English

User and maintenance manual
for generating sets
J88 - APM303
33533309401NE_12
Industrial Diesel Generator Set – J88
50 Hz
RATINGS 400 V - 50 Hz
Standby kVA 88
kWe 70
Prime kVA 80
kWe 64
Benefits & features GENERAL SPECIFICATIONS
KOHLER premium quality Engine brand JOHN DEERE

 Design offices using the latest technical innovations Alternator commercial brand KOHLER
 Modern fully certified factories Voltage (V) 400/230
 A cutting edge laboratory Standard Control Panel APM303
 The generating set, its components and a wide range of options
Optional control panel APM403
have been fully developed, prototype tested, factory built, and
production tested Optional Control Panel M80
 Approved for use with HVO (Hydrotreated Vegetable Oil) Optional control panel Terminal block
according to EN15940
Consumption @ 100% load ESP (L/h) * 21
KOHLER premium performances
 Optimized and certified sound levels
Consumption @ 100% load PRP (L/h) * 19
 Reliable power, even in extreme conditions
 Optimized fuel consumption Emission level Fuel consumption optimization
 Compact footprint
 Best quality of electricity, high starting and loading capacity, Type of Cooling Mechanical driven fan
according to ISO8528-5 Performance class G3
 Robust base frames and high-quality enclosures
 Protection of installations and people
 Approved in line with the most stringent standards GENERATOR SETS RATINGS
Engines
 Premium level engines, in-house or from strong partners
 High power density, small footprint Standby Rating Prime Rating
 Low temperature starting capability
 Long maintenance interval Voltage PH Hz kWe kVA Amps kWe kVA
415/240 3 50 70 88 122 64 80
Alternator
400/230 3 50 70 88 127 64 80
 Provide industry leading motor starting capability
 Made in Europe J88 380/220 3 50 70 88 134 64 80
240 TRI 3 50 70 88 212 64 80
 Built with a class H insulation and IP23
230 TRI 3 50 70 88 221 64 80
Cooling
220 TRI 3 50 70 88 231 64 80
 A compact and complete solution using a mechanically driven
radiator fan DIMENSIONS COMPACT VERSION
 Designed or optimized by KOHLER Length (mm) 1950
 High temperature and altitude product capacity available
Width (mm) 1084
Base frame and enclosure
Height (mm) 1455
 High quality steel with enhanced corrosion resistance
 Highly durable QUALICOAT-certified epoxy paint Tank capacity (L) 190
 Minimum 1000 hours of resistance to salt spray in accordance Dry weight (kg) 985
with ISO12944
DIMENSIONS SOUNDPROOFED VERSION NA
 Ergonomic access to allow easy maintenance and
connection of the generator Type soundproofing M138
 Robust design optimized for transportation Length (mm) 2572
Width (mm) 1126
Height (mm) 1571
Tank capacity (L) 190
Dry weight (kg) 1310
Acoustic pressure level @1m in dB(A) 50Hz
79
(75% PRP)
Acoustic pressure level @7m in dB(A) 50Hz
67
(75% PRP)
Reference Conditions: 25°C Air Inlet Temperature, 40°C Fuel Inlet Temperature, 100 kPa Barometric Pressure; 10.7 g/kg of dry air Humidity. Intake Restriction
set to maximum allowable limit for clean filter; Exhaust Back pressure set to maximum allowable limit; Fuel density at 0.85 kg/L.
Data was taken from a single engine test according to the test methods, fuel specification and reference conditions stated above and is subjected to
instrumentation and engine-to-engine variability. Test conducted with alternate test methods, instrumentation, fuel or reference conditions can yield
different results. Data and specifications subject to change without notice.
50 Hz
°°°°°
50 Hz
Engine
General Lubrication System

