respirator before heating or welding.
• If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
• If you use solvent or paint stripper, remove stripper with
soap and water before welding. Remove solvent or
paint stripper containers and other flammable material
from area. Allow fumes to disperse at least 15 minutes
before welding or heating.
Do not use a chlorinated solvent in areas where welding
will take place.
Do all work in an area that is well ventilated to carry toxic
fumes and dust away.
Dispose of paint and solvent properly.
DX,PAINT –19–24JUL02–1/1
Service Cooling System Safely
Explosive release of fluids from pressurized cooling
system can cause serious burns.
TS281
–UN–23AUG88
Shut off engine. Only remove filler cap when cool enough
to touch with bare hands. Slowly loosen cap to first stop
to relieve pressure before removing completely.
DX,RCAP –19–04JUN90–1/1
05-9
061208
PN=34
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Safety
Avoid Harmful Asbestos Dust
Avoid breathing dust that may be generated when
handling components containing asbestos fibers. Inhaled
asbestos fibers may cause lung cancer.
TS220
–UN–23AUG88
Components in products that may contain asbestos fibers
are brake pads, brake band and lining assemblies, clutch
plates, and some gaskets. The asbestos used in these
components is usually found in a resin or sealed in some
way. Normal handling is not hazardous as long as
airborne dust containing asbestos is not generated.
Avoid creating dust. Never use compressed air for
cleaning. Avoid brushing or grinding material containing
asbestos. When servicing, wear an approved respirator. A
special vacuum cleaner is recommended to clean
asbestos. If not available, apply a mist of oil or water on
the material containing asbestos.
Keep bystanders away from the area.
DX,DUST –19–15MAR91–1/1
Dispose of Waste Properly
–UN–26NOV90
Improperly disposing of waste can threaten the
environment and ecology. Potentially harmful waste used
with John Deere equipment include such items as oil, fuel,
coolant, brake fluid, filters, and batteries.
TS1133
Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.
Do not pour waste onto the ground, down a drain, or into
any water source.
Air conditioning refrigerants escaping into the air can
damage the Earth’s atmosphere. Government regulations
may require a certified air conditioning service center to
recover and recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of waste
from your local environmental or recycling center, or from
your John Deere dealer.
DX,DRAIN –19–03MAR93–1/1
05-10
061208
PN=35
105/256
Fuels, Lubricants and Coolant
Diesel Fuel
Consult your local fuel distributor for properties of the
diesel fuel available in your area.
In general, diesel fuels are blended to satisfy the low
temperature requirements of the geographical area in
which they are marketed.
Diesel fuels specified to EN 590 or ASTM D975 are
recommended. Renewable diesel is basically identical
to petroleum diesel fuel that is created by
Hydrotreating fats and oils. Renewable diesel that
meets EN 590 or ASTM D975 is acceptable for use at
all percentage mixture levels.
Required fuel properties
In all cases, the fuel shall meet the following
properties:
Cetane number of 45 minimum. Cetane number
greater than 50 is preferred, especially for
temperatures below –20°C (–4°F) or elevations above
1500 m (5000 ft).
Cold Filter Plugging Point (CFPP) should be at least
5°C (9°F) below the expected lowest temperature or
Cloud Point below the expected lowest ambient
temperature.
Fuel lubricity should pass a maximum scar diameter
of 0.45 mm as measured by ASTM D6079 or ISO
12156-1.
Sulfur content:
• Diesel fuel quality and fuel sulfur content must
comply with all existing emissions regulations for the
area in which the engine operates.
• Use of diesel fuel with sulfur content less than
0.10% (1000 ppm) is STRONGLY recommended.
• Use of diesel fuel with sulfur content 0.10% (1000
ppm) to 0.50% (5000 ppm) may result in REDUCED
oil and filter change intervals as shown in the table.
• BEFORE using diesel fuel with sulfur content greater
than 0.50% (5000 ppm), contact your John Deere
dealer.
IMPORTANT: Do not mix used diesel engine oil or
any other type of lubricating oil with
diesel fuel.
IMPORTANT: Improper fuel additive usage may
cause damage on fuel injection
equipment of diesel engines.
DX,FUEL1 –19–05OCT07–1/1
10-1
061208
PN=36
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Fuels, Lubricants and Coolant
Handling and Storing Diesel Fuel
CAUTION: Handle fuel carefully. Do not fill
the fuel tank when engine is running.
DO NOT smoke while you fill the fuel tank or
service the fuel system.
Fill the fuel tank at the end of each day’s operation to
prevent water condensation and freezing during cold
weather.
Keep all storage tanks as full as practicable to
minimize condensation.
Ensure that all fuel tank caps and covers are installed
properly to prevent moisture from entering.
When using bio-diesel fuel, the fuel filter may require
more frequent replacement due to premature plugging.
Check engine oil level daily prior to starting engine. A
rising oil level may indicate fuel dilution of the engine
oil.
IMPORTANT: The fuel tank is vented through the
filler cap. If a new filler cap is
required, always replace it with an
original vented cap.
When fuel is stored for an extended period or if there
is a slow turnover of fuel, add a fuel conditioner to
stabilize the fuel and prevent water condensation.
Contact your fuel supplier for recommendations.
Monitor water content of the fuel regularly.
DX,FUEL4 –19–19DEC03–1/1
10-2
061208
PN=37
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Fuels, Lubricants and Coolant
Diesel Engine Break-In Oil
New engines are filled at the factory with John Deere
ENGINE BREAK-IN OIL. During the break-in period,
add John Deere ENGINE BREAK-IN OIL as needed to
maintain the specified oil level.
Change the oil and filter after the first 100 hours of
operation of a new or rebuilt engine.
After the break-in period, use John Deere PLUS-50
or other diesel engine oil as recommended in this
manual.
IMPORTANT: Do not use PLUS-50 oil or engine
oils meeting any of the following
during the first 100 hours of
operation of a new or rebuilt engine:
After engine overhaul, fill the engine with John Deere
ENGINE BREAK-IN OIL.
API
API
API
API
API
API
API
API
If John Deere ENGINE BREAK-IN OIL is not available,
use a diesel engine oil meeting one of the following
during the first 100 hours of operation:
•
•
•
•
•
API Service Classification CE
API Service Classification CD
API Service Classification CC
ACEA Oil Sequence E2
ACEA Oil Sequence E1
CJ-4
CI-4 PLUS
CI-4
CH-4
CG-4
CF-4
CF-2
CF
ACEA
ACEA
ACEA
ACEA
ACEA
E7
E6
E5
E4
E3
These oils will not allow the engine
to break-in properly.
PLUS-50 is a trademark of Deere & Company.
DX,ENOIL4 –19–13SEP06–1/1
10-3
061208
PN=38
108/256
Fuels, Lubricants and Coolant
Diesel Engine Oil
Use oil viscosity based on the expected air temperature
range during the period between oil changes.
Depending on Emission Regulation requirements, the oil
recommendations are different. Refer to the chart to
identify the proper oil to be used.
Stage II Emission Certified
Engines
John Deere PLUS-50
(Preferred)
John Deere TORQ-GARD
SUPREME
John Deere TORQ-GARD
SUPREME
ACEA-E3, ACEA-E2
ACEA-E7, ACEA-E6, ACEA-E5,
ACEA-E4, ACEA-E3
API-CH4, API-CG4, API-CF4
API-CJ4, API-CI4 PLUS, API-CI4,
API-CH4
TS1675
John Deere PLUS-50
(Preferred)
–UN–09OCT06
Non Emission Certified Engines
Multi-viscosity diesel engine oils are preferred.
Oil Viscosities for Air Temperature Ranges
If diesel fuel with sulfur content greater than 0.5% is used
or if oil does not meet the classification above, reduce the
service interval by 50%.
DO NOT use diesel fuel with sulfur content greater than
1%.
PLUS-50 is a trademark of Deere & Company
TORQ-GARD SUPREME is a trademark of Deere & Company
CD,ENOIL –19–25JAN07–1/1
10-4
061208
PN=39
109/256
Fuels, Lubricants and Coolant
Lubricant Storage
Your equipment can operate at top efficiency only
when clean lubricants are used.
Make certain that all containers are properly marked to
identify their contents.
Use clean containers to handle all lubricants.
Properly dispose of all old containers and any residual
lubricant they may contain.
Whenever possible, store lubricants and containers in
an area protected from dust, moisture, and other
contamination. Store containers on their side to avoid
water and dirt accumulation.
DX,LUBST –19–18MAR96–1/1
Mixing of Lubricants
In general, avoid mixing different brands or types of oil.
Oil manufacturers blend additives in their oils to meet
certain specifications and performance requirements.
Consult your John Deere dealer to obtain specific
information and recommendations.
Mixing different oils can interfere with the proper
functioning of these additives and degrade lubricant
performance.
DX,LUBMIX –19–18MAR96–1/1
10-5
061208
PN=40
110/256
Fuels, Lubricants and Coolant
Diesel Engine Coolant
The engine cooling system is filled to provide
year-round protection against corrosion and cylinder
liner pitting, and winter freeze protection to -37°C
(-34°F).
A 50% mixture of propylene glycol engine coolant in
water provides freeze protection to -33°C (-27°F).
If protection at lower temperatures is required, consult
your John Deere dealer for recommendations.
John Deere COOL-GARD is preferred for service.
Water quality
If John Deere COOL-GARD is not available, use a low
silicate ethylene glycol or propylene glycol base
coolant concentrate in a 50% mixture of concentrate
with quality water.
The coolant concentrate shall be of a quality that
provides cavitation protection to cast iron and
aluminum parts in the cooling system. John Deere
COOL-GARD meets this requirement.
Freeze protection
Water quality is important to the performance of the
cooling system. Distilled, deionized, or demineralized
water is recommended for mixing with ethylene glycol
and propylene glycol base engine coolant concentrate.
IMPORTANT: Do not use cooling system sealing
additives or antifreeze that contains
sealing additives.
IMPORTANT: Do not mix ethylene glycol and
propylene glycol base coolants.
A 50% mixture of ethylene glycol engine coolant in
water provides freeze protection to -37°C (-34°F).
DX,COOL8 –19–16NOV01–1/1
Operating in Warm Temperature Climates
John Deere engines are designed to operate using
glycol base engine coolants.
Foaming, hot surface aluminum and
iron corrosion, scaling, and
cavitation will occur when water is
used as the coolant, even when
coolant conditioners are added.
Always use a recommended glycol base engine
coolant, even when operating in geographical areas
where freeze protection is not required.
Drain cooling system and refill with
recommended glycol base engine
coolant as soon as possible.
IMPORTANT: Water may be used as coolant in
emergency situations only.
DX,COOL6 –19–18MAR96–1/1
10-6
061208
PN=41
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Operating the Engine
Using Diagnostic Gauge to Access Engine
Information (Optional equipment)
–UN–09SEP03
NOTE: Generator sets powered by an electronically
controlled engine (DE10 or HPCR fuel system)
can be optionally equipped with the diagnostic
gauge shown. Depending on the generator set
manufacturer, other instrumentations can be used.
Refer to the generator set documentation for more
information.
RG13132
The diagnostic gauge (A) allows the operator to view
many readouts of engine functions and trouble codes
(DTCs). The gauge is linked to the electronic control
system and its sensors. This allows the operator to
monitor engine functions and to troubleshoot the engine
systems when needed.
Diagnostic Gauge
A—Diagnostic Gauge
B—Menu Key
C—Arrow Keys
D—Enter Key
E—Red ”STOP ENGINE” Indicator Light
F—Amber ”WARNING” Indicator Light
Press the menu key (B) to access the various engine
functions in sequence. The displays can be selected as
either customary English or metric units. The following
menu of engine parameters can be displayed on the
diagnostic gauge window:
•
•
•
•
•
•
•
•
•
•
•
•
•
Engine hours
Engine rpm
System voltage
Percent engine load at the current rpm
Coolant temperature
Oil pressure
Throttle position
Intake manifold temperature
Current fuel consumption
Active service (diagnostic) codes
Stored service (diagnostic) codes from the engine
Set the units for display
View the engine configuration parameters
Continued on next page
15-1
CD03523,000018B –19–22JAN07–1/2
061208
PN=42
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Operating the Engine
NOTE: Engine parameters which can be accessed will
vary with the engine application. Six languages for
readouts are available and can be selected during
setup of gauge.
The diagnostic gauge includes a graphical backlit Liquid
Crystal Display (LCD) screen. The display can show either
a single parameter or a quadrant display showing four
parameters simultaneously. The diagnostic gauge uses
two arrow keys (C) for scrolling through the engine
parameter list and viewing the menu list and an enter key
(D) for selecting highlighted items. The red (E) and amber
(F) lights are used to signal active trouble code received
by the diagnostic gauge.
CD03523,000018B –19–22JAN07–2/2
–UN–26SEP03
Main Menu Navigation
RG13159
NOTE: The engine does not need to be running to
navigate the diagnostic gauge screens. If engine
start up is desired, See Starting The Engine. All of
the engine values illustrated on the diagnostic
gauge indicate the engine is running.
1. Turn the key switch to the ON position. Starting at the
single or four engine parameter display, press the
"Menu" key.
Menu Key
OURGP11,00000A9 –19–03SEP03–1/5
RG13160
–UN–02OCT03
2. The first seven items of the "Main Menu" will be
displayed.
Menu Display
Continued on next page
15-2
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PN=43
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Operating the Engine
RG13161
–UN–02OCT03
3. Pressing the "Arrow" keys will scroll through the menu
selections.
Main Menu Items
OURGP11,00000A9 –19–03SEP03–3/5
RG13162
–UN–26SEP03
4. Pressing the right arrow key will scroll down to reveal
the last items of "Main Menu" screen, highlighting the
next item down.
Last Items On Main Menu
OURGP11,00000A9 –19–03SEP03–4/5
RG13163
–UN–02OCT03
5. Use the arrow keys to scroll to the desired menu item
or press the "Menu Button" to exit the main menu and
return to the engine parameter display.
Use Arrow Buttons To Scroll / Quadrant Display
OURGP11,00000A9 –19–03SEP03–5/5
15-3
061208
PN=44
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Operating the Engine
–UN–26SEP03
Engine Configuration Data
NOTE: The engine configuration data is a read only
function.
RG13159
NOTE: The engine does not need to be running to
navigate the diagnostic gauge screens. If engine
start up is desired, See Starting The Engine. All of
the engine values illustrated on the diagnostic
gauge indicate the engine is running.
Menu Key
1. Turn the key switch to the ON position. Starting at the
single or four engine parameter display, press the
"Menu" key.
OURGP11,00000AB –19–03SEP03–1/6
RG13164
–UN–07OCT03
2. The main menu will be displayed. Use the "Arrow" keys
to scroll through the menu until "Engine Config" is
highlighted.
Select Engine Configuration
OURGP11,00000AB –19–03SEP03–2/6
RG13165
–UN–02OCT03
3. Once "Engine Config" menu item has been highlighted,
press the "Enter" key to view the engine configuration
data.
Enter Key
Continued on next page
15-4
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PN=45
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Operating the Engine
RG13166
–UN–29SEP03
4. Use the "Arrow" keys to scroll through the engine
configuration data.
Use Arrow Keys To Scroll
OURGP11,00000AB –19–03SEP03–4/6
RG13167
–UN–29SEP03
5. Press the "Menu" key to return to the main menu.
Return To Main Menu
OURGP11,00000AB –19–03SEP03–5/6
RG13159
–UN–26SEP03
6. Press the "Menu" key to exit the main menu and return
to the engine parameter display.
Exit Main Menu
OURGP11,00000AB –19–03SEP03–6/6
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Operating the Engine
–UN–26SEP03
Accessing Stored Trouble Codes
RG13159
NOTE: The engine does not need to be running to
navigate the diagnostic gauge screens. If engine
start up is desired, See Starting The Engine. All of
the engine values illustrated on the diagnostic
gauge indicate the engine is running.
For description of trouble codes, see chart in
Troubleshooting Section.
Menu Key
1. Turn the key switch to the ON position. Starting at the
single or four engine parameter display, press the
"Menu" key.
OURGP11,00000AC –19–03SEP03–1/6
RG13168
–UN–02OCT03
2. The main menu will be displayed. Use the "Arrow" keys
to scroll through the menu until "Stored Codes" is
highlighted.
Select Stored Codes
Continued on next page
15-6
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Operating the Engine
RG13169
–UN–02OCT03
3. Once the "Stored Codes" menu item has been
highlighted press the "Enter" key to view the stored
codes.
Enter Key
OURGP11,00000AC –19–03SEP03–3/6
RG13245
–UN–02OCT03
4. If the word "Next" appears above the "Arrow" keys,
there are more stored codes that may be viewed. Use
the "Arrow" key to scroll to the next stored code.
Use Arrow Keys To Scroll
OURGP11,00000AC –19–03SEP03–4/6
RG13246
–UN–02OCT03
5. Press the "Menu" key to return to the main menu.
Return To Main Menu
Continued on next page
15-7
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Operating the Engine
RG13159
–UN–26SEP03
6. Press the "Menu" key to exit the main menu and return
to the engine parameter display.
Exit Main Menu
OURGP11,00000AC –19–03SEP03–6/6
–UN–26SEP03
Accessing Active Trouble Codes
RG13172
NOTE: The engine does not need to be running to
navigate the diagnostic gauge screens. If engine
start up is desired, See Starting The Engine. All of
the engine values illustrated on the diagnostic
gauge indicate the engine is running.
Normal Operation
For description of trouble codes, see chart in
Troubleshooting Section.
1. During normal operation the single or four parameter
screen will be displayed.
OURGP11,00000AD –19–03SEP03–1/7
–UN–30SEP03
2. When the diagnostic gauge receives a trouble code
from an engine control unit, the single or four
parameter screen will be replaced with the "Warning"
message. The SPN and FMI number will be displayed
along with a description of the problem and the
corrective action needed.
RG13240
IMPORTANT: Ignoring active trouble codes can result
in severe engine damage.
Active Trouble Codes Displayed
Continued on next page
15-8
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Operating the Engine
RG13241
–UN–30SEP03
3. If the word "Next" appears above the arrow keys, there
are more trouble codes that can be viewed by using
the arrow keys to scroll to the next trouble code.
Use Arrow Keys To Scroll
OURGP11,00000AD –19–03SEP03–3/7
IMPORTANT: Ignoring active trouble codes can result
in severe engine damage.
RG13242
–UN–30SEP03
4. To acknowledge and hide the code and return to the
single or four parameter display, press the "Enter" Key.
Hide Trouble Codes
OURGP11,00000AD –19–03SEP03–4/7
RG13176
–UN–26SEP03
5. The display will return to the single or four parameter
display, but the display will contain the warning icon.
Pressing the "Enter" key will redisplay the hidden
trouble code.
Active Trouble Code Icon
OURGP11,00000AD –19–03SEP03–5/7
IMPORTANT: Ignoring active trouble codes can result
in severe engine damage.
RG13242
–UN–30SEP03
6. Pressing the "Enter" key once again will hide the
trouble code and return the screen to the single or four
parameter display.
Enter Key
Continued on next page
15-9
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Operating the Engine
RG13243
–UN–01OCT03
7. The single or four parameter screen will display the
warning icon until the trouble code condition is
corrected.
Active Trouble Code Condition
OURGP11,00000AD –19–03SEP03–7/7
–UN–26SEP03
Engine Shutdown Codes
RG13172
1. During normal operation the single or four parameter
screen will be displayed.
Normal Operation
OURGP11,00000AE –19–03SEP03–1/6
–UN–29SEP03
2. When the diagnostic gauge receives a severe trouble
code from an engine control unit, the single or four
parameter screen will be replaced with the "Shutdown"
message. The SPN and FMI number will be displayed
along with a description of the problem and the
corrective action needed.
RG13238
If the word "Next" appears above the arrow keys, there
are more trouble codes that can be viewed by using
the arrow keys to scroll to the next trouble code.
Shutdown Message
OURGP11,00000AE –19–03SEP03–2/6
3. To acknowledge and hide the trouble code and return
to the single or four parameter display, press the
"Enter" key".
RG13239
–UN–29SEP03
IMPORTANT: Ignoring the shutdown message can
result in severe engine damage.
Hide Trouble Code
Continued on next page
15-10
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Operating the Engine
–UN–26SEP03
4. The display will return to the single or four parameter
display, but the display will contain the "Shutdown"
icon. Pressing the "Enter" key will redisplay the hidden
trouble code.
RG13179
IMPORTANT: Ignoring the shutdown message can
result in severe engine damage.
Flashing Shutdown Icon
OURGP11,00000AE –19–03SEP03–4/6
RG13239
–UN–29SEP03
5. Pressing the "Enter" key once again will hide the
trouble code and return the screen to the single or four
parameter display.
Redisplay Trouble Code
OURGP11,00000AE –19–03SEP03–5/6
–UN–26SEP03
6. The single or four parameter screen will display the
shutdown icon until the trouble code condition is
corrected.
RG13180
IMPORTANT: Ignoring the shutdown message can
result in severe engine damage.
Shutdown Icon
OURGP11,00000AE –19–03SEP03–6/6
–UN–26SEP03
Adjusting Backlighting
RG13159
1. Turn the key switch to the ON position. Starting at the
single or four engine parameter display, press the
"Menu" key.
Menu Key
Continued on next page
15-11
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Operating the Engine
RG13181
–UN–02OCT03
2. The main menu will be displayed. Use the "Arrow" keys
to scroll through the menu until "Adjust Backlight" is
highlighted.
Select Adjust Backlight
OURGP11,0000237 –19–21OCT03–2/6
RG13182
–UN–02OCT03
3. Once the "Adjust Backlight" menu item has been
highlighted, press the "Enter" key to activate the
"Adjust Backlight" function.
Press Enter Key
OURGP11,0000237 –19–21OCT03–3/6
RG13183
–UN–29SEP03
4. Use the "Arrow" keys to select the desired backlight
intensity.
Adjust Backlight Intensity
Continued on next page
15-12
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Operating the Engine
RG13184
–UN–26SEP03
5. Press the "Menu" key to return to the main menu.
Return To Main Menu
OURGP11,0000237 –19–21OCT03–5/6
RG13159
–UN–26SEP03
6. Press the "Menu" key to exit the main menu and return
to the engine parameter display.
Exit Main Menu
OURGP11,0000237 –19–21OCT03–6/6
–UN–26SEP03
Adjusting Contrast
RG13159
1. Turn the key switch to the ON position. Starting at the
single or four engine parameter display press the
"Menu" key.
Menu Key
Continued on next page
15-13
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Operating the Engine
RG13161
–UN–02OCT03
2. The main menu will be displayed. Use the "Arrow" keys
to scroll through the menu until "Adjust Contrast" is
highlighted.
Select Adjust Contrast
OURGP11,00000AF –19–03SEP03–2/6
RG13185
–UN–02OCT03
3. Once the "Adjust Contrast" menu item has been
highlighted, press the "Enter" key to activate the
"Adjust Contrast" function.
Press Enter Key
OURGP11,00000AF –19–03SEP03–3/6
RG13186
–UN–29SEP03
4. Use the "Arrow" keys to select the desired contrast
intensity.
Adjust Contrast Intensity
Continued on next page
15-14
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Operating the Engine
RG13187
–UN–26SEP03
5. Press the "Menu" key to return to the main menu.
Return To Main Menu
OURGP11,00000AF –19–03SEP03–5/6
RG13159
–UN–26SEP03
6. Press the "Menu" key to exit the main menu and return
to the engine parameter display.
Exit Main Menu
OURGP11,00000AF –19–03SEP03–6/6
–UN–26SEP03
Selecting Units Of Measurement
RG13159
1. Turn the key switch to the ON position. Starting at the
single or four engine parameter display, press the
"Menu" key.
Menu Key
Continued on next page
15-15
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Operating the Engine
RG13188
–UN–02OCT03
2. The main menu will be displayed. Use the "Arrow" keys
to scroll through the menu until "Select Units" is
highlighted.
Select Units
OURGP11,00000B0 –19–03SEP03–2/7
RG13189
–UN–02OCT03
3. Once the "Select Units" menu item has been
highlighted press the "Enter" key to access the "Select
Units" function.
Press Enter Key
OURGP11,00000B0 –19–03SEP03–3/7
4. There are three choices for units of measurement,
English, Metric kPa or Metric Bar.
–UN–26SEP03
English is for Imperial units, with pressures displayed
in PSI and temperatures in °F.
RG13190
Metric kPa and Metric bar are for IS units, with
pressures displayed in kPa and bar respectively, and
temperatures in °C.
Use the "Arrow" keys to highlight the desired units of
measurement.
Select Desired Units
Continued on next page
15-16
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Operating the Engine
RG13191
–UN–30SEP03
5. Press the "Enter" key to select the highlighted units.
Press Enter Key to Select
OURGP11,00000B0 –19–03SEP03–5/7
RG13192
–UN–26SEP03
6. Press the "Menu" key to return to the main menu.
Return To Main Menu
OURGP11,00000B0 –19–03SEP03–6/7
RG13159
–UN–26SEP03
7. Press the "Menu" key to return to the engine
parameter display.
Press Menu Key
OURGP11,00000B0 –19–03SEP03–7/7
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Operating the Engine
–UN–26SEP03
Setup 1-Up Display
RG13159
1. Turn the key switch to the ON position. Starting at the
single engine parameter display, press the "Menu" key.
Menu Key
OURGP11,00000B1 –19–03SEP03–1/18
RG13193
–UN–02OCT03
2. Use the "Arrow" keys to scroll through the menu until
"Setup 1-Up Display" is highlighted.
