Ingersoll-Rand M 50 Users Manual And Maintenance Manual
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Ingersoll-Rand M 50 Users Manual And Maintenance Manual

Ingersoll-Rand M 50 Users Manual And Maintenance Manual

Generating sets
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Users guide and maintenance
manual for the generating sets
Model(s) : G200
Control device : M150
Doosan purchased Bobcat Company from Ingersoll-Rand Company in
2007. Any reference to Ingersoll-Rand Company or use of trademarks,
service marks, logos, or other proprietary identifying marks belonging
to Ingersoll-Rand Company in this manual is historical or nominative
in nature, and is not meant to suggest a current affiliation between
Ingersoll-Rand Company and Doosan Company or the products of
either.
Réf. GPAO : 33501185101NE
Réf. constructeur : 33501185101
Revised (10-12)

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  • Page 1 Control device : M150 Doosan purchased Bobcat Company from Ingersoll-Rand Company in 2007. Any reference to Ingersoll-Rand Company or use of trademarks, service marks, logos, or other proprietary identifying marks belonging to Ingersoll-Rand Company in this manual is historical or nominative...
  • Page 3 Users guide and maintenance manual All generating sets General considerations Safety instructions Réf. constructeur : MUE-IR A Réf. GPAO : 33522051901 - 1 -...

  • Page 4: Table Of Contents

    1. Preamble ..........................4 1.1. Introduction ........................4 1.1.1 General recommendations..................4 1.1.2. Structure of the reference material ................5 1.2. Pictograms and their meanings..................5 1.3. Safety instructions and regulations ................7 1.3.1 General advice......................7 1.3.2 Risks related to feed gas (concerns gas sets)............. 9 1.3.3 Risks related to exhaust gases and fuels..............
  • Page 5 Attached documents User manual for the control unit User and maintenance manual for the engine User and maintenance manual and spare parts catalogue for the alternator Wiring diagrams (supplied with the electrical generating set) Genset parts catalog. - 3 -...

  • Page 6: Preamble

    1. P REAMBLE 1.1. Introduction 1.1.1 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. Read the safety instructions carefully in order to prevent any accident, incident or damage. These instructions must always be followed.

  • Page 7: Structure Of The Reference Material

    1.1.2. Structure of the reference material The reference material delivered with the generating sets enables you to get to know the equipment, operate it and maintain it, both on a daily basis and periodically. The reference material for the engines and alternators fitted to the sets consists of engine user and maintenance manuals (from the manufacturer) and alternator user and maintenance manuals (from the manufacturer).
  • Page 8 Warning, rotating or moving parts (risk of Lifting point required getting caught in the machinery) Stacking point required Warning, corrosive product Naked flames and Warning, risk of explosion unprotected lights prohibited. No smoking Exctinction by water Entry prohibited to non- prohibited authorised persons When on a trailer,...

  • Page 9: Safety Instructions And Regulations

    1.3. Safety instructions and regulations THESE SAFETY PRECAUTIONS 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.
  • Page 10 Disconnect the battery and pneumatic starter (if there is one) before carrying out any repair, to prevent the engine from starting accidentally. Fit a panel over the controls to prevent any attempt at starting. Do not modify the engine. Only use the correct techniques for turning the crankshaft to rotate the crankshaft manually.

  • Page 11: Risks Related To Feed Gas (Concerns Gas Sets)

    1.3.2 Risks related to feed gas (concerns gas sets) WARNING – DANGER The gas is explosive. It is forbidden to smoke, go near or create sparks when the tank is being filled and near to the generating set. Request the user technical notes and LPG or NG safety data sheets from your gas supplier.

  • Page 12: Risks Related To Toxic Products

    1.3.4 Risks related to toxic products WARNING – DANGER The corrosion inhibitor contains alkali. This substance should not come into contact with the eyes. Avoid any prolonged or repeated contact with skin. It should not be swallowed. In the event of skin contact, wash thoroughly with water and soap. In the event of contact with eyes, rinse immediately with plenty of water for at least 15 minutes.

  • Page 13: Risks Related To Electrical Networks

    Good ventilation is required for your generating set to work properly. Without ventilation, the engine will quickly reach an excessive temperature that could lead to accidents or damage to the equipment and surrounding items. Do not take off the radiator cap when the engine is hot and the coolant is pressurised due to risk of burns.

  • Page 14: Dangers Presented By Electric Currents (First Aid)

    1.3.7 Dangers presented by electric currents (first aid) First aid In the event of an electric shock, cut off the voltage immediately and activate the set's emergency stop. If the voltage has not yet been cut off, move the victim out of contact with the live conductor as quickly as possible.

  • Page 15: Recommendation For The Operator And Environment

    1.3.9 Recommendation for the operator and environment Operating personnel should be aware of the safety and operating instructions. These will be regularly updated. Operating should be monitored, directly or indirectly, by someone designated by the operator who is familiar with the installation and dangers and problems regarding products stored and used in the installation.

  • Page 16: Identifying Sets

    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 documents contained in this manual. Examples of identification plates generating set Engines - 14 -...
  • Page 17 Alternator - 15 -...

  • Page 18: Installation

    2. I NSTALLATION 2.1. Unloading 2.1.1 Safety during unloading In order to unload generating sets from their transport mountings, under optimum conditions of safety and efficiency, you should check that the following points are being followed correctly. - Suitable lifting vehicles or equipment for the work. - Slings positioned in the rings provided for this procedure or lifting arms resting fully underneath the frame cross beams.

  • Page 19: Fork Lift Truck

    2.1.3.2 Fork lift truck - position the arms of the fork lift under the frame, making sure that only the cross beams are resting on the arms. - lift and handle the equipment carefully. - set down the generating set in its unloading position. It is recommended to use a fork lift truck with arms that are longer than the width of the frame - 17 -...

  • Page 20: Installation Of Mobile Site Sets

    3. I NSTALLATION OF MOBILE SITE SETS 3.1 Specific arrangements An area will be reserved to install the generating set. Its should be flat and strong enough so that the generator does not sink into it. It could be made of concrete or even large planks fitted together.

  • Page 21: Road Trailer

    4. R OAD TRAILER 4.1 Trailer linkage Before attaching the trailer, check the trailer hook on the tow vehicle; it should fit the trailer ring perfectly. WARNING – DANGER Trying to tow a trailer with a non-matching device (bar, wires, cords, etc.) could lead to serious accidents.

  • Page 22: Check Before Towing

    4.2 Check before towing Before towing carry out the following checks: - wheel torquing - lock trailer hook - tyre pressure - light signals working - cover doors closed - parking brake off - front wheels and rear supports lifted. - tightening and fixing the draw bar arms locking levers - brake test for "road"...

  • Page 23: Implementation For Installation

    4.5 Implementation for installation Procedures to be carried out: - check that the ground is strong enough for the assembly not to sink into it - using the front wheel, position the set as horizontally as possible - engage the handbrake. - lower the rear trailer supports and lock them - 21 -...

  • Page 24: Battery Maintenance

    5. B ATTERY MAINTENANCE WARNING – DANGER install the battery so that it has the correct ventilation never place the battery close to a flame or fire use only insulated tools never use sulphuric acid or acid water to top up the electrolyte level. PROCEDURE FOR TESTING STARTER BATTERIES TEST TYPE PROCEDURE...

  • Page 25: Fuel And Consumables

    6. F UEL AND CONSUMABLES All specifications (product features) are given in the engine and alternator maintenance manuals attached to this manual. 6.1 Circuit capacities – Mitsubishi engines Engines S4L2-SD S4Q2 (series SL) (series SQ) (series SS) CIRCUIT AND TANK CAPACITY MODEL G 16...

  • Page 26: Circuit Capacities - John Deere Engines

    6.2 Circuit capacities – john Deere engines Engines CIRCUIT AND TANK CAPACITY G 66 MODEL G 44 G 77 G 110 G 130 G 160 G 200 LUBRICATION (in litres) 13.5 13.5 21.5 21.5 31.5 COOLING 16.1 23.6 20.2 27.3 25.8 25.8 (in litres)

  • Page 27: Circuit Capacities - Volvo Engines

    6.3 Circuit capacities – Volvo engines ENGINES TWD 740 TAD 740 TAD 1032 TAD 1242 TAD 1631 CIRCUIT AND TANK CAPACITY MODEL G 220 G 270 G 330 G 440 G 550 LUBRICATION (in litres) COOLING (in litres) 41.9 36.9 37.3 FUEL (in litres)
  • Page 31 Instructions for use M 50 M150 X200 INS / ATS Réf. constructeur : Réf. GPAO : 33502013301...
  • Page 32 SAFETY S S YMBOLS Caution : danger Caution, refer to the publications supplied with the Genset Protective clothing required. Caution : risk of electric shock Eye and hearings protection necessary Caution : toxic substances Periodic maintenance required Caution : pressuried fluids Check battery charge Caution : high temperature (risk of burning) Recommended Lifting point...
  • Page 33 1 1 0 0 1 1 2 2 1 1 1 1 1 1 5 5 2 2 3 3 1 1 3 3 1 1 4 4 INS/ATS M150 1 1 0 0 2 2 0 0 1 1 5 5 1 1 1 1 1 1 2 2 1 1 6 6...
  • Page 34 A – – D D ESCRIPTION The manual control panels and the automatic control boxes are equipped with various switchgear and standard indicators. The following figures define the functions of the different switchgear. The key has 4 positions : - S S TARTING A A ND S S TOPPING K K EY: :Position of the key when the generator set is not running.
  • Page 35 1 1 2 2 - V V OLTMETER (A50-M M 150): It allows selection of the operating mode : - O O PERATING S S ELECION S S WITCH ( ( A50): -STOP : manual operation from the console M50 1 1 3 3 S S T T O O P P A A U U T T O O...
  • Page 36 - Let the generator set run empty for several minutes depending on the ambient temperature. - M50 : Close the circuit breaker. - From this moment the generator set is outputting to the installations. B) N N ORMAL O O PERATION - During operation of the generator set, carry out a regular inspection to ensure there are no anomalies.
  • Page 37 - In the «O» position the output is cut and the operation of the generating set is stopped as soon as mains voltage is restored. C) M M 50 W W IRING D D IAGRAM I I – – P P O O W W E E R R SINGLE PHASE –...
  • Page 38 I I I I - A A U U T T O O M M A A T T I I C C S S 1. STOP 2. CONTACT 3. PREHEATING OF PLUG 4. STARTING STRAP TO POSITION IF NO A50 BOX CONNECTED 9 POINT CONNECTOR 9 POINT MALE CONNECTOR...
  • Page 77 C10-MOT 09-01 09-01...
  • Page 78 C10-MOT 09-01 09-01...
  • Page 79 C10-MOT 09-01 09-01...
  • Page 83 Use and maintenance manual John Deere Electronically – Controlled POWERTECH 4.5 L & 6.8 L 4045 and 6068 OEM Diesel Engines 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.
  • Page 85 Warning about the dangers linked to fuel discharges under high pressure on engines equipped with Denso high pressure Danger common rail (HPCR). Watch out for fuel under high pressure throughout the system Never dismantle the fuel lines, when the engine is running (lines under high pressure) It is better to work on the injection system when the fuel temperature is less than 30°C Wait at least 5 minutes after the engine...
  • Page 86 Introduction Foreword READ THIS MANUAL carefully to learn how to operate John Deere. This operator’s manual applies only to the and service your engine correctly. Failure to do so engine and those options available through the John could result in personal injury or equipment damage. Deere distribution network.
  • Page 87 Introduction Engine Owner John Deere Engine Owner: Impari a conoscere chi e ` e dove si trova. Alla Sua prima occasione cerchi d’incontrarlo. Egli desidera farsi Don’t wait until you need warranty or other service to conoscere e conoscere le Sue necessita ` . meet your local John Deere Engine Distributor or Service Dealer.
  • Page 88 Introduction ® 4.5 L Engines With Electronic Fuel Systems (Tier II Emission Certified) OWER (Two-Valve Cylinder Head Models) 4045 Engine 4045 Engine (Stanadyne DE10 Injection Pump Shown) is a trademark of Deere & Company OWER OUOD002,0000162 –19–26APR02–1/1 061902 PN=4...
  • Page 89 Introduction ® 6.8 L Engines With Electronic Fuel Systems (Tier II Emission Certified) OWER (Two-Valve Cylinder Head Models) 6068 Engine (Bosch VP44 Injection Pump Shown) 6068 Engine is a trademark of Deere & Company OWER OUOD002,0000163 –19–26APR02–1/1 061902 PN=5...
  • Page 90 Introduction ® 4.5/6.8 L Engines With Electronic Fuel Systems (Tier II Emission Certified) OWER (Four-Valve Cylinder Head Models) 6068HF475 Engine Shown (Level 11 Electronic Fuel System With 6068HF475 Shown Denso High Pressure Common Rail) is a trademark of Deere & Company OWER OUOD005,000017F –19–26APR02–1/1 061902...
  • Page 91 Contents Page Page Record Keeping Viewing Active Engine Service Codes (DTC) . . 15-15 PowerTech Medallion ..... 01-1 Viewing Stored Service Codes (DTC) in Engine Serial Number Plate .
  • Page 92 Contents Page Page Checking Engine Electrical Ground Engine Wiring Layout (Electronic Fuel System With Bosch VP44 Injection Pump) . . . 45-4 Connections ......30-15 Checking Cooling System.
  • Page 93 Contents Page Emission Control System Certification Label..65-2 061902 PN=3...
  • Page 94 Contents 061902 PN=4...

  • Page 95: Record Keeping

    Record Keeping ® Medallion OWER A medallion is located on the rocker arm cover which ® identifies each engine as a John Deere P OWER engine. NOTE: Four-valve head engines also have “16V” or ”24V” printed on their medallions. The 4045HF475 has “16V”...

  • Page 96: Record Engine Serial Number

    Record Keeping Record Engine Serial Number Record all of the numbers and letters found on your engine serial number plate in the spaces provided below. This information is very important for repair parts or warranty information. Engine Serial Number (B) Saran Engine Serial Number Plate Engine Model Number (C) Coefficient of Absorption Value (D)

  • Page 97: Engine Option Codes

    Record Keeping Engine Option Codes A—Engine Base Code 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.
  • Page 98 Record Keeping NOTE: Your engine option code label may not contain An additional option code label may also be all option codes if an option has been added delivered with the engine. Place this sticker or after the engine left the producing factory. tag, for reference, either on this page or in the engine owner’s warranty booklet under If option code label is lost or destroyed,...

  • Page 99: Record Fuel Injection Pump Model Number

    Record Keeping Record Fuel Injection Pump Model Number Record the fuel injection pump model and serial information found on the serial number plate (A). Model No. Manufacturer’s No. Serial No. A—Serial Number Plate Record Injection Pump Serial Number RG,RG34710,5511 –19–10NOV01–1/1 01-5 061902 PN=13...

  • Page 100: Safety

    Safety Recognize Safety Information 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. 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.
  • Page 101 Safety Replace Safety Signs Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement. DX,SIGNS1 –19–04JUN90–1/1 Prevent Bypass Starting Avoid possible injury or death from engine runaway. Do not start engine by shorting across starter terminal. Engine will start with PTO engaged if normal circuitry is bypassed.
  • Page 102 Safety Prepare for Emergencies Be prepared if a fire starts. Keep a first aid kit and fire extinguisher handy. 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. Keep all sparks and flame away when using it.
  • Page 103 Safety Service Engines Safely Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near engine tools or moving parts. If these items were to get caught, severe injury could result. Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.
  • Page 104 Safety Handle Chemical Products Safely 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. A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques.
  • Page 105 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.
  • Page 106 Safety Avoid High-Pressure Fluids Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids.
  • Page 107 Safety Remove Paint Before Welding or Heating Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. Remove paint before heating: • Remove paint a minimum of 76 mm (3 in.) from area to be affected by heating.
  • Page 108 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. Components in products that may contain asbestos fibers are brake pads, brake band and lining assemblies, clutch plates, and some gaskets.
  • Page 109 Safety Prevent Acid Burns Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. Avoid the hazard by: 1. Filling batteries in a well-ventilated area. 2.
  • Page 110 Safety Dispose of Waste Properly 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. Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

  • Page 111: Fuels, Lubricants, And Coolant

    Fuels, Lubricants, and Coolant Diesel Fuel Consult your local fuel distributor for properties of the Fuel lubricity should pass a minimum load level of diesel fuel available in your area. 3100 grams as measured by ASTM D6078 or, maximum scar diameter of 0.45 mm as measured by In general, diesel fuels are blended to satisfy the low ASTM D6079.

  • Page 112: Lubricity Of Diesel Fuel

    Fuels, Lubricants, and Coolant Lubricity of Diesel Fuel Diesel fuel must have adequate lubricity to ensure Use of low lubricity diesel fuels may also cause proper operation and durability of fuel injection system accelerated wear, injection nozzle erosion or corrosion, components.

  • Page 113: Bio-Diesel Fuel

    Fuels, Lubricants, and Coolant Bio-Diesel Fuel Consult your local fuel distributor for properties of the A major environmental benefit of bio-diesel fuel is its bio-diesel fuel available in your area. ability to biodegrade. This makes proper storage and handling of bio-diesel fuel especially important. Areas Bio-diesel fuels may be used ONLY if the bio-diesel of concern include: fuel properties meet the latest edition of ASTM PS121,...

  • Page 114: Handling And Storing Bio-Diesel Fuel

    Fuels, Lubricants, and Coolant Handling And Storing Bio-Diesel Fuel Fuel filter may require more frequent replacement due CAUTION: Handle fuel carefully. Do not fill to premature plugging. the fuel tank when engine is running. Check engine oil level daily prior to starting engine. A DO NOT smoke while you fill the fuel tank or rising oil level may indicate fuel dilution of the engine service the fuel system.

  • Page 115: Diesel Fuel Storage

    Fuels, Lubricants, and Coolant Diesel Fuel Storage Store diesel fuel in plastic, aluminum, and steel CAUTION: Handle fuel carefully. Do not fill containers specially coated for diesel fuel storage. the fuel tank when engine is running. Avoid storing fuel over long periods of time. If fuel is DO NOT smoke while you fill the fuel tank or stored for more than a month prior to use, or there is a service the fuel system.

  • Page 116: Minimizing The Effect Of Cold Weather On Diesel Engines

    Fuels, Lubricants, and Coolant Minimizing the Effect of Cold Weather on Diesel Engines John Deere diesel engines are designed to operate while the other location is at the inlet port of the final effectively in cold weather. fuel filter. However, for effective starting and cold weather Coolant Heaters operation, a little extra care is necessary.
  • Page 117 Fuels, Lubricants, and Coolant Winterfronts such a way that the shutters are completely open by the time the coolant reaches 93°C (200°F) to prevent Use of fabric, cardboard, or solid winterfronts is not excessive intake manifold temperatures. Manually recommended with any John Deere engine. Their use controlled systems are not recommended.

  • Page 118: Diesel Engine Break-In Oil

    Fuels, Lubricants, and Coolant Diesel Engine Break-In Oil New engines are filled at the factory with John Deere IMPORTANT: Do not use PLUS-50 oil or engine ENGINE BREAK-IN OIL. During the break-in period, oils meeting any of the following add John Deere ENGINE BREAK-IN OIL as needed to during the first 100 hours of maintain the specified oil level (order TY22041).

  • Page 119: Diesel Engine Oil

    Fuels, Lubricants, and Coolant Diesel Engine Oil Use oil viscosity based on the expected air temperature range during the period between oil changes. 50˚C 122˚F The following oil is preferred: 40˚C 104˚F • John Deere PLUS-50 ® 30˚C 86˚F The following oils are also recommended: 20˚C 68˚F •...

  • Page 120: Diesel Engine Oil Service Intervals

    Fuels, Lubricants, and Coolant Diesel Engine Oil Service Intervals ® When John Deere PLUS-50 or ACEA-E4/E5 oil and the specified John Deere filter are used, the service interval for the engine oil and filter is 500 hours. ® If other than PLUS-50 or ACEA-E4/E5 oil and the specified John Deere filter are used, the service interval for the engine oil and filter is reduced to 250 hours.

  • Page 121: Alternative And Synthetic Lubricants

    Fuels, Lubricants, and Coolant Alternative and Synthetic Lubricants Conditions in certain geographical areas may require lubricant recommendations different from those printed in this manual. Some John Deere brand coolants and lubricants may not be available in your location. Consult your John Deere dealer to obtain information and recommendations.

  • Page 122: Grease

    Fuels, Lubricants, and Coolant Grease Use grease based on NLGI consistency numbers and the expected air temperature range during the service interval. The following greases are preferred: • John Deere SD POLYUREA GREASE The following greases are also recommended: • John Deere HD MOLY GREASE •...

  • Page 123: Diesel Engine Coolant

    Fuels, Lubricants, and Coolant Diesel Engine Coolant The engine cooling system is filled to provide protection at lower temperatures is required, consult year-round protection against corrosion and cylinder your John Deere dealer for recommendations. liner pitting, and winter freeze protection to -37°C (-34°F).

  • Page 124: Diesel Engine Coolants, Supplemental Additive Information

    Fuels, Lubricants, and Coolant Diesel Engine Coolants, Supplemental Additive Information Engine coolants are a combination of three chemical help form a protective film on cylinder liner surfaces. components: ethylene glycol (antifreeze), inhibiting This film acts as a barrier against the harmful effects coolant additives, and quality water.

  • Page 125: Testing Diesel Engine Coolant

    Fuels, Lubricants, and Coolant Testing Diesel Engine Coolant Maintaining adequate concentrations of glycol and inhibiting additives in the coolant is critical to protect the engine and cooling system against freezing, corrosion, and cylinder liner erosion and pitting. Test the coolant solution at intervals of 12 month or less and whenever excessive coolant is lost through leaks or overheating.

  • Page 126: Supplemental Coolant Additives

    Fuels, Lubricants, and Coolant Supplemental Coolant Additives The concentration of coolant additives is gradually depleted during engine operation. For all recommended coolants, replenish additives between drain intervals by adding a supplemental coolant additive every 12 months or as determined necessary by coolant testing. John Deere COOLANT CONDITIONER is recommended as a supplemental coolant additive in John Deere engines.

  • Page 127: Operating In Warm Temperature Climates

    Fuels, Lubricants, and Coolant Operating in Warm Temperature Climates John Deere engines are designed to operate using glycol base engine coolants. Always use a recommended glycol base engine coolant, even when operating in geographical areas where freeze protection is not required. IMPORTANT: Water may be used as coolant in emergency situations only.

  • Page 128: Engine Operating Guidelines

    Engine Operating Guidelines Electronic Instrument (Gauge) Panel The electronic instrument panel is linked to the John Deere engine control unit (ECU). This allows the operator to monitor engine performance as well as to diagnose any troubles during engine operation. IMPORTANT: Any time an electric gauge or meter does not register correctly, replace with a new one.
  • Page 129 Engine Operating Guidelines Electronic Instrument (Gauge) Panel Engine Oil Pressure Gauge information. Also see TROUBLESHOOTING section for a list of diagnostic trouble codes (DTCs) and The engine oil pressure gauge (A) indicates engine oil corresponding engine problems.) pressure in pounds per square inch (psi). It is connected to an audible alarm (G) to warn the Touch Switches operator if oil pressure drops below the preset safe...
  • Page 130 Engine Operating Guidelines Electronic Instrument (Gauge) Panel Engine Preheater Indicator (Optional) The engine preheater indicator (K) lights up while the engine is being preheated for cold weather starting. When the engine is warmed up, the light goes off, indicating the engine can now be started.
  • Page 131 Engine Operating Guidelines Electronic Instrument (Gauge) Panel Speed Select Rocker Switch The voltmeter (T) indicates system battery voltage. The amber “WARNING” light (B) will illuminate when The speed select switch (P) is used to bump engine battery voltage is too low for proper operation of the speed up (+) or down (-) in small increments during fuel injection system.
  • Page 132 Engine Operating Guidelines The Cruise Control has the normal functions of: On 12-volt ECU’s, the engine speed can be set from two different locations. The primary location would • Cruise Control power “ON” or “OFF” normally be in the cab of the vehicle and is used to set •...
  • Page 133 Engine Operating Guidelines 15-6 061902 PN=47...

  • Page 134: Using Diagnostic Gauge To Access Engine Information

    Engine Operating Guidelines Using Diagnostic Gauge To Access Engine Information The diagnostic gauge (A) allows the operator to view many readouts of engine functions and diagnostic 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.
  • Page 135 Engine Operating Guidelines • Coolant pressure • Coolant level • Wheel base vehicle speed • Fuel rate • Instant fuel economy check • Average fuel economy • Barometric pressure • Air inlet temperature • Boost pressure • Intake manifold temperature •...

  • Page 136: Using Touch Switches To Display Information

    Engine Operating Guidelines Using Touch Switches To Display Information Using Touch Switches Continued on next page DPSG,OUOD007,2841 –19–21OCT99–1/2 15-9 061902 PN=50...
  • Page 137 Engine Operating Guidelines The touch switches on the diagnostic gauge allow To read any of the engine parameters, press either UP quick and easy navigation through the menu to find the or DOWN switches (as shown on diagram) until the information needed.

  • Page 138: Changing Units Of Measure (English Or Metric)

    Engine Operating Guidelines Changing Units Of Measure (English Or Metric) Changing Units Of Measure The diagnostic gauge can display engine data in either diagram shows the steps for selecting the desired units English or Metric units. To toggle between these, the of measure.
  • Page 139 Engine Operating Guidelines 15-12 061902 PN=53...

  • Page 140: Viewing Engine Configuration Data

    Engine Operating Guidelines Viewing Engine Configuration Data Viewing Engine Configuration Data Continued on next page DPSG,OUOD002,1927 –19–19DEC00–1/2 15-13 061902 PN=54...
  • Page 141 Engine Operating Guidelines The diagnostic gauge can display the engine “E-Config”. Then press BOTH the UP and DOWN configuration data stored in the Engine Control Unit switches at the same time to select the Engine (ECU). To select the Engine Configuration Sub-Menu Configuration Sub-Menu .

  • Page 142: Viewing Active Engine Service Codes (Dtc)

    Engine Operating Guidelines Viewing Active Engine Service Codes (DTC) Viewing Active Service Codes The diagnostic gauge continuously monitors all BOTH the UP and DOWN switches at the same time messages broadcast over the Control Area Network to select the Service (DTC) Code Sub-Menu. The (CAN) and displays all Active Service Codes (DTCs) at diagnostic gauge has the ability to display all Active the time the message is broadcast.