Setup 1-Up Display
OURGP11,00000B1 –19–03SEP03–2/18
RG13194
–UN–02OCT03
3. Once "Setup 1-Up Display" menu item has been
highlighted press the "Enter" key to access the "Setup
1-Up Display" function.
Press Enter Key
Continued on next page
15-18
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Operating the Engine
4. Three options are available for modification of the 1-Up
Display.
–UN–26SEP03
a. Use Defaults – This option contains the following
engine parameters for display: Engine Hours,
Engine Speed, Battery Voltage, % Load, Coolant
Temperature and Oil Pressure.
RG13196
b. Custom Setup – This option contains a list of
engine parameters. Engine parameters from this list
can be selected to replace any or all of the default
parameters. This option can be used to add
parameters available for scrolling in the 1-Up
Display.
1-Up Display Options
c. Automatic Scan – Selecting the scan function will
allow the 1-Up Display to scroll through the selected
set of parameters one at a time, momentarily
pausing at each.
OURGP11,00000B1 –19–03SEP03–4/18
RG13195
–UN–26SEP03
5. Use Defaults - To select "Use Defaults" use the Arrow
keys to scroll to and highlight "Use Defaults" in the
menu display.
Select Defaults
Continued on next page
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Operating the Engine
RG13197
–UN–29SEP03
6. Press the "Enter" key to activate the "Use Defaults"
function.
Defaults Selected
OURGP11,00000B1 –19–03SEP03–6/18
RG13149
–UN–24SEP03
7. The display parameters are reset to the factory
defaults, then the display will return to the "Setup 1-Up
Display" menu.
Restored To Defaults
OURGP11,00000B1 –19–03SEP03–7/18
RG13198
–UN–26SEP03
8. Custom Setup - To perform a custom setup of the
1-Up Display, use the arrow buttons to scroll to and
highlight "Custom Setup" on the display.
Select Custom Setup
Continued on next page
15-20
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Operating the Engine
RG13199
–UN–26SEP03
9. Press the "Enter" key to display a list of engine
parameters.
Engine Parameters
OURGP11,00000B1 –19–03SEP03–9/18
RG13150
–UN–24SEP03
10. Use the "Arrow" keys to scroll to and highlight a
selected parameter (parameter with a number to right
of it).
Select Parameters
OURGP11,00000B1 –19–03SEP03–10/18
RG13219
–UN–26SEP03
11. Press the "Enter" key to deselect the selected
parameter, removing it from the list of parameters
being displayed on the 1-Up Display.
Deselect Parameters
Continued on next page
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Operating the Engine
RG13151
–UN–24SEP03
12. Use the "Arrow" keys to scroll and highlight the
desired parameter that has not been selected for
display (parameter without a number to right of it).
Select Desired Parameters
OURGP11,00000B1 –19–03SEP03–12/18
13. Press the "Enter" key to select the parameter for
inclusion in the Single Engine Parameter Display.
RG13220
–UN–26SEP03
14. Continue to scroll through and select additional
parameters for the custom 1-Up Display. Press the
"Menu" key at any time to return to the "Custom
Setup" menu.
Select Parameters For Display
OURGP11,00000B1 –19–03SEP03–13/18
RG13221
–UN–26SEP03
15. Automatic Scan - Selecting the scan function will
allow the 1- Up Display to scroll through the selected
set of parameters one at a time. Use the "Arrow" keys
to scroll to the "Automatic Scan" function.
Automatic Scan Off
Continued on next page
15-22
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Operating the Engine
RG13222
–UN–26SEP03
16. Press the "Enter" key to toggle the "Automatic Scan"
function on.
Automatic Scan On
OURGP11,00000B1 –19–03SEP03–15/18
RG13223
–UN–26SEP03
17. Press the "Enter" key again to toggle the "Automatic
Scan" function off.
Automatic Scan Off
Continued on next page
15-23
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Operating the Engine
RG13224
–UN–26SEP03
18. Once the "Use Defaults", "Custom Setup" and
"Automatic Scan" functions have been set, press the
"Menu" key to return to the main menu.
Menu Key
OURGP11,00000B1 –19–03SEP03–17/18
RG13159
–UN–26SEP03
19. Press the "Menu" key to exit the main menu and
return to the engine parameter display.
Exit Main Menu
OURGP11,00000B1 –19–03SEP03–18/18
–UN–26SEP03
Setup 4-Up Display
RG13159
1. Turn the key switch to the ON position. From the single
or four engine parameter display, press the "Menu"
key.
Menu Key
Continued on next page
15-24
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Operating the Engine
RG13225
–UN–02OCT03
2. The main menu will be displayed. Use the "Arrow" keys
to scroll through the menu until "Setup 4-Up Display" is
highlighted.
Select Setup 4-Up Display
OURGP11,00000B2 –19–03SEP03–2/14
RG13226
–UN–02OCT03
3. Once the "Setup 4-Up Display" menu item has been
highlighted, press the "Enter" key to activate the "Setup
4-Up Display" menu.
Press Enter Key
Continued on next page
15-25
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Operating the Engine
4. Two options are available for the 4-Up Display.
–UN–02OCT03
a. Use Defaults – This option contains the following
engine parameters for display: Engine Speed,
Battery Voltage, Coolant Temperature and Oil
Pressure.
RG13244
b. Custom Setup – This option contains a list of
engine parameters. Engine parameters from this list
can be selected to replace any or all of the default
parameters.
Select Factory Defaults
OURGP11,00000B2 –19–03SEP03–4/14
RG13149
–UN–24SEP03
5. To reset the display parameters to the factory defaults,
scroll to and highlight "Use Defaults". Press the "Enter"
key to activate the "Use Defaults" function. A message
indicating the display parameters are reset to the
factory defaults will be displayed, then the display will
return to the "Setup 4-Up Display" menu.
Restored To Defaults
OURGP11,00000B2 –19–03SEP03–5/14
RG13227
–UN–26SEP03
6. Custom Setup - To perform a custom setup of the
4-Up Display, use the arrow buttons to scroll to and
highlight "Custom Setup" on the display.
Custom Setup
Continued on next page
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Operating the Engine
RG13228
–UN–26SEP03
7. The quadrant with the highlighted parameter value is
the current selected parameter. Use the "Arrow" keys
to highlight the value in the quadrant you wish to
change to a new parameter.
Select Parameters
OURGP11,00000B2 –19–03SEP03–7/14
RG13229
–UN–26SEP03
8. Press the "Enter" key and a list of engine parameters
will be displayed.
List Of Engine Parameters
OURGP11,00000B2 –19–03SEP03–8/14
RG13230
–UN–26SEP03
9. The parameter that is highlighted is the selected
parameter for the screen. Use the "arrow" keys to
highlight the new parameter to be placed in the "4-Up
Display".
Select Desired Engine Parameter
Continued on next page
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Operating the Engine
RG13231
–UN–26SEP03
10. Press the "Enter" key to change the selected
parameter in the quadrant to the new parameter.
Enter Selected Parameter
OURGP11,00000B2 –19–03SEP03–10/14
RG13232
–UN–26SEP03
11. Use the "Menu" keys to return to the "4-Up Custom
Setup" screen.
Return To 4-Up Custom Setup
OURGP11,00000B2 –19–03SEP03–11/14
RG13153
–UN–24SEP03
12. The selected quadrant has now changed to the new
selected parameter.
4-Up Display
Continued on next page
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Operating the Engine
13. Repeat the parameter selection process until all
spaces are as desired.
RG13154
–UN–24SEP03
14. Press the "Menu" key to return to the main menu.
Return To Main Menu
OURGP11,00000B2 –19–03SEP03–13/14
RG13155
–UN–07OCT03
15. Press the "Menu" key to exit the main menu and
return to the engine parameter display.
Select Remaining Parameters
OURGP11,00000B2 –19–03SEP03–14/14
Break-in period
Within first 100 hours of operation:
During the first 100 hours of operation, avoid
overloading, excessive idling and no-load operation.
change the oil filter (see CHANGING ENGINE OIL
AND FILTER). Fill crankcase with seasonal viscosity
grade oil (see DIESEL ENGINE OIL).
If oil has to be added during this time, see ENGINE
BREAK-IN OIL.
Check tension of alternator belt.
Check connections of air intake hoses.
NOTE: During the break-in period a higher-than-usual
oil consumption should be considered as
normal.
Check for proper tightening of cap screws all around
the engine.
After first 100 hours of operation:
After the first 100 hours, drain the crankcase and
DPSG,CD03523,17 –19–22JAN07–1/1
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Operating the Engine
Starting the engine
2. Open the fuel supply shut-off valve, if equipped.
CAUTION: Before starting engine in a
confined building, install proper outlet
exhaust ventilation equipment. Always use
safety approved fuel storage and piping.
3. Activate the starter motor switch to crank the
engine and release it as soon as engine starts.
NOTE: If temperature is below 0 ° C (32 ° F), it may
be necessary to use cold weather starting aids
(See COLD WEATHER OPERATION).
NOTE: Do not operate the starter motor more than 20
seconds at a time.
1. Perform all prestarting checks outlined in
Maintenance/Daily Section.
DPSG,CD03523,18 –19–22JAN07–1/1
Cold weather operation
Depending on equipment, various cold weather starting
aids are available to assist in starting the engine at
temperature below 0° C (32 °F).
Continued on next page
15-30
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Operating the Engine
Air intake heater
–UN–18MAR92
CAUTION: DO NOT use starting fluid on
engines equipped with grid-type air intake
heater or glow plug (s). Ether starting fluid is
highly flammable and may explode, causing
serious injury.
TS1356
NOTE: On engines with electronically controlled fuel
system (DE10, HPCR), the air intake heater
operates automatically, controlled by the ECU. An
engine preheater indicator light comes on when
the key switch is turned ON. In warm weather, the
light comes on briefly for a light check. In cold
weather, the light remains ON during the
automatic operation of the air intake heater or
glow plug (s). Operating time depends on
temperature. Do not crank engine until light goes
OFF.
Handle starting fluid with care
CD30750
–UN–03SEP99
• 3029 and 4039 engines are optionally equipped with
the single glow plug (B) screwed in cylinder head intake
manifold. Activate the glow plug (preheater position) for
30 seconds maximum then start the engine.
• 4045 and 6068 engines (except HPCR, 4-valve head)
are optionally equipped with the grid-type air heater (A)
installed between cylinder head and air intake pipe.
- For mechanical fuel system, activate the heating
element (preheater position) for 30 seconds maximum
then start the engine.
- For electronically controlled engines (DE10, HPCR
2-valve head), turn key switch ON, but DO NOT crank
engine until engine preheater indicator light turns OFF.
• HPCR, 4-valve head engines are equipped with glow
plugs (one per cylinder) (C). Turn key switch ON, but
DO NOT crank engine until preheater indicator light
turns OFF.
–UN–23JAN07
Glow Plug or Grid-Type air heater
CD30925
A—Grid-Type heater (4045 and 6068 non HPCR
4-valve head engines)
B—Single Glow Plug (3029 and 4039 engines)
C—Multiple Glow Plugs (HPCR 4-valve head engines)
Glow Plugs on HPCR, 4-valve head engine
Continued on next page
15-31
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Operating the Engine
Coolant heater
Connect plug of coolant heater (A) to a proper power
source (110 or 220 V).
LX1017768
–UN–24OCT97
At an ambient temperature of -15°C (5°F), the heating
process takes approximatively 2 hours. Extend heating
period if ambient temperature is lower.
DPSG,CD03523,19 –19–06FEB07–3/4
Fuel preheater
LX1017708
–UN–09OCT97
Fuel preheater (A) switches ON and OFF automatically in
relation with the ambient temperature.
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Operating the Engine
Using a booster battery or charger
–UN–23AUG88
A 12-volt booster battery can be connected in parallel with
battery(ies) on the unit to aid in cold weather starting.
ALWAYS use heavy duty jumper cables.
TS204
CAUTION: Gas given off by battery is explosive.
Keep sparks and flames away from battery.
Before connecting or disconnecting a battery
charger, turn charger off. Make last connection
and first disconnection at a point away from
battery. Always connect NEGATIVE (–) cable
last and disconnect this cable first.
RG4678
–UN–14DEC88
IMPORTANT: Be sure polarity is correct before
making connections. Reversed polarity
will damage electrical system. Always
connect positive to positive and
negative to ground. Always use 12-volt
booster battery for 12-volt electrical
systems and 24-volt booster battery(ies)
for 24-volt electrical systems.
12-Volt System
1. Connect booster battery or batteries to produce the
required system voltage for your engine application.
NOTE: To avoid sparks, DO NOT allow the free ends of
jumper cables to touch the engine.
–UN–14DEC88
2. Connect one end of jumper cable to the POSITIVE (+)
post of the booster battery.
RG4698
3. Connect the other end of the jumper cable to the
POSITIVE (+) post of battery connected to starter.
4. Connect one end of the other jumper cable to the
NEGATIVE (–) post of the booster battery.
24-Volts System
5. ALWAYS complete the hookup by making the last
connection of the NEGATIVE (–) cable to a good
ground on the engine frame and away from the
battery(ies).
A—12-Volt Machine battery (ies)
B—12-Volt Booster battery (ies)
C—Booster cable
D—Cable to starter motor
6. Start the engine. Disconnect jumper cables
immediately after engine starts. Disconnect NEGATIVE
(–) cable first.
DPSG,CD03523,20 –19–22JAN07–1/1
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Operating the Engine
Engine operation
Warming engine
Operate engine at high idle for 1 to 2 minutes before
applying the load.
• Excessive fuel consumption
• Excessive oil consumption
• Fluid leaks
NOTE: This procedure does not apply to standby
generator sets where the engine is loaded
immediately upon reaching rated speed.
Recommendation for turbocharger engines
Should the engine stall when operating under load,
IMMEDIATELY restart it to prevent overheating of
turbocharger components.
Normal engine operation
Compare engine coolant temperature and engine oil
pressure with specifications below:
Specification
Minimum oil pressure at full
load rated speed1—Pressure ................... 275 kPa (2.75 bar) (40 psi)
Coolant temperature range—
Temperature ............................................... 82°—94°C (180°—202°F)
Stop engine immediately if coolant temperature is
above or oil pressure below specifications or if there
are any signs of part failure. Symptoms that may be
early signs of engine problems could be:
NOTE: Generator set applications have the governor
locked at a specified speed and do not have a
slow idle function. These engines idle at no
load governed speed (fast idle).
• Sudden loss of power
• Unusual noise or vibration
• Excessive black exhaust
1
Idling engine
Avoid excessive engine idling. Prolonged idling may
cause the engine coolant temperature to fall below its
normal range. This, in turn, causes crankcase oil
dilution, due to incomplete fuel combustion, and
permits formation of gummy deposits on valves,
pistons, and piston rings. It also promotes rapid
accumulation of engine sludge and unburned fuel in
the exhaust system. If an engine will be idling for more
than 5 minutes, stop and restart later.
Oil at normal operating temperature of 115°C (240°F).
DPSG,CD03523,21 –19–22JAN07–1/1
Standby power units
To assure that your engine will deliver efficient standby
operation when needed, start engine and run at rated
speed (with 50%—70% load) for 30 minutes every 2
weeks. DO NOT allow engine to run extended period
of time with no load.
DPSG,CD03523,22 –19–22JAN07–1/1
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Operating the Engine
Stopping the engine
1. Before stopping, run engine for at least 2 minutes at
fast idle and no load.
2. Stop the engine.
DPSG,CD03523,23 –19–22JAN07–1/1
Changing Generator Frequency
Generator sets powered by 6068HFU74 engine are
dual-frequency; 50 Hz (1500 rpm) or 60 Hz (1800 rpm).
Refer to the generator set documentation for more
information.
CD03523,000018C –19–26JAN07–1/1
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Maintenance
Observe service intervals
Using hour meter as a guide, perform all services at
the hourly intervals indicated on following pages. At
each scheduled maintenance interval, perform all
previous maintenance operations in addition to the
ones specified. Keep a record of hourly intervals and
services performed using charts provided in
Maintenance Records Section.
IMPORTANT: Recommended service intervals are
for normal operating conditions.
Service MORE OFTEN if engine is
operated under adverse conditions.
Neglecting maintenance can result in
failures or permanent damage to the
engine.
DPSG,CD03523,24 –19–22JAN07–1/1
Use correct fuels, lubricants and coolant
–UN–23AUG88
IMPORTANT: Use only fuels, lubricants, and coolants
meeting specifications outlined in
Fuels, Lubricants, and Coolant Section
when servicing your John Deere
Engine.
TS100
Consult your John Deere engine distributor, servicing
dealer or your nearest John Deere Parts Network for
recommended fuels, lubricants, and coolant. Also
available are necessary additives for use when operating
engines in tropical, arctic, or any other adverse conditions.
DPSG,CD03523,25 –19–22JAN07–1/1
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Maintenance
Maintenance interval chart
Item
10 H /
daily
Check engine oil and coolant level
•
Check air filter restriction indicatora
•
Change engine oil and filter
500 H
1000 H /
1 year
2500 H /
3 years
As
required
•
b
•
Replace fuel filter element(s)
Check belt tension and automatic tensioner
•
c
•
Check and adjust valve clearanced
•
Clean crankcase vent tube
•
Check air intake hoses, connections and system
•
Pressure test cooling system
•
Check vibration damper (6 cyl.)
2000 H /
2 years
•
•
e
Check engine speed and speed drop governor
•
Drain and flush cooling systemf
•
•
Drain water and sediment from fuel filter
•
Clean filter element (see note a)
•
Test thermostat and injection nozzles (see your dealer)g
•
•
Test glow plugs (HPCR, 4-valve head)
a
Clean air filter element when restriction indicator is red. Replace filter element after 6 cleanings or once a year.
b
Change oil and filter after the first 100 hours of operation, then every 500 hours maximum thereafter (see DIESEL ENGINE OIL information).
Change oil and filter at least once a year.
c
Check belt tension every 500 hours on 3029 and 4039 engines and on 4045 and 6068 engines with manual tensioner. Check automatic belt
tensioner every 1000 hours/1 year on 4045 and 6068 engines when equipped.
d
Have your authorized servicing dealer or engine distributor adjust valve clearance as follows. After the first 500 hours of operation then every
1000 hours thereafter on 3029 and 4039 engines. Every 2000 hours on 4045 and 6068 engines.
e
Have your authorized dealer or engine distributor replace the vibration damper every 4500 hours/5 years.
f
Drain and flush cooling system every 2500 hours/3 years when John Deere COOL-GARD coolant is used. Otherwise every 2000 hours/2
years.
g
Contact your dealer when thermostat or injection nozzles are suspected to be defective. Replace injection nozzles every 5000 hours and
thermostat every 10000 hours.
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Maintenance/Daily or every 10 hours
–UN–26AUG99
CD30754
CD30753
–UN–26AUG99
Daily prestarting checks
3029 and 4039 engines
FD000047
CD30755
–UN–13MAR96
–UN–24SEP99
4045 and 6068 engines
Do the following BEFORE STARTING THE ENGINE
for the first time each day:
IMPORTANT: DO NOT add makeup oil until the oil
level is BELOW the add mark.
1. Check engine oil level on dipstick (A). Add as
required, using seasonal viscosity grade oil. (See
DIESEL ENGINE OIL). Add oil at rocker arm cover
filler cap (B).
IMPORTANT: DO NOT fill above the crosshatch
area. Oil levels anywhere within
crosshatch are considered in the
acceptable operating range.
Continued on next page
25-1
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TS281
CD30756
–UN–23AUG88
–UN–26AUG99
Maintenance/Daily or every 10 hours
hands. Slowly loosen cap to first stop to
relieve pressure before removing completely.
2.
CAUTION: Explosive release of fluids from
pressurized cooling system can cause
serious burns.
Remove radiator cap (E) and check coolant level
which should be at bottom of filler neck. Fill radiator
with proper coolant solution if level is low. (See
DIESEL ENGINE COOLANT). Check entire cooling
system for leaks.
Only remove filler cap when engine is cold
or when cool enough to touch with bare
DPSG,CD03523,27 –19–07FEB07–2/4
3. If air filter has a dust unloader valve (C), squeeze
valve tip to release any trapped dirt particles.
–UN–20DEC88
4. Check air intake restriction indicator (D). When
indicator is red, air filter needs to be cleaned.
RG4687
IMPORTANT: Maximum air intake restriction is 6.25
kPa (0.06 bar) (1.0 psi) (25 in. H2O). A
clogged air cleaner element will cause
excessive intake restriction and a
reduced air supply to the engine.
5. Make a thorough inspection of the engine
compartment.
CD30757
–UN–26AUG99
NOTE: Wipe all fittings, caps, and plugs before
performing any maintenance to reduce the chance
of system contamination.
Continued on next page
25-2
DPSG,CD03523,27 –19–07FEB07–3/4
061208
PN=80
150/256
Maintenance/Daily or every 10 hours
6.
CD30929
–UN–07FEB07
NOTE: Engines with mechanical fuel system have a
single fuel filter while electronically controlled
engines (DE10 and HPCR fuel systems) have two
fuel filters (primary and final). Moreover these
electronically controlled engines may be equipped
with a water sensor at the fuel filters. An indicator
light on the instrument panel will signal the
operator that water should be drained from filter
bowls.
Check fuel filters (C) and (D) for water and debris as
follows:
Drain fuel filter(s)
A—Drain plug
B—Air bleed plug
C—Primary fuel filter
D—Final fuel filter
a. Loosen drain plug(s) (A) at bottom of fuel filter(s) or
bowl(s) two or three turns.
b. Loosen air bleed plug(s) (B) two full turns and drain
water into a suitable container.
c. When fuel starts to drain out, tighten drain plug(s)
securely.
d. Bleed fuel system.
DPSG,CD03523,27 –19–07FEB07–4/4
25-3
061208
PN=81
151/256
Maintenance/500 hours
Changing engine oil and filter
–UN–26AUG99
IMPORTANT: Filtration of oils is critical to proper
lubrication. Always change filter
regularly. Use filter meeting John Deere
performance specifications.
CD30758
NOTE: Change engine oil and filter for the first time after
100 hours maximum of operation, then every 500
hours thereafter. Change oil and filter at leat once
a year.
1. Run engine approximately 5 minutes to warm up oil.
Shut engine off.
2. Open oil pan drain valve (A).
3. Drain crankcase oil from engine while warm.
CD30760
CD30926
–UN–30JAN07
–UN–26AUG99
DPSG,CD03523,29 –19–06FEB07–1/4
Oil new filter element packing
Oil filter on 3029 and 4039 engines
4. Replace oil filter
values printed on filter element. If values are
not provided, tighten element approximately
3/4 — 1-1/4 turn after packing contacts filter
housing. DO NOT overtighten filter element.
• 3029 and 4039 engines
a. Remove and discard oil filter element (B)
using a suitable filter wrench.
b. Oil new packing (C) and install new filter
element. Hand tighten element according to
Continued on next page
30-1
DPSG,CD03523,29 –19–06FEB07–2/4
061208
PN=82
152/256
CD30759A
RG11617
–UN–29JAN07
–UN–24OCT01
Maintenance/500 hours
Oil filter seals
Oil filter on 4045 and 6068 engines
RG11618
–UN–24OCT01
• 4045 and 6068 engines
a. Remove and discard oil filter element (A) using a
suitable filter wrench.
b. Apply clean engine oil to inner (B) and outer (C)
seals and to filter threads.
c. Wipe both sealing surfaces of the header (D, E)
with a clean rag. Ensure notches in dust seal (F)
are properly installed in the slots in the housing.
Replace dust seal if damaged.
d. Install and tighten oil filter by hand until firmly
against dust seal (F). DO NOT overtighten.
Filter and mounting header
A—Oil filter element
B—Inner seal
C—Outer seal
D—Sealing surface
E—Sealing surface
F—Dust seal
5. Close oil pan drain valve.
Continued on next page
30-2
DPSG,CD03523,29 –19–06FEB07–3/4
061208
PN=83
153/256
CD30927
CD30761
–UN–01FEB07
–UN–24SEP99
Maintenance/500 hours
Oil filler cap on rocker arm cover
Oil filler neck on engine side
6. Fill engine crankcase with correct John Deere engine
oil through opening on rocker arm cover (C) or on the
side of the engine (D). See DIESEL ENGINE OIL
Section for determining correct engine oil.
–UN–13MAR96
To determine the correct oil fill quantity for your engine,
see the Specifications Section.
FD000047
NOTE: Crankcase oil capacity may vary slightly.
ALWAYS fill crankcase to full mark or within
crosshatch on dipstick, whichever is present. DO
NOT overfill.
Oil dipstick
IMPORTANT: Immediately after completing any oil
change, crank engine for 30 seconds
without permitting engine to start. This
will help insure adequate lubrication to
engine components before engine
starts.
7. Start engine and run to check for possible leaks.
8. Stop engine and check oil level after 10 minutes. If
necessary, top up.
DPSG,CD03523,29 –19–06FEB07–4/4
30-3
061208
PN=84
154/256
Maintenance/500 hours
CD30930
X9811
–UN–07FEB07
–UN–23AUG88
Replacing fuel filter element(s)
Fuel filters
A—Retaining ring
B—Final fuel filter element
C—Drain plug
D—Bleed plug
CAUTION: Escaping fluid under pressure
can penetrate the skin causing serious
injury. Relieve pressure before
disconnecting fuel or other lines. Tighten all
connections before applying pressure. Keep
hands and body away from pinholes and
nozzles which eject fluids under high
pressure. Use a piece of cardboard or paper
to search for leaks. Do not use your hand.