  • Page 143: Viewing Stored Service Codes (Dtc) In Engine Ecu

    Engine Operating Guidelines Viewing Stored Service Codes (DTC) In The Engine ECU Viewing Stored Service Codes The diagnostic gauge can request Stored Service reads “DM2Codes”. Then press BOTH the UP and Codes (DTCs) from the engine. The Stored Service DOWN switches at the same time to select the Codes may be used for diagnostic and service needs.

  • Page 144: Engine Break-In Service

    Engine Operating Guidelines Engine Break-In Service The engine is ready for normal operation. However, extra care during the first 100 hours of operation will result in more satisfactory long-term engine performance and life. DO NOT exceed 100 hours of operation with break-in oil. 1.
  • Page 145 Engine Operating Guidelines RG8028A –UN–15JAN99 IMPORTANT: DO NOT add makeup oil until the oil level is BELOW the ADD mark on dipstick. John Deere ENGINE BREAK-IN OIL (TY22041) should be used to make up any oil consumed during the Crosshatch Pattern On Dipstick break-in period.
  • Page 146 Engine Operating Guidelines 4. During the first 20 hours, avoid prolonged periods of engine idling or sustained maximum load operation. If engine will idle longer than 5 minutes, stop engine. 5. Before the first 100 hours (maximum), change engine oil and replace engine oil filter (A). (See CHANGING ENGINE OIL AND REPLACING FILTER in Lubrication and Maintenance/500 Hour/12 Month Section.) Fill crankcase with seasonal viscosity grade oil.

  • Page 147: Starting The Engine

    Engine Operating Guidelines Starting the Engine The following instructions apply to the optional controls and instruments available through the John Deere Parts Distribution Network. The controls and instruments for your engine may be different from those shown here; always follow manufacturer’s instructions. CAUTION: Before starting engine in a confined building, install proper outlet exhaust ventilation equipment.
  • Page 148 Engine Operating Guidelines NOTE: Hand throttle (A) may have an analog potentiometer for changing engine speeds (See “Changing Engine Speeds” later in this section). 4. Turn the throttle (A) clockwise 1/3 of the way (see illustration). (If not equipped with an analog throttle, move throttle control 1/3 of the distance away from slow idle stop.) IMPORTANT: Do not operate the starter for more than...

  • Page 149: Normal Engine Operation

    Engine Operating Guidelines Normal Engine Operation Observe engine coolant temperature and engine oil remove load and restart the engine. pressure. Temperatures and pressures will vary Overheating of the turbocharger between engines and with changing operating parts may occur when oil flow is conditions, temperatures, and loads.

  • Page 150: Warming Engine

    Engine Operating Guidelines Warming Engine The electronically-controlled engines will operate at an accelerated slow idle of 1050 rpm until the engine coolant warms up to 20° C (68° F). IMPORTANT: To assure proper lubrication, operate engine at or below 1200 rpm with no load for 1–2 minutes.

  • Page 151: Cold Weather Operation

    Engine Operating Guidelines Cold Weather Operation CAUTION: Ether injector starting fluid is highly flammable. DO NOT use starting fluid on engines equipped with air intake heaters or glow plugs. DO NOT use starting fluid near fire, sparks, or flames. DO NOT incinerate or puncture a starting fluid container.
  • Page 152 Engine Operating Guidelines NOTE: Air intake heaters (275 engines) and glow plugs (475 engines) operate automatically through the ECU. The Engine Preheater Indicator light on these engines, located above the key switch, should always illuminate when the switch is turned ON.

  • Page 153: Using A Booster Battery Or Charger

    Engine Operating Guidelines Using a Booster Battery or Charger 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. CAUTION: Gas given off by battery is explosive. Keep sparks and flames away from battery.

  • Page 154: Avoid Excessive Engine Idling

    Engine Operating Guidelines 6. Start the engine. Disconnect jumper cables immediately after engine starts. Disconnect NEGATIVE (–) cable first. RG,RG34710,5564 –19–20MAY96–2/2 Avoid Excessive Engine Idling Prolonged idling may cause the engine coolant speed. Slow idle speed for this engine is 850 rpm at temperature to fall below its normal range.

  • Page 155: Changing Engine Speeds

    Engine Operating Guidelines Changing Engine Speeds Changing from slow to fast speed using High-Low Speed Select Rocker Switch (A): • For slow speed, press lower half of switch (indicated by turtle symbol). • For fast speed, press upper half of switch (indicated by rabbit symbol).

  • Page 156: Stopping The Engine

    Engine Operating Guidelines Stopping The Engine 1. Disengage clutch, if equipped, controlling engine power driveline. IMPORTANT: Before stopping an engine that has been operating at working load, idle engine at least 2 minutes at 1000—1200 rpm to cool hot engine parts. Engines in generator set applications where the ECU is locked at a specified speed and no slow idle function is...

  • Page 157: Auxiliary Gear Drive Limitations

    Engine Operating Guidelines Auxiliary Gear Drive Limitations IMPORTANT: When attaching an air compressor, hydraulic pump, or other accessory to be driven by the auxiliary gear drive (A) (engine timing gear train at front of engine), power requirements of the accessory must be limited to values listed below: •...

  • Page 158: Lubrication And Maintenance

    Lubrication and Maintenance Observe Service Intervals Using hour meter (A) as 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 Lubrication and Maintenance Records Section.

  • Page 159: Lubrication And Maintenance Service Interval Chart-Standard Industrial Engines

    Lubrication and Maintenance Lubrication and Maintenance Service Interval Chart—Standard Industrial Engines NOTE: The service intervals below are for standard industrial engines. See details in Sections which follow these charts. Lubrication and Maintenance Service Intervals 500 Hour/ 2000 Hour/ Item Daily 12 Month 24 Month As Required...
  • Page 160 Lubrication and Maintenance Lubrication and Maintenance Service Intervals 500 Hour/ 2000 Hour/ Item Daily 12 Month 24 Month As Required • Check Fuses • Bleed Fuel System RG,RG34710,7559 –19–04JUN02–2/2 20-3 061902 PN=74...

  • Page 161: Lubrication And Maintenance Service Interval Chart-Generator (Standby) Applications

    Lubrication and Maintenance Lubrication and Maintenance Service Interval Chart—Generator (Standby) Applications NOTE: Use service intervals listed below for generator (standby) applications. Match service items below to titles in Lubrication and Maintenance Sections for procedures. Lubrication and Maintenance Service Intervals 500 Hours or 2000 Hours or Item Every 2 Weeks...
  • Page 162 Lubrication and Maintenance Lubrication and Maintenance Service Intervals 500 Hours or 2000 Hours or Item Every 2 Weeks 12 Months 24 Months As Required • Check Fuses • Bleed Fuel System RG,RG34710,7560 –19–04JUN02–2/2 20-5 061902 PN=76...

  • Page 163: Lubrication & Maintenance/Daily

    Lubrication & Maintenance/Daily Daily Prestarting Checks 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 crosshatch marks on the dipstick. 1. Check engine oil level on dipstick. Add as required, using seasonal viscosity grade oil.
  • Page 164 Lubrication & Maintenance/Daily CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. Only remove filler cap when engine is cold or when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.
  • Page 165 Lubrication & Maintenance/Daily NOTE: Engine may be equipped with a water sensor at the fuel filter. In this case, an indicator light will signal the operator that water should be drained from the filter bowl. 3. Check the fuel filters for water or debris. If filter is fitted with a see-through bowl, drain as needed based on a daily visual inspection.
  • Page 166 Lubrication & Maintenance/Daily 4. If the air cleaner has an automatic dust unloader valve (A), squeeze the unloader valve on air cleaner assembly to clear away any dust buildup. If equipped with air intake restriction indicator gauge (B), check gauge to determine if air cleaner needs to be serviced.

  • Page 167: Lubrication & Maintenance/500 Hour/12 Month

    Lubrication & Maintenance/500 Hour/12 Month Servicing Fire Extinguisher A fire extinguisher (A) is available from your authorized servicing dealer or engine distributor. Read and follow the instructions which are packaged with it. The extinguisher should be inspected at least every 500 hours of engine operation or once a month.

  • Page 168: Servicing Battery

    Lubrication & Maintenance/500 Hour/12 Month Servicing Battery CAUTION: Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check battery electrolyte level. Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.
  • Page 169 Lubrication & Maintenance/500 Hour/12 Month CAUTION: Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. Avoid the hazard by: 1. Filling batteries in a well-ventilated area. 2.

  • Page 170: Manual Belt Tensioner Adjustment

    Lubrication & Maintenance/500 Hour/12 Month Manual Belt Tensioner Adjustment NOTE: Two types of manual tensioners shown. NOTE: Inspect belts for cracks, fraying, or stretched-out areas. Replace if necessary. As a reference check, twist belt in the middle of a 254—305 mm (10—12 in.) span with two fingers. A properly tensioned belt will turn 75—85 degrees.

  • Page 171: Manual Belt Tensioner Adjustment Using Belt Tension Tool (Alternate Method For Engines Without Auxiliary Drive)

    Lubrication & Maintenance/500 Hour/12 Month Manual Belt Tensioner Adjustment Using Belt Tension Tool (Alternate Method For Engines Without Auxiliary Drive) NOTE: The JD1520 Belt Tension Tool may not be compatible with all alternators. In that case, use the preceding method for belt tensioning. NOTE: Inspect belts for cracks, fraying, or stretched-out areas.
  • Page 172 Lubrication & Maintenance/500 Hour/12 Month 3. Place torque wrench (C) on belt tensioning tool (B) at 90° to tool. Pivot alternator (A) until desired torque is achieved according to specification using the following table. Specification New Belt—Tension ......... 470—650 N (105—145 lb-force) Used Belt—Tension ........

  • Page 173: Changing Engine Oil And Replacing Filter

    Lubrication & Maintenance/500 Hour/12 Month Changing Engine Oil and Replacing Filter Your engine is equipped with a special oil filter (A). NOTE: During break-in, change engine oil and filter for the first time before 100 hours maximum of operation. ® After break-in, if John Deere PLUS-50 or ACEA-E4/E5 engine oil and a John Deere special oil filter are used, the...
  • Page 174 Lubrication & Maintenance/500 Hour/12 Month 4. Turn filter element (A) using a suitable filter wrench to remove. Discard oil filter element. NOTE: Depending on engine application, oil filter may be located on either side of the engine in a high- or low-mount location.

  • Page 175: Cleaning Crankcase Vent Tube

    Lubrication & Maintenance/500 Hour/12 Month 9. Fill engine crankcase with correct John Deere engine oil through rocker arm cover opening (A) or either side oil filler (B) depending on engine application. (See DIESEL ENGINE OIL in Fuels, Lubricants, and Coolant Section for determining correct engine oil.) To determine the correct oil fill quantity for your engine, see ENGINE CRANKCASE OIL FILL QUANTITIES in...

  • Page 176: Checking Air Intake System

    Lubrication & Maintenance/500 Hour/12 Month Checking Air Intake System IMPORTANT: The air intake system must not leak. Any leak, no matter how small, may result in internal engine damage due to abrasive dirt and dust entering the intake system. 1. Inspect all intake hoses (piping) for cracks. Replace as necessary.

  • Page 177: Replacing Fuel Filter Elements

    Lubrication & Maintenance/500 Hour/12 Month Replacing Fuel Filter Elements Engines may be equipped with either a primary fuel filter (or pre-filter) with water bowl and a final filter, or only a final filter including water bowl. Both filters are replaced at the same 500-hour interval.
  • Page 178 Lubrication & Maintenance/500 Hour/12 Month NOTE: Raised locators on fuel filter canisters must be indexed properly with slots in mounting base for correct installation. 7. Install new filter elements onto mounting bases. Be sure elements are properly indexed and firmly seated on bases.

  • Page 179: Checking Belt Tensioner Spring Tension And Belt Wear (Automatic Tensioner)

    Lubrication & Maintenance/500 Hour/12 Month Checking Belt Tensioner Spring Tension and Belt Wear (Automatic Tensioner) 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.
  • Page 180 Lubrication & Maintenance/500 Hour/12 Month 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: 1.

  • Page 181: Checking Engine Electrical Ground Connections

    Lubrication & Maintenance/500 Hour/12 Month Checking Engine Electrical Ground Connections Keep all engine ground connections clean and tight to prevent electrical arcing which can damage electronic components. Also see precautions in Troubleshooting Section when welding on engine or machine. OUOD002,0000169 –19–23NOV01–1/1 Checking Cooling System CAUTION: Explosive release of fluids from pressurized cooling system can cause serious...

  • Page 182: Replenishing Supplemental Coolant Additives (Scas) Between Coolant Changes

    Lubrication & Maintenance/500 Hour/12 Month Replenishing Supplemental Coolant Additives (SCAs) Between Coolant Changes IMPORTANT: Do not add supplemental coolant additives when the cooling system is drained and refilled with John Deere ® COOL-GARD NOTE: If system is to be filled with coolant that does not contain SCAs, the coolant must be precharged.
  • Page 183 Lubrication & Maintenance/500 Hour/12 Month IMPORTANT: ALWAYS maintain coolant at correct level and concentration. DO NOT operate engine without coolant even for a few minutes. If frequent coolant makeup is required, the glycol concentration should be checked with JTO7298 Coolant/Battery Tester to ensure that the desired freeze point is maintained.