If any fluid is injected into the skin, it must
be surgically removed within a few hours by
a doctor familiar with this type injury or
gangrene may result. Doctors unfamiliar with
this type of injury may call the Deere &
Company Medical Department in Moline,
Illinois, or other knowledgeable medical
source.
NOTE: Engines with mechanical fuel system have a
single fuel filter while electronically controlled
engines (DE10, HPCR) have two fuel filters
(primary and final). Both the primary and the
final filters have to be replaced together at the
same time.
E—Water separator bowl
F—Primary fuel filter element
1. Thoroughly clean fuel filter assembly and
surrounding area.
2. Loosen drain plug (C) and drain fuel into a suitable
container.
NOTE: Lifting up on retaining ring as it is rotated helps
to get it past raised locators.
3. Firmly grasp the retaining ring (A) and rotate it
clockwise 1/4 turn. Remove ring with filter element
(B).
IMPORTANT: Do not dump the old fuel into the
new filter element. This could cause
fuel injection problem.
A plug is provided with the new
element for plugging the used
element.
4. Inspect filter mounting base for cleanliness. Clean
as required.
Continued on next page
30-4
DPSG,CD03523,30 –19–07FEB07–1/2
061208
PN=85
155/256
Maintenance/500 hours
NOTE: Raised locators on fuel filter canister must be
indexed properly with slots in mounting base
for correct installation.
5. Install new filter element dry onto mounting base.
Be sure element is properly indexed and firmly
seated on base. It may be necessary to rotate filter
for correct alignment.
tighten ring (about 1/3 turn) until it ”snaps” into the
detent. DO NOT overtighten retaining ring.
NOTE: The proper installation is indicated when a
"click" is heard and a release of the retaining
ring is felt.
7. Bleed the fuel system.
6. Install retaining ring onto mounting base making
certain dust seal is in place on filter base. Hand
DPSG,CD03523,30 –19–07FEB07–2/2
30-5
061208
PN=86
156/256
Maintenance/500 hours
Checking belt (3029 and 4039 Engines)
1. Inspect belt for cracks, fraying, or stretched out areas.
Replace as necessary.
–UN–04MAY98
2. Check belt tension using one of following methods:
a) Use of JDG529 Tension Gauge (A)
CD30644
Specification
Belt tension—New belt ........................... 578—622 N (130—140 lb-force)
Used belt .................................................... 378—423 N (85—94 lb-force)
NOTE: Belt is considered used after 10 minutes of
operation.
–UN–04MAY98
b) Use of tension tester (B) and straightedge (C)
A 89 N (20 lb) force applied halfway between pulleys
should deflect belt by 19 mm (0.75 in.).
CD30645
3. If adjustment is necessary, loosen alternator nuts (D)
and (E). Pull alternator frame outward until belt is
correctly tensioned.
IMPORTANT: Do not pry against the alternator rear
frame. Do not tighten or loosen belts
while they are hot.
4. Tighten alternator bracket nuts firmly.
5. Run engine for 10 minutes then recheck belt tension.
CD30646
–UN–04MAY98
A—JDG529 Tension Gauge
B—Tension tester
C—Straightedge
D—Upper nut
E—Lower nut
DPSG,CD03523,31 –19–30JAN07–1/1
30-6
061208
PN=87
157/256
Maintenance/500 hours
Checking belt (4045 and 6068 Engines with
manual tensioner)
–UN–04OCT99
Inspect belts for cracks, fraying, or stretched out areas.
Replace if necessary.
NOTE: Belt adjustment is measured using a gauge
stamped on the top edge of the alternator bracket.
RG9132
1. Loosen cap screws (B) and (C).
2. Slide alternator in slot by hand to remove all excess
slack in belt. Scribe a reference mark (D) on line with
notch (E) on upper alternator bracket.
Manual belt tensioner on 4045 and 6068 engines
IMPORTANT: Do not pry against alternator rear frame.
–UN–10JAN03
3. Using the gauge (A) on the alternator bracket, stretch
belt by prying outward on alternator front frame.
Stretch the belt 1 gauge unit for a used belt and 1.5
gauge units for a new belt.
4. Tighten cap screws (B) and (C).
CD30843
A—Belt gauge
B—Cap screw
C—Cap screw
D—Reference mark
E—Alternator upper bracket notch
Reference marks
DPSG,CD03523,57 –19–30JAN07–1/1
30-7
061208
PN=88
158/256
Maintenance/1000 hours/1 year
Cleaning crankcase vent tube
If you operate the engine in dusty conditions, clean the
tube at shorter intervals.
–UN–27AUG99
1. Remove and clean crankcase vent tube (A).
CD30773
2. Install the vent tube. Be sure the O-ring fits correctly in
the rocker arm cover for elbow adapter. Tighten hose
clamp securely.
DPSG,CD03523,32 –19–22JAN07–1/1
CD30762
–UN–27AUG99
Checking air intake system
IMPORTANT: The air intake system must not leak.
Any leak, no matter how small, may
result in engine failure due to
abrasive dirt and dust entering the
intake system.
2. Check clamps on piping (A) which connect the air
filter, engine and, if present, turbocharger and
air-to-air radiator. Tighten clamps as necessary.
3. Test air restriction indicator (B) for proper operation.
Replace indicator as necessary.
1. Inspect all intake hoses (piping) for cracks. Replace
as necessary.
Continued on next page
35-1
DPSG,CD03523,33 –19–22JAN07–1/2
061208
PN=89
159/256
Maintenance/1000 hours/1 year
4.
–UN–20DEC88
If engine has a rubber dust unloader valve (C), inspect
the valve on bottom of air filter for cracks or plugging.
Replace as necessary.
RG4687
5. Service air filter as necessary.
DPSG,CD03523,33 –19–22JAN07–2/2
Checking automatic belt tensioner (4045 and
6068 Engines)
–UN–18NOV97
Belt drive systems equipped with automatic (spring) belt
tensioners cannot be adjusted or repaired. The automatic
belt tensioner is designed to maintain proper belt tension
over the life of the belt. If tensioner spring tension is not
within specification, replace tensioner assembly.
RG8098
• Checking belt wear
The belt tensioner is designed to operate within the limit
of arm movement provided by the cast stops (A and B)
when correct belt length and geometry is used. If the
tensioner stop on swing arm (A) is hitting the fixed stop
(B), check mounting brackets (alternator, belt tensioner,
idler pulley, etc.) and the belt length. Replace belt as
needed (see REPLACING FAN AND ALTERNATOR
BELTS).
–UN–11NOV04
Earlier design tensioner
RG13744
A—Swing arm stop
B—Fixed cast stop
Later design tensioner
Continued on next page
35-2
DPSG,CD03523,34 –19–30JAN07–1/2
061208
PN=90
160/256
Maintenance/1000 hours/1 year
RG7977
–UN–14NOV97
• Checking tensioner spring tension
A belt tension gauge will not give an accurate measure
of the belt tension when automatic spring tensioner is
used. Measure tensioner spring tension using a torque
wrench and procedure outlined below:
a. Release tension on belt using a breaker bar and
socket on tension arm. Remove belt from pulleys.
b. Release tension on tension arm and remove breaker
bar.
c. Put a mark (A) on swing arm of tensioner as shown.
d. Measure 21 mm (0.83 in.) from (A) and put a mark
(B) on tensioner mounting base.
Marks on tensioner
NOTE: Earlier engines have a LEFT-HAND thread roller
cap screw while later engines have a 12.7 mm
(1/2 in.) square hole in tensioner.
RG12054
–UN–08JAN02
e. Install torque wrench on roller cap screw or in
square hole so that it is aligned with center of roller
and tensioner as shown. Rotate the swing arm using
a torque wrench until marks (A and B) are aligned.
f. Record torque wrench measurement and compare
with specification below. Replace tensioner assembly
as required.
Specification
Spring—Force................................................... 18—22 N•m (13—16 lb-ft)
Align marks
A—Mark on swing arm
B—Mark on tensioner mounting base
DPSG,CD03523,34 –19–30JAN07–2/2
35-3
061208
PN=91
161/256
Maintenance/1000 hours/1 year
Check and adjust engine valve clearance
(3029 and 4039 Engines)
–UN–19MAY98
NOTE: Valve clearance must be adjusted after the first
500 hours of operation, then every 1000 hours
thereafter.
CD30544
Adjust engine valve clearance as follows or have your
authorized servicing dealer or engine distributor adjust the
engine valve clearance.
1. Remove rocker arm cover and crankcase vent tube.
2. Using JDE83 or JDG820 Flywheel Turning Tool (A),
rotate engine flywheel in running direction (clockwise
viewed from water pump) until No.1 piston (front) has
reached top dead center (TDC) on compression stroke.
Insert timing pin JDE81-4 or JDG1571 (B) into flywheel
bore.
DPSG,CD03523,35 –19–31JAN07–1/4
3. Check and adjust valve clearance to specifications
according to following procedures.
–UN–19MAY98
Specification
Valve clearance (engine cold)—
Intake .......................................................................... 0.35 mm (0.014 in.)
Exhaust ....................................................................... 0.45 mm (0.018 in.)
CD30545
NOTE: If rocker arm is equipped with adjusting screw and
jam nut (A), tighten jam nut to 27 N•m (20 lb-ft)
after adjusting valve clearance.
RG6307
–UN–03AUG92
4. Reinstall rocker arm cover and crankcase vent tube.
Continued on next page
35-4
DPSG,CD03523,35 –19–31JAN07–2/4
061208
PN=92
162/256
Maintenance/1000 hours/1 year
• 3-Cylinder Engine:
NOTE: Firing order is 1-2-3
–UN–16JUN98
a. Lock No. 1 piston at TDC compression stroke (D).
b. Adjust valve clearance on No. 1 and 2 exhaust
valves and No.1 and 3 intake valves.
c. Rotate flywheel 360°. Lock No. 1 piston at TDC
exhaust stroke (E).
d. Adjust valve clearance on No. 3 exhaust valve and
No. 2 intake valve.
CD30549
A—Front of engine
B—Exhaust valve
C—Intake valve
D—No.1 Piston at TDC compression stroke
E—No.1 Piston at TDC exhaust stroke
DPSG,CD03523,35 –19–31JAN07–3/4
• 4-Cylinder Engine:
NOTE: Firing order is 1-3-4-2
RG4776
–UN–31OCT97
a. Lock No. 1 piston at TDC compression stroke (B).
b. Adjust valve clearance on No. 1 and 3 exhaust
valves and No.1 and 2 intake valves.
c. Rotate flywheel 360°. Lock No. 4 piston at TDC
compression stroke (C).
d. Adjust valve clearance on No. 2 and 4 exhaust
valves and No. 3 and 4 intake valves.
A—Front of engine
B—No.1 Piston at TDC compression stroke
C—No.4 Piston at TDC compression stroke
E—Exhaust valve
I—Intake valve
DPSG,CD03523,35 –19–31JAN07–4/4
35-5
061208
PN=93
163/256
Maintenance/1000 hours/1 year
RG6557
–UN–20JAN93
–UN–20JAN93
Pressure testing cooling system
RG6558
Test radiador cap
Test cooling system
1. Allow engines to cool, then carefully remove
radiator cap.
CAUTION: Explosive release of fluids from
pressurized cooling system can cause
serious burns.
2. Fill radiator with coolant to the normal operating
level.
Shut off engines. Only remove filler cap
when cool enough to touch with bare hands.
Slowly loosen cap to first stop to relieve
pressure before removing completely.
IMPORTANT: DO NOT apply excessive pressure to
cooling system, doing so may
damage radiator and hoses.
Test Radiator Cap
3. Connect gauge and adapter to radiator filler neck.
Pressurize cooling system to specification listed for
radiator cap.
1. Remove radiator cap and attach to D05104ST
tester as shown.
4. With pressure applied, check all cooling system
hose connections, radiator, and overall engine for
leaks.
2. Pressurize cap to specification listed. Gauge should
hold pressure for 10 seconds within the normal
range if cap is acceptable.
If leakage is detected, correct as necessary and
pressure test system again.
If gauge does not hold pressure, replace radiator
cap.
If no leakage is detected, but the gauge indicated a
drop in pressure, coolant may be leaking internally
within the system or at the block-to-head gasket.
Have your engine distributor or servicing dealer
correct this problem immediately.
Specification
Radiator Cap Calibration—
Pressure............................................. 70 kPa (0.7 bar) (10 psi) for 10
seconds minimum
3. Remove the cap from gauge, turn it 180°, and
retest cap to confirm measurement.
Test Cooling System
NOTE: Engine should be warmed up to test overall
cooling system.
CD03523,00000EC –19–22JAN07–1/1
35-6
061208
PN=94
164/256
Maintenance/2000 hours/2 years
Check and adjust engine valve clearance
(4045 and 6068 Engines)
–UN–19MAY98
Adjust engine valve clearance as follows or have your
authorized servicing dealer or engine distributor adjust the
engine valve clearance.
1. Remove rocker arm cover and crankcase vent tube.
CD30544
2. Using JDE83 or JDG820 Flywheel Turning Tool (A),
rotate engine flywheel in running direction (clockwise
viewed from water pump) until No.1 piston (front) has
reached top dead center (TDC) on compression stroke.
Insert timing pin JDE81-4 (B) into flywheel bore.
DPSG,CD03523,36 –19–31JAN07–1/4
3. Check and adjust valve clearance to specifications
according to following procedures.
–UN–06AUG96
Specification
Valve clearance (engine cold)—
Intake .......................................................................... 0.35 mm (0.014 in.)
Exhaust ....................................................................... 0.45 mm (0.018 in.)
RG7409
4. If valves need adjusting, loosen the locknut on rocker
arm adjusting screw. Turn adjusting screw until feeler
gauge slips with a slight drag. Hold the adjusting screw
from turning with screwdriver and tighten locknut to 27
N•m (20 lb-ft). Recheck clearance after tightening
locknut. Readjust clearance as necessary
5. Reinstall rocker arm cover and crankcase vent tube.
Continued on next page
40-1
DPSG,CD03523,36 –19–31JAN07–2/4
061208
PN=95
165/256
Maintenance/2000 hours/2 years
• 4-Cylinder Engine:
NOTE: Firing order is 1-3-4-2
RG4776
–UN–31OCT97
a. Lock No. 1 piston at TDC compression stroke (B).
b. Adjust valve clearance on No. 1 and 3 exhaust
valves and No.1 and 2 intake valves.
c. Rotate flywheel 360°. Lock No. 4 piston at TDC
compression stroke (C).
d. Adjust valve clearance on No. 2 and 4 exhaust
valves and No. 3 and 4 intake valves.
A—Front of engine
B—No.1 Piston at TDC compression stroke
C—No.4 Piston at TDC compression stroke
E—Exhaust valve
I—Intake valve
DPSG,CD03523,36 –19–31JAN07–3/4
• 6-Cylinder Engine:
NOTE: Firing order is 1-5-3-6-2-4.
RG4777
–UN–31OCT97
a. Lock No. 1 piston at TDC compression stroke (B).
b. Adjust valve clearance on No. 1, 3, and 5 exhaust
valves and No. 1, 2, and 4 intake valves.
c. Rotate flywheel 360°. Lock No. 6 piston at TDC
compression stroke (C).
d. Adjust valve clearance on No. 2, 4, and 6 exhaust
valves and No. 3, 5, and 6 intake valves.
A—Front of engine
B—No.1 Piston at TDC compression stroke
C—No.6 Piston at TDC compression stroke
E—Exhaust valve
I—Intake valve
DPSG,CD03523,36 –19–31JAN07–4/4
40-2
061208
PN=96
166/256
Maintenance/2000 hours/2 years
Checking engine speed (Mechanical fuel
system)
–UN–24SEP99
NOTE: Most engines for generator set application (1500
rpm for 50 Hz or 1800 rpm for 60 Hz) run only at
fast idle and therefore they do not have slow idle.
CD30763
Specification
Fast idle—50 Hz Generator set ...................................... 1550—1580 rpm
60 Hz Generator set ........................................................ 1865—1890 rpm
NOTE: Fast idle is settled by the factory then the idle
adjusting screw (A) is sealed to prevent from
tampering. Fast idle adjustment can only be done
by an authorized fuel system agent.
A—Fast idle adjusting screw
DPSG,CD03523,38 –19–31JAN07–1/1
Adjust speed droop governor (Mechanical
fuel system)
1. Warm engine to normal operating temperature.
–UN–24SEP99
2. Run engine at fast idle.
3. Apply full load.
CD30764
4. If specified power cannot be obtained, turn screw (B)
to adjust droop until the requested power is reached.
NOTE: If surging exits upon removing the load, turn
screw (B) clockwise to eliminate.
B—Speed droop governor adjusting screw
DPSG,CD03523,39 –19–31JAN07–1/1
40-3
061208
PN=97
167/256
Maintenance/2000 hours/2 years
Checking crankshaft vibration damper
(6-CYLINDER ENGINE ONLY)
1. Remove belts (shown removed).
–UN–15JAN99
2. Grasp vibration damper with both hands and attempt to
turn it in both directions. If rotation is felt, damper is
defective and should be replaced.
RG8018
IMPORTANT: The vibration damper assembly is not
repairable and should be replaced every
4500 hours or 5 years, whichever
occurs first.
3. Check vibration damper radial runout by positioning a
dial indicator so probe contacts damper outer
circumference.
–UN–23NOV97
4. With engine at operating temperature, rotate crankshaft
using JDG820 or JDE83 Flywheel Turning Tool.
RG7508
5. Note dial indicator reading. If runout exceeds
specifications given below, replace vibration damper.
Specification
Damper—Maximum radial runout .............................. 1.50 mm (0.060 in.)
DPSG,CD03523,40 –19–22JAN07–1/1
40-4
061208
PN=98
168/256
Maintenance/2500 hours/3 years
Drain and flush cooling system
–UN–23AUG88
NOTE: Drain and flush cooling system every 2500
hours/3 years when John Deere COOL-GARD
coolant is used. Otherwise every 2000 hours/2
years
TS281
CAUTION: Explosive release of fluids from
pressurized cooling system can cause serious
burns.
Shut off engine. Only remove filler cap when
cool enough to touch with bare hands. Slowly
loosen cap to first stop to relieve pressure
before removing completely.
1. Slowly open the radiator cap.
–UN–14DEC88
2. Remove engine block drain plug (A).
RG4894
3. On POWERTech engines, remove oil cooler housing
drain plug (B).
4. Open radiator drain valve (C). Drain all coolant from
radiator.
5. Close all drain orifices after coolant has drained.
–UN–11JAN99
6. Fill the cooling system with clean water. Run engine
until water passes through the thermostat to stir up
possible rust or sediment.
ZX016192
7. Stop engine and immediately drain the water from
system before rust and sediment settle.
8. After draining water, close all drain orifices and fill the
cooling system with cleaning product such as
PMCC2610 or PMCC2638 Cooling System Cleaners
available from your John Deere Dealer. Follow
manufacturer’s directions on label.
CD30765
–UN–27AUG99
9. After cleaning the cooling system, drain cleaner and fill
with water to flush the system. Run engine until water
passes through the thermostat, then drain out flushing
water.
Continued on next page
45-1
DPSG,CD03523,41 –19–06JUN08–1/3
061208
PN=99
169/256
Maintenance/2500 hours/3 years
10. Check cooling system hoses for proper condition.
Replace as necessary.
11. Close all drain orifices and fill the cooling system with
specified coolant (see DIESEL ENGINE COOLANT).
Specification
Cooling system capacity—
CD3029DF128 ................................................................... 14.5 L (15.5
CD3029TF158 ................................................................... 14.5 L (15.5
CD3029HFS70 .................................................................. 14.5 L (15.5
CD3029TFS70 ................................................................... 14.5 L (15.5
CD3029HFU70 .................................................................. 14.5 L (15.5
CD3029TFU70................................................................... 14.5 L (15.5
CD4039DF008 ................................................................... 16.5 L (17.5
CD4039TF008 ................................................................... 16.5 L (17.5
CD4045DF158 ......................................................................... 20 L (21
CD4045HF158 ...................................................................... 28 L (29.5
CD4045TF158 ...................................................................... 25 L (26.5
CD4045TF258 ...................................................................... 25 L (26.5
CD4045HFS72 ..................................................................... 28 L (29.5
CD4045HFS73 ........................................................................ 32 L (34
CD4045HFS80 ..................................................................... 25 L (26.5
CD4045HFS82 ........................................................................ 32 L (34
CD4045HFS83 ........................................................................ 32 L (34
CD4045HFU72 ..................................................................... 28 L (29.5
CD4045HFU79 ........................................................................ 32 L (34
CD4045TFU70...................................................................... 25 L (26.5
CD6068HF158 ......................................................................... 32 L (34
CD6068HF258 ......................................................................... 32 L (34
CD6068TF158 ...................................................................... 28 L (29.5
CD6068TF258 ...................................................................... 28 L (29.5
CD6068HFS72 ........................................................................ 32 L (34
CD6068HFS73 ........................................................................ 32 L (34
CD6068HFS76 ........................................................................ 35 L (37
CD6068HFS77 ........................................................................ 35 L (37
CD6068HFS82 ........................................................................ 32 L (34
CD6068HFS83 ........................................................................ 32 L (34
CD6068HFS89 ........................................................................ 35 L (37
CD6068HFU72 ........................................................................ 32 L (34
CD6068HFU74 ........................................................................ 35 L (37
CD6068HFU79 ........................................................................ 32 L (34
qt)
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Continued on next page
45-2
DPSG,CD03523,41 –19–06JUN08–2/3
061208
PN=100
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Maintenance/2500 hours/3 years
12. When refilling cooling system, loosen temperature
sensor (B) or plug at the rear of cylinder head to
allow air to escape.
CD30643
–UN–04MAY98
13. Run engine until it reaches operating temperature
then check coolant level and entire cooling system for
leaks.
DPSG,CD03523,41 –19–06JUN08–3/3
45-3
061208
PN=101
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Maintenance/As required
Additional service information
–UN–15DEC88
This manual does not allow a complete repair of your
engine. If you want want more detailed service information
the following publications are available from your regular
parts channel.
RG4624
• PC2451 — Parts Catalog for Non-Emission Certified
engines
• PC3235 — Parts Catalog for Stage II Emission Certified
engines
• CTM3274 — Component Technical Manual for 3029
and 4039 engines (English)
• CTM104 — Component Technical Manual for 4045 and
6068 base engines (English)
• CTM207 — Component Technical Manual for
Mechanical Fuel Systems on 4045 and 6068 engines
(English)
• CTM320 — Component Technical Manual for HPCR
Fuel System on 4045 and 6068 with 4-Valve Head
Engines (English)
• CTM331 — Component Technical Manual for DE10
Fuel Systems on 4045 and 6068 engines (English)
• CTM502 — Component Technical Manual for HPCR
Fuel System on 4045 and 6068 with 2-Valve Head
Engines (English)
• CTM67 — Component Technical Manual for OEM
Engine accessories (English only)
• CTM77 — Component Technical Manual for Alternators
and Starter Motors (English only)
DPSG,CD03523,42 –19–31JAN07–1/1
50-1
061208
PN=102
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Maintenance/As required
Do not modify fuel system
–UN–24SEP99
IMPORTANT: Modification or alteration of the
injection pump, the injection pump
timing, or the fuel injectors in ways not
recommended by the manufacturer will
terminate the warranty obligation to the
purchaser.
CD30768
Do not attempt to service injection
pump or fuel injectors yourself. Special
training and special tools are required.
(See your authorized servicing dealer or
engine distributor.)
DPSG,CD03523,43 –19–22JAN07–1/1
50-2
061208
PN=103
173/256
Maintenance/As required
Clean or replace air filter (one-piece)
Clean air filter when restriction indicator (A) is red. Air
filter can be cleaned up to six times. Thereafter, or at
least once a year, it must be replaced.
–UN–06SEP99
Proceed as follows:
CD30766
1. Thoroughly clean all dirt around air filter area.
2. Loosen clamp (B) then remove air filter.
IMPORTANT: Never reinstall an air filter which shows
evidence of bad condition (punched,
dented...) allowing no filtered air to
enter the engine.
–UN–25FEB99
3. Clean air filter with compressed air working from
”clean” to ”dirty” side.
NOTE: Compressed air pressure must not exceed 600
kPa (6 bar; 88 psi).
RG9912
4. Mark air filter to keep track of each cleaning operation.
5. Fully depress air restriction indicator reset button and
release to reset indicator.
6. Check air system entirely for proper condition (see
CHECKING AIR INTAKE SYSTEM).
DPSG,CD03523,44 –19–22JAN07–1/1
50-3
061208
PN=104
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Maintenance/As required
CD30772
–UN–27AUG99
Clean or replace air filter element
A—Primary element
B—Secondary (safety) element
Clean air filter when restriction indicator (C) is red.
Replace both primary (A) and secondary (B) filter
elements after primary element has been cleaned six
times or at least once a year.
C—Air restriction indicator
D—Wing nut
dented...), replace both the primary
and the secondary elements.
4. Clean primary element with compressed air working
from ”clean” to ”dirty” side.
Proceed as follows:
1. Thoroughly clean all dirt around air filter area.
NOTE: Compressed air pressure must not exceed 600
kPa (6 bar; 88 psi).
2. Remove wing nut (D) and remove primary element
(A) from canister.
5. Mark air filter to keep track of each cleaning
operation.
IMPORTANT: Do not attempt to clean the
secondary (safety) element (B). It
must be only replaced as
recommended.
6. Fully depress air restriction indicator reset button
and release to reset indicator.
7. Check air system entirely for proper condition (see
CHECKING AIR INTAKE SYSTEM).