  • Page 184: Testing Diesel Engine Coolant

    Lubrication & Maintenance/500 Hour/12 Month Testing Diesel Engine Coolant Maintaining adequate concentrations of glycol and Compare the results to the supplemental coolant inhibiting additives in the coolant is critical to protect additive (SCA) chart to determine the amount of the engine and cooling system against freezing, inhibiting additives in your coolant and whether more corrosion, and cylinder liner erosion and pitting.

  • Page 185: Pressure Testing Cooling System

    Lubrication & Maintenance/500 Hour/12 Month Pressure Testing Cooling System Test Radiator Cap Test Cooling System If gauge does not hold pressure, replace radiator CAUTION: Explosive release of fluids from cap. pressurized cooling system can cause serious burns. Specification Radiator Cap Holding Pressure Shut off engine.
  • Page 186 Lubrication & Maintenance/500 Hour/12 Month Test Cooling System 4. With pressure applied, check all cooling system hose connections, radiator, and overall engine for NOTE: Engine should be warmed up to test overall leaks. cooling system. If leakage is detected, correct as necessary and 1.

  • Page 187: Lubrication & Maint./2000 Hour/24 Month

    Lubrication & Maint./2000 Hour/24 Month Checking Crankshaft Vibration Damper (6-Cylinder Engine Only) 1. Remove belts (shown removed). 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. IMPORTANT: The vibration damper assembly is not repairable and should be replaced every 4500 hours or 60 months, whichever...

  • Page 188: Flushing Cooling System

    Lubrication & Maint./2000 Hour/24 Month Flushing Cooling System 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.
  • Page 189 Lubrication & Maint./2000 Hour/24 Month 3. All Except 4045HF475 and 6068HF475 Engines: Open engine block drain valve (A) on left side of engine. Drain all coolant from engine block. NOTE: On 475 engines, the engine block drain valve is located behind the fuel rail, and is not easily accessible.
  • Page 190 Lubrication & Maint./2000 Hour/24 Month 9. After draining water, close drain valves. Reinstall radiator cap and radiator hose and clamp. Fill the cooling system with clean water and a heavy duty ® cooling system cleaner such as Fleetguard RESTORE™ and RESTORE PLUS™. These products may be available from your John Deere dealer.

  • Page 191: Testing Thermostats Opening Temperature

    Lubrication & Maint./2000 Hour/24 Month Testing Thermostats Opening Temperature To Remove Thermostat(s) CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. DO NOT drain coolant until it has cooled below operating temperature. Always loosen radiator pressure cap or drain valve slowly to relieve pressure.
  • Page 192 Lubrication & Maint./2000 Hour/24 Month Testing Thermostats Opening Temperature 1. Remove thermostat(s). 2. Visually inspect thermostat(s) for corrosion or damage. If dual thermostats, replace as a matched set as necessary. CAUTION: DO NOT allow thermostat or thermometer to rest against the side or bottom of container when heating water.
  • Page 193 Lubrication & Maint./2000 Hour/24 Month To Install Thermostats IMPORTANT: Install manifold gasket so that smaller (round) holes are at lower left and upper right corners of manifold (matching studs A). 1. Clean all gasket material from thermostat cover and housing mounting surfaces. 2.

  • Page 194: Check And Adjust Valve Clearance (All Engines Except 4045Hf475 And 6068Hf475)

    Lubrication & Maint./2000 Hour/24 Month Check and Adjust Valve Clearance (All Engines Except 4045HF475 And 6068HF475) CAUTION: To prevent accidental starting of engine while performing valve adjustments, always disconnect NEGATIVE (—) battery terminal. IMPORTANT: Valve clearance MUST BE checked and adjusted with engine COLD.
  • Page 195 Lubrication & Maint./2000 Hour/24 Month 4. With engine lock-pinned at TDC of No. 1 piston’s compression stroke, check valve clearance to following specifications. (Use sequence for 4-cylinder or 6-cylinder engines as outlined on next page.) Specification Intake Valve Clearance For Checking (Rocker Arm-to-Valve Tip) (Engine Cold)—Clearance .........
  • Page 196 Lubrication & Maint./2000 Hour/24 Month 4-Cylinder Engine: NOTE: Firing order is 1-3-4-2. 1. Using JDE81-4 Timing Pin, lock No. 1 piston at TDC compression stroke (B). 2. Adjust valve clearance on No. 1 and 3 exhaust valves and No. 1 and 2 intake valves. 3.

  • Page 197: Check And Adjust Valve Clearance (4045Hf475 And 6068Hf475 Engines)

    Lubrication & Maint./2000 Hour/24 Month Check and Adjust Valve Clearance (4045HF475 And 6068HF475 Engines) CAUTION: To prevent accidental starting of engine while performing valve adjustments, always disconnect NEGATIVE (—) battery terminal. IMPORTANT: Valve clearance MUST BE checked and adjusted with engine COLD. 1.
  • Page 198 Lubrication & Maint./2000 Hour/24 Month 4. With engine lock-pinned at TDC of No. 1 piston’s compression stroke, check valve clearance to following specifications. (Use sequence for 4-cylinder or 6-cylinder engines as outlined on next page.) Specification Intake Valve Clearance Checking (Rocker Arm-to-Bridge) (Engine Cold)—Clearance ........
  • Page 199 Lubrication & Maint./2000 Hour/24 Month 4-Cylinder Engine: NOTE: Firing order is 1-3-4-2. 1. Using JDG1571 or JDE81-4 Timing Pin, lock No. 1 piston at TDC compression stroke (B). 2. Adjust valve clearance on No. 1 and 3 exhaust valves and No. 1 and 2 intake valves. 3.

  • Page 200: Test Glow Plugs For Continuity (4045Hf475 And 6068Hf475 Engines)

    Lubrication & Maint./2000 Hour/24 Month Test Glow Plugs for Continuity (4045HF475 And 6068HF475 Engines) CAUTION: To prevent accidental starting of engine while performing this test, always disconnect NEGATIVE (—) battery terminal. While checking valve clearance with rocker arm cover removed, check each glow plug for continuity using a multimeter.

  • Page 201: Service As Required

    Service as Required Additional Service Information This is not a detailed service manual. If you want more detailed service information, use the Publications Information in the back of this manual to order a component technical manual. Component Technical Manual RG,RG34710,5591 –19–23NOV01–1/1 Do Not Modify Fuel System IMPORTANT: Modification or alteration of the injection pump (arrow), the injection...

  • Page 202: Adding Coolant

    Service as Required Adding Coolant 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.
  • Page 203 Service as Required 4. Run engine until it reaches operating temperature. RG,RG34710,5593 –19–12NOV01–2/2 40-3 061902 PN=117...

  • Page 204: Replacing Single Stage Air Cleaner

    Service as Required Replacing Single Stage Air Cleaner IMPORTANT: ALWAYS REPLACE air cleaner when air restriction indicator shows a vacuum of 625 mm (25 in.) H O, is torn, or visibly dirty. NOTE: This procedure applies to John Deere single stage air cleaner kits.

  • Page 205: Replacing Axial Seal Air Cleaner Filter Element

    Service as Required Replacing Axial Seal Air Cleaner Filter Element IMPORTANT: ALWAYS REPLACE primary air cleaner element when air restriction indicator shows a vacuum of 625 mm (25 in.) O, is torn, or visibly dirty. NOTE: This procedure applies to John Deere 2-stage axial seal air cleaner kits.
  • Page 206 Service as Required IMPORTANT: Whenever the air cleaner has been serviced or had cover removed, ALWAYS fully depress the air restriction indicator reset button (if equipped) to assure accurate readings. 6. If equipped, fully depress air restriction indicator reset button and release to reset indicator. RG41165,000008A –19–12NOV01–2/2 40-6 061902...

  • Page 207: Replacing Radial Seal Air Cleaner Filter Element

    Service as Required Replacing Radial Seal Air Cleaner Filter Element IMPORTANT: ALWAYS REPLACE primary air cleaner element when air restriction indicator shows a vacuum of 625 mm (25 in.) O, is torn, or visibly dirty. NOTE: This procedure applies to John Deere 2-stage radial seal air cleaner kits.
  • Page 208 Service as Required IMPORTANT: Whenever the air cleaner has been serviced or cover has been removed, ALWAYS fully depress the air restriction indicator reset button (if equipped) to assure accurate readings. 8. If equipped, fully depress air restriction indicator reset button and release to reset indicator.

  • Page 209: Replacing Fan And Alternator Belts

    Service as Required Replacing Fan and Alternator Belts Refer to CHECKING BELT TENSIONER SPRING TENSION AND BELT WEAR in Lubrication and Maintenance/500 Hour/12 Month Section for additional information on the belt tensioner. 1. Inspect belts for cracks, fraying, or stretched out areas. Replace if necessary.

  • Page 210: Checking Fuses

    Service as Required Checking Fuses Check the fuse (A) located in the fuse holder on the face of the instrument panel. If defective, replace with a 5-amp fuse. A separate wiring harness fuse (10 amp) and a main system fuse (20 amp) are shown in the Wiring Diagrams in the Troubleshooting Section.

  • Page 211: Bleeding The Fuel System (Engines With Electronic Fuel Systems And Bosch Vp44 Pump)

    Service as Required Bleeding the Fuel System (Engines With Electronic Fuel Systems And Bosch VP44 Pump) 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.
  • Page 212 Service as Required Bleed Using Electronic Transfer Pump The bleed is automatically performed by a small orifice (A) inside the final fuel filter base connected to the overflow valve on injection pump. The system allows air to escape continually through the fuel return line (B) when ignition is 1.

  • Page 213: Bleed The Fuel System (Engines With Electronic Fuel Systems And Stanadyne De10 Pump)

    Service as Required Bleed the Fuel System (Engines with Electronic Fuel Systems and Stanadyne DE10 Pump) CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid hazards by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.
  • Page 214 Service as Required 2. Operate fuel supply pump primer lever (B) or primer button on fuel filter base (if equipped). 3. Tighten bleed plug securely, continue operating primer until pumping action is not felt 4. Start engine and check for leaks. If engine will not start, it may be necessary to bleed air from fuel system at fuel injection pump or injection nozzles as explained next.
  • Page 215 Service as Required At Fuel Injection Nozzles IMPORTANT: Always use a backup wrench when loosening or tightening fuel lines at nozzles and/or injection pump to avoid damage. 1. Using two open-end wrenches, loosen two fuel line connections at injection nozzles. 2.

  • Page 216: Bleed The Fuel System (Engines With Electronic Fuel Systems And Denso High Pressure Common Rail) (4045Hf475, 6068Hf475)

    Service as Required Bleed the Fuel System (Engines with Electronic Fuel Systems and Denso High Pressure Common Rail) (4045HF475, 6068HF475) CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid hazards by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.
  • Page 217 Service as Required 2. Operate fuel supply pump primer lever (B), or primer button on fuel filter base (if equipped), until fuel flows out of bleed vent screw. 3. Tighten bleed vent screw securely. Continue operating primer until pumping action is not felt. 4.

  • Page 218: Troubleshooting

    Troubleshooting General Troubleshooting Information • Know the engine and all related systems. Troubleshooting engine problems can be difficult. An • Study the problem thoroughly. engine wiring diagram is provided in this section to • Relate the symptoms to your knowledge of engine help isolate electrical problems on power units using John Deere wiring harness and instrument (gauge) and systems.

  • Page 219: Precautions For Welding On Engines Equipped With Electronic Engine Control Unit (Ecu)

    Troubleshooting Precautions For Welding On Engines Equipped With Electronic Engine Control Unit (ECU) IMPORTANT: ALWAYS disconnect Electronic Control Unit (ECU) connectors and engine control system-to-machine ground before welding on engine or machine. High currents or electro-static discharge in electronic components from welding may cause permanent damage.

  • Page 220: Engine Wiring Layout (Electronic Fuel System With Stanadyne De10 Injection Pump)

    Troubleshooting Engine Wiring Layout (Electronic Fuel System With Stanadyne DE10 Injection Pump) A—Coolant Temperature G—Starter Relay Connector M—Remote ON/ OFF Q—21-pin Instrument Panel Sensor Connector H—Oil Pressure Sensor Connector Connector B—Fuel Temperature Sensor Connector N—CAN Network Diagnostic R—Engine Wiring Harness Connector I—Main System Fuse (10 amp) Connector...

  • Page 221: Engine Wiring Layout (Electronic Fuel System With Bosch Vp44 Injection Pump)

    Troubleshooting Engine Wiring Layout (Electronic Fuel System With Bosch VP44 Injection Pump) A—Oil Pressure Sensor I—Manifold Air Temperature Q—Engine Control Unit (ECU) W—Remote ON/OFF B—Fuel Pump Relay (MAT) Sensor R—ECU Connector Connector C—Fuel Pump Relay Fuse J—Fuel Transfer Pump S—System Ground (ECU must X—Instrument Panel D—Crankshaft Position Sensor K—Fuel Heater also be grounded to frame)

  • Page 222: Engine Wiring Layout (Electronic Fuel System With Denso High Pressure Common Rail)

    Troubleshooting Engine Wiring Layout (Electronic Fuel System With Denso High Pressure Common Rail) A—Engine Coolant D—(ECU) Connector H—Power and Ground Battery K—Pump Position Sensor Temperature (ECT) Sensor E—Optional Instrument Panel Connections L—Pump Control Valve B—Electronic Injector F—Engine Wiring Harness I—Fuel Rail Pressure Sensor Solenoid Connector G—Engine Oil Pressure...

  • Page 223: Engine Wiring Diagram (Electronic Instrument Panel)

    Troubleshooting Engine Wiring Diagram (Electronic Instrument Panel) 464 SENSOR RETURN 2 020 CAN SHIELD 904 CAN H 905 CAN L 012 IGN +12V OR +24V 412 ACC 422 STARTER RELAY SOLENOID 002 BAT ANALOG THROTTLE EMULATOR ACC. 4700 OVERRIDE SHUTDOWN START BUMP ENABLE...

  • Page 224: Engine Wiring Diagram

    Troubleshooting Engine Wiring Diagram (Electronic Instrument Panel)—Continued B1—Analog Throttle or N1—Transient Voltage S1—Ignition Key Switch V1—Diode Emulator Protector S2—Speed Select Switch X1—Vehicle Harness E1—Back Light Regulator N2—Voltage Regulator (for (Momentary) Connector (24V) or Plug (12V) 24V Operation) S3—Bump Enable Switch X2—Alternator Harness F1—Fuse (10 Amp) (for P1—Optional Gauge...
  • Page 225 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. Exhaust restricted. Check and correct exhaust restriction. Fuel filter plugged or full of water. Replace fuel filter or drain water from filter.
  • Page 226 Troubleshooting Symptom Problem Solution Engine hard to start or will not Engine starting under load. Disengage PTO. start 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.
  • Page 227 Troubleshooting Symptom Problem Solution Engine runs irregularly or stalls Low coolant temperature. Remove and check thermostat. frequently 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.
  • Page 228 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.
  • Page 229 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.
  • Page 230 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 technician check. Stretched poly-vee belt or defective Check automatic belt tensioner and belt tensioner.
  • Page 231 Troubleshooting Symptom Problem Solution Undercharged electrical system Excessive electrical load from added Remove accessories or install higher accessories. output alternator. Excessive engine idling. Increase engine rpm when heavy electrical load is used. Poor electrical connections on Inspect and clean as necessary. battery, ground strap, starter, or alternator.
  • Page 232 Troubleshooting Symptom Problem Solution Starter and hour meter functions; Blown fuse on magnetic switch. Replace fuse. rest of electrical system does not function Entire electrical system does not Faulty battery connection. Clean and tighten connections. function Sulfated or worn-out batteries. See your authorized servicing dealer or engine distributor.

  • Page 233: Electronic Instrument Panel)

    Troubleshooting Diagnostic Trouble Code Procedure (Using Electronic Instrument Panel) IMPORTANT: Care should be used during diagnostic procedures to avoid damaging the terminals of connectors, sensors, and actuators. Probes should not be poked into or around the terminals or damage will result. Probes should only be touched against the terminals to make measurements.

  • Page 234: Displaying Of Diagnostic Trouble Codes (Dtcs)

    Troubleshooting Displaying Of Diagnostic Trouble Codes (DTCs) Stored and active diagnostic trouble codes are output on the diagnostic gauge on the instrument panel according to the J1939 standard as a two-part code as shown on the tables on the following pages. The first part is a two to four-digit Suspect Parameter Number (SPN) followed by a one or two-digit Failure Mode Identifier (FMI) code.

  • Page 235: Listing Of Diagnostic Trouble Codes (Dtcs) (Engines With Electronic Fuel Systems And Stanadyne De10 Pump)

    Troubleshooting Listing of Diagnostic Trouble Codes (DTCs) (Engines With Electronic Fuel Systems And Stanadyne DE10 Pump) NOTE: Not all of these codes are used on all OEM engine applications Trouble Codes Displayed Code Definition Analog Throttle (B) Input Voltage High Analog Throttle (B) Input Voltage Low Analog Throttle (A) Input Voltage High Analog Throttle (A) Input Voltage Low...
  • Page 236 Troubleshooting NOTE: The Diagnostic Gauge on the electronic instrument panel can have communication problems that result in Error Codes being shown on its LCD display window. The following Error Codes all indicate that there is a Diagnostic Gauge communication error with the ECU. Contact your servicing dealer for help in correcting these codes: EE—Error...

  • Page 237: Listing Of Diagnostic Trouble Codes (Dtcs) (Engines With Electronic Fuel Systems And Bosch Vp44 Pump)

    Troubleshooting Listing of Diagnostic Trouble Codes (DTCs) (Engines With Electronic Fuel Systems And Bosch VP44 Pump) NOTE: Not all of these codes are used on all OEM engine applications Trouble Codes Displayed Code Definition Analog Throttle (A) No. 3 Voltage High Analog Throttle (A) No.
  • Page 238 Troubleshooting Displayed Code Definition Pump Position Sensor Input Noise Pump Position Sensor Input Missing Pump Position Sensor Input Pattern Error Crankshaft Position Input Noise Crankshaft Position Input Missing Crankshaft Position Input Pattern Error Inlet Air Heater Signal High Inlet Air Heater Signal Low Calculated Vehicle Speed Input Noise Vehicle Speed Invalid/Missing Auxiliary Engine Shutdown Switch Signal Invalid...

  • Page 239: Listing Of Diagnostic Trouble Codes (Dtcs) (Engines With Electronic Fuel Systems And Denso High Pressure Common Rail)

    Troubleshooting Listing of Diagnostic Trouble Codes (DTCs) (Engines With Electronic Fuel Systems And Denso High Pressure Common Rail) NOTE: Not all of these codes are used on all OEM engine applications Trouble Codes Displayed Code Definition Analog Throttle (B) Input High Analog Throttle (B) Input Low Analog Throttle (A) Input High Analog Throttle (A) Input Low...
  • Page 240 Troubleshooting Displayed Code Definition Pump Position Sensor Input Noise Pump Position Sensor Input Missing Pump Position Sensor Input Pattern Error Crankshaft Position Input Noise Crank Position/Pump Position Timing Moderately Out Of Sync Crankshaft Position Input Missing Crankshaft Position Input Pattern Error CAN Bus Error Cylinder #1 Electronic Injector (EI) Circuit Open Cylinder #1 Electronic Injector (EI) Circuit Shorted...

  • Page 241: Intermittent Fault Diagnostics (With Electronic Controls)

    Troubleshooting Intermittent Fault Diagnostics (With Electronic Controls) Intermittent faults are problems that periodically “go sets, the ECU stores a freeze frame of the data away”. A problem such as a terminal that intermittently parameter values the instant the DTC sets. doesn’t make contact can cause an intermittent fault.

  • Page 242: Storage

    Storage Engine Storage Guidelines 1. John Deere engines can be stored outside for up to 4. John Deere engines expected to be stored more three (3) months with no long term preparation IF than six (6) months, long term storage preparation COVERED BY WATERPROOF COVERING.

  • Page 243: Preparing Engine For Long Term Storage

    Storage Preparing Engine for Long Term Storage The following storage preparations are good for long Coolant Section and ADDING COOLANT in Service term engine storage up to one year. After that, the As Required Section.) engine should be started, warmed up, and retreated for an extended storage period.

  • Page 244: Removing Engine From Long Term Storage

    Storage Removing Engine from Long Term Storage Refer to the appropriate section for detailed services IMPORTANT: DO NOT operate starter more than listed below or have your authorized servicing dealer 30 seconds at a time. Wait at least 2 or engine distributor perform services that you may not minutes for starter to cool before be familiar with.

  • Page 245: Specifications

    Specifications General OEM Engine Specifications ITEM 4045TF275 4045HF275 4045HF475 6068TF275 6068HF275 6068HF475 Number of Cylinders Bore 106 mm 106 mm 106 mm 106 mm 106 mm 106 mm (4.19 in.) (4.19 in.) (4.19 in.) (4.19 in.) (4.19 in.) (4.19 in.) Stroke 127 mm 127 mm...
  • Page 246 Specifications ITEM 4045TF275 4045HF275 4045HF475 6068TF275 6068HF275 6068HF475 Oil Pressure At Rated 345 kPa 345 kPa 345 kPa 345 kPa 345 kPa 345 kPa Speed, Full Load (± 15 (50 psi) (50 psi) (50 psi) (50 psi) (50 psi) (50 psi) psi) Oil Pressure At Low Idle 105 kPa...

  • Page 247: Engine Power Ratings And Fuel System

    Specifications Engine Power Ratings And Fuel System Specifications Engine Model Fuel System Electronic System Power Rated Slow Idle Fast Idle Option Codes Software Option Voltage Rating @ Speed (rpm) (rpm) Codes Rated (rpm) Speed Without Fan kW (hp) 4045TF275 161K, 163H ..7288 ....
  • Page 248 Specifications Engine Model Fuel System Electronic System Power Rated Slow Idle Fast Idle Option Codes Software Option Voltage Rating @ Speed (rpm) (rpm) Codes Rated (rpm) Speed Without Fan kW (hp) 6068TF275 161H, 163F ..7294 ....12V ....116 (155) ..2500 ..

  • Page 249: Engine Crankcase Oil Fill Quantities

    Specifications Engine Crankcase Oil Fill Quantities To determine the option code for the oil fill quantity of NOTE: Crankcase oil capacity may vary slightly from your engine, refer to the engine option code label amount shown. ALWAYS fill crankcase to affixed to the rocker arm cover.

  • Page 250: Unified Inch Bolt And Cap Screw Torque Values

    Specifications Unified Inch Bolt and Cap Screw Torque Values Top, SAE Grade and Head Markings; Bottom, SAE Grade and Nut Markings Grade 1 (No Mark) Grade 2 (No Mark) Grade 5, 5.1 or 5.2 Grade 8 or 8.2 Size Lubricated Lubricated Lubricated Lubricated...

  • Page 251: Metric Bolt And Cap Screw Torque Values

    Specifications Metric Bolt and Cap Screw Torque Values Top, Property Class and Head Markings; Bottom, Property Class and Nut Markings Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9 Size Lubricated Lubricated Lubricated Lubricated N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft)

  • Page 252: Lubrication And Maintenance Records

    Lubrication and Maintenance Records Using Lubrication and Maintenance Records Refer to specific Lubrication and Maintenance Section complete listing of all items to be performed and the for detailed service procedures. service intervals required, refer to the quick-reference chart near the front of the 1.

  • Page 253: Hour/12 Month Service

    Lubrication and Maintenance Records 500 Hour/12 Month Service • Change engine oil and filter. • Replace fuel filter element. • Service fire extinguisher. • Check automatic belt tensioner and belt wear. • Service battery. • Check engine electrical ground connection. •...

  • Page 254: 2000 Hour/24 Month Service

    Lubrication and Maintenance Records 2000 Hour/24 Month Service • Check crankshaft vibration damper (6-cylinder only). • Check and adjust valve clearance. • Flush cooling system. • Test glow plugs (4045HF475, 6068HF475) • Test thermostats. Hours Date Hours Date Hours Date Hours Date Hours...

  • Page 255: Service As Required

    Lubrication and Maintenance Records Service as Required • Add coolant • Service air cleaner. • Replace poly-vee belts. • Check fuses • Bleed fuel system Hours Date Hours Date Hours Date Hours Date Hours Date Hours Date Hours Date Hours Date RG,RG34710,5627 –19–20MAY96–1/1 60-4...

  • Page 256: Emission System Warranty

    Emission System Warranty U.S. EPA Emissions Control Warranty Statement Emissions control-related parts and components are Warranties stated in this manual refer only to warranted by John Deere for five years or 3000 hours emissions-related parts and components of your of operation, whichever occurs first. John Deere further engine.
  • Page 257 Emission System Warranty Emissions Control System Certification Label Emissions Label engines having the certification label affixed to the CAUTION: Statutes providing severe engine and sold as stated above in the geographic penalties for tampering with emissions areas. The presence of an EU number in the third line controls may apply to the user or dealer.
  • Page 258 John Deere Service Literature Available Technical Information Technical information is available from John Deere. Some of this information is available in electronic as well as printed form. Order from your John Deere dealer or call 1-800-522-7448. Please have available the model number, serial number, and name of the product.
  • Page 259 John Deere Service Literature Available Publications for this Engine Technical information is available from John Deere in support of our products. Some of this information is available in electronic as well as printed form. Order from your John Deere dealer or call 1-800-522-7448. Please have available the model number, and name of your engine.
  • Page 260 John Deere Service Literature Available 70-3 061902 PN=174...
  • Page 261 Index Page Page Disposing ......10-17 Replenishing supplemental additives..30-16 Acid burns .
  • Page 262 Index Page Page Engine oil Break-In ......10-8 Idling engine......15-27 Change .
  • Page 263 Index Page Page Power ratings ......55-3 Thermostat Precautions for welding on engines equipped Install .
  • Page 264 Index Index-4 061902 PN=4...
  • Page 267 GENERATOR PARTS LISTS GENERATOR MODEL G200 EDITION: MAY2002 CPN 85620839 33519008901...
  • Page 268 SALES OFFICES Sales Office United Kingdom Ingersoll-Rand European Sales Ltd Facility details Swan Lane Hindley Green Wigan WN2 4EZ United Kingdom Phone +44 (0) 1942 257 171 +44 (0) 1942 523 417 Structure de l'Organisation en France Ingersoll-Rand Portable Power Coordonnées du Site...
  • Page 269 TABLE OF CONTENTS G200 ENGINE FUNCTION 6068H..................5 ENGINE JD 6068H DETAIL..................6 OIL SUMP DRAIN PUMP ASSEMBLY...............7 AIR FILTER HEAVY DUTY ASSEMBLY ..............8 AIR FILTER 080350 DETAIL ..................9 AIR HEATER ASSEMBLY..................10 TRANS. WATER TEMPERATURE-OIL PRESSURE ASSEMBLY ......11 ENGINE WIRING LOOM 6068H ................12 OUTPUT CABLES ALTERNATOR ASSEMBLY............13 ALTERNATOR LS 462M ASSEMBLY ..............14 ALTERNATOR LS 462M3 SAE 3/11,5 DETAIL ............15...
  • Page 270 SOCKET TYPE 2 SOCKET PANEL EU M216 TYPE 2 ASSEMBLY ............52 SOCKETS PANEL T2-T6-T9 M216 ASSEMBLY .............53 SOCKETS ASSEMBLY ....................54 SOCKET TYPE 4 SOCKET PANEL FR M216 TYPE 4 ASSEMBLY.............55 SOCKETS ASSEMBLY ....................56 SOCKET TYPE 6 SOCKET PANEL FR M216 TYPE 6 ASSEMBLY.............57 SOCKETS PANEL T2-T6-T9 M216 ASSEMBLY .............58 SOCKETS ASSEMBLY ....................59 GALVANIZED SKID KIT ...................60...