3. Thoroughly clean all dirt from inside canister.
IMPORTANT: If primary element shows evidence
of bad condition (punched,
DPSG,CD03523,58 –19–22JAN07–1/1
50-4
061208
PN=105
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Maintenance/As required
Replacing fan and alternator belt (4045 and
6068 Engines)
NOTE: Refer to CHECKING BELT TENSIONER SPRING
TENSION AND BELT WEAR for additional
information on the belt tensioner.
–UN–01SEP99
1. Inspect belts for cracks, fraying, or stretched out areas.
Replace if necessary.
CD30769
2. On engines with automatic belt tensioner, release
tension on belt using a breaker bar and socket on
tension arm.
On engines with manual tensioner, loosen cap screws
holding the alternator.
Installation on 4045 engines
3. Remove poly V-belt from pulleys and discard belt.
4. Install new belt, making sure belt is correctly seated in
all pulley grooves. Refer to belt routing at right for your
application.
–UN–01SEP99
5. Apply tension to belt (See CHECKING BELT).
6. Start engine and check belt alignment.
CD30770
ALT—Alternator
CP—Crank Pulley
FD—Fan Drive
I—Idler Pulley
T—Tensioner
WP—Water Pump
Installation on 6068 engines
DPSG,CD03523,45 –19–31JAN07–1/1
50-5
061208
PN=106
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Maintenance/As required
Bleeding the fuel system
X9811
–UN–23AUG88
CAUTION: Escaping fluid under pressure can
penetrate the skin causing serious injury.
Relieve pressure before disconnecting fuel or
other lines. Tighten all connections before
applying pressure. Keep hands and body away
from pinholes and nozzles which eject fluids
under high pressure. Use a piece of cardboard
or paper to search for leaks. Do not use your
hand.
–UN–13NOV97
If ANY fluid is injected into the skin, it must be
surgically removed within a few hours by a
doctor familiar with this type injury or gangrene
may result. Doctors unfamiliar with this type of
injury may call the Deere & Company Medical
Department in Moline, Illinois, or other
knowledgeable medical source.
RG7947
NOTE: Engines with mechanical fuel system have a
single fuel filter while electronically controlled
engines (DE10 and HPCR fuel systems) have two
fuel filters (primary and final). Whenever the fuel
system has been opened up for service (lines
disconnected or filters removed), it will be
necessary to bleed air from the system. On dual
fuel filter system, bleed air only from final filter.
Fuel filter bleed screw
A.) Mechanical and DE10 fuel systems
–UN–15JAN99
1. Loosen the air bleed screw (A) two full turns. On DE10
fuel system, loosen only air bleed screw on final fuel
filter.
RG8013A
2. Operate supply pump primer lever (B) until fuel flow is
free from air bubbles.
Fuel pump primer lever
3. Tighten bleed screw securely, continue operating hand
primer until pumping action is not felt.
4. Start engine and check for leaks.
If engine does not start, it will be necessary to bleed air
from fuel system at fuel injection pump or injection
nozzles as explained next.
Continued on next page
50-6
DPSG,CD03523,46 –19–09FEB07–1/4
061208
PN=107
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CD30928
CD30771
–UN–02FEB07
–UN–24SEP99
Maintenance/As required
Mechanical injection pump return line
DE10 Fuel return line
• At Fuel Injection Pump:
a. Slightly loosen fuel return line connector (C) at
fuel injection pump.
b. Operate fuel supply pump primer lever until fuel,
without air bubbles, flows from fuel return line
connection.
c. Securely tighten return line connector.
DPSG,CD03523,46 –19–09FEB07–2/4
RG7725
–UN–08JAN97
• At Fuel Injection Nozzles:
a. Using two open-end wrenches, loosen fuel line
connection at injection nozzle.
b. Crank engine over with starting motor, (but do not
start engine), until fuel free from bubbles flows out of
loosened connection. Retighten connection to 27
N•m (20 lb-ft).
c. Repeat procedure for remaining injection nozzles (if
necessary) until all air has been removed from fuel
system.
If engine still will not start, see your authorized servicing
dealer or engine distributor.
Bleed fuel system at fuel injection nozzles
Continued on next page
50-7
DPSG,CD03523,46 –19–09FEB07–3/4
061208
PN=108
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TS1343
RG12220
–UN–18MAR92
–UN–24MAY02
Maintenance/As required
Final fuel filter bleed screw
B.) HPCR fuel system (2 or 4-valve head)
CAUTION: High-pressure fluid remaining in fuel
lines can cause serious injury. Do not
disconnect fuel lines between the high pressure
fuel pump and nozzles. Only bleed the fuel
system at the fuel filter bleed screw (A).
–UN–24MAY02
1. Loosen the air bleed screw (A) two full turns on final
filter base only.
RG12221
2. Operate fuel supply pump primer lever (B) until fuel
flow is free from air bubbles.
3. Tighten bleed screw securely. Continue operating
primer until pumping action is not felt.
Fuel supply pump primer lever
4. Start engine and check for leaks.
If engine will not start, repeat steps 1-4.
DPSG,CD03523,46 –19–09FEB07–4/4
50-8
061208
PN=109
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Troubleshooting
General troubleshooting information
Troubleshooting electronically controlled engine
problems can be difficult. The first thing to do is to
identify the type of problem which can be mechanical
or electrical.
An engine wiring layout is provided in this section to
identify electrical components (engine controller,
sensors, connectors... ).
Later in this section is a list of possible engine
problems and diagnostic trouble codes that may be
encountered accompanied by possible causes and
corrections. This troubleshooting information is of a
general nature. See also the generator documentation
for a complete information of your application.
A reliable program for troubleshooting engine problems
should include the following basic diagnostic thought
process:
• Know the engine and all related systems.
• Study the problem thoroughly.
• Relate the symptoms to your knowledge of engine
and systems.
• Diagnose the problem starting with the easiest
things first.
• Double-check before beginning the disassembly.
• Determine cause and make a thorough repair.
• After making repairs, operate the engine under
normal conditions to verify that the problem and
cause was corrected.
CD03523,000018D –19–08FEB07–1/1
55-1
061208
PN=110
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Troubleshooting
RG12201
–UN–24MAY02
Engine Wiring Layout (Electronic Fuel System With Stanadyne DE10 Injection Pump)
A—Coolant Temperature
Sensor Connector
B—Fuel Temperature Sensor
Connector
C—Injection Pump Solenoid
Connector
D—SAE 1939 CAN Connector
E—Crankshaft Position Sensor
Connector
F—ECU Connector
G—Starter Relay Connector
H—Oil Pressure Sensor
Connector
I—Main System Fuse (10 amp)
J—Power and Ground Battery
Connections
K—Fuse Holder
L—Transient Voltage
Protection (TVP) Module
Connector
M—Remote ON/ OFF
Connector
N—CAN Network Diagnostic
Connector
O—Instrument Panel
Connector Harness
P—23-pin Optional Feature
Connector
(Extended-feature ECU
only)
Q—21-pin Instrument Panel
Connector
R—Engine Wiring Harness
S—Fuel Heater Connector
T—Manifold Air Temperature
(MAT) Sensor Connector
U—Alternator Ignition
Connector
V—Optional Instrument Panel
or Generator Instrument
Panel
CD03523,000018E –19–02FEB07–1/1
55-2
061208
PN=111
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Troubleshooting
RG12224
–UN–19JUN02
Engine Wiring Layout (Electronic Fuel System With Denso High Pressure Common Rail)
6068HFU74 Engine shown
A—Engine Coolant
Temperature (ECT) Sensor
B—Electronic Injector
Connector
C—Manifold Air Temperature
(MAT) Sensor
D—ECU Connector
E—Optional Instrument Panel
or Generator Instrument
Panel
F—Engine Wiring Harness
G—Engine Oil Pressure
Sensor Connector
H—Power and Ground Battery
Connections
I—Fuel Rail Pressure Sensor
J—Crankshaft Position Sensor
K—Pump Position Sensor
L—Pump Control Valve
Solenoid
M—Fuel Temperature Sensor
CD03523,000018F –19–02FEB07–1/1
55-3
061208
PN=112
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Troubleshooting
Engine troubleshooting
Symptom
Problem
Solution
Engine cranks but will not start
Incorrect starting procedure.
Verify correct starting procedure.
No fuel.
Check fuel in tank and manual
shut-off valve.
Exhaust restricted.
Check and correct exhaust
restriction.
Fuel filter plugged or full of water.
Replace fuel filter or drain water
from filter.
Injection pump not getting fuel or air
in fuel system.
Check fuel flow at supply pump or
bleed fuel system.
Faulty injection pump or nozzles.
Consult authorized diesel repair
station for repair or replacement.
Engine starting under load.
Remove load.
Improper starting procedure.
Review starting procedure.
No fuel.
Check fuel tank.
Air in fuel line.
Bleed fuel line.
Cold weather.
Use cold weather starting aids.
Slow starter speed.
See ”Starter Cranks Slowly”.
Crankcase oil too heavy.
Use oil of proper viscosity.
Improper type of fuel.
Consult fuel supplier; use proper
type fuel for operating conditions.
Water, dirt, or air in fuel system.
Drain, flush, fill, and bleed system.
Clogged fuel filter.
Replace filter element.
Dirty or faulty injection nozzles.
Have authorized servicing dealer or
engine distributor check injectors.
Injection pump shut-off not reset.
Turn key switch to ”OFF” then to
”ON”.
Engine hard to start or will not
start
Continued on next page
55-4
DPSG,CD03523,49 –19–22JAN07–1/5
061208
PN=113
183/256
Troubleshooting
Symptom
Problem
Solution
Engine knocks
Low engine oil level.
Add oil to engine crankcase.
Injection pump out of time.
See your authorized servicing dealer
or engine distributor.
Low coolant temperature.
Remove and check thermostat.
Engine overheating.
See ”Engine Overheats”.
Low coolant temperature.
Remove and check thermostat.
Clogged fuel filter.
Replace fuel filter element.
Water, dirt, or air in fuel system.
Drain, flush, fill, and bleed system.
Dirty or faulty injection nozzles.
Have authorized servicing dealer or
engine distributor check injectors.
Defective thermostat.
Remove and check thermostat.
Defective temperature gauge or
sender.
Check gauge, sender, and
connections.
Engine runs irregularly or stalls
frequently
Below normal engine
temperature
Continued on next page
55-5
DPSG,CD03523,49 –19–22JAN07–2/5
061208
PN=114
184/256
Troubleshooting
Symptom
Problem
Solution
Lack of power
Engine overloaded.
Reduce load.
Intake air restriction.
Service air cleaner.
Clogged fuel filter.
Replace filter elements.
Improper type of fuel.
Use proper fuel.
Overheated engine.
See ”Engine Overheats”.
Below normal engine temperature.
Remove and check thermostat.
Improper valve clearance.
See your authorized servicing dealer
or engine distributor.
Dirty or faulty injection nozzles.
Have authorized servicing dealer or
engine distributor check injectors.
Injection pump out of time.
See your authorized servicing dealer
or engine distributor.
Turbocharger not functioning.
See your authorized servicing dealer
or engine distributor.
Leaking exhaust manifold gasket.
See your authorized servicing dealer
or engine distributor.
Defective aneroid control line.
See your authorized servicing dealer
or engine distributor.
Restricted fuel hose.
Clean or replace fuel hose.
Low fast idle speed.
See your authorized servicing dealer
or engine distributor.
Low oil level.
Add oil.
Improper type of oil.
Drain, fill crankcase with oil of proper
viscosity and quality.
Low oil pressure
Continued on next page
55-6
DPSG,CD03523,49 –19–22JAN07–3/5
061208
PN=115
185/256
Troubleshooting
Symptom
Problem
Solution
High oil consumption
Crankcase oil too light.
Use proper viscosity oil.
Oil leaks.
Check for leaks in lines, gaskets,
and drain plug.
Restricted crankcase vent tube.
Clean vent tube.
Defective turbocharger.
See your authorized servicing dealer
or engine distributor.
Improper type of fuel.
Use proper fuel.
Low engine temperature.
Warm up engine to normal operating
temperature.
Defective thermostat.
Remove and check thermostat.
Defective injection nozzles.
See your authorized servicing dealer
or engine distributor.
Engine out of time.
See your authorized servicing dealer
or engine distributor.
Improper type of fuel.
Use proper fuel.
Clogged or dirty air cleaner.
Service air cleaner.
Engine overloaded.
Reduce load.
Injection nozzles dirty.
See your authorized servicing dealer
or engine distributor.
Engine out of time.
See your authorized servicing dealer
or engine distributor.
Turbocharger not functioning.
See your authorized servicing dealer
or engine distributor.
Engine emits white smoke
Engine emits black or gray
exhaust smoke
Continued on next page
55-7
DPSG,CD03523,49 –19–22JAN07–4/5
061208
PN=116
186/256
Troubleshooting
Symptom
Problem
Solution
Engine overheats
Engine overloaded.
Reduce load.
Low coolant level.
Fill radiator to proper level, check
radiator and hoses for loose
connections or leaks.
Faulty radiator cap.
Have serviceman check.
Stretched poly V-belt or defective
belt tensioner.
Check automatic belt tensioner and
check belts for stretching. Replace
as required.
Low engine oil level.
Check oil level. Add oil as required.
Cooling system needs flushing.
Flush cooling system.
Defective thermostat.
Remove and check thermostat.
Defective temperature gauge or
sender.
Check water temperature with
thermometer and replace, if
necessary.
Incorrect grade of fuel.
Use correct grade of fuel.
Improper type of fuel.
Use proper type of fuel.
Clogged or dirty air cleaner.
Service air cleaner.
Engine overloaded.
Reduce load.
Improper valve clearance.
See your authorized servicing dealer
or engine distributor.
Injection nozzles dirty.
See your authorized servicing dealer
or engine distributor.
Engine out of time.
See your authorized servicing dealer
or engine distributor.
Defective turbocharger.
See your authorized servicing dealer
or engine distributor.
Low engine temperature.
Check thermostat.
High fuel consumption
DPSG,CD03523,49 –19–22JAN07–5/5
55-8
061208
PN=117
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Troubleshooting
Electrical troubleshooting
Symptom
Problem
Solution
Undercharged system
Excessive electrical load from added
accessories.
Remove accessories or install higher
output alternator.
Excessive engine idling.
Increase engine rpm when heavy
electrical load is used.
Poor electrical connections on
battery, ground strap, starter, or
alternator.
Inspect and clean as necessary.
Defective battery.
Test battery.
Defective alternator.
Test charging system.
Cracked battery case.
Check for moisture and replace as
necessary.
Defective battery.
Test battery.
Battery charging rate too high.
Test charging system.
Loose or corroded connections.
Clean and tighten connections.
Sulfated or worn-out batteries.
See your authorized servicing dealer
or engine distributor.
Stretched poly V-belt or defective
belt tensioner.
Adjust belt tension or replace belts.
Engine under load
Remove load
Loose or corroded connections.
Clean and tighten loose connections.
Low battery output voltage.
See your authorized servicing dealer
or engine distributor.
Faulty start circuit relay.
See your authorized servicing dealer
or engine distributor.
Blown fuse.
Replace fuse.
Battery uses too much water
Batteries will not charge
Starter will not crank
Continued on next page
55-9
DPSG,CD03523,50 –19–22JAN07–1/2
061208
PN=118
188/256
Troubleshooting
Symptom
Problem
Solution
Starter cranks slowly
Low battery output.
See your authorized servicing dealer
or engine distributor.
Crankcase oil too heavy.
Use proper viscosity oil.
Loose or corroded connections.
Clean and tighten loose connections.
Faulty battery connection.
Clean and tighten connections.
Sulfated or worn-out batteries.
See your authorized servicing dealer
or engine distributor.
Blown fuse.
Replace fuse.
Entire electrical system
DPSG,CD03523,50 –19–22JAN07–2/2
Displaying Of Diagnostic Trouble Codes (DTCs)
There are several different methods for displaying both
stored and active DTCs from the ECU via a fault lamp
or a diagnostic gauge on the electronic instrument
panel.
The SPN identifies the system or the component that
has the failure; for example SPN 000110 indicates a
failure in the engine coolant temperature circuit.
The FMI identifies the type of failure that has occurred;
for example FMI 03 indicates value above normal.
Combining SPN 000110 with FMI 03 yields engine
coolant temperature input voltage too high, or the
equivalent of 2-digit fault code 18.
2-DIGIT CODES
Some engines display Service Codes or DTCs as
2-digit codes read from a fault lamp which gives blink
codes.
SPN/FMI CODES
Stored and active diagnostic trouble codes are output
on the diagnostic gauge on the Deere electronic
instrument panel according to the J1939 standard as a
two-part code as shown on the tables on the following
pages.
If diagnosing an application that shows DTCs as SPNs
and FMIs, using the following list, determine the
equivalent 2-digit code and have your dealer use the
diagnostic procedure in the component technical
manual for that 2-digit code.
Always contact your servicing dealer for help in
correcting diagnostic trouble codes which are
displayed for your engine.
The first part is a six-digit Suspect Parameter Number
(SPN) followed by a two-digit Failure Mode Identifier
(FMI) code. In order to determine the exact failure,
both parts (SPN and FMI) of the code are needed.
CD03523,0000190 –19–02FEB07–1/1
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061208
PN=119
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Troubleshooting
Using blink code method for retrieving Diagnostic Trouble Codes (DTC’s)
active DTC, the ECU will flash each code in
numerical order. If there are no active DTCs, the
Fault Lamp will flash a code 88.
NOTE: The method below applies to applications
having a fault lamp on instrument panel (refer
to the generator documentation for more
information).
The Electronic Control Unit (ECU) has the ability to
display DTCs using blinking sequence of the fault
lamp.
NOTE: The ECU blinks the codes in 2-digit codes
only. See LISTING OF DIAGNOSTIC
TROUBLE CODES (DTCS) later in this Group.
4. Following the active codes, the Fault Lamp will
flash a code 33. This indicates the start of blinking
stored codes. If there are any stored DTCs, the
Fault Lamp will flash its 2–digit number. If there is
more than one stored DTC, the ECU will flash each
code in numerical order. If there are no stored
DTCs, the Fault Lamp will flash a code 88.
5. Once complete, this sequence will repeat.
1. Press down Override Shutdown Switch while
turning the ignition switch ”ON”.
2. The Fault Lamp will begin to flash a code number.
For example, flash three times...short pause...flash
two times...long pause. This example is code 32.
3. The ECU begins the flashing sequence by flashing
a code 32, this indicates the start of blinking active
codes. If there are any active DTCs, the ECU will
flash its 2–digit number. If there is more than one
6. When complete, turn ignition ”OFF”.
As an example, if an engine had an active DTC 18
and stored DTC 53, the flashing sequence would be:
flash three times...short pause...flash two times...long
pause...flash one time...short pause...flash eight
times...long pause...flash three times...short
pause...flash three times...long pause...flash five
times...short pause...flash three times.
CD03523,0000191 –19–02FEB07–1/1
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Troubleshooting
Using diagnostic gauge for retrieving
Diagnostic Trouble Codes (DTC’s)
NOTE: The method below applies on applications having
the optional diagnostic gauge shown (refer to the
generator documentation for more information).
RG13740
–UN–11NOV04
1. Make sure all engine mechanical and other systems not
related to the electronic control system are operating
properly. (See ENGINE TROUBLESHOOTING in this
section).
NOTE: Diagnostic gauge (A) uses the menu key (B) to
access various engine functions, two arrow keys
(C) to scroll through the engine parameter list and
view the menu list, and an enter key (D) for
selecting highlighted items.
Trouble Code Display On Instrument Panel
A—Diagnostic Gauge
B—Menu Key
C—Arrow Keys
D—Enter Key
2. Read and record DTC(s) displayed on LCD of
diagnostic gauge (A). For procedure to access diagnostic
trouble codes, refer to ”Using Diagnostic Gauge to Access
Engine Information”, earlier in this manual.
3. Go to the LISTING OF DIAGNOSTIC TROUBLE
CODES (DTCs) later in this section, to interpret the
DTC(s) present.
4. Contact your nearest engine distributor or servicing
dealer with a list of DTC(s) so that necessary repairs can
be made.
CD03523,0000192 –19–02FEB07–1/1
55-12
061208
PN=121
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Troubleshooting
Listing of Diagnostic Trouble Codes (DTCs)
NOTE: Not all of these codes are used on all OEM
engine applications
Trouble Codes
DTC’s Listing in Ascending SPN/FMI Codes
SPN
FMI
Description of Fault
000028
03
Throttle #3 Signal Out of Range High
04
Throttle #3 Signal Out of Range Low
000029
03
Throttle #2 Signal Out of Range High
04
Throttle #2 Signal Out of Range Low
000084
31
Vehicle Speed Signal Unreliable
000091
03
Throttle #1 Signal Out of Range High
04
Throttle #1 Signal Out of Range Low
09
Throttle #1 Communication Signal Erratic
000094
03
Low Pressure Fuel Signal Out of Range High
04
Low Pressure Fuel Signal Out of Range Low
10
Low Pressure Fuel Rate of Change Abnormal
13
Low Pressure Fuel Out of Calibration
17
High Pressure Fuel System- Pressure Slightly Low
000097
00
Water in Fuel Continuously Detected
03
Water-in-Fuel Signal Out of Range High
04
Water-in-Fuel Signal Out of Range Low
16
Water in Fuel Detected
000100
01
Engine Oil Pressure Signal Extremely Low
03
Engine Oil Pressure Signal Out of Range High
04
Engine Oil Pressure Signal Out of Range Low
18
Engine Oil Pressure Signal Moderately Low
000105
00
Intake Manifold Air Temperature Signal Extremely High
Corrective Action
Check Sensor and Wiring
Check Sensor and Wiring
Check Sensor and Wiring
Check Sensor and Wiring
Contact Servicing Dealer
Check Switch and Wiring
Check Switch and Wiring
Check Sensor and Wiring
Check Sensor and Wiring
Check Sensor and Wiring
Contact Servicing Dealer
Contact Servicing Dealer
Contact Servicing Dealer
Contact Servicing Dealer
Check Sensor and Wiring
Check Sensor and Wiring
Stop and Drain Water Separator
Check Oil Level
Check Sensor and Wiring
Check Sensor and Wiring
Check Oil Level
Check Air Cleaner, Aftercooler, or Room Temperature
03
Intake Manifold Air Temperature Signal Out of Range High
04
Intake Manifold Air Temperature Signal Out of Range Low
16
Intake Manifold Air Temperature Signal Moderately High
00
00
03
Air Filter Pressure Differential Extremely High
Engine Coolant Temperature Signal Extremely High
Engine Coolant Temperature Signal Out of Range High
04
Engine Coolant Temperature Signal Out of Range Low
15
16
01
17
02
00
03
04
16
00
Engine Coolant Temperature Signal Slightly High
Engine Coolant Temperature Signal Moderately High
Engine Coolant Level Low
ECU Power Down Error (Internal ECU Problem)
Axle Speed Signal Unreliable
Fuel Temperature Signal Extremely High
Fuel Temperature Signal Out of Range High
Fuel Temperature Signal Out of Range Low
Fuel Temperature Signal Moderately High
Engine Speed Derate Condition Exists
Check Sensor and Wiring
Check Sensor and Wiring
000107
000110
Check Air Cleaner, Aftercooler, or Room Temperature
Check for plugged air filter
Check Cooling System, Reduce Power
Check Sensor and Wiring
000111
000158
000160
000174
000174
000189
Check Sensor and Wiring
Check Cooling System, Reduce Power
Check Cooling System, Reduce Power
Check Operator’s Manual, “Adding Coolant”
Contact Servicing Dealer
Contact Servicing Dealer
Add Fuel or Switch Fuel Tanks
Check Sensor and Wiring
Check Sensor and Wiring
Add Fuel or Switch Fuel Tanks
Check Fault Codes or Contact Servicing Dealer
Continued on next page
55-13
OURGP12,00001E2 –19–15MAR06–1/3
061208
PN=122
192/256
Troubleshooting
SPN
000190
000611
000620
000627
000629
000636
000637
000639
000651
000652
000653
000654
000655
000656
000898
000970
000971
001069
001079
001080
001109
001110
001347
FMI
00
16
03
04
03
04
01
13
02
08
10
Description of Fault
Engine Speed Extremely High
Engine Speed Moderately High
Injector Shorted to Power
Injector Shorted to Ground
Sensor Supply 2 Voltage High
Sensor Supply 2 Voltage Low
All Injector Currents Are Low
ECU Programming Error
Engine Position Sensor Signal Unreliable
Engine Position Sensor Signal Missing
Engine Position Sensor Signal Rate of Change Abnormal
02
07
08
10
13
05
06
07
05
06
07
05
06
07
05
06
07
05
06
07
05
06
07
09
31
31
09
31
03
04
03
04
31
31
03
Engine Timing Sensor Signal Unreliable
Engine Timing and Position Sensors Out of Sync
Engine Timing Sensor Signal Missing
Engine Timing Signal Rate of Change Abnormal
CAN Bus Error (Communication network problem)
Injector Number 1 Circuit Has High Resistance
Injector Number 1 Circuit Has Low Resistance
Injector Number 1 Not Responding
Injector Number 2 Circuit Has High Resistance
Injector Number 2 Circuit Has Low Resistance
Injector Number 2 Not Responding
Injector Number 3 Circuit Has High Resistance
Injector Number 3 Circuit Has Low Resistance
Injector Number 3 Not Responding
Injector Number 4 Circuit Has High Resistance
Injector Number 4 Circuit Has Low Resistance
Injector Number 4 Not Responding
Injector Number 5 Circuit Has High Resistance
Injector Number 5 Circuit Has Low Resistance
Injector Number 5 Not Responding
Injector Number 6 Circuit Has High Resistance
Injector Number 6 Circuit Has Low Resistance
Injector Number 6 Not Responding
Vehicle Speed or Torque Message Unreliable
External Shutdown Commanded
External Fuel Derate Switch Active
Tire Size Invalid
Tire Size Error
Sensor Supply 1 Voltage High
Sensor Supply 1 Voltage Low
Fuel Rail Pressure Sensor Supply Voltage High
Fuel Rail Pressure Sensor Supply Voltage Low
Engine Protection Shutdown Warning
Engine Protection Shutdown
High Pressure Fuel Pump Control Valve Signal Out of
Range High
High Pressure Fuel Pump Solenoid Number 1 Circuit Has
High Resistance
High Pressure Fuel Pump Not Able to Meet Required Rail
Pressure
Requested Torque Curve Signal Unreliable
Engine in Derate Condition
05
07
001568
001569
02
31
Corrective Action
Reduce Engine Speed
Reduce Engine Speed
Check Wiring
Check Wiring
Check Wiring
Check Wiring
Check Battery Voltage and Wiring
Contact Service Dealer
Check Sensor and Wiring
Check Sensor and Wiring
Check Sensor and Wiring
Check Sensor and Wiring
Check Sensor and Wiring
Check Sensor and Wiring
Check Sensor and Wiring
Contact Servicing Dealer
Check Injector Wiring or Injector Solenoid
Check Injector Wiring or Injector Solenoid
Injector Failed or Flow Limiter Closed
Check Injector Wiring or Injector Solenoid
Check Injector Wiring or Injector Solenoid
Injector Failed or Flow Limiter Closed
Check Injector Wiring or Injector Solenoid
Check Injector Wiring or Injector Solenoid
Injector Failed or Flow Limiter Closed
Check Injector Wiring or Injector Solenoid
Check Injector Wiring or Injector Solenoid
Injector Failed or Flow Limiter Closed
Check Injector Wiring or Injector Solenoid
Check Injector Wiring or Injector Solenoid
Injector Failed or Flow Limiter Closed
Check Injector Wiring or Injector Solenoid
Check Injector Wiring or Injector Solenoid
Injector Failed or Flow Limiter Closed
Contact Servicing Dealer
Not Engine Fault. Check Other Shutdown Devices
Not Engine Fault. Check Other Shutdown Devices
Contact Servicing Dealer
Contact Servicing Dealer
Check Wiring
Check Wiring
Check Wiring
Check Wiring
Shut Down Engine, Check Fault Codes
Shut Down Engine, Check Fault Codes
Contact Servicing Dealer
Check Pump Wiring
Check Fuel Filter and Lines
Contact Servicing Dealer
Check Fault Codes
Continued on next page
55-14
OURGP12,00001E2 –19–15MAR06–2/3
061208
PN=123
193/256
Troubleshooting
SPN
002000
FMI
13
Description of Fault
Security Violation
Corrective Action
Contact Servicing Dealer
OURGP12,00001E2 –19–15MAR06–3/3
Intermittent Fault Diagnostics (With Electronic Controls)
Intermittent faults are problems that periodically ”go
away”. A problem such as a terminal that intermittently
doesn’t make contact can cause an intermittent fault.