  • Page 271: Engine Function 6068H

    G200 Item Part Number Description Quantity Units F01042 ENGINE FUNCTION 6068H 010160 85509149 ENGINE JD 6068HF SAE 3/11.5 EDITION: MAY2002 - 5 -...

  • Page 272: Engine Jd 6068H Detail

    G200 Item Part Number Description Quantity Units F30028 ENGINE JD 6068H DETAIL 301410 36881696 OIL FILTER 301740 85400976 FUEL FILTER 301710 85400851 BELT 301730 85400893 INJECTOR 302200 85400927 STARTER 301720 85400877 CHARGING ALTERNATOR 301810 85401313 WATER PUMP 301750 85401099 PRESSURE SWITCH 301770 85401164 TEMPERATURE SWITCH...

  • Page 273: Oil Sump Drain Pump Assembly

    G200 Item Part Number Description Quantity Units F04001 85403442 OIL SUMP DRAIN PUMP ASSEMBLY 040110 85403426 OIL SUMP PUMP BRACKET 040120 85403434 MANUAL PUMP 182320 85409209 SCREW H M12x25 180340 85409258 PIPE UNION MAL/MAL 3/8G 181520 85492551 PIPE UNION FEMAL/MAL 1/2G 180350 85409308 PIPE UNION ELBOW 90°...

  • Page 274: Air Filter Heavy Duty Assembly

    G200 Item Part Number Description Quantity Units F08007 85404002 AIR FILTER HEAVY DUTY ASSEMBLY 080330 85403848 AIR CLEANER CLAMP D330 080340 85403863 RAIN CAP 080350 85403921 AIR FILTER HEAVY DUTY 080160 85404069 AIR FILTER BRACKET JD 4039 080300 85404101 AIR FILTER BRACKET ALL JD 180420 85409407 HOSE CLIP D70/90...

  • Page 275: Air Filter 080350 Detail

    G200 Item Part Number Description Quantity Units F30014 85403921 AIR FILTER 080350 DETAIL 300200 85400737 FILTER CARTRIDGE 300210 85400786 FILTER CARTRIDGE 300120 85501229 VACUATOR VALVE 300230 85501294 DUST CUP 080340 85403863 RAIN CAP 181680 85501872 HOSE CLIP D140/160 EDITION: MAY2002 - 9 -...

  • Page 276: Air Heater Assembly

    G200 Item Part Number Description Quantity Units F08008 85404291 AIR HEATER ASSEMBLY 080200 85404267 AIR HEATER RESISTANCE 1200W 12V 160880 85408177 AIR HEATER WIRING LOOM JD 6068 160550 85408938 RELAY 12V 180A 160170 85408896 RELAY 12V 20/30A EDITION: MAY2002 - 10 -...

  • Page 277: Trans. Water Temperature-Oil Pressure Assembly

    G200 Item Part Number Description Quantity Units F11002 85404705 TRANS. WATER TEMPERATURE-OIL PRESSURE ASSEMBLY 110110 85404598 PRESSURE SWITCH 00/10 BAR 110140 85404606 TEMPERATURE SENSOR 40/120° 180440 85409134 PIPE UNION REDUCER MAL/FEM 3/8SAE 1/8G 180260 85409340 PIPE UNION REDUCER MAL/FEM M14x150 1/8NPTF EDITION: MAY2002 - 11 -...

  • Page 278: Engine Wiring Loom 6068H

    G200 Item Part Number Description Quantity Units F16204 85509339 ENGINE WIRING LOOM 6068H 168790 85509164 CONNECTOR BRACKET 160950 85407963 WIRING BRACKET JD 6068 160580 85407971 STARTING RELAY PROTECTION PANEL 160960 85408045 ENGINE WIRING LOOM JD 6068 160270 85408078 COPPER BAR 5x25 160170 85408896 RELAY 12V 20/30A...

  • Page 279: Output Cables Alternator Assembly

    G200 Item Part Number Description Quantity Units F16004 85407484 OUTPUT CABLES ALTERNATOR ASSEMBLY 160420 85406742 CABLE OUTLET PLATE 160500 85406874 FOAM CABLE PROTECTION EDITION: MAY2002 - 13 -...

  • Page 280: Alternator Ls 462M Assembly

    G200 Item Part Number Description Quantity Units F02006 ALTERNATOR LS 462M ASSEMBLY 020150 85509172 ALTERNATOR LS 462M EDITION: MAY2002 - 14 -...

  • Page 281: Alternator Ls 462M3 Sae 3/11,5 Detail

    G200 Item Part Number Description Quantity Units F30197 ALTERNATOR LS 462M3 SAE 3/11,5 DETAIL 320730 85509180 WOUND STATOR ASSEMBLY 320740 85509198 WOUND ROTOR ASSEMBLY 320600 85508877 N.D.E BRACKET 302310 85425916 BEARING LSA 462/471 319880 85509065 WAVY WASHER 320610 85508927 WOUND EXCITER FIELD 320620 85508968 WOUND EXCITER ARMATURE...

  • Page 282: Radiator Fittings Jd6068H Assembly

    G200 Item Part Number Description Quantity Units F03041 85509354 RADIATOR FITTINGS JD6068H ASSEMBLY 030180 85403251 RADIATOR BRACKET ENGINE JD 6068 030620 85503605 RADIATOR JD 6068H WITH HOSE KIT 030190 85509206 RADIATOR BRACKET JD 6CYL 080370 85404135 AIR INLET PIPE JD 6068H 080380 85404143 AIR HOSE BRACKET JD 6068H...

  • Page 283: Radiator 030620 Detail

    G200 Item Part Number Description Quantity Units F30082 85503605 RADIATOR 030620 DETAIL 300970 85426013 RADIATOR BOTTOM HOSE 300980 85426047 RADIATOR TOP HOSE 180630 85426393 RUBBER HOSE D50 300990 85502623 RADIATOR CHARGE AIR HOSE 080370 85404135 AIR INLET PIPE JD 6068H 301010 85500619 WATER RADIATOR...

  • Page 284: Fuel Tank M214 Assembly

    G200 Item Part Number Description Quantity Units F05005 85403533 FUEL TANK M214 ASSEMBLY 050170 85403475 FUEL SUCCION PIPE L240 D8 3/8G 050110 85403517 FUEL FILLING FUNNEL BASE TANK 181750 85503035 PLUG TANK 050120 85403509 LEVEL SENSOR ADAPTER 110100 85404572 LEVEL SENSOR 180130 85409068 SQARE FLANGE GASKET...

  • Page 285: Fuel Filler 050110 Detail

    G200 Item Part Number Description Quantity Units F30019 85403517 FUEL FILLER 050110 DETAIL 181750 85509222 PLUG TANK 050420 85431120 FUEL FILTER EDITION: MAY2002 - 19 -...

  • Page 286: Fuel Prefilter Kit Assembly

    G200 Item Part Number Description Quantity Units F05004 85403558 FUEL PREFILTER KIT ASSEMBLY 050160 85403483 FUEL FILTER BRACKET 050150 85403525 FUEL FILTER SEPARATOR 180240 85409274 BANJO CONNECTOR MALE D08 180250 85409282 BANJO SCREW M14X150 L26 180150 85409514 SPRING CLAMP D13/15 180270 85409522 GASKET D14x20...
  • Page 287 G200 Item Part Number Description Quantity Units F07004 85403830 ELECTRIC STARTER ISOLATED ASSEMBLY 070100 85403699 BATTERY FIXING BRACKET 070170 85403707 BATTERY ISOLATOR BRACKET 070120 85403723 BATTERY ISOLATOR SWITCH 070180 85403731 STARTING BATTERY 12V 100Ah 450A 070160 85403806 BATTERY SUPPORT BRACKET M214/216 160430 85406387 BATTERY CABLE (+) 50mm2 L700 RED...

  • Page 288: Exhaust Muffler M216 Assembly

    G200 Item Part Number Description Quantity Units F09010 85404358 EXHAUST MUFFLER M216 ASSEMBLY 090200 85404366 29dB MUFFLER 090150 85503597 EXHAUST PIPE D114 JD 181910 85509230 HOSE CLAMP D115 180500 85409449 NOT FITTED EDITION: MAY2002 - 22 -...

  • Page 289: Hot Spot Guards Assembly

    G200 Item Part Number Description Quantity Units F09011 85404473 HOT SPOT GUARDS ASSEMBLY 130360 85405025 HOT SPOT GUARD BRACKET JD 6068 130370 85405033 HOT SPOT GUARD JD 6068 130380 85405157 HOT SPOT GUARD JD 6068 130390 85405165 HOT SPOT GUARD JD 6068 EDITION: MAY2002 - 23 -...

  • Page 290: Frame M216 Jd 6068 Assembly

    G200 Item Part Number Description Quantity Units F13073 85509362 FRAME M216 JD 6068 ASSEMBLY 130410 85404895 FRAME TANK 410L M216 130420 85401883 ANTI-VIBRATION MOUNT 330daN 3.5mm 130250 85509248 ENGINE SUPPORT JD 4045/6068 LEFT SIDE 130260 85509255 ENGINE SUPPORT JD 4045/6068 RIGHT SIDE 180110 85409050 SPACER Th10 D80...

  • Page 291: G200 Accessory Assembly

    G200 Item Part Number Description Quantity Units F18051 85509370 G200 ACCESSORY ASSEMBLY 050420 85431120 FUEL FILTER 090300 85422772 MUFFLER EXTENSION D114 090220 85404341 EXHAUST RAIN FLAP D114 144560 85509263 WBH LATCHE KEY 181910 85509230 HOSE CLAMP D115 181600 85428019 RECTANGULAR STICKER 450x600 181900 85500213 ROUND STICKER D385...

  • Page 292: M216 Miscellaneous Assembly

    G200 Item Part Number Description Quantity Units F13014 85404945 M216 MISCELLANEOUS ASSEMBLY 140890 85405942 RADIATOR PANEL M216 JD 6068H 160890 85406460 GROUND WIRES 16mm2 160110 85406940 NOT FITTED EDITION: MAY2002 - 26 -...
  • Page 293 G200 EDITION: MAY2002 - 27 -...

  • Page 294: Wbh Canopy M216 Assembly Beige

    G200 Item Part Number Description Quantity Units F14047 85405637 WBH CANOPY M216 ASSEMBLY BEIGE 130430 85491892 LIFTING EYE D61 140730 85405660 CANOPY SIDE PANEL LOWER LEFT M216 140710 85509297 SUPPORT ARCH M216 140700 85405561 AIR DEFLECTOR M216 FRONT 140720 85405652 CANOPY SIDE PANEL LOWER RIGHT M216 140740 85405678...

  • Page 295: Panel Door M216/413 Assembly

    G200 Item Part Number Description Quantity Units F14004 85406288 PANEL DOOR M216/413 ASSEMBLY 140900 85405462 DOOR STOP 140330 85406148 CANOPY DOOR LOCK KEY LOCK 140340 85406155 DOOR HINGE 140350 85406189 ANTI-VIBRATION MOUNT 140daN 15mm 140910 85406262 STRIKER PLATE M403 CANOPY MICS/MCPS DOOR 140920 85406296 CONTROL PANEL DOOR M216...

  • Page 296: Emergency Stop Panel Assembly

    G200 Item Part Number Description Quantity Units F16015 85407187 EMERGENCY STOP PANEL ASSEMBLY 161080 85406726 SOCKET BRACKET CLOSURE PANEL 161070 85407294 EMERGENCY STOP PANEL EDITION: MAY2002 - 30 -...

  • Page 297: R3000 Bracket Assembly

    G200 Item Part Number Description Quantity Units F16216 85427862 R3000 BRACKET ASSEMBLY 168330 85427177 RUBBER GROMET SUPPORT 163330 85427193 INTELLISYSTM RACK BRACKET 160520 85408391 RUBBER GROMMET D47 EDITION: MAY2002 - 31 -...

  • Page 298: Earth Rod With Cable Canopy Assembly

    G200 Item Part Number Description Quantity Units F16006 85407906 EARTH ROD WITH CABLE CANOPY ASSEMBLY 160140 85408227 NEUTRAL/EARTH SYSTEM CABLE 25mm2 L10000 Gr/Ye 160150 85408334 EARTH ROD L1000 180120 85409191 CLIP-ON BRACKET EDITION: MAY2002 - 32 -...