Other intermittent faults may be set only under certain
operating conditions such as heavy load, extended
idle, etc. When diagnosing intermittent faults, take
special note of the condition of wiring and connectors,
since a high percentage of intermittent problems
originate here. Check for loose, dirty or disconnected
connectors. Inspect the wiring routing, looking for
possible shorts caused by contact with external parts
(for example, rubbing against sharp sheet metal
edges). Inspect the connector vicinity, looking for wires
that have pulled out of connectors, poorly positioned
terminals, damaged connectors and corroded or
damaged splices and terminals. Look for broken wires,
damaged splices, and wire-to-wire shorts. Use good
judgement if component replacement is thought to be
required.
NOTE: The engine control unit (ECU) is the
component LEAST likely to fail.
• If the problem is intermittent, try to reproduce the
operating conditions that were present when the
diagnostic trouble code (DTC) set.
• If a faulty connection or wire is suspected to be the
cause of the intermittent problem: clear DTCs, then
check the connection or wire by wiggling it while
watching the diagnostic gauge to see if the fault
resets.
Possible causes of intermittent faults:
• Faulty connection between sensor or actuator
harness.
• Faulty contact between terminals in connector.
• Faulty terminal/wire connection.
• Electromagnetic interference (EMI) from an
improperly installed 2-way radio, etc., can cause
faulty signals to be sent to the ECU.
NOTE: Refer also to generator documents for more
information about connections and wirings.
Suggestions for diagnosing intermittent faults:
CD03523,0000193 –19–05FEB07–1/1
55-15
061208
PN=124
194/256
Storage
Engine storage guidelines
1. John Deere engines can be stored outside for up to
three (3) months with no long term preparation IF
COVERED BY WATERPROOF COVERING.
4. John Deere engines expected to be stored more
than six (6) months, long term storage preparation
MUST BE taken. (See PREPARING ENGINE FOR
LONG TERM STORAGE).
2. John Deere engines can be stored in a standard
overseas shipping container for up to three (3)
months with no long term preparation.
3. John Deere engines can be stored inside,
warehoused, for up to six (6) months with no long
term preparation.
DPSG,CD03523,51 –19–22JAN07–1/1
Preparing engine for long term storage
The following storage preparations are good for long
term engine storage up to one year. After that, the
engine should be started, warmed up, and retreated
for an extended storage period.
IMPORTANT: Any time your engine will not be
used for over six (6) months, the
following recommendations for
storing it and removing it from
storage will help to minimize
corrosion and deterioration.
1. Change engine oil and replace filter. Used oil will
not give adequate protection. (See CHANGING
ENGINE OIL AND FILTER).
2. Service air cleaner. (See CLEAN OR REPLACE
AIR FILTER).
3. Draining and flushing of cooling system is not
necessary if engine is to be stored only for several
months. However, for extended storage periods of a
year or longer, it is recommended that the cooling
system be drained, flushed, and refilled. Refill with
appropriate coolant. (See DIESEL ENGINE
COOLANT).
4. Fill the fuel tank.
5. Remove fan/alternator belt, if desired.
6. Remove and clean batteries. Store them in a cool,
dry place and keep them fully charged.
7. Clean the exterior of the engine with salt-free water
and touchup any scratched or chipped painted
surfaces with a good quality paint.
8. Coat all exposed (machined) metal surfaces with
grease or corrosion inhibitor if not feasible to paint.
9. Seal all openings on engine with plastic bags and
tape.
10. Store the engine in a dry protected place. If
engine must be stored outside, cover it with a
waterproof canvas or other suitable protective
material and use a strong waterproof tape.
DPSG,CD03523,53 –19–22JAN07–1/1
60-1
061208
PN=125
195/256
Storage
Removing engine from long term storage
Refer to the appropriate section for detailed services
listed below or have your authorized servicing dealer
or engine distributor perform services that you may not
be familiar with.
IMPORTANT: DO NOT operate starter more than
30 seconds at a time. Wait at least 2
minutes for starter to cool before
trying again.
1. Remove all protective coverings from engine.
Unseal all openings in engine and remove covering
from electrical systems.
6. Crank engine for 20 seconds with starter (do not
allow the engine to start). Wait 2 minutes and crank
engine an additional 20 seconds to assure bearing
surfaces are adequately lubricated.
2. Remove the batteries from storage. Install batteries
(fully charged) and connect the terminals.
3. Install fan/alternator belt if removed.
4. Check for filled fuel tank.
5. Perform all appropriate prestarting checks. (See
DAILY PRESTARTING CHECKS).
7. Start engine and run at no load for several minutes.
Warm up carefully and check all gauges before
placing engine under load.
8. On the first day of operation after storage, check
overall engine for leaks and check all gauges for
correct operation.
DPSG,CD03523,54 –19–22JAN07–1/1
60-2
061208
PN=126
196/256
Specifications
General engine pack specifications
(Non-Emission Certified Engines)
ITEM
UNIT OF
MEASURE
Number of
Cylinders
Fuel
3029DF128
3029TF158
4039DF008
4039TF008
3
3
4
4
Diesel
Diesel
Diesel
Diesel
Bore
mm
106.5
106.5
106.5
106.5
Stroke
mm
110
110
110
110
L
2.9
2.9
3.9
3.9
17.8:1
17.8:1
17.8:1
17.8:1
Displacement
Compression
Ratio
POWERa @ 1500
rpm (Prime)
kW (hp)
26 (35)
36 (49)
35 (48)
55 (75)
POWERa @ 1500
rpm (Standby)
kW (hp)
30 (41)
40 (54)
38 (52)
61 (83)
POWERa @ 1800
rpm (Prime)
kW (hp)
30 (41)
40 (54)
41 (56)
67 (91)
POWERa @ 1800
rpm (Standby)
kW (hp)
34 (46)
45 (61)
47 (64)
73 (99)
Width (overall)
mm
582
582
588
588
Length (overall)
mm
888
888
1016
1016
Height (overall)
mm
931
979
960
979
Weight (dry)b
kg
345
350
475
487
Engine oil
quantity
L
6
8
12
12
Engine coolant
quantity
L
14.5
14.5
16.5
16.5
a
b
With Fan
Approximate
Continued on next page
65-1
DPSG,CD03523,55 –19–05FEB07–1/3
061208
PN=127
197/256
Specifications
ITEM
UNIT OF MEASURE
Number of Cylinders
Fuel
4045DF158
4045HF158
4045TF158
4045TF258
4
4
4
4
Diesel
Diesel
Diesel
Diesel
Bore
mm
106.5
106.5
106.5
106.5
Stroke
mm
127
127
127
127
L
4.5
4.5
4.5
4.5
17.6:1
17.0:1
17.0:1
17.0:1
Displacement
Compression Ratio
POWERa @ 1500
rpm (Prime)
kW (hp)
41 (56)
88 (120)
61 (83)
72 (98)
POWERa @ 1500
rpm (Standby)
kW (hp)
42 (57)
96 (131)
68 (92)
80 (109)
POWERa @ 1800
rpm (Prime)
kW (hp)
48 (65)
108 (147)
72 (98)
80 (109)
POWERa @ 1800
rpm (Standby)
kW (hp)
51 (69)
120 (163)
79 (107)
88 (120)
Width (overall)
mm
606
798
606
652
Length (overall)
mm
1038
1209
1191
1225
Height (overall)
mm
959
1197
1027
1027
Weight (dry)b
kg
493
599
505
520
Engine oil quantity
L
8
12
12
12
Engine coolant
quantity
L
20
28
25
25
a
b
With Fan
Approximate
Continued on next page
65-2
DPSG,CD03523,55 –19–05FEB07–2/3
061208
PN=128
198/256
Specifications
ITEM
UNIT OF
MEASURE
Number of
Cylinders
Fuel
6068HF158
6068HF258
6068TF158
6068TF258
6
6
6
6
Diesel
Diesel
Diesel
Diesel
Bore
mm
106.5
106.5
106.5
106.5
Stroke
mm
127
127
127
127
L
6.8
6.8
6.8
6.8
17.0:1
17.0:1
17.0:1
17.0:1
Displacement
Compression
Ratio
POWERa @ 1500
rpm (Prime)
kW (hp)
134 (182)
160 (218)
92 (125)
105 (143)
POWERa @ 1500
rpm (Standby)
kW (hp)
148 (201)
177 (241)
101 (137)
116 (158)
POWERa @ 1800
rpm (Prime)
kW (hp)
164 (223)
179 (243)
108 (147)
124 (169)
POWERa @1800
rpm (Standby)
kW (hp)
187 (254)
200 (272)
119 (162)
137 (186)
Width (overall)
mm
798
798
652
652
Length (overall)
mm
1500
1500
1364
1364
Height (overall)
mm
1136
1204
1070
1070
Weight (dry)b
kg
705
764
651
651
Engine oil quantity
L
20
32
20
20
Engine coolant
quantity
L
32
32
28
28
a
b
With Fan
Approximate
DPSG,CD03523,55 –19–05FEB07–3/3
65-3
061208
PN=129
199/256
Specifications
General engine pack specifications (Stage II
Emission Certified Engines)
ITEM
UNIT OF
MEASURE
Number of
Cylinders
Fuel
3029HFS70
3029HFU70
3029TFS70
3029TFU70
3
3
3
3
Diesel
Diesel
Diesel
Diesel
Bore
mm
106.5
106.5
106.5
106.5
Stroke
mm
110
110
110
110
L
2.9
2.9
2.9
2.9
17.2:1
17.2:1
17.2:1
17.2:1
Displacement
Compression
Ratio
POWERa @ 1500
rpm (Prime)
kW (hp)
37 (50)
37 (50)
28 (37)
28 (37)
POWERa @ 1500
rpm (Standby)
kW (hp)
41 (56)
41 (56)
31 (41)
31 (41)
POWERa @ 1800
rpm (Prime)
kW (hp)
POWERa @1800
rpm (Standby)
kW (hp)
Width (overall)
mm
582
582
582
582
Length (overall)
mm
888
888
888
888
Height (overall)
mm
974
974
974
974
Weight (dry)b
kg
350
350
350
350
Engine oil quantity
L
8
8
8
8
Engine coolant
quantity
L
14.5
14.5
14.5
14.5
a
b
With Fan
Approximate
Continued on next page
65-4
CD03523,0000194 –19–06JUN08–1/5
061208
PN=130
200/256
Specifications
ITEM
UNIT OF
MEASURE
Number of
Cylinders
Fuel
4045HFS72
4045HFS73
4045HFS80
4045HFS82
4
4
4
4
Diesel
Diesel
Diesel
Diesel
Bore
mm
106.5
106.5
106.5
106.5
Stroke
mm
110
110
127
127
L
4.5
4.5
4.5
4.5
17.0:1
19.0:1
19.0:1
19.0:1
Displacement
Compression
Ratio
POWERa @ 1500
rpm (Prime)
kW (hp)
75 (100)
94 (126)
POWERa @ 1500
rpm (Standby)
kW (hp)
83 (111)
103 (138)
POWERa @ 1800
rpm (Prime)
kW (hp)
67 (90)
85 (114)
POWERa @1800
rpm (Standby)
kW (hp)
74 (99)
94 (126)
Width (overall)
mm
751
765
600
765
Length (overall)
mm
1362
1365
1230
1365
Height (overall)
mm
1137
1162
1010
1162
Weight (dry)b
kg
505
505
505
505
Engine oil quantity
L
16
16
12
16
Engine coolant
quantity
L
28
32
25
32
a
b
With Fan
Approximate
Continued on next page
65-5
CD03523,0000194 –19–06JUN08–2/5
061208
PN=131
201/256
Specifications
ITEM
UNIT OF
MEASURE
Number of
Cylinders
Fuel
4045HFS83
4045HFU72
4045HFU79
4045TFU70
4
4
4
4
Diesel
Diesel
Diesel
Diesel
Bore
mm
106.5
106.5
106.5
106.5
Stroke
mm
110
127
127
127
L
4.5
4.5
4.5
4.5
19.0:1
17.0:1
19.0:1
17.0:1
Displacement
Compression
Ratio
POWERa @ 1500
rpm (Prime)
kW (hp)
75 (100)
94 (126)
55 (75)
POWERa @ 1500
rpm (Standby)
kW (hp)
83 (111)
103 (138)
61 (83)
POWERa @ 1800
rpm (Prime)
kW (hp)
107 (143)
POWERa @1800
rpm (Standby)
kW (hp)
118 (158)
Width (overall)
mm
765
751
765
600
Length (overall)
mm
1365
1362
1365
1230
Height (overall)
mm
1162
1137
1162
1010
Weight (dry)b
kg
505
505
505
505
Engine oil quantity
L
16
16
16
12
Engine coolant
quantity
L
32
28
32
25
a
b
With Fan
Approximate
Continued on next page
65-6
CD03523,0000194 –19–06JUN08–3/5
061208
PN=132
202/256
Specifications
ITEM
UNIT OF
MEASURE
Number of
Cylinders
Fuel
6068HFS72
6068HFS73
6068HFS76
6068HFS77
6068HFS82
6
6
6
6
6
Diesel
Diesel
Diesel
Diesel
Diesel
Bore
mm
106.5
106.5
106.5
106.5
106.5
Stroke
mm
127
127
127
127
127
L
6.8
6.8
6.8
6.8
6.8
17.0:1
19.0:1
17.0:1
17.0:1
19.0:1
Displacement
Compression
Ratio
POWERa @ 1500
rpm (Prime)
kW (hp)
112 (150)
139 (186)
167 (224)
189 (253)
POWERa @ 1500
rpm (Standby)
kW (hp)
123 (165)
153 (205)
184 (247)
207 (277))
POWERa @ 1800
rpm (Prime)
kW (hp)
134 (180)
POWERa @1800
rpm (Standby)
kW (hp)
147 (197)
Width (overall)
mm
784
784
960
960
784
Length (overall)
mm
1500
1500
1509
1509
1500
Height (overall)
mm
1137
1137
1381
1381
1137
Weight (dry)b
kg
764
764
764
764
764
Engine oil quantity
L
32
32
32
32
32
Engine coolant
quantity
L
32
32
35
35
32
a
b
With Fan
Approximate
Continued on next page
65-7
CD03523,0000194 –19–06JUN08–4/5
061208
PN=133
203/256
Specifications
ITEM
UNIT OF
MEASURE
Number of
Cylinders
Fuel
6068HFS83
6068HFS89
6068HFU72
6068HFU74
6068HFU79
6
6
6
6
6
Diesel
Diesel
Diesel
Diesel
Diesel
Bore
mm
106.5
106.5
106.5
106.5
106.5
Stroke
mm
127
127
127
127
127
L
6.8
6.8
6.8
6.8
6.8
19.0:1
17.0:1
17.0:1
17.0:1
19.0:1
Displacement
Compression
Ratio
POWERa @ 1500
rpm (Prime)
kW (hp)
111 (149)
166(223) / 188
(252)
139 (186)
POWERa @ 1500
rpm (Standby)
kW (hp)
123 (165)
184 (247) / 207
(277))
153 (205)
POWERa @ 1800
rpm (Prime)
kW (hp)
161(216)
214 (287)
191(256)
POWERa @1800
rpm (Standby)
kW (hp)
177 (237)
235 (315)
201 (269)
Width (overall)
mm
784
960
784
960
812
Length (overall)
mm
1500
1509
1500
1509
1532
Height (overall)
mm
1137
1381
1137
1381
1200
Weight (dry)b
kg
764
764
764
764
764
Engine oil quantity
L
32
32
32
32
32
Engine coolant
quantity
L
32
35
32
35
32
a
b
With Fan
Approximate
CD03523,0000194 –19–06JUN08–5/5
65-8
061208
PN=134
204/256
Specifications
Unified Inch Bolt and Screw Torque Values
TS1671 –UN–01MAY03
Bolt or
SAE Grade 2a
SAE Grade 1
b
Screw
Lubricated
Size
c
Lubricatedb
Dry
SAE Grade 5, 5.1 or 5.2
Dryc
Lubricatedb
Dryc
SAE Grade 8 or 8.2
Lubricatedb
Dryc
N•m
lb-in
N•m
lb-in
N•m
lb-in
N•m
lb-in
N•m
lb-in
N•m
lb-in
N•m
lb-in
N•m
lb-in
1/4
3.7
33
4.7
42
6
53
7.5
66
9.5
84
12
106
13.5
120
17
150
N•m
lb-ft
N•m
5/16
7.7
68
9.8
86
12
106
15.5
137
19.5
172
25
221
N•m
3/8
13.5
120
17.5
N•m
7/16
22
N•m
194
155
lb-ft
22
N•m
194
lb-ft
27
N•m
240
lb-ft
N•m
lb-ft
28
20.5
35
26
lb-ft
35
26
44
32.5
49
36
63
46
56
41
70
52
80
59
100
74
lb-ft
28
20.5
35
26
44
32.5
lb-ft
1/2
34
25
42
31
53
39
67
49
85
63
110
80
120
88
155
115
9/16
48
35.5
60
45
76
56
95
70
125
92
155
115
175
130
220
165
5/8
67
49
85
63
105
77
135
100
170
125
215
160
240
175
305
225
3/4
120
88
150
110
190
140
240
175
300
220
380
280
425
315
540
400
7/8
190
140
240
175
190
140
240
175
490
360
615
455
690
510
870
640
1
285
210
360
265
285
210
360
265
730
540
920
680
1030
760
1300
960
1-1/8
400
300
510
375
400
300
510
375
910
670
1150
850
1450
1075
1850
1350
1-1/4
570
420
725
535
570
420
725
535
1280
945
1630
1200
2050
1500
2600
1920
1-3/8
750
550
950
700
750
550
950
700
1700
1250
2140
1580
2700
2000
3400
2500
1-1/2
990
730
1250
930
990
730
1250
930
2250
1650
2850
2100
3600
2650
4550
3350
Torque values listed are for general use only, based on the strength of the
bolt or screw. DO NOT use these values if a different torque value or
tightening procedure is given for a specific application. For plastic insert or
crimped steel type lock nuts, for stainless steel fasteners, or for nuts on
U-bolts, see the tightening instructions for the specific application. Shear
bolts are designed to fail under predetermined loads. Always replace shear
bolts with identical grade.
Replace fasteners with the same or higher grade. If higher
grade fasteners are used, tighten these to the strength of the
original. Make sure fastener threads are clean and that you
properly start thread engagement. When possible, lubricate
plain or zinc plated fasteners other than lock nuts, wheel bolts
or wheel nuts, unless different instructions are given for the
specific application.
a
Grade 2 applies for hex cap screws (not hex bolts) up to 6. in (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long,
and for all other types of bolts and screws of any length.
b
“Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or 7/8 in. and larger fasteners with
JDM F13C zinc flake coating.
c
“Dry” means plain or zinc plated without any lubrication, or 1/4 to 3/4 in. fasteners with JDM F13B zinc flake coating.
DX,TORQ1 –19–24APR03–1/1
65-9
061208
PN=135
205/256
Specifications
8.8
9.8
10.9
12.9
12.9
4.8
8.8
9.8
10.9
12.9
12.9
TS1670
4.8
–UN–01MAY03
Metric Bolt and Screw Torque Values
Bolt or
Screw
Class 4.8
a
Lubricated
Class 8.8 or 9.8
b
a
Dry
Class 10.9
b
Lubricated
a
Dry
Lubricated
Class 12.9
b
Lubricateda
Dry
Dryb
Size
N•m
lb-in
N•m
lb-in
N•m
lb-in
N•m
lb-in
N•m
lb-in
N•m
lb-in
N•m
lb-in
N•m
lb-in
M6
4.7
42
6
53
8.9
79
11.3
100
13
115
16.5
146
15.5
137
19.5
172
M8
11.5
102
14.5
128
22
194
27.5
243
M10
23
204
N•m
N•m
N•m
M12
40
lb-ft
N•m
lb-ft
N•m
N•m
lb-ft
32
lb-ft
23.5
N•m
40
lb-ft
29.5
N•m
37
lb-ft
27.5
47
35
lb-ft
29
21
43
32
55
40
63
46
80
59
75
55
95
70
50
37
75
55
95
70
110
80
140
105
130
95
165
120
lb-ft
29.5
M14
63
46
80
59
120
88
150
110
175
130
220
165
205
150
260
190
M16
100
74
125
92
190
140
240
175
275
200
350
255
320
235
400
300
M18
135
100
170
125
265
195
330
245
375
275
475
350
440
325
560
410
M20
190
140
245
180
375
275
475
350
530
390
675
500
625
460
790
580
M22
265
195
330
245
510
375
650
480
725
535
920
680
850
625
1080
800
M24
330
245
425
315
650
480
820
600
920
680
1150
850
1080
800
1350
1000
M27
490
360
625
460
950
700
1200
885
1350
1000
1700
1250
1580
1160
2000
1475
M30
660
490
850
625
1290
950
1630
1200
1850
1350
2300
1700
2140
1580
2700
2000
M33
900
665
1150
850
1750
1300
2200
1625
2500
1850
3150
2325
2900
2150
3700
2730
M36
1150
850
1450
1075
2250
1650
2850
2100
3200
2350
4050
3000
3750
2770
4750
3500
Torque values listed are for general use only, based on the strength
of the bolt or screw. DO NOT use these values if a different torque
value or tightening procedure is given for a specific application. For
stainless steel fasteners or for nuts on U-bolts, see the tightening
instructions for the specific application. Tighten plastic insert or
crimped steel type lock nuts by turning the nut to the dry torque
shown in the chart, unless different instructions are given for the
specific application.
Shear bolts are designed to fail under predetermined loads. Always
replace shear bolts with identical property class. Replace fasteners
with the same or higher property class. If higher property class
fasteners are used, tighten these to the strength of the original. Make
sure fastener threads are clean and that you properly start thread
engagement. When possible, lubricate plain or zinc plated fasteners
other than lock nuts, wheel bolts or wheel nuts, unless different
instructions are given for the specific application.
a
“Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or M20 and larger fasteners with
JDM F13C zinc flake coating.
b
“Dry” means plain or zinc plated without any lubrication, or M6 to M18 fasteners with JDM F13B zinc flake coating.