  • Page 299: Intelisys Tm Assembly

    G200 Item Part Number Description Quantity Units F16200 85509396 INTELISYS ASSEMBLY 168200 85411569 INTELLISYSTM OPTION CB CARD 168220 85411619 INTELLISYSTM OPTION USING PLATEN 168230 85412286 INTELLISYSTM OPTION ELECTRIC PACK 12V 168240 85412260 INTELLISYSTM OPTION EARTH LEAKAGE RELAY 168190 85412013 INTELLISYSTM PANEL ASSEMBLY 168180 85412005 INTELLISYSTM PANEL SHEET METAL ASSEMBLY...
  • Page 300 G200 Item Part Number Description Quantity Units F30041 85412005 INTELLISYSTM PANEL SHEET METAL ASSEMBLY 302880 85504108 RIGHT HOUSING 302890 85504116 LEFT HOUSING 302900 85504124 ROTOR 302910 85504132 SLAM SHUT DOOR LATCH 302920 85504140 ORDER THE 302890 302930 85504157 RING 302940 85504165 SCREW M6X16 302950...

  • Page 301: Intellisystm Option Cb12 Card

    G200 Item Part Number Description Quantity Units F30045 85411569 INTELLISYSTM OPTION CB12 CARD 166390 85504058 RUBBER GROMMET 166430 85402592 INTELLISYSTM CARD CB12 166370 85504033 INTELLISYSTM WIRING LOOM C35S 166440 85426112 FUSE CYLINDRICAL 12A 166470 85426120 FUSE CYLINDRICAL 10A 166450 85426138 FUSE CYLINDRICAL 1A 166460 85426146...

  • Page 302: Intellisystm Option Using Platen

    G200 Item Part Number Description Quantity Units F30051 85411619 INTELLISYSTM OPTION USING PLATEN 166030 85408854 STOP 303120 85504256 WIRING LOOM SUPPORT 0.21 303170 85504306 USING TERMINAL EDITION: MAY2002 - 36 -...

  • Page 303: Intellisystm Option Tension Potentiometer

    G200 Item Part Number Description Quantity Units F30052 85412286 INTELLISYSTM OPTION TENSION POTENTIOMETER 302980 85504207 CLAMP D4.7 303050 85504215 LOCK AXE SYSTEM 166520 85504009 INTELLISYSTM WIRING LOOM C106 L560 303130 85504264 POTENTIOMETER 1kOHMS EDITION: MAY2002 - 37 -...

  • Page 304: Intellisystm Option Earth Leakage Relay

    G200 Item Part Number Description Quantity Units F30053 85412260 INTELLISYSTM OPTION EARTH LEAKAGE RELAY 303090 85504249 FLASK 164080 85413482 FUSE CYLINDRICAL 5A 166500 85503985 INTELLISYSTM WIRING LOOM C39 L2000 303140 85504272 EARTH LEAKAGE RELAY 12V 303110 85423473 TORE 303080 85504231 FUSE HOUSING 168410 85508570...

  • Page 305: Intellisystm Panel 12Vdc Assembly

    G200 Item Part Number Description Quantity Units F30042 85412013 INTELLISYSTM PANEL 12VDC ASSEMBLY 302990 85426781 EMERGENCY STOP SWITCH 302970 85504199 GROUND WIRES 10mm2 166350 85504017 INTELLISYSTM WIRING LOOM C3 L810 166360 85504025 INTELLISYSTM WIRING LOOM C11 L460 303060 85504983 INTELLISYSTM PLASTIC PLATE 166380 85504041 EARTHING INTELLISYSTM WIRING LOOM...

  • Page 306: Intellisystm Option Emergency Stop

    G200 Item Part Number Description Quantity Units F30055 85411676 INTELLISYSTM OPTION EMERGENCY STOP 166490 85503977 INTELLISYSTM WIRING LOOM C11 L2000 EDITION: MAY2002 - 40 -...

  • Page 307: Intellisystm Wiring Loom Function

    G200 Item Part Number Description Quantity Units F16103 85509388 INTELLISYSTM WIRING LOOM FUNCTION 166480 85411221 INTELLISYSTM WIRING LOOM 037/041 166630 85410546 INTELLISYSTM WIRING LOOM 001 166790 85509321 INTELLISYSTM WIRING LOOM 106 166770 85410520 INTELLISYSTM WIRING LOOM 006 166810 85411452 INTELLISYSTM WIRING LOOM 119 166820 85411460 INTELLISYSTM WIRING LOOM 120...

  • Page 308: Terminal Block Housing 250

    G200 Item Part Number Description Quantity Units F16045 85419851 TERMINAL BLOCK HOUSING 250<I<=480A ASSEMBLY 161390 85424067 GLAND NUT PLATE TERMINAL CONNECTION M204/205 161900 85417111 CABLE OUTPUT RUBBER SCREEN 161910 85423739 WIRE BIB OUTPUT BRACKET M403 161940 85417822 PANEL ANGLE BAR 162090 85423796 CIRCUIT BREAKER BRACKET M403...

  • Page 309: Panel Door M403 Assembly

    G200 Item Part Number Description Quantity Units F16054 85420081 PANEL DOOR M403 ASSEMBLY 140660 85406130 DOOR HINGE 162130 85422731 TERMINAL CONNECTION DOOR M403 162180 85422756 TERMINAL CONNECTION DOOR M403 160760 85407708 HINGE FIXING PLATE M214 180460 85409225 1/4 TURN SCREW D9 180470 85409233 CAPTIVE NUT FOR 1/4 TURN BOLT...

  • Page 310: Power Terminal Connections 360A Assembly

    G200 Item Part Number Description Quantity Units F16066 85427086 POWER TERMINAL CONNECTIONS 360A ASSEMBLY 161410 85417319 EARTHING CABLE D8xD10 25mm2 L2500 Gr/Ye 161420 85406601 EARTHING CABLE D8xD10 25mm2 L1800 Gr/Ye 161460 85417335 POWER CABLE SINGLE CORE 100mm2 L1800 161480 85416915 COPPER BAR 10x30 161550 85416899...

  • Page 311: Terminal Connection Block Assembly

    G200 Item Part Number Description Quantity Units F16076 85418176 TERMINAL CONNECTION BLOCK ASSEMBLY 161850 85417061 COPPER BAR 10x50 161860 85416972 COPPER BAR 10x30 161870 85416980 COPPER BAR 10x30 161880 85416998 COPPER BAR 10x30 161890 85417004 COPPER BAR 10x30 161930 85418077 PHASE ISOLATOR M403 162360 85413706...

  • Page 312: Compact Circuit Breaker 100A

    G200 Item Part Number Description Quantity Units F16036 COMPACT CIRCUIT BREAKER 100A<I<630A ACCESSORIES 162450 85408573 CIRCUIT BREAKER SHUNT RELEASE COIL 200/280VAC Part number listed is the only part used in this model EDITION: MAY2002 - 46 -...

  • Page 313: Retention Bund M216

    G200 Item Part Number Description Quantity Units F99004 RETENTION BUND M216 130405 85404861 RETENTION BUND M216 140690 85405553 NOT FITTED 130400 85404846 NOT FITTED EDITION: MAY2002 - 47 -...
  • Page 314 G200 EDITION: MAY2002 - 48 -...

  • Page 315: Way Fuel Valve Assembly

    G200 3 WAY FUEL VALVE OPTION 992370 Item Part Number Description Quantity Units F05006 85403574 3 WAY FUEL VALVE ASSEMBLY 050180 85403566 3 WAY FUEL VALVE BRACKET ALL JD 050570 85426963 3 WAY FUEL VALVE LEVER 3/8G 180170 85507861 PIPE UNION REDUCER MAL/FEM 3/8G D8 180560 85409266 PIPE UNION REDUCER MAL/MAL D8 D8...

  • Page 316: Air Shut Off Valve Jd 6068H Assembly

    G200 EXPLOSIVE ATMOSPHERE OPTION 992380 Item Part Number Description Quantity Units F08017 85410348 AIR SHUT OFF VALVE JD 6068H ASSEMBLY 080510 85426294 ENGINE AIR INLET PIPE D50 080520 85426302 ENGINE AIR INLET PIPE D50 080420 85410249 AIR SHUT OFF VALVE D51 160160 85408367 RELAY 12V/24V 75A...

  • Page 317: Spark Arrester Ineris Dn100 Assembly

    G200 EXPLOSIVE ATMOSPHERE OPTION 992380 Item Part Number Description Quantity Units F09013 85404556 SPARK ARRESTER INERIS DN100 ASSEMBLY 090160 85404325 INERIS SPARK ARRESTER DN100 181910 85509230 HOSE CLAMP D115 180500 85409381 NOT FITTED EDITION: MAY2002 - 51 -...

  • Page 318: Socket Panel Eu M216 Type 2 Assembly

    SOCKET TYPE 2 G200 SOCKET OPTION 992390 Item Part Number Description Quantity Units F16138 85506913 SOCKET PANEL EU M216 TYPE 2 ASSEMBLY 162880 85406429 COPPER BAR 5x25 166200 85499440 ELECTRICAL SHAFT D36 160770 85408342 INSULATION PIN 167720 85408607 POWER CONNECTION BLOCK 164360 85408680 GLAND NUT PG36...

  • Page 319: Sockets Panel T2-T6-T9 M216 Assembly

    SOCKET TYPE 2 G200 SOCKET OPTION 992390 Item Part Number Description Quantity Units F16121 85505774 SOCKETS PANEL T2-T6-T9 M216 ASSEMBLY 166660 85427334 SOCKETS PANEL EC M223/214/223 167540 85407765 REAR PANEL M223/216 CONTROL PANEL HOUSING 167550 85407773 GLAND NUT PLATE CONTROL PANEL M223/216 167560 85407781 REAR PANEL M216 CONTROL PANEL HOUSING...

  • Page 320: Sockets Assembly

    SOCKET TYPE 2 G200 SOCKET OPTION 992390 Item Part Number Description Quantity Units F16126 85505881 SOCKETS ASSEMBLY 167750 85408748 COMPACT CIRCUIT BREAKER 1x10A 167770 85408763 CIRCUIT BREAKER PROTECTION 167760 85413169 COMPACT CIRCUIT BREAKER 1x15A 167770 85408763 CIRCUIT BREAKER PROTECTION 166180 85501542 SOCKETS ADAPTATION PLATE 167650...

  • Page 321: Socket Type

    SOCKET TYPE 4 G200 SOCKET OPTION 992390 Item Part Number Description Quantity Units F16143 85507051 SOCKET PANEL FR M216 TYPE 4 ASSEMBLY 162880 85406429 COPPER BAR 5x25 166660 85427334 SOCKETS PANEL EC M223/214/223 167540 85407765 REAR PANEL M223/216 CONTROL PANEL HOUSING 167550 85407773 GLAND NUT PLATE CONTROL PANEL M223/216...

  • Page 322: Sockets Assembly

    SOCKET TYPE 4 G200 SOCKET OPTION 992390 Item Part Number Description Quantity Units F16131 85505964 SOCKETS ASSEMBLY 167750 85408748 COMPACT CIRCUIT BREAKER 1x10A 167770 85408763 CIRCUIT BREAKER PROTECTION 167760 85413169 COMPACT CIRCUIT BREAKER 1x15A 167770 85408763 CIRCUIT BREAKER PROTECTION 167650 85506020 MOULDED CASE CIRCUIT BREAKER 4x32A 164060...

  • Page 323: Socket Type

    SOCKET TYPE 6 G200 SOCKET OPTION 992390 Item Part Number Description Quantity Units F16149 85507259 SOCKET PANEL FR M216 TYPE 6 ASSEMBLY 162880 85406429 COPPER BAR 5x25 166200 85499440 ELECTRICAL SHAFT D36 160770 85408342 INSULATION PIN 167720 85408607 POWER CONNECTION BLOCK 164360 85408680 GLAND NUT PG36...

  • Page 324: Sockets Panel T2-T6-T9 M216 Assembly

    SOCKET TYPE 6 G200 SOCKET OPTION 992390 Item Part Number Description Quantity Units F16121 85505774 SOCKETS PANEL T2-T6-T9 M216 ASSEMBLY 166660 85427334 SOCKETS PANEL EC M223/214/223 167540 85407765 REAR PANEL M223/216 CONTROL PANEL HOUSING 167550 85407773 GLAND NUT PLATE CONTROL PANEL M223/216 167560 85407781 REAR PANEL M216 CONTROL PANEL HOUSING...

  • Page 325: Sockets Assembly

    SOCKET TYPE 6 G200 SOCKET OPTION 992390 Item Part Number Description Quantity Units F16128 85505915 SOCKETS ASSEMBLY 167760 85413169 COMPACT CIRCUIT BREAKER 1x15A 167770 85408763 CIRCUIT BREAKER PROTECTION 167650 85506020 MOULDED CASE CIRCUIT BREAKER 4x32A 167660 85506038 MOULDED CASE CIRCUIT BREAKER 4x63A 164060 85408284 CIRCUIT BREAKER SUPPORT PLATE 12 MODULES...

  • Page 326: Galvanized Skid Kit

    SOCKET TYPE 6 G200 SIMPLIFIED RETENTION TANK OPTION 992400 Item Part Number Description Quantity Units F13066 GALVANIZED SKID KIT 140690 85405553 HOOD UNDERSHEETING M216 130400 85404846 NOT FITTED EDITION: MAY2002 - 60 -...

  • Page 327: Intellisystm Option Dual Frequency

    SOCKET TYPE 6 G200 DUAL FREQUENCY OPTION 992410 Item Part Number Description Quantity Units F30075 85506723 INTELLISYSTM OPTION DUAL FREQUENCY 304390 85506673 BUTTON 304400 85506681 POTENTIOMETER 200kOHMS 167460 85506566 INTELLISYSTM WIRING LOOM 124 167470 85506574 INTELLISYSTM WIRING LOOM 125 304410 85506699 POTENTIOMETER SUPPORT 304420...

  • Page 328: Hood Undersheeting M214

    SOCKET TYPE 6 G200 SINGLE BASE PLATE OPTION 992420 Item Part Number Description Quantity Units F14034 HOOD UNDERSHEETING M214 130400 85404846 RETENTION BUND M216 EDITION: MAY2002 - 62 -...

  • Page 329: Electronic Regulation Kit

    SOCKET TYPE 6 G200 ELECTRONIC REGULATION OPTION 992430 Item Part Number Description Quantity Units F06002 54602925 ELECTRONIC REGULATION KIT 060100 85403616 ELECTRONIC ACTUATOR 060130 85426260 SPEED ELECTRONIC GOVERNOR 12VCC 060120 85403632 MAGNETIC SPEED SENSOR L75 3/4UNF 161090 85407328 ELECTRONIC REGULATOR HOUSING BRACKET 166780 85411445 INTELLISYSTM WIRING LOOM 105...

  • Page 330: Intellisystm Option Speed Potentiometer

    SOCKET TYPE 6 G200 ELECTRONIC REGULATION OPTION 992430 Item Part Number Description Quantity Units F30047 85412161 INTELLISYSTM OPTION SPEED POTENTIOMETER 302980 85504207 CLAMP D4.7 303050 85504215 LOCK AXE SYSTEM 166510 85503993 INTELLISYSTM WIRING LOOM C105 L540 303070 85504223 POTENTIOMETER 4.7kOHMS EDITION: MAY2002 - 64 -...

  • Page 331: Coolant Heater Resistance 1000W 240V

    SOCKET TYPE 6 G200 AUTO START OPTION 992440 Item Part Number Description Quantity Units F16165 030130 85401081 COOLANT HEATER RESISTANCE 1000W 240V 110120 85404655 TEMPERATURE SWITCH 35/45° 162460 85408581 AUXILARY CONTACT 166670 85411155 INTELLISYSTM WIRING LOOM 035 166650 85410827 INTELLISYSTM WIRING LOOM 013 166870 85426898 INTELLISYSTM WIRING LOOM 016...

  • Page 332: Intellisystm Option Water Preheating

    SOCKET TYPE 6 G200 AUTO START OPTION 992440 Item Part Number Description Quantity Units F30078 85412179 INTELLISYSTM OPTION WATER PREHEATING 167410 85506517 INTELLISYSTM WIRING LOOM 031/33/34 167420 85506525 INTELLISYSTM WIRING LOOM 100 167430 85506533 INTELLISYSTM WIRING LOOM 027 304360 85506640 SURGE SUPRESSOR BLOCK 304370 85506657...

  • Page 333: Intellisystm Option Battery Charger 12V/2.5A

    SOCKET TYPE 6 G200 AUTO START OPTION 992440 Item Part Number Description Quantity Units F30079 85412054 INTELLISYSTM OPTION BATTERY CHARGER 12V/2.5A 304380 85507622 CHARGER 167440 85506541 INTELLISYSTM WIRING LOOM 022/024 167450 85506558 INTELLISYSTM WIRING LOOM 009 EDITION: MAY2002 - 67 -...

  • Page 334: Road Trailer M216 Assembly

    SOCKET TYPE 6 G200 ROAD TRAILER OPTION 992450 Item Part Number Description Quantity Units F13017 85405314 ROAD TRAILER M216 ASSEMBLY 130460 85405249 TOWING BALL D50 130490 85405223 TOWING EYE 76x42 130470 85405231 TOWING EYE DIN 40 130530 85405306 ROAD TRAILER M216 130520 85405363 SPARE WHEEL M216 ROAD TRAILER ASSEMBLY...

  • Page 335: Earth Rod With Cable Canopy Assembly

    SOCKET TYPE 6 G200 ROAD TRAILER OPTION 992450 Item Part Number Description Quantity Units F16006 85407906 EARTH ROD WITH CABLE CANOPY ASSEMBLY 160140 85408227 NEUTRAL/EARTH SYSTEM CABLE 25mm2 L10000 Gr/Ye 160150 85408334 EARTH ROD L1000 180120 85409191 CLIP-ON BRACKET EDITION: MAY2002 - 69 -...

  • Page 336: Road Trailer 130530 Detail

    SOCKET TYPE 6 G200 ROAD TRAILER OPTION 992450 Item Part Number Description Quantity Units F30063 85405306 ROAD TRAILER 130530 DETAIL 303690 85504769 RIGHT SPECIAL SIDE MEMBER 303700 85504777 LEFT SPECIAL SIDE MEMBER 303710 85504785 SOLDERED PROCESSING FRAME 303720 85504793 FRONT CROSS MEMBER 303730 85504801 LIGHTS CROSS MEMBER...
  • Page 337 SOCKET TYPE 6 G200 Item Part Number Description Quantity Units 303770 85504843 POLE 303590 85504660 INTERMEDIARY ARMS 303780 85504850 BREAK GEAR 303610 85504686 GALVANIZED MUDGUARD 303620 85504694 JOCKEY WHEEL SUPPORT 303630 85504702 SQUARE JOCKEY WHEEL 303790 85504868 COMPLETE WHEEL 303800 85504876 WHITE SQARE LIGHT WITH REFLECTOR 303810...

  • Page 338: Break Gear 303780 Detail

    SOCKET TYPE 6 G200 ROAD TRAILER OPTION 992450 Item Part Number Description Quantity Units F30071 85504850 BREAK GEAR 303780 DETAIL 304150 85505378 BELLOW 304160 85505386 TRACTION TUBE 304170 85505394 SHOCK ABSORBER 304180 85505402 CONNECTING ROD 304040 85505261 BREAK DOWN CABLE 304190 85505410 COMPENSATOR...

  • Page 339: Axle 303750 Detail

    SOCKET TYPE 6 G200 ROAD TRAILER OPTION 992450 Item Part Number Description Quantity Units F30074 85504827 AXLE 303750 DETAIL 303950 85505170 HUB CAP 304300 85505535 BEARING KIT 303980 85505204 BOLTS KIT 303990 85505212 NUTS KIT 304280 85505519 BRAKE KIT 304290 85505527 ADJUSTMENT KIT 304250...
  • Page 343 Users guide and maintenance manual Leroy Somer Alternators LSA 46.2 / 47.1 Réf. constructeur : 2981 GB - 4.33/a - 04.00 Réf. GPAO : 33522035901...
  • Page 344 LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS This manual concerns the alternator which We wish to draw your attention to the contents you have just purchased. of this maintenance manual. By following certain important points during installation, The latest addition to a whole new generation use and servicing of your alternator, you can...
  • Page 345 LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS CONTENTS 1 - RECEIPT ............4 4 - SERVICING - MAINTENANCE ......15 Standards and safety measures Safety measures Inspection Regular maintenance Identification Checks after start-up Storage Cooling circuit Bearings...

  • Page 346: Receipt

    LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS RECEIPT 1 - RECEIPT 1.3 - Identification The alternator is identified by means of a nameplate fixed on the frame (see drawing). 1.1 - Standards and safety measures Make sure that the nameplate on the machine conforms to Our alternators comply with most international standards and your order.

  • Page 347: Technical Characteristics

    LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS TECHNICAL CHARACTERISTICS 2 - TECHNICAL CHARACTERISTICS 2.1 - Electrical characteristics LSA 46.2/47.1 alternators are machines without sliprings or revolving field brushes, wound as « 2/3 pitch»; 6 or 12-wire, with class H insulation and a field excitation system available in either AREP or "PMG"...

  • Page 348: Options

    LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS TECHNICAL CHARACTERISTICS 2.3 - Excitation system adjustable via potentiometer P4 - max. excitation current adjustment via P5 : 4 to 10A For both the AREP & PMG excitation systems, the alternator - 50/60 Hz selection via strap ST3.

  • Page 349: Frequency Compared With Voltage

    LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS TECHNICAL CHARACTERISTICS PMG excitation R448 Voltage Transient voltage drop (U/f) 2.3.3 - Frequency compared with voltage (without LAM) Frequency Max. speed drop Voltage Bend 57.5 Hz 48 Hz 100 %...

  • Page 350: Installation

    LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS INSTALLATION 3 - INSTALLATION 3.1.3 - Location Ensure that the ambient temperature in the room where the 3.1 - Assembly alternator is placed cannot exceed 40°C for standard power ratings (for temperatures >...

  • Page 351: Terminal Connection Diagrams

    LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS INSTALLATION 3.3 - Terminal connection diagrams To modify the connections, change the position of the terminal links or shunts. The winding code is specified on the nameplate.

  • Page 352: Terminal Connection : Lsa 46.2/47.1 - 6-Wire

    LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS INSTALLATION 3.3.2 - Terminal connection : LSA 46.2/47.1 - 6-wire Connection codes Voltage L.L Factory connection LSA 46.2 - 6-WIRE L1(U) 50 Hz 60 Hz Winding L3(W) 3-phase...

  • Page 353: Option Connection Diagram

    LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS INSTALLATION 3.3.3 - Option connection diagram Remote voltage potentiometer R 791 T interference suppression kit (standard for CE marking) Connections Black Black Black Voltage adjustment via remote potentiometer Blue White...
  • Page 354 LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS INSTALLATION 3.4 - Commissioning 3.5.1 - R 448 settings The machine can only be started up and used if the installation has been set up in accordance with the regulations and instructions defined in this manual.
  • Page 355 LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS INSTALLATION Adjustments in standalone operation machines, try to cancel (or minimise) the current circulating between the machines. b) Install a D.C. analogue voltmeter (needle dial) cal. 100V on From now on, do not touch the voltage settings.
  • Page 356 LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS INSTALLATION 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 <...

  • Page 357: Servicing - Maintenance

    LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS SERVICING - MAINTENANCE 4 - SERVICING - MAINTENANCE The factory lubrication is performed with grease : SHELL - ALVANIA G3. 4.1 - Safety measures Before using another grease, check for compatibility with the original one.

  • Page 358: Fault Detection

    LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS SERVICING - MAINTENANCE 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 diagrams in the manuals...

  • Page 359: Electrical Faults

    LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS SERVICING - MAINTENANCE 4.5 - Electrical faults Fault Action Effect Check/Cause The alternator builds up and its voltage is still correct when the - Lack of residual magnetism battery is removed.

  • Page 360: Checking The Diode Bridge

    LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS SERVICING - MAINTENANCE 4.5.2 - Checking the diode bridge ASSEMBLY A DIODE BRIDGE Exciter field A n o d e A diode in good Rh.

  • Page 361: Dismantling, Reassembly

    LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS SERVICING - MAINTENANCE 4.6 - Dismantling, reassembly 4.6.3 - Access to diodes (see sections 5.4.1. & 5.4.2.) - Open the air inlet louvre (51) - Disconnect the diodes.

  • Page 362: Replacing The De Bearing On

    LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS SERVICING - MAINTENANCE 4.6.6 - Replacing the DE bearing on 4.6.9 - Reassembling the rotor two-bearing machines On single bearing machines : - Mount the rotor (4) in the stator (1) (see drawing below) - Remove the screws (31) and (62).

  • Page 363: Installation And Maintenance Of The Pmg

    LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS SERVICING - MAINTENANCE 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.

  • Page 364: Table Of Characteristics

    LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS SERVICING - MAINTENANCE 4.8 - Table of characteristics 4.8.2 - Average values for LSA 47.1 Resistances at 20°C (Ω) Table of average values Alternator - 4 poles - 50 Hz - Standard winding No. 6. LSA 47.1 Stator L/N Rotor...

  • Page 365: Spare Parts

    LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS SPARE PARTS 5 - SPARE PARTS 5.3 - Accessories 5.3.1 - Space heater for use when stopped 5.1 - First maintenance parts The space heater must start up as soon as the alternator Emergency repair kits are available as an option.

  • Page 366: Single Bearing

    LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS SPARE PARTS 5.4 - Exploded view, parts list 5.4.1 - Single bearing Ref. Description Ref. Description Stator assembly Terminal block with terminals Rotor assembly AVR support bracket Turbine Voltage regulator (AVR)

  • Page 367: Two-Bearing

    LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS SPARE PARTS 5.4.2 - Two-bearing Ref. Description Ref. Description Stator assembly Exciter armature Rotor assembly Crescent support Turbine Terminal support Balancing disc Console support Lifting ring Terminal block with terminals Shaft extension key...
  • Page 368 LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS SPARE PARTS...
  • Page 369 LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS SPARE PARTS...
  • Page 370 MOTEURS LEROY-SOMER 16015 ANGOULÊME CEDEX - FRANCE Imprimerie MOTEURS LEROY-SOMER R C A N G O U L E M E B 6 7 1 8 2 0 2 2 3...

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