DX,TORQ2 –19–24APR03–1/1
65-10
061208
PN=136
206/256
Index
Page
Page
A
E
Air filter
Clean or replace element . . . . . . . . . . . . . . . . 50-4
Clean or replace (one-piece). . . . . . . . . . . . . . 50-3
Air intake system
Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-1
Engine
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-34
Engine Control Unit (ECU) serial number . . . . . . 03-5
Engine oil
Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
Engine speed (Mechanical fuel system) . . . . . . . 40-3
Engine wiring layout
With Denso High Pressure Common Rail . . . . 55-3
With Stanadyne DE10 pump . . . . . . . . . . . . . . 55-2
B
Belt
Check automatic tensioner . . . . . . . . . . . . . . .
Check tension . . . . . . . . . . . . . . . . . . . . . . . . .
Replace (4045 and 6068 engines) . . . . . . . . .
Break-in engine oil . . . . . . . . . . . . . . . . . . . . . . .
35-2
30-6
50-5
10-3
C
Configuration data, viewing . . . . . . . . . . . . . . . .
Coolant
Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . .
Drain and flush cooling system . . . . . . . . . . . .
Pressure testing cooling system . . . . . . . . . . .
Warm temperature climates . . . . . . . . . . . . . .
Crankcase vent tube
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15-4
10-6
45-1
35-6
10-6
35-1
D
Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-4
Diagnostic procedure . . . . . . . . . . . . . . . . . . . . 55-12
Using diagnostic gauge. . . . . . . . . . . . . . . . . . 15-1
Diagnostic Trouble Codes (DTCs) . . . . . . . . . . 55-13
Diagnostic trouble codes (DTCs)
Active engine service codes, viewing . . . . . . . 15-8
Diagnostic Trouble Codes (DTCs)
Diagnostic gauge . . . . . . . . . . . . . . . . . . . . . 55-12
Diagnostic trouble codes (DTCs)
Stored service codes, viewing. . . . . . . . . . . . . 15-6
Diesel engine oil. . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
DTCs (Diagnostic Trouble Codes)
View active service codes . . . . . . . . . . . . . . . . 15-8
View stored service codes . . . . . . . . . . . . . . . 15-6
F
Fuel
Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Handling and storing . . . . . . . . . . . . . . . . . . . .
Fuel filter
Replacement. . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel pump model number. . . . . . . . . . . . . . . . . .
Fuel system
Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1
10-2
30-4
03-5
50-6
I
Identification views, . . . . . . . . . . . . . . . . . .01-1, 01-2
Instrument panel
Adjust backlighting . . . . . . . . . . . . . . . . . . . . 15-11
Adjust contrast . . . . . . . . . . . . . . . . . . . . . . . 15-13
Changing units of measure . . . . . . . . . . . . . . 15-15
Main menu navigation . . . . . . . . . . . . . . . . . . . 15-2
Setup 1-up display . . . . . . . . . . . . . . . . . . . . 15-18
Setup 4-up display . . . . . . . . . . . . . . . . . . . . 15-24
Shutdown codes . . . . . . . . . . . . . . . . . . . . . . 15-10
Using diagnostic gauge. . . . . . . . . . . . . . . . . . 15-1
Viewing active service codes . . . . . . . . . . . . . 15-8
Viewing configuration data . . . . . . . . . . . . . . . 15-4
Viewing stored service codes . . . . . . . . . . . . . 15-6
Intermittent fault diagnostics . . . . . . . . . . . . . . . 55-15
L
Listing of DTCs. . . . . . . . . . . . . . . . . . . . . . . . . 55-13
Lubricant
Mixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Index-1
061208
PN=1
207/256
Index
Page
Page
S
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
M
Maintenance
As required
Additional service information . . . . . . . . . . . 50-1
Clean or replace air filter element . . . . . . . . 50-4
Clean or replace air filter (one-piece). . . . . . 50-3
Do not modify fuel system . . . . . . . . . . . . . . 50-2
Replace fan and alternator belts (4045 and 6068
engines) . . . . . . . . . . . . . . . . . . . . . . . . . . 50-5
Daily or every 10 hours. . . . . . . . . . . . . . . . . . 25-1
Observe service intervals . . . . . . . . . . . . . . . . 20-1
Use correct fuel, lubricant and coolant . . . . . . 20-1
1000 hours/1 year
Check and adjust valve clearance (3029 and
4039 engines) . . . . . . . . . . . . . . . . . . . . . 35-4
Checking air intake system . . . . . . . . . . . . . 35-1
Checking automatic belt tensioner (4045 and
6068 Engines) . . . . . . . . . . . . . . . . . . . . . 35-2
Cleaning crankcase vent tube . . . . . . . . . . . 35-1
Pressure testing cooling system . . . . . . . . . 35-6
2000 hours/2 years
Adjust speed droop governor (Mechanical fuel
system) . . . . . . . . . . . . . . . . . . . . . . . . . . 40-3
Adjust valve clearance (4045 and 6068
engines) . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1
Check engine speed (Mechanical fuel
system) . . . . . . . . . . . . . . . . . . . . . . . . . . 40-3
Damper check . . . . . . . . . . . . . . . . . . . . . . . 40-4
2500 hours/3 years
Drain and flush cooling system . . . . . . . . . . 45-1
500 hours
Changing engine oil and filter . . . . . . . . . . . 30-1
Checking belt. . . . . . . . . . . . . . . . . . . . . . . . 30-6
Replace fuel filter. . . . . . . . . . . . . . . . . . . . . 30-4
Maintenance records . . . . . . . . . . . . . . . . . . . . . 02-1
Mixing lubricants. . . . . . . . . . . . . . . . . . . . . . . . . 10-5
03-5
03-5
03-5
03-3
03-1
03-5
03-1
03-2
03-5
65-1
65-4
60-1
10-2
10-5
T
Trouble codes . . . . . . . . . . . . . . . . . . . . . . . . . 55-13
Troubleshooting
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-9
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-4
General information. . . . . . . . . . . . . . . . . . . . . 55-1
U
Units of measure, changing . . . . . . . . . . . . . . . 15-15
V
Valve clearance
Adjust (3029 and 4039 engines) . . . . . . . . . . . 35-4
Adjust (4045 and 6068 engines) . . . . . . . . . . . 40-1
O
Operating the engine
Break-in period . . . . . . . . . . . . . . . . . . . . . . .
Changing Generator Frequency . . . . . . . . . .
Standby power units . . . . . . . . . . . . . . . . . . .
Starting the engine . . . . . . . . . . . . . . . . . . . .
Stopping the engine . . . . . . . . . . . . . . . . . . .
Using a booster battery or charger . . . . . . . .
Serial number
Engine Control Unit (ECU) . . . . . . . . . . . . . . .
High-pressure fuel pump . . . . . . . . . . . . . . . . .
Serial numbers
Engine Control Unit (ECU) serial number . . . .
Engine option codes . . . . . . . . . . . . . . . . . . . .
Engine serial number plate . . . . . . . . . . . . . . .
Fuel pump model number . . . . . . . . . . . . . . . .
POWERTech label . . . . . . . . . . . . . . . . . . . . .
Record engine serial number . . . . . . . . . . . . .
Record fuel injection pump model number . . .
Specifications
Engine Pack
Non-Emission Certified Engines . . . . . . . . .
Stage II Emission Certified Engines. . . . . . .
Storage
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storing fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storing lubricants . . . . . . . . . . . . . . . . . . . . . . . .
15-29
15-35
15-34
15-30
15-35
15-33
W
Wiring harness
With Denso High Pressure Common Rail . . . . 55-3
With Stanadyne DE10 pump . . . . . . . . . . . . . . 55-2
Index-2
061208
PN=2
208/256
9.2. Appendix B - Alternator user and maintenance manual
209/256
210/256
User's guide and maintenance manual
LEROY SOMER
ALTERNATOR
43-2 & 44-2
SHUNT & AREP & PMG
3434.en/g
06/2007
33522059401_4_1
211/256
212/256
3434 en - 06.2007 / g
120
207
124
198
44.2 coupling
gi v
e
b
o
l i s t s er
a
u
n
ma
du
This o the en
t
en
323
324
322
325
320
33
30
LSA 43.2/44.2 - 4-POLE
ALTERNATORS
Installation and maintenance
213/256
15
4
37
28
1
P
LEROY-SOMER
INSTALLATION AND MAINTENANCE
3434 en - 06.2007 / g
LSA 43.2/44.2 - 4-POLE
ALTERNATORS
This manual concerns the alternator which
you have just purchased.
The latest addition to a whole new generation
of alternators, this range benefits from the
experience
of
the
world’s
leading
manufacturer, using advanced technology and
incorporating strict quality control.
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 alternator, you can
look forward to many years of trouble-free
operation.
SAFETY MEASURES
WARNING SYMBOLS
Before using your machine for the first time, it is important to
read the whole of this installation and maintenance manual.
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
machine has been fully installed.
All necessary operations and interventions on this machine
must be performed by a qualified 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 or
destroying the machine or surrounding equipment.
Warning symbol for general danger to personnel.
Warning symbol 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.
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.
2
214/256
LEROY-SOMER
INSTALLATION AND MAINTENANCE
3434 en - 06.2007 / g
LSA 43.2/44.2 - 4-POLE
ALTERNATORS
CONTENTS
1 - RECEIPT
4 - SERVICING - MAINTENANCE
1.1 - Standards and safety measures ....................4
4.1 - Safety measures ......................................... 10
1.2 - Inspection.......................................................4
4.2 - Regular maintenance.................................. 10
1.3 - Identification...................................................4
4.3 - Fault detection ............................................ 10
1.4 - Storage ..........................................................4
4.4 - Mechanical defects ..................................... 11
4.5 - Electrical faults............................................ 11
2 - TECHNICAL CHARACTERISTICS
4.6 - Dismantling, reassembly............................. 13
2.1 - Electrical characteristics ................................5
4.7 - Installation and maintenance of the PMG ... 14
2.2 - Mechanical characteristics.............................5
4.8 - Table of characteristics ............................... 15
3 - INSTALLATION - COMMISSIONING
5 - SPARE PARTS
3.1 - Assembly .......................................................6
3.2 - Inspection prior to first use.............................6
3.3 - Terminal connection diagrams.......................7
3.4 - Commissioning ..............................................9
5.1 - First maintenance parts .............................. 17
5.2 - Bearing designations .................................. 17
5.3 - Technical support service ........................... 17
5.4 - Exploded view, parts list ............................. 18
3.5 - Settings ..........................................................9
3
215/256
INSTALLATION AND MAINTENANCE
LEROY-SOMER
3434 en - 06.2007 / g
LSA 43.2/44.2 - 4-POLE
ALTERNATORS
RECEIPT
1 - RECEIPT
1.3 - Identification
Our alternators comply with most international standards and
are compatible with:
- the recommendations of the
International Electrotechnical Commission
IEC 34-1, (EN 60034)
- the recommendations of the
International Standards Organisation ISO 8528
- the European Community directive 89/336/EEC on
Electromagnetic Compatibility (EMC)
- the European Community directives
73/23/EEC and 93/68/EEC (Low Voltage Directive)
They are CE marked with regard to the LVD (Low Voltage
Directive) in their role as a machine component. A declaration
of incorporation can be supplied on request.
Before using your generator for the first time, read carefully
the contents of this installation and maintenance manual,
supplied with the machine. All operations performed on the
generator should be undertaken by qualified personnel
trained in the commissioning, servicing and maintenance of
electrical and mechanical components. This maintenance
manual should be retained for the whole of the machine's life
and be handed over with the contractual file.
The various operations described in this manual are
accompanied by recommendations or symbols to alert the
user to potential risks of accidents. It is vital that you
understand and take notice of the different warning symbols
used.
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.
Nameplate
So that you can identify your machine quickly and accurately,
we suggest you fill in its specifications on the 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 machine can be
placed in a sealed enclosure (heatshrunk plastic for example)
with dehydrating sachets inside, away from significant 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.
ALTERNATEURS
LSA
Date
N
Hz
Min-1/R.P.M.
Protection
Cos Ø /P.F.
Cl. ther. / Th. class
Régulateur/A.V.R.
Altit.
m Masse / Weight
Rlt AV/D.E bearing
Rlt AR/N.D.E bearing
Graisse / Grease
Valeurs excit / Excit. values
en charge / full load
à vide
/ at no load
LR 0021
ALTERNATORS
PUISSANCE / RATING
Tension
Voltage
V
Ph.
Connex.
Continue
Continuous
40C
Secours
Std by
27C
kVA
kW
A
kVA
kW
A
Conforme à C.E.I 34-1(1994). According to I.E.C 34-1(1994).
4
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Made by Leroy Somer - 1 024 930/b
1.1 - Standards and safety measures
The alternator is identified by means of a nameplate glued to
the frame.
Make sure that the nameplate on the machine conforms to
your order.
The machine name is defined 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
INSTALLATION AND MAINTENANCE
LEROY-SOMER
3434 en - 06.2007 / g
LSA 43.2/44.2 - 4-POLE
ALTERNATORS
TECHNICAL CHARACTERISTICS
2 - TECHNICAL
CHARACTERISTICS
2.2 - Mechanical characteristics
2.1 - Electrical characteristics
PARTNER LSA 43.2/44.2 alternators are machines without
sliprings or revolving field brushes, wound as "2/3 pitch",
12-wire; the insulation is class H and the field 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).
- Steel frame
- Cast iron end shields
- Protected ball bearings, greased for life
- Mounting arrangements:
IM 1201 (MD 35) foot and flange mounted, single-bearing
with SAE coupling disc.
IM 1001 (B 34) double-bearing with SAE flange and standard
cylindrical shaft extension.
- Drip-proof machine, self-cooled
- Degree of protection: IP 23
2.2.1 - Mechanical options
- Air inlet filter
- Regreasable ball bearings
- IP 44 protection
2.1.2 - SHUNT system with R 250 AVR
Other version R 251 AVR for dedicated single-phase or R 448 for additional function
MAIN FIELD
Exciter
STATOR : 12 wires (marked T1 to T12)
T1 T7
T2 T8
T3 T9
T4 T10
T5 T11
T6 T12
Varistor
Armature
Field
5+
6–
SERIES connection
R 250
Power supply and voltage reference
2.1.3 - AREP system with R 438 AVR
STATOR : 12 wires (marked T1 to T12)
MAIN FIELD
Exciter
Auxiliary windings
T1 T7
T2 T8
T3 T9
T4 T10
T5 T11
T6 T12
PARALLEL
connection
Black
6–
Yellow
Field
Red
5+
Green
Varistor
Armature
R 438
Voltage reference
2.1.4 - PMG system with R 438 AVR
MAIN FIELD
STATOR : 12 wires (marked T1 to T12)
Exciter
Varistor
Armature
5+
Field
T1 T7
T2 T8
T3 T9
T4 T10
T5 T11
T6 T12
PMG
6–
PARALLEL
connection
R 438
Voltage reference
5
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LEROY-SOMER
INSTALLATION AND MAINTENANCE
3434 en - 06.2007 / g
LSA 43.2/44.2 - 4-POLE
ALTERNATORS
INSTALLATION
3 - INSTALLATION
3.1.2.2 - Two-bearing alternator
- Semi-flexible coupling
Careful alignment of the machines is recommended,
checking that the concentricity and parallelism of both parts of
the coupling does not exceed 0.1 mm.
3.1 - Assembly
All mechanical handling operations must be undertaken
using approved equipment.
Whilst being handled, the machine should remain
horizontal.
3.1.1 - Handling
The generously-sized lifting rings are for handling the
alternator alone. They must not be used to lift the genset.
Choose a lifting system which respects the positioning of the
rings.
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
coefficient). 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. It is essential to prevent not only the
recycling of hot air from the machine or engine, but also
exhaust fumes.
3.2 - Inspection prior to first
use
3.2.1 - Electrical checks
3.1.2 - Coupling
3.1.2.1 - Single-bearing alternator
Before coupling the two machines, check that both are
compatible by:
- undertaking a torsional analysis of the transmission on both
units
- checking the dimensions of the flywheel and its housing, the
flange, coupling discs and offset
CAUTION
When coupling the alternator to the prime mover, the
holes of the coupling discs should be aligned with the
flywheel holes by cranking the engine.
Do not use the alternator fan to turn the rotor.
Tighten the coupling disc screws to the recommended torque
(see section 4.6.2) and check that there is lateral play on the
crankshaft.
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 field 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 field terminals,
respecting the polarity
- Open all the alternator openings fully
- Run the alternator at its rated speed, and adjust the exciter
field 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.
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INSTALLATION AND MAINTENANCE
LEROY-SOMER
3434 en - 06.2007 / g
LSA 43.2/44.2 - 4-POLE
ALTERNATORS
INSTALLATION
3.2.2 - Mechanical checks
3.3 - Terminal connection diagrams
Before starting the machine for the first time, check that:
- the fixing 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 anticlockwise rotation, swap 2 and 3.
- the winding connection corresponds to the site operating
voltage (see section 3.3)
To modify the connection, change the position of the terminal
cables. The winding code is specified on the nameplate.
Connection codes
L.L voltage
L1(U)
A
T1
3 phases
T7
T4
N
T10
T12
T5
T9
T6
L3(W)
T3
L2(V)
T8
L1(U)
T1
D
3 phases
T4
T7
N
T10
T12
T9
T5
T8
T6
T3
T2
L2(V)
L3(W)
FF
1 phase
T2
T3
T11
T5
T9
T4
T1
L
T12
T8
T6
T7
T10
M
L
LM voltage = 1/2 LL voltage
L1(U)
F
1 phase
ou
3 phases
T12
T1
T9
T4
T7
T6
T3
L3(W)
L
T10
T11
T8
T5
M
LM voltage = 1/2 LL voltage
50 Hz
6
190 - 208
190 - 240
7
220 - 230
-
T2
L2(V)
L
-
60 Hz
190 - 208
R 250 voltage sensing:
0 => (T8) / 110 V => (T11)
R 438 voltage sensing:
0 => (T3) / 220 V => (T2)
T11
T5
T12
T10
N
T4
T9
L3(W)
T3
T8
L2(V)
T7
L1(U)
AR
T1
50 Hz
60 Hz
6
380 - 415
380 - 480
7
440 - 460
-
T11
T12
N
T10
T9
L3(W)
T6
-
T6
T2
Winding
8
T11
Factory connection
Winding
8
T2
T11
Any intervention on the alternator terminals during
reconnection or checks should be performed with the
machine stopped.
380 - 416
T3
T8
L2(V)
T5
R 250 voltage sensing:
0 => (T8) / 110 V => (T11)
R 438 voltage sensing:
0 => (T3) / 380 V => (T2)
T2
T7
L1(U)
T4
Winding
50 Hz
60 Hz
6
220 - 240
220 - 240
7
250 - 260
-
8
200
T11
T1
AR
T4
T7
M
T3
T9
L
T10
220 - 240
T8
T6
T12
T5
T2
R 250 voltage sensing:
0 => (T1) / 110 V => (T4)
R 438 voltage sensing:
0 => (T10) / 220 V => (T1)
T1
Winding
50 Hz
60 Hz
6
220 - 240
220 - 240
7
250 - 260
-
T9
8
200
220 - 240
T8
AR
T11
T6
T3
L
L3(W)
T5
R 250 voltage sensing:
0 => (T8) / 110 V => (T11)
R 438 voltage sensing:
0 => (T3) / 220 V => (T2)
T10
T4
T2
T7
T12
T1
L2(V)
L
L1(U)
AR
7
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INSTALLATION AND MAINTENANCE
LEROY-SOMER
3434 en - 06.2007 / g
LSA 43.2/44.2 - 4-POLE
ALTERNATORS
INSTALLATION
Connection codes
1 phase
or
T12
3 phases
T6
T9
T1
T7
L3(W)
T10
T5
L
L2(V)
T2
T11
L
T8
T6
T12
M
T1
120
7
120 - 130
-
T7
L
T9
110 - 120
-
B
T8
T4
T12
T2
T7
T6
T2
T10
T9
T5
L
L
T8
T11
LM voltage = 1/2 LL voltage
L
L2(V)
L1(U)
T1
AR
IS NOT POSSIBLE
50 Hz
60 Hz
T5
T11
6
220 - 240
220 - 240
T10
7
250 - 260
-
T9
8
200
220 - 240
T8
M
T4
L
T4
T3
L3(W)
T3
T10
Winding
Connection not
recommended
1 PH
110 - 120
T5
T11
R 250 voltage sensing:
0 => (T8) / 110 V => (T11)
R 438 voltage sensing:
0 => (T3) / 110 V => (T2)
FOR LSA 44.2, THE COUPLING
G
60 Hz
6
8
T4
T3
50 Hz
Winding
L1(V)
B
Factory connection
L.L voltage
T3
R 250 voltage sensing:
0 => (T8) / 110 V => (T11)
R 438 voltage sensing:
0 => (T3) / 220 V => (T2)
L
T12
T2
T7
T6
AR
T1
SINGLE-PHASE 4-WIRE - type M or M1 DEDICATED WINDING
PARALLEL CONNECTION (Not possible with LSA 44.2)
SERIAL CONNECTION
T3
T3
T2
T1
T4
M
L
Voltage 50/60 Hz
L-M
L-L
110
220
115
230
120
240
L
Link
T2 - T3
T4
T1
T2
L
L
L
Output
L
M
T1
T4
T2 - T3
Voltage 50/60 Hz
L-M
L-L
110
115
120
-
R 251 voltage sensing: 0 => (T1) / 110 V => (T2)
Link
T1 - T3
T2 - T4
L
Output
L
T1-T3 T2 - T4
M
-
R 251 voltage sensing: 0 => (T1) / 110 V => (T2)
3.3.1 - Exciter field connection
Series connection (shunt excitation)
Parallel connection (AREP or PMG excitation)
White
White
Blue
– –
Blue
– –
Black
Black
5+
5+
6+
+
6-
6–
Red
R 250
+
8
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+
6–
Red
R 438
INSTALLATION AND MAINTENANCE
LEROY-SOMER
3434 en - 06.2007 / g
LSA 43.2/44.2 - 4-POLE
ALTERNATORS
INSTALLATION
3.3.2 - Option connection diagram
R 791 T interference suppression kit (standard for CE marking)
Connections
Black
Black
Black
Blue
White
A
D
F
B
F/F
G
T1
T2
T3
N
T1
T2
T3
N
T1
T2
T3
T1
T2
T3
T1
T9
T3
T2
T4
T3
Voltage potentiometer
ST4
Voltage adjustment
by remote potentiometer
Anti condensation heater
Thermistor (PTC) temperature
103
101
102
LSA 43.2, 44.2
104
Ph1
130 C
blue
Ph2
150C
black
Ph3
180 C
red/white
3.3.3 - Connection checks
3.4 - Commissioning
Electrical installations must comply with the current
legislation in force in the country of use.
The machine can only be started up and used if the
installation is in accordance with the regulations and
instructions defined in this manual.
The machine is tested and set at the factory. When first used
with no load, make sure that the drive speed is correct and
stable (see the nameplate). On application of the load, the
machine should achieve its rated speed and voltage;
however, in the event of abnormal operation, the machine
setting can be altered (follow the adjustment procedure: see
section 3.5). If the machine still operates incorrectly, the
cause of the malfunction must be located (see section 4.4).
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 circuitbreakers or cubicle relays)
- The machine has been connected with the busbar
separating the terminals as shown in the terminal connection
diagram
3.5 - Setting up
The various adjustments during tests must be made by a
qualified engineer. Take care that the drive speed
specified on the nameplate is reached before
commencing adjustment. After operational testing,
replace all access panels or covers.
The AVR is used to make any adjustments to the
machine.
9
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INSTALLATION AND MAINTENANCE
LEROY-SOMER
3434 en - 06.2007 / g
LSA 43.2/44.2 - 4-POLE
ALTERNATORS
SERVICING / MAINTENANCE
4 - SERVICING / MAINTENANCE
- Ciclohexare (non toxic); inflammable
4.1 - Safety measures
Cleaning of the stator, rotor, exciter and diode bridge
Servicing or troubleshooting must be carried out strictly
in accordance with instructions so as to avoid the risk of
accidents and to maintain the machine in its original
state.
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 machine.
4.2.5 - Mechanical servicing
CAUTION
All such operations performed on the alternator should
be undertaken by personnel trained in the
commissioning, servicing and maintenance of electrical
and mechanical components.
Before any intervention on the machine, ensure that it cannot
be started by a manual or automatic system and that 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 fixing
screws on the machine are still tight, plus the general state of
the machine and the various electrical connections in the
installation.
4.2.2 - Cooling circuit
It is advisable to check that circulation of air is not reduced by
partial blocking of the air intake and outlet grilles: mud, fibre,
grease, etc.
4.2.3 - Bearings
The bearings are permanently greased: approximate life of
the grease (depending on use) = 20,000 hours or 3 years.
Monitor the temperature rise in the bearings, which must not
exceed 60 °C above the ambient temperature. Should this
value be exceeded, the machine must be stopped and checks
carried out.
Cleaning the machine using a water spray or a
high-pressure washer is strictly prohibited.
Any problems arising from such treatment are not
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 filters have been added to the machine after manufacture
and do not have thermal protection, the service personnel
should clean the air filters 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.
Petrol or 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 identified.
To do this, check that:
- the protective devices are fitted 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 defined in section 3
4.2.4 - Electrical servicing
Cleaning product for the windings
CAUTION
Do not use: trichlorethylene, perchlorethylene,
trichloroethane or any alkaline products.
Certain strictly defined pure volatile degreasing agents can be
used, such as:
- Normal petrol (without additives); inflammable
- Toluene (slightly toxic); inflammable
- Benzene (or benzine, toxic); inflammable
10
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INSTALLATION AND MAINTENANCE
LEROY-SOMER
3434 en - 06.2007 / g
LSA 43.2/44.2 - 4-POLE
ALTERNATORS
SERVICING / MAINTENANCE
4.4 - Mechanical defects
Fault
Bearing
Temperature
abnormal
Action
Excessive overheating of one or both
bearings (temperature > 80 °C on the
bearing 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 (flanges not properly fitted).
Excessive overheating of alternator frame
(more than 40 °C above the ambient
temperature)
- Air flow (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
- Misalignment (coupling)
- Defective mounting or play in coupling
- Rotor balancing fault
Excessive vibration
Vibration
Excessive vibration and humming noise
coming from the machine
Abnormal noise
- Alternator operating in single-phase mode (single-phase load or faulty contactor
or installation fault)
- Stator short-circuit
- System short-circuit
- Mis-paralleling
Alternator damaged by a significant impact, Possible consequences
followed by humming and vibration
- Broken or damaged coupling
- Broken or bent shaft end
- Shifting and short-circuit of main field
- Fan fractured or coming loose on shaft
- Irreparable damage to rotating diodes or AVR
4.5 - Electrical faults
Fault
Action
Effect
Check/Cause
The alternator builds up and its voltage is - Lack of residual magnetism
still correct when the battery is removed.
The alternator builds up but its voltage
does 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 field winding open circuit. Check the resistance
Correct speed
Check the AVR connections (AVR may be faulty)
- Field windings short-circuited
- Rotating diodes burnt out
- Main field 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
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)
No
voltage
at no load
on start-up
Connect between E- and
E+ a new battery of 4 to
12 volts, respecting
the AVR polarities, for
2 to 3 seconds
Voltage too low Check the drive speed
Adjust AVR stability
potentiometer
Voltage correct Run at no load and check
at no load and the voltage between E+
too low when on and E- on the AVR
load (*)
Voltage between E+ and ESHUNT < 20 V - AREP/PMG < 10 V
Voltage between E+ and ESHUNT > 30 V - AREP/PMG > 15 V
- Check the speed (or LAM set too high)
- Faulty rotating diodes
- Short-circuit in the main field. 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
Voltage
disappears
during operation
(**)
Check the AVR, the surge
suppressor, the rotating
diodes, and replace any
defective components
The voltage does not return to the rated - Exciter winding open circuit
value
- Faulty exciter armature
- Faulty AVR
- Main field open circuit or short-circuited
(**) Caution: Internal protection may be activated (overload, open circuit, short-circuit)
11
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INSTALLATION AND MAINTENANCE
LEROY-SOMER
3434 en - 06.2007 / g
LSA 43.2/44.2 - 4-POLE
ALTERNATORS
SERVICING / MAINTENANCE
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.
Assembly A: Connect a 12 V battery in series with a rheostat
of approximately 50 ohms - 300 W and a diode on both exciter
field wires (5+) and (6-).
CAUTION
ASSEMBLY A
6 – Exciter field 5 +
Damage caused to the AVR in such conditions is not
covered by our warranty.
Diode 1 A
Rh. 50 Ω - 300 W
4.5.2 - Checking the diode bridge
+
-
LSA 43.2 / 44.2 Diode bridge
Anode
-
12 V battery
C
A
~ ~ ~
C
C
C
A
A
A
Cathode
-
+
~ ~ ~
A
C
A
C
Assembly B: Connect a "Variac" variable power supply and
a diode bridge on both exciter field wires (5+) and (6-).
+
A
Both these systems should have characteristics which are
compatible with the field excitation power of the machine (see
the nameplate).
C
A diode in good working condition allows the
current to flow in only one direction, from anode
to cathode.
3) Run the unit at its rated speed.
4.5.3 - Checking the windings and rotating
diodes using separate excitation
4) Gradually increase the exciter field 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 and at full 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).
ASSEMBLY B
50
20
10
90
0
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Diode 1 A
80
AC
220 V
12
5+
+
60
30
40
6 – Exciter field
70
1) Stop the unit, disconnect and isolate the AVR wires.
2) There are two ways of creating an assembly with separate
excitation.
Variac
100
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.
-
DC
12 V
INSTALLATION AND MAINTENANCE
LEROY-SOMER
3434 en - 06.2007 / g
LSA 43.2/44.2 - 4-POLE
ALTERNATORS
SERVICING / MAINTENANCE
4.6 - Dismantling, reassembly (see sections
4.6.3 - Access to connections and the
regulation system
5.5.1/5.5.2)
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.
During the warranty period, this operation should only be
carried out in an LEROY-SOMER approved workshop or
in our factory, otherwise the warranty may be invalidated.
Whilst being handled, the machine should remain
horizontal (rotor not locked when moved).
4.6.4 - Accessing, checking and
replacing 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]
- Refit the air intake grille [51]
- Replace the terminal box lid [48]
4.6.5 - Replacing the NDE bearing on singlebearing machines
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 flat 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 size 6 Allen key (eg. Facom: ET6)
- 1 size 10 Allen key (eg. Facom: ET10)
- 1 size 14 Allen key (eg. Facom: ET14)
- 1 T20 and T30 TORX bit
- 1 puller (eg. Facom: U35)
- 1 puller (eg. Facom: U32/350).
4.6.5.1 - Dismantling
- Remove the terminal box lid [48]
- Remove the air intake grille [51]
- Unscrew the fixing 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
4.6.2 - Screw tightening torque
IDENTIFICATION
Field terminal block screw
Field screw
Diode bridge/RP
Diode nut
43.2 tie rod
44.2 tie rod
Earth screw
43.2 disc/shaft screw
44.2 disc/shaft screw
44.2 turbine screw
Grille screws
Cover screws
Terminal block nut
screw Ø
M4
M6
M6
M5
M12
M14
M8
M12
M16
M6
M6
M6
M10
Torque N.m
4 N.m
10 N.m
5 N.m
4 N.m
57 Nm
90 Nm
26 Nm
110 Nm
250 Nm
5 Nm
5 Nm
5 Nm
20 Nm
4.6.5.2 - Reassembly
- 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 fit it to the
machine.
- Place the preloading wavy washer [79] in the shield and fit a
new O ring seal [349].
Refit the NDE shield and pass the bundle of wires between
the top bars of the shield.
- Refit the fixing clamps on the cables, the R 791 module and
the exciter connector.
13
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INSTALLATION AND MAINTENANCE
LEROY-SOMER
3434 en - 06.2007 / g
LSA 43.2/44.2 - 4-POLE
ALTERNATORS
SERVICING / MAINTENANCE
- Refit the air intake grille [51].
- Replace the terminal box lid [48].
NDE shield
Rotor
Screw rod
4.6.6 - Replacing the bearings on two-bearing
machines
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.
4.6.6.2 - Reassembly
- Heat the new bearings by induction or in a drying oven at
80 °C (do not use an oil-bath) and fit them to the machine.
- Check that both the preloading wavy washer [79] and the
new O ring seal [349] have been fitted on the NDE shield [36].
Refit the NDE shield and pass the bundle of wires between
the top bars of the shield.
- Refit the DE shield [30] and tighten the 4 fixing screws.
- Check that the machine assembly is correctly mounted and
that all screws are tightened.
4.6.7 - Accessing the main field 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 machine) or the
DE end shield (two-bearing machine) and insert a tube of the
corresponding diameter on the shaft end or a support made
according to the following diagram.
- 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 field
(rewinding, replacement of components), the rotor
assembly must be rebalanced.
4.6.7.2 - Reassembling the main field
- Follow the dismantling procedure in reverse order.
Take care not to knock the windings when refitting 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 fixed by screws on the hub.
Follow the procedure for reassembling the bearings (see
sections 4.6.5.2 and 4.6.6.2).
After operational testing, 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.
4.7.1 - Mechanical characteristics
The components are:
- An adaptation shaft (to position the rotor on the shaft
extension)
- A tie rod and nut for assembling the rotor on the shaft
- A rotor with 16 magnets
- An assembly consisting of: housing + wound stator + plastic
connection sheath + plastic ferrules
- The housing closure cover (4 CBLXS M5 screws)
- 4 HM6 screws (for fixing the housing to the NDE shield)
14
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INSTALLATION AND MAINTENANCE
LEROY-SOMER
3434 en - 06.2007 / g
LSA 43.2/44.2 - 4-POLE
ALTERNATORS
SERVICING / MAINTENANCE
If mounting in kit form, follow the following instructions
(see section 5.4):
1 - Remove the PMG cover [297] and the alternator NDE
shield seal.
2 - Mount the PMG housing assembly [290] on the shield
using the 4 HM6 screws.
3 - Put a coating of anti-vibration adhesive on the tie rod [295]
and fix it on the alternator shaft extension.
4 - Mount the magnetized rotor on the adaptation shaft, then
using 2 threaded rods screwed into the rotor, slide the
assembly onto the tie rod.
5 - Install the cable gland washer [296].
6 - Tighten the assembly with the M10 nut.
7 - Close the PMG with the cover [297].
8 - Pierce the cover (Ø 21 hole) and insert the plastic sheath
and its ferrule.
9 - Connect the PMG to the AVR (see sections 2.5 and 4.7.2).
4.8.1 - 3-phase LSA 43.2 4 P, SHUNT excitation
Resistances at 20 °C (Ω)
Electrical characteristics of the PMG
Stator phase/phase resistance 20 °C: 0.7 Ω
No-load voltage
: 73 V
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 excitation current i exc (A) - 400 V - 50 Hz
"i exc": excitation current of the exciter field
4.7.2 - Electrical connection
Mounting the PMG-1 on a SHUNT machine
(when using an R438):
- Disconnect the connection wires from the R 250 and remove
the AVR.
- Take out both the R 250 voltage reference wires, marked 2
and 3, by removing them from the terminals (T8 and T11) in
which they are inserted.
- Use these same wires for voltage sensing on the R 438 by
inserting them in terminals T2 (wire 2) and T3 (wire 3).
- Fit the AVR support plate fitted with the R 438 (2 HM6
screws tightened to 10 Nm).
- Connect the 3 PMG wires (14/15/16), the 2 exciter field wires
(5/6) and the 2 previously mentioned voltage sensing wires
(2/3) according to the connection diagram no. 2725-02-98.
- Modify the connection by replacing the single jumper on the
connector located on the terminal box rear panel with 2
jumpers (see internal connection diagram).
Mounting the PMG-1 on an AREP machine
- Connect the 3 PMG wires (14/15/16), to terminals X1, X2,
Z2 on the AVR. The 4 auxiliary winding wires X1.X2.Z1.Z2
should be isolated using the domino fitting supplied with the
kit. Both exciter field wires (5/6) and the voltage sensing wires
(2/3) remain in place.
LSA 43.2
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
1,6
L8
0,4
1,6
4.8.2 - 3-phase LSA 43.2 4 P, AREP excitation
Resistances at 20 °C (Ω)
LSA 43.2 Stator
L/N Rotor
Wind. Widing.
X1,X2 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 excitation current i exc (A) -400 V -50 Hz
"i exc": excitation current of the exciter field
4.8 - Electrical characteristics
Table of average values:
Alternator - 2 and 4 poles - 50 Hz/60 Hz - Winding n° 6 and M
or 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 field
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.
LSA 43.2
no load
on load
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
15
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INSTALLATION AND MAINTENANCE
LEROY-SOMER
3434 en - 06.2007 / g
LSA 43.2/44.2 - 4-POLE
ALTERNATORS
SERVICING / MAINTENANCE
4.8.3 - Dedicated single-phase LSA 43.2:
4-pole, SHUNT excitation (60 Hz only)
4.8.5 - 3-phase LSA 44.2: 4-pole, AREP
excitation
Resistances at 20 °C (Ω)
Resistances at 20 °C (Ω)
LSA 43.2
Stator L/N
Rotor
Field
Armature
S1
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
Field excitation current i exc (A) -240 V -60 Hz
"i exc": excitation current of the exciter field
LSA 43.2
no load
on load
S1
0,59
1,44
S25
0,59
1,68
S35
0,66
1,65
M45
0,61
1,48
L65
0,62
1,48
L8
0,74
1,46
LSA 44.2
Stator L/N
Rotor
Field
Armature
VS3
0,046
2,51
18,4
0,5
VS45
0,046
2,51
18,4
0,5
S7
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
no load
on load
VS3
0,5
1,8
VS45
0,5
2,1
S7
0,5
1,9
S75
0,5
2,1
M95
0,6
2
L12
0,6
1,9
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
0,5
L12
0,019
3,66
0,16
0,21
4,9
0,5
LSA 44.2
no load
on load
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)
Resistances at 20 °C (Ω)
LSA 44.2
Wind.
X1,X2
Field excitation current i exc (A) -400 V -50 Hz
"i exc": excitation current of the exciter field
4.8.4 - 3-phase LSA 44.2: 4-pole, SHUNT
excitation
Field excitation current i exc (A) - 400 V - 50 Hz
"i exc": excitation current of the exciter field
LSA 44.2 Stator
L/N Rotor
Resistances at 20 °C (Ω)
LSA 44.2
Stator L/N
Rotor
Field
Armature
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
Field excitation current i exc (A) -240 V -60 Hz
"i exc": excitation current of the exciter field
16
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LSA 44.2
no load
on load
VS3
0,44
1,18
VS45
0,44
1,25
S7
0,43
1,2
M95
0,55
1,28
3971c_NotRegR438_en.fm Page 1 Jeudi, 9. novembre 2006 10:13 10
3971 en - 11.2006 / c
Armature
6-
Field
10 Yellow
11 Red
12 Black
9
Gr
een
en to
giv
o be
t
s
i
er
ual
man e end us
h
This
t
1
X2 Z1 X1 Z2 E+ E- 0V 110 220
Slow fuse
250V 8 A
T5
with LAM without LAM
T3
quency
50Hz
60Hz
LAM 13 %
T10
R438
A.V.R.
Installation and maintenance
229/256
R 438
3971c_NotRegR438_en.fm Page 2 Jeudi, 9. novembre 2006 10:13 10
LEROY-SOMER
Installation and maintenance
3971 en - 11.2006 / c
R438
A.V.R.
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 can look forward to many years of trouble-free operation.
SAFETY MEASURES
WARNING
Before using your machine for the first time,
it is important to read the whole of this
installation and maintenance manual.
All necessary operations and interventions
on this machine must be performed by a
qualified technician.
Warning symbol for an operation
capable of damaging or destroying the
machine or surround-ing equipment.
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 risks of accidents. It is vital that
you understand and take notice of the
following warning symbols.
Warning symbol for general danger to
personnel.
This A.V.R. can be incorporated in a
machine marked C.E.
Warning symbol 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.
2
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3971c_NotRegR438_en.fm Page 3 Jeudi, 9. novembre 2006 10:13 10
LEROY-SOMER
Installation and maintenance
3971 en - 11.2006 / c
R438
A.V.R.
CONTENTS
1 - SUPPLY .............................................................................................................................4
1.1 - AREP excitation system ..............................................................................................4
1.2 - PMG excitation system ................................................................................................5
1.3 - SHUNT or separate excitation system.........................................................................5
2 - R438 A.V.R. .......................................................................................................................6
2.1 - Characteristics .............................................................................................................6
2.2 - Frequency compared with voltage (without LAM)........................................................6
2.3 - LAM (Load Acceptance Module) characteristics .........................................................6
2.4 - 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.......................................................................................8
3.2 - Settings........................................................................................................................8
3.3 - Electrical faults...........................................................................................................11
4 - SPARE PARTS ................................................................................................................12
4.1 - Designation................................................................................................................12
4.2 - Technical support service ..........................................................................................12
All such operations performed on the A.V.R. should be undertaken by personnel trained
in the commissioning, servicing and maintenance of electrical and mechanical
components.
Copyright 2005 : 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.
231/256
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LEROY-SOMER
Installation and maintenance
3971 en - 11.2006 / c
R438
A.V.R.
1 - SUPPLY
1.1 - AREP excitation system
to that of the alternator (characteristic
Shunt), the second has a voltage in
proportion to the stator current (compound
characteristic: Booster effect).
The power supply voltage is rectified and
filtered before being used by the AVR
monitoring transistor. This principle
ensures that regulation is not affected by
distortions generated by the load.
For both AREP & PMG excitation systems,
the alternator voltage regulator is the R438.
With AREP excitation, the R438 electronic
AVR is powered by two auxiliary windings
which are independent of the voltage
match circuit.
The first winding has a voltage in proportion
MAIN FIELD
STATOR: 6 wires (marked T1 to T6)
STATOR: 12 wires (marked T1 to T12)
T1 T7
T2 T8
T3 T9
T4 T10
T5 T11
T6 T12
Varistor
AREP SYSTEM
Aux. windings
Armature
5+
6-
Field
10 Yellow
11 Red
12 Black
9
Gr
een
according voltage
F1
X2 Z1 X1 Z2 E+ E- 0V 110 220 380
Slow fuse
250V 8 A
200 mm
140 mm
4 x holes Ø 5.8 x
175 x 115 mm
ST5
with LAM without LAM
P1
ST3
Frequency
50Hz
60Hz
R 438
LAM 13 %
ST10
ST9
T.I.
LAM 25 %
S2
S1
ST4
ST11
P3
4
AREP
PMG
P2
Option
Ph.1
P1
Excitation
ceiling
P5
ST2
Quad
droop
open
knee-point: 65 Hz
Response
time
Stability
normal
fast
Option
External potentiometer
for adjusting the voltage
ST1
Singlephase
detection
P2
Voltage
Option
R731 3-ph. dete ction
in 3-ph. detection ST1 op
en
232/256
3971c_NotRegR438_en.fm Page 5 Jeudi, 9. novembre 2006 10:13 10
LEROY-SOMER
Installation and maintenance
3971 en - 11.2006 / c
R438
A.V.R.
1.2 - PMG excitation system
alternator winding. As a result the machine
has a short-circuit current capacity and
good immunity to distortions generated by
the load.
The AVR monitors and corrects the
alternator output voltage by adjusting the
excitation current.
- 50/60 Hz selection via the ST3 jumper.
This excitation system consists of a "PMG"
(permanent magnet generator). This is
fitted at the rear of the machine and
connected to the R438 AVR.
The PMG supplies the AVR with constant
voltage which is independent of the main
T1 T7
T2 T8
T3 T9
T4 T10
T5 T11
T6 T12
Varistor
PMG SYSTEM
STATOR : 6 wires (marked T1 to T6)
STATOR : 12 wires (marked T1 to T12)
MAIN FIELD
PMG
Armature
5+
6-
Field
according voltage
14 15
16
F1
X2 Z1 X1 Z2 E+ E- 0V 110 220 380
Slow fuse
250V 8 A
200 mm
140 mm
4 x holes Ø 5.8 x
175 x 115 mm
ST5
with LAM without LAM
P1
ST3
Frequency 50Hz
60Hz
R 438
LAM 13 %
ST10
ST9
T.I.
LAM 25 %
S2
S1
ST4
ST11
P3
AREP
PMG
P2
Option
Ph.1
P1
Excitation
ceiling
P5
ST2
Quad
droop
open
knee-point: 65 Hz
Response
time
Stability
normal
fast
Option
External potentiometer
for adjusting the voltage
ST1
Singlephase
detection
P2
Voltage
Option
R731 3-ph. detection
in 3-ph. detection ST1 open
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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LEROY-SOMER
Installation and maintenance
3971 en - 11.2006 / c
R438
A.V.R.
2.1.2 - Setting potentiometers
function
2 - R438 A.V.R.
2.1 - Characteristics
- Standard power supply: AREP or PMG.
- Rated overload current: 8 A - 10 s
- Electronic protection (overload, shortcircuit on opening of voltage sensing
circuit): excitation overload current for 10
seconds then return to approximately 1A.
The alternator 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
transformer ;
• 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
potentiometer P1.
- Max. excitation current adjustment via P5
(see below).
2.1.1 - Configuration jumpers function
Pot.
Delivrery
config.
Open Closed
ST1
3-ph.
ST2
ST3
Fast
Position
Open for module
installation tri detection
Normal
Response time
50 ou 60 Hz Frequency selection
Mono
External
ST4 potentio- Without
meter
ST5 Without With
Others
ST9
AREP
(PMG...)
6
Potentiometer
LAM
Supply
13% or 25%
ST10
ST11
65 Hz
Function
48 or
58 Hz
LAM voltage drop
amplitude
U/f function bend
position
Delivrery
position
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)
Voltage
Bend
57.5 Hz
48 Hz
100 %
U/UN
50 Hz
60 Hz
Frequency
50 Hz
60 Hz
Hz
2.3 - LAM (Load Acceptance
Module) characteristics
2.3.1 - Voltage drop
The LAM system is integrated in the R 438
AVR as standard.
Role of the "LAM" (Load Adjustment
Module) :
On application of a load, the rotation speed
of the generator set decreases. When it
passes below the preset frequency
threshold, the LAM causes the voltage to
drop by approximately 13% or 25% and
consequently the amount of active load
applied is reduced by approximately 25%
to 50%, until the speed reaches its rated
value again.
Hence the LAM can be used either to
reduce the speed variation (frequency) and
its duration for a given applied load, or to
increase the applied load possible for one
speed variation (turbo-charged engine).
To avoid voltage oscillations, the trip
threshold for the LAM function should be
set approximately 2 Hz below the lowest
frequency in steady state.
234/256
3971c_NotRegR438_en.fm Page 7 Jeudi, 9. novembre 2006 10:13 10
LEROY-SOMER
Installation and maintenance
3971 en - 11.2006 / c
R438
A.V.R.
- LAM : action eliminated by cutting the ST5
jumper.
2.4.2 - Frequency
Max speed drop
Voltage
with
LAM
fN
Underspeed and LAM
ST5 disconnected
UN
P2
Voltage
0,9
without
LAM
U/f
0,8
LAM
0.85 UN
1s
0
48 or 57.5 Hz
0
ST3
fC
2s
Time
3s
2.4.3 - Power
50 or 60 Hz
fN
During load impacts, the function helps the
genset to return to its rated speed faster
thanks to a gradual increase in voltage
according to the principle:
- If the speed drops between 46 and 50 Hz,
the rated voltage follows a fast gradient as
it is restored.
- If the speed drops below 46 Hz, since the
engine needs more help, the voltage
follows a slow gradient as it returns to the
reference value.
U
Drop N ≤ 46 Hz
Drop N > 46 Hz
Time
0
2.4 - Typical effects of the LAM with
a diesel engine with or without a
LAM (U/F only)
2.4.1 - Voltage
Transient voltage drop
UN
0,9
(U/f)
without LAM
with
LAM
0,8
0
1s
Time
2s
Load on the
shaft (kW)
LAM
2.3.2 - Gradual voltage return function
Variation in the load
Load shedding due to "LAM"
0
1s
2s
Time
3s
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
potentiometer P2). Remove ST4 to connect
the poten-tiometer. (A 1 kΩ potentiometer
can also be used to extend the adjustment
range).
- R 731 external module: sensing of 3phase voltage 200 to 500 V, compatible with
parallel operation. Disconnect ST1 to
connect the module; set the voltage via the
module potentiometer.
- R 734 module: detection of 3-phase
current and voltage for parallel operation on
unbalanced installations (imbalance > 15%).
- R 726 module: 3 functions (mounted
externally)
P.F. regulation (2F) and voltage sensing
circuit before paralleling (3 F).
- Control through DC voltage used
monitoring apply to the terminals for
connection of a potentiometer DC voltage :
• internal impedance 1,5 kΩ
• ± 0,5V enable a voltage setting of 10%.
3s
235/256
7
3971c_NotRegR438_en.fm Page 8 Jeudi, 9. novembre 2006 10:13 10
LEROY-SOMER
Installation and maintenance
3971 en - 11.2006 / c
R438
A.V.R.
3 - INSTALLATION - COMMISSIONING
3.1 - Electrical checks on the AVR
- Check that all connections have been
made properly as shown in the attached
wiring diagram.
- Check that the ST3 frequency selection
jumper is on the correct frequency setting.
- Check whether the ST4 jumper or the
remote adjustment potentiometer have
been connected.
- Optional operating modes.
• ST1 jumper : open to connect the R
731or R 734 3-phase
sensing module.
• ST2 jumper : open if rapid response time
used
• ST5 jumper : open to suppress the LAM
function.
3.2 - Settings
a) Initial potentiometer settings (see table
below)
- Remote voltage adjustment potentiometer :
centre (ST4 jumper removed).
Action
Factory setting
Pot.
minimum fully anti-clockwise
400V - 50 Hz
(Input
0 - 380 V)
P2
Not set
(centre position)
P3
Not set
(fully anticlockwise)
P1
Voltage
Stability
Voltage quadrature droop
(// operation with C.T.)
- 0 quadrature loop fully
anti-clockwise.
Excitation ceiling
Limit of excitation and
short-circuit current,
minimum fully anti-clockwise.
10 A
maximum
P5
Stability adjustments in standalone
operation
b) Install a D.C. analogue voltmeter
(needle dial) cal. 50V on terminals E+, Eand an A.C. voltmeter cal 300 - 500 or
1000V on the alternator output terminals.
The machine is tested and set at the
factory. When first used with no load,
make sure that the drive speed is
correct and stable (see the nameplate).
After operational testing, replace all
access panels or covers.
The only possible adjustments to the
machine should be made on the AVR.
d) Voltage potentiometer P2 at minimum,
fully anti-clockwise.
3.2.1 - R438 settings (AREP or PMG
system)
e) Stability potentiometer P3 to around 1/3
of the anti-clockwise limit.
WARNING
Before any intervention on the A.V.R.,
make sure that the ST9 jumper is closed
with AREP excitation and disconnected
with PMG or SHUNT or separate
excitation.
8
c) Make sure that the ST3 jumper is
positioned on the desired frequency (50 or
60 Hz).
f) Start the engine and set its speed to a
frequency of 48 Hz for 50 Hz, or 58 for 60
Hz.
g) Set the output voltage to the desired
value using P2.
- Rated voltage UN for solo operation (eg.
400 V)
- Or UN + 2 to 4% for parallel operation with
C.T. (eg. 410 V)
If the voltage oscillates, use P3 to make
adjustments (try both directions) observing
236/256
3971c_NotRegR438_en.fm Page 9 Jeudi, 9. novembre 2006 10:13 10
LEROY-SOMER
Installation and maintenance
3971 en - 11.2006 / c
R438
A.V.R.
the voltage between E+ and E- (approx.
10V D.C.). The best response times are
obtained at the limit of the instability. If no
stable position can be obtained, try
disconnecting or replacing the ST2 jumper
(normal/fast).
3.2.2 - Max. excitation setting (excitation
ceiling)
ST3
P5
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 that observed previously (~ 15%).
P3
P2
j) Readjust the speed of the unit to its rated
no-load value.
Adjustments in parallel operation
Before any intervention on the
alternator, make sure that the speed
droop is identical for all engines.
k) Preset for parallel operation (with C.T.
connected to S1, S2)
- Potentiometer P1 (quadrature droop) in
centre position.
Apply the rated load (cos ϕ = 0.8 inductive).
The voltage should drop by 2 to 3%. If it
increases, check that V and W and also S1
and S2 have not been reversed.
l) The no-load voltages should be identical
for all the alternators intended to run in
parallel.
- 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)
the current circulating between the
machines.
- From now on, do not touch the voltage
settings.
m) Apply the available load (the setting is only
correct if a reactive load is available)
- By altering the speed, match the kW (or
divide the rated power of the units
proportionally)
- By altering the quadrature droop
potentiometer P1, match or divide the
currents.
237/256
Depending on
the mains frequency
Max. excitation
X2
Z1
X1
Z2
E+
R 438
E0V
110 V
220 V
ST4
380 V
Main
(50/60 Hz supply)
48 V
50Hz 60Hz
A
–
A
+
Field
~ 5 ohms
10 A CC/DC
110/220/380 V
D
Voltage
Static adjustment of the current limit,
potentiometer P5 (factory setting: 7.5 A,
fuse rating: 8 A - 10 seconds).
The maximum factory setting corresponds
to that of the excitation current required to
obtain a 3-phase short-circuit current of
approximately 3 IN at 50 Hz for industrial
power, unless otherwise specified(*).
A static method can be used to reduce this
value or adapt the Isc to the actual
operating power (derated machine), which
is safer for the alternator and the
installation. Disconnect power supply wires
X1,X2 and Z1,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 field. Turn P5 fully
anti-clockwise and activate the power
supply. If there is no output current from the
AVR, turn potentiometer P2 (voltage)
clockwise until the ammeter indicates a
stable current. Switch the power supply off,
then on again, turn P5 clockwise until the
required max. current is obtained (no more
than 8 A).
Checking the internal protection :
Open switch (D) : the excitation current
should increase to its preset ceiling, remain
at that level for ≥ 10 seconds and then drop
to < 1A.
9
3971c_NotRegR438_en.fm Page 10 Jeudi, 9. novembre 2006 10:13 10
LEROY-SOMER
Installation and maintenance
3971 en - 11.2006 / c
R438
A.V.R.
To reset, switch off the power supply by
opening switch (A).
Note: After setting the excitation ceiling as
described, adjust the voltage again (see
section 2.1.1)
(*) In some countries it is a legal
requirement to have a short-circuit current
of 3 IN, so as to offer selective protection.
3.2.3 - Special type of use
Connection is identical for resetting the
AVR internal protection.
In case of using the de-excitation,
provide a forced excitation.
3.2.3.3 - R438 field forcing
WARNING
(400V - 10A)
X2
Z1
X1
Z2
E+
E-
Excitation circuit E+, E- must not be left
open when the machine is running :
AVR damage will occur.
3.2.3.1 - R438 field weakening (SHUNT)
t
Diode
+
Battery (B Volt)
Exciter field
X2
Z1
X1
Z2
E+
E-
Forced excitation
B Volt
t
Time
Applications
The exciter is switched off by disconnecting
the AVR power supply (1 wire - X1 or X2).
Contact rating 16 A - 250V A.C.
3.2.3.2 - R438 field weakening (AREP/
PMG)
Time t
Guaranteed voltage build-up
12 (1A)
1-2 s
Parallel operation, de-energized
12 (1A)
1-2 s
Parallel operation, at standstill
24 (2A)
5 - 10 s
Frequency starting
48 (4A)
5 - 10 s
Sustained voltage on overload
48 (4A)
5 - 10 s
X2
Z1
X1
Z2
E+
EThe exciter is switched off by disconnecting
the AVR power supply (1 wire on each
auxiliary winding) - contact rating 16 A 250V A.C.
10
B volts
238/256
3971c_NotRegR438_en.fm Page 11 Jeudi, 9. novembre 2006 10:13 10
LEROY-SOMER
Installation and maintenance
3971 en - 11.2006 / c
R438
A.V.R.
3.3 - Electrical faults
Fault
Action
No voltage at Connect a new battery
no load on
of 4 to 12 volts to
start-up
terminals E- and E+,
respecting the polarity,
for 2 to 3 seconds
Effect
Check/Cause
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
voltage does 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 field winding open circuit - check the
resistance
Check the AVR connections (AVR may be
faulty)
- Field windings short-circuited
- Rotating diodes burnt out
- Main field winding short-circuited - Check
the resistance
Correct speed
Voltage too
low
Check the drive speed
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 / fast
recovery modes (ST2)
- Check the speed : possibility of cyclic
irregularity
- Loose connections
- Faulty AVR
- Speed too low when on load (or U/F bend
set too high)
Voltage
correct at no
load and too
low when on
load (*)
Run at no load and
check the voltage
between E+ and E- on
the AVR
Voltage between E+ and ESHUNT < 20 V - AREP / PMG <
10V
Voltage between E+ and ESHUNT > 30V - AREP / PMG >
15V
- Check the speed (or U/F bend set too
high)
- Faulty rotating diodes
- Short-circuit in the main field. 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
Voltage
disappears
during
operation (**)
Check the AVR, the
surge suppressor, the
rotating diodes, and
replace any defective
components
The voltage does not return to the - Exciter winding open circuit
rated value.
- Faulty exciter armature
- Faulty AVR
- Main field 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.
239/256
11
3971c_NotRegR438_en.fm Page 16 Jeudi, 9. novembre 2006 10:13 10
MOTEURS LEROY-SOMER 16015 ANGOULÊME CEDEX - FRANCE
338 567 258 RCS ANGOULÊME
S.A. au capital de 62 779 000 €
www.leroy-somer.com
240/256
9.3. Appendix C - Common spare parts
R66C2
Rental Power
GENCOOL
GENLUB
-ENGINE
JOHN DEERE
4045TFS70
Starter motor brush
330362331
X1
Radiator cap
31802000304
X1
Charging alternator diode bridge
330360144
X1
Fan belt
330360183
X1
Thermostat
330360012
X1
Thermostat seal
Alarm oil pressure sensor
Alarm water temperature sensor
330361286
330360059
330360060
X1
X1
x 20 L
330910115
X1
x 208 L
330910095
x 20 L
330910098
x 60 L
330910099
x 210 L
330910100
241/256
X1
330570092 + 330570118
X1
330560611 + 330510015
x1
330361669
x1
ALTERNATOR
LEROY-SOMER
LSA432M45
Note:
Diode bridge
330410713
x1
Varistor
330410335
X1
For all technical assistance or spare part requests, contact your nearest SDMO agent.
242/256
SID
PID
PPID
FMI
28
Throttle #3 Position
Short to V+
4
Throttle Voltage low, short to V-
Short to V-
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
Throttle #2 Position
Vehicle speed
91
91
2
Vehicle invalid or missing
31
Vehicle speed mismatch
132
Accelerator pedal position
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
97
98
99
Commentary
Throttle Voltage high, short to V+
84
94
Description
3
29
91
Perkins
CID
Volvo
SPN
John Deere
9.4. Appendix D - List of John Deere - Volvo and Perkins fault codes
94
FMI non déterminé pour
tous les VOLVO
Not possible with genset
application, codes declared
by the CAN J1587 for
VOLVO.
Throttle voltage out of range
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
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
99
Not possible with genset
application
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
Engine Oil filter Differential Pressure
243/256
100
102
273
PID
PPID
FMI
100
Oil pressure sensor
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
Manifold air pressure sensor
0
Manifold air pressure above normal
1
15
Manifold air pressure below normal
Manifold air pressure sensor input
Short to V+
voltage high
Manifold air pressure sensor input
Short to Vvoltage low
Manifold air pressure moderately low
16
Manifold air pressure low
105
Manifold air temperature sensor
0
3
4
5
16
106
3
5
107
3
4
5
31
274
Air inlet pressure above normal
Air inlet pressure sensor input voltage
high
Air inlet pressure sensor open circuit
Air filter differential pressure sensor
0
108
Manifold air temperature extremely high
Manifold air temperature sensor input
voltage high
Manifold air temperature sensor input
voltage low
Manifold air temperature sensor open
circuit
Manifold air temperature moderately high
Air inlet pressure sensor
0
107
Commentary
Engine oil pressure extremely low
4
106
Description
1
3
105
Perkins
100
SID
Volvo
CID
John Deere
SPN
108
Air filter restriction high
Air filter differential pressure sensor input
voltage high
Air filter differential pressure sensor input
voltage low
Air filter differential pressure sensor open
circuit
Air filter restriction high
Barometric pressure sensor
3
4
17
Not use with EDC III and
EMS2
High barometric pressure sensor short to
high
High barometric pressure sensor short to
low
High barometric pressure
244/256
ECM option,
connected
sensor
not
110
PID
PPID
FMI
110
5
Coolant temperature extremely high
Coolant temperature sensor input voltage
high
Coolant temperature sensor input voltage
low
Coolant temperature sensor open circuit
15
Coolant temperature high least severe
16
Coolant temperature moderately high
31
Coolant temperature high
3
4
111
Engine coolant level low
3
Coolant level sensor input voltage high
4
Coolant level sensor input voltage low
0
Value above normal
Crankcase pressure sensor input voltage
high
Crankcase pressure sensor open circuit
Crankcase pressure sensor
3
5
158
Battery voltage sensor
1
Voltage above normal
17
ECU power down error
160
Wheel speed sensor
2
164
168
164
168
172
Electrical system voltage
172
Electrical system voltage low
Inlet
air
temperature
sensor for PERKINS
Ambiant air temperature sensor input Inlet air temperature sensor
voltage high
input voltage high
Ambiant air temperature sensor input Inlet air temperature sensor
voltage low
input voltage low
Ambiant air temperature sensor open
circuit
High Inlet air temperature
alarm-warning
High Inlet air temperature
alarm-action alert
Fuel temperature sensor
Ambiant air temperature sensor
3
4
5
15
16
174
Wheel speed input noise
Injection Control Pressure
2
172
Engine coolant level low
1
153
158
Commentary
Coolant level sensor
0
153
Description
Coolant temperature sensor
0
111
Perkins
110
SID
Volvo
CID
John Deere
SPN
174
0
15
Fuel temperature high most severe
Fuel temperature sensor input voltage
high
Fuel temperature sensor input voltage
low
Fuel temperature high
16
Fuel temperature high moderately high
31
Fuel temperature sensor faulty
3
4
245/256
175
PID
PPID
FMI
175
3
Oil temperature sensor input voltage high
4
Oil temperature sensor input voltage low
5
Oil temperature sensor open circuit
Transmission oil temperature sensor
189
252
190
0
Engine speed de rated
31
Engine speed de rated
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
261
Speed sensor calibration
13
Engine timing abnormal calibration
11
Incorrect engine software
252
253
281
281
Software
Check system parameters
2
285
3
Action alert output open/short to B+
4
Action alert output short to ground
5
Action alert output open circuit
282
Overspeed output status
3
Overspeed output open/short to B+
4
Overspeed output short to ground
285
4
323
Incorrect parameters
Action alert output status
3
286
Transmission oil temperature invalid
Rated engine speed
234
282
Commentary
Oil temperature sensor
Oil temperature extremely high
9
228
Description
0
177
190
Perkins
SID
Volvo
CID
John Deere
SPN
286
Coolant temperature output status
Coolant temperature lamp open/short to
B+
Coolant temperature lamp short to
ground
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
Shutdown output status
3
Shutdown output open/short to B+
4
Shutdown output short to ground
5
Shutdown output open circuit
246/256
not possible with Genset
application
324
443
PID
PPID
FMI
Description
Warning output open/short to B+
4
Warning output short to ground
5
Warning output open circuit
443
ENGINE RUN output status
3
Engine run output open/short to B+
4
Engine run output short to BGear selection
9
608
250
262
3
Injector wiring shorted to power source
4
Injector wiring shorted to ground
232
626
Gear selection invalid
Not possible with Genset
application
Data link faulty J1587 Start/Stop
redundancy / J1939 communication
bus
Injector wiring status
98
611
5 Volt sensor power supply
FMI not
VOLVO
informed
by
3
Sensor power supply open/short to B+
4
5
Sensor power supply short to ground
Start enable device (intake heater and
ether)
Start enable device output short to B+
Not use, the control panel is
Start enable device output short to
in charge to manage the
ground
start enable device
Start enable device output open circuit
1
Injector supply voltage problem
For 6125HF070 only
4
ECU unswitched power missing
For 6068HF275 VP44 only
45
3
4
627
Power supply
628
240
Memory fault in EMS2
629
254
ECU status/controller 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
ECU to injection pump communication Possible
only
error
6068HF475 VP44
Data set memory EEPROM
19
630
Commentary
Warning output status
3
523
620
Perkins
324
SID
Volvo
CID
John Deere
SPN
253
632
Injection status
2
Fuel shutoff error
5
Fuel shutoff non-functional
247/256
with
636
PID
PPID
FMI
21
2
3
8
9
10
637
22
2
3
247
Pump position sensor/Cam position
Pump position or CAM
sensor/Speed sensor CAM
position in function of the
Pump position sensor/cam position
type of injection
sensor input noise
Permanent loss of signal
Pump position sensor/cam position
sensor input missing
Not informed by VOLVO
Pump position sensor/cam position
sensor input pattern error
Crank position sensor/Speed sensor
flywheel
Crank position input noice
9
Not informed by VOLVO
10
Crank position sensor input pattern error
231
out
of
Communication status
2
Bus Off error
9
Passive bus error
11
Data registers read back failure
12
Loss of message error
13
Bus CAN error
Engine shutdown vehicle status
1
1
11
Engine shutdown vehicle request invalid
31
Engine shutdown vehicle request
651
Cylinder #1 status injector
2
4
Short circuit high side to B+
Short circuit high side to low side or low
side to B+
Short circuit high or low side to ground
5
Cylinder #1 circuit open
6
Cylinder #1 circuit shorted
Cylinder #1 balancing error/mechanical
failure
Cylinder #1 unknown error/mechanical
failure
Cylinder #2 status injector
3
7
11
652
Commentary
8
640
651
Description
Permanent loss of signal
Crank position/Cam position
synchronisation
Crank position input missing
7
639
Perkins
SID
Volvo
CID
John Deere
SPN
2
2
652
2
4
Short circuit high side to B+
Short circuit high side to low side or low
side to B+
Short circuit high or low side to ground
5
Cylinder #2 circuit open
6
Cylinder #2 circuit shorted
Cylinder #2 balancing error/mechanical
failure
Cylinder #2 unknown error/mechanical
failure
3
7
11
248/256
PID
653
3
3
653
PPID
FMI
4
Short circuit high side to B+
Short circuit high side to low side or low
side to B+
Short circuit high or low side to ground
5
Cylinder #3 circuit open
6
Cylinder #3 circuit shorted
Cylinder #3 balancing error/mechanical
failure
Cylinder #3 unknown error/mechanical
failure
Cylinder #4 status injector
3
7
11
4
4
654
2
4
Short circuit high side to B+
Short circuit high side to low side or low
side to B+
Short circuit high or low side to ground
5
Cylinder #4 circuit open
6
Cylinder #4 circuit shorted
Cylinder #4 balancing error/mechanical
failure
Cylinder #4 unknown error/mechanical
failure
Cylinder #5 status injector
3
7
11
655
5
5
655
2
4
Short circuit high side to B+
Short circuit high side to low side or low
side to B+
Short circuit high or low side to ground
5
Cylinder #5 circuit open
6
Cylinder #5 circuit shorted
Cylinder #5 balancing error/mechanical
failure
Cylinder #5 unknown error/mechanical
failure
Cylinder #6 status injector
3
7
11
656
6
6
656
2
4
Short circuit high side to B+
Short circuit high side to low side or low
side to B+
Short circuit high or low side to ground
5
Cylinder #6 circuit open
6
Cylinder #6 circuit shorted
7
Cylinder #6 balancing error/mechanical failure
11
Cylinder #6 unknown error/mechanical failure
3
676
677
Description
Cylinder #3 status injector
2
654
Perkins
SID
Volvo
CID
John Deere
SPN
39
Glow plug relay status
3
Glow plug relay voltage high
5
Glow plug relay voltage low
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
249/256
Commentary
41
679
723
PID
PPID
FMI
4
11
ACM 8 Volt DC supply open/short to ground
Injection control pressure
regulator/pressure release valve
Secondary speed sensor
Secondary engine speed sensor data
intermittent
Secondary engine speed sensor loss of signal
12
Loss of signal/sensor failure
342
70
Inlet air heater signal/Preheat sense
3
Inlet air heater signal high
5
Inlet air heater signal low
810
Vehicle speed
2
861
Calculated vehicle speed input noise
Not possible with Genset
application
Diagnostic output status
3
Diagnostic output open/short to B+
4
Diagnostic output short to ground
898
CAN throttle status
9
970
Commentary
8 Volt power supply
ACM 8 Volt DC supply open/short to B+
2
861
Description
3
42
729
Perkins
678
SID
Volvo
CID
John
Deere
SPN
6
Speed value invalid or missing
Auxiliary engine shutdown switch status EMS
2
Auxiliary engine shutdown switch signal invalid
31
Auxiliary engine shutdown switch active
31
External engine de rate switch active
971
Not used
External engine de rate switch status
1069
Not used
Tire size status
2
Tire size error
9
Tire size invalid
31
Tire size error
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
1076
Not possible with Genset
application
Fuel Injection pump status
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
250/256
Injection DE10
PID
PPID
FMI
1078
7
11
31
1079
1080
Description
Sensor supply voltage high
4
3
Sensor supply voltage low
Sensor supply voltage (Oil
pressure)/+5V sensor supply 2
Sensor supply voltage high
4
Sensor supply voltage low
31
Engine shutdown warning
211
temp,
fuel
> 5,5 Volt
< 4,40 Volt
Engine status
31
268
1136
55
1184
Programmed parameter fault
ECU Temperature
173
1188
Engine shutdown
Check parameters
2
Exhaust gas temperature sensor
32
Wastegate
1231
CAN bus 2
1239
Rail pressure system
1266
General fault output status
3
General fault output open/short to B+
4
General fault output short to ground
1347
Pump control valve status
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
1485
> 5,5 Volt
< 4,44 Volt
pressure, Coolant
Engine/ECU status
1110
1266
Commentary
ECU/Pump timing status
ECU/Pump timing moderately out of
synchronisation
ECU/Pump timing speed out of
synchronisation
ECU/Pump timing extremely out of
synchronisation
Sensor supply voltage (+5 Volt)
Analog throttle reference
3
1109
1111
Perkins
SID
Volvo
CID
John Deere
SPN
Pump control valve #2 status
1485
5
Pump control valve #2 error/mismatch
10
Pump control valve #2 fuel flow not detected
5
Pump power relay status
2
Torque curve selection
Torque curve selection invalid
4
Torque curve input voltage high
9
Torque curve selection missing
Fuel supply status
31
ECU main relay of VOLVO
EMS/EDC
ECU main relay short circuit high
2
1569
Only for 6081HF070
Pump power relay fault
3
1568
Pump control valve #1
status for 6081HF070
Fuel de rate
251/256
PID
PPID
FMI
1639
Description
Commentary
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
1675
1690
Perkins
SID
Volvo
CID
John Deere
SPN
Engine starter motor relay
1690
Analogue throttle status
Abnormal pulse signal
2000
ECU status
2017
6
Vehicle ID missing
13
Security violation
J1939 Communication bus
2791
19
Internal EGR status
520192
8
Piston cooling switch
520193
267
520194
4
520195
6
Sea water pressure
Starter input sensor (start request)
Key off input sensor (stop request)
CIU
252/256
Not possible with Genset
application
SAE J1939-73 : March 2004
FMI and Description
FMI=0—DATA VALID BUT ABOVE NORMAL OPERATIONAL RANGE - MOST SEVERE LEVEL
The signal communicating information is within a defined acceptable and valid range, but the real world condition is above
what 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—DATA VALID BUT BELOW NORMAL OPERATIONAL RANGE - MOST 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 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—DATA ERRATIC, INTERMITTENT OR INCORRECT
Erratic or intermittent data includes all measurements that change at a rate that is not considered possible in the real
world 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, 5
and 6. Data may also be considered incorrect if it is inconsistent with other information collected or known about the
system.
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 range
definition). 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 it
to 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 range
definition). 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 it
to 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 range
definition). 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 range
definition). 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 a
mechanical 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 bound
the 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 is
substituted with the “error indicator” value.
FMI=9—ABNORMAL UPDATE RATE
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 that
causes the ECM not to send information at the rate required by the system. This type of fault may or may not be directly
associated with the value of general broadcast information.
253/256
FMI=10—ABNORMAL RATE OF CHANGE
Any data, exclusive of the abnormalities covered by FMI 2, that is considered valid but whose data is changing at a rate
that 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 CAUSE NOT KNOWN
It 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—BAD INTELLIGENT DEVICE OR COMPONENT
Internal diagnostic procedures have determined that the failure is one which requires the replacement of the ECU, used
here to mean the packaged unit that includes some microprocessor and its associated components and circuits. It can be
assumed that the communications subsystem is not the part that has failed, and the manufacturer has determined that
there is no serviceable component smaller than the ECU involved in the failure. Broadcast of data value is substituted
with the “error indicator” value if appropriate, as there may or may not be any broadcast involved. This error is to include
all internal controller trouble codes that can not be caused by connections or systems external to the controller.
FMI=13—OUT OF CALIBRATION
A failure that can be identified to be the result of not being properly calibrated. This may be the case for a subsystem
which can identify that the calibration attempting to be used by the controller is out of date. Or it may be the case that the
mechanical subsystem is determined to be out of calibration. This failure mode does not relate to the signal range
definition 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 choices
but not to a single point of failure. When the FMI is used, there is clear necessity for the service technician to take some
action to complete the specific diagnosis, and the manufacturer has provided instructions for the completion of that
diagnosis. There are two cases where this will be used: 1. for emission-related diagnostics where the particular failure
cannot be separated between a sensor out of range and the case where the actual value is at the edge of a diagnostic
region, and 2. for the older SPN 611 to 615 where the problem is in determining which of two or more circuits (which may
interact) 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 a
specific field replaceable component. Specific subsystem fault isolation is the goal of any diagnostic system, but for
various reasons this cannot always be accomplished. These SPNs allow the manufacturer some flexibility to
communicate non-“specific component” diagnostic information. Since SPNs 611-615 use the standard SPN/FMI format it
allows the use of standard diagnostic tools, electronic dashboards, satellite systems and other advanced devices that
scan Parameter Groups containing the SPN/FMI formats. Because manufacturer defined codes are not desirable in terms
of standardization, the use of these codes should only occur when diagnostic information cannot be communicated as a
specific component and failure mode.
Possible reasons for using a System Diagnostic Code include:
1. Cost of specific component fault isolation is not justified, or
2. New concepts in Total Vehicle Diagnostics are being developed, or
3. 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 have
little meaning. Therefore, FMI 14, “Special Instructions”, is usually used. The goal is to refer the service personnel to the
manufacturer's troubleshooting manual for more information on the particular diagnostic code. This failure mode does not
relate to the signal range definition as do many of the FMIs. This type of fault may or may not be directly associated with
the value of general broadcast information.
FMI=15—DATA VALID BUT ABOVE NORMAL OPERATING RANGE - LEAST SEVERE LEVEL
The signal communicating information is within a defined acceptable and valid range, but the real world condition is above
what 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—DATA VALID BUT ABOVE NORMAL OPERATING RANGE - MODERATELY SEVERE LEVEL
The signal communicating information is within a defined acceptable and valid range, but the real world condition is above
what 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 as
normal.
254/256
FMI=17—DATA VALID BUT BELOW NORMAL OPERATING RANGE - LEAST 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 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—DATA VALID BUT BELOW NORMAL OPERATING RANGE - 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 particular
measure of the real world condition (Region j of the signal range definition). Broadcast of data values is continued as
normal.
FMI=19—RECEIVED NETWORK DATA 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 J1939-71). This type of failure is associated with received network data. The component used to measure
the real world signal is wired directly to the module sourcing the data to the network and not to the module receiving the
data via the network. The FMI is applicable to Region f and g of the signal range definition. This type of fault may or may
not 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 cases
when the reported SPN name spells out the component and a non-standard failure mode. This type of fault may or may
be directly associated with the value of general broadcast information. This FMI will mean “not available” when the
associated SPN is also “not available” as when the remainder of the packet is filled with binary ones after all data has
been transmitted.
255/256
256/256
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