Engine brand JOHN DEERE Oil system capacity including filters (l) 13.50
Engine ref. 4045TSG20 * Min. oil pressure (bar) 1
Air inlet system Turbo Max. oil pressure (bar) 5
Fuel Diesel Fuel/HVO Oil sump capacity (l) 12.50
Fuel consumption Oil consumption 100% ESP 50Hz (l/h) 0.0540
Emission level
optimization
Cylinder configuration L Air Intake system
Number of cylinders 4 Max. intake restriction (mm H2O) 625
Displacement (l) 4.48 Combustion air flow (l/s) 91
Bore (mm) * Stroke (mm) 106 * 127 Exhaust system
Compression ratio 17 : 1 PRP ESP
Speed 50Hz (RPM) 1500 Exhaust gas flow (L/s) 241 265
Maximum stand-by power at rated RPM (kW) 85 Exhaust gas temperature @ ESP (°C) 590
Injection Type Direct Max. exhaust back pressure (mm H2O) 750
Governor type Mechanical Cooling system
Air cleaner type, models Dry Radiator & Engine capacity (l) 23.60
Fuel system Fan power 50Hz (kW) 2.50
Maximum fuel pump flow (l/h) 108 Fan air flow w/o restriction (m3/s) 3.10
Max head on fuel return line (m fuel) 1 Available restriction on air flow (mm H2O) 20
Consumption with cooling system Type of coolant Glycol-Ethylene
Fuel consumption @ ESP Max Power (l/h) 21.50 Radiated heat to ambiant (kW) 10
Fuel consumption @ PRP Max Power (l/h) 19.20 Heat rejection to coolant HT (kW) 41
Fuel consumption @ 75% of PRP Power (l/h) 14.60 Max coolant temperature, Shutdown (°C) 105
Fuel consumption @ 50% of PRP Power (l/h) 10.10 Thermostat begin of opening HT (°C) 82
Thermostat end of opening HT (°C) 94
Emissions Cooling system and charge air cooler
Emission CO (g/kW.h) 0.70 Radiator & Engine capacity (l) 23.60
Emission NOx (g/kW.h) 11.10 Fan power 50Hz (kW) 2.50
Emission HC (g/kW.h) 0.30 Fan air flow w/o restriction (m3/s) 3.10
Available restriction on air flow (mm H2O) 20
Type of coolant Glycol-Ethylene
Radiated heat to ambiant (kW) 10
Heat rejection to coolant HT (kW) 41
Coolant capacity HT, engine only (l)
Outlet coolant temperature (°C)
Max coolant temperature, Shutdown (°C) 105
Max. pressure at inlet of HT water pump (mbar)
Thermostat begin of opening HT (°C) 82
CAC Heat Rejection (kW)
Cooling system (HT/LT)
Radiator & Engine capacity (l) 23.60
Fan power 50Hz (kW) 2.50
Fan air flow w/o restriction (m3/s) 3.10
Available restriction on air flow (mm H2O) 20
50 Hz
Type of coolant Glycol-Ethylene
Radiated heat to ambiant (kW) 10
Heat rejection to coolant HT (kW) 41
Coolant capacity HT, engine only (l)
Outlet coolant temperature (°C)
Max coolant temperature, Shutdown (°C) 105
Max. pressure at inlet of HT water pump (mbar)
Thermostat begin of opening HT (°C) 82
Heat rejection to coolant LT (kW)
LT circuit flow rate (l/min)
Coolant capacity LT, engine only (l)
* Engine reference may be partially modified depending on genset

application, options selected by the customer and lead time required.
50 Hz
Alternator Specifications Alternator Standard Features
Alternator commercial brand KOHLER - All models are brushless, rotating-field alternators
Kohler Alternator description KH00590T
- NEMA MG1, IEEE, and ANSI standards compliance for
Number of pole 4
temperature rise and motor starting
Number of bearing Single Bearing
Technology Brushless
- The AVR voltage regulator provides superior short
circuit capability
Indication of protection IP23
Insulation class H - Self-ventilated and dip proof construction
Number of wires 06 - Superior voltage waveform
AVR Regulation Yes
Note: See Alternator Data Sheets for alternator application data
Coupling Direct and ratings, efficiency curves, voltage dip with motor starting
Capacity for maintaining short circuit curves, and short circuit decrement curves.
Yes
at 2.7 ln for 5 s
Application data
Overspeed (rpm) 2250
Power factor (Cos Phi) 0.80
Voltage regulation at established
0.50
rating (+/- %)
Wave form : NEMA=TIF <50
Wave form : CEI=FHT <2
Total Harmonic Distortion in no-load
<3.5
DHT (%)
Total Harmonic Distortion, on linear
<5
load DHT (%)
Recovery time (Delta U = 20%
500
transcient) (ms)
Performance datas
Continuous Nominal Rating 40°C
80
(kVA)
Unbalanced load acceptance ratio
100
(%)
Peak motor starting (kVA) based on x% voltage dip power factor at 0.3
50 Hz
Dimensions compact version
Length (mm) * Width (mm) * Height (mm) 1950 * 1084 * 1455

Dry weight (kg) 985
M138 - Dimensions soundproofed version

Acoustic pressure level @1m in dB(A) 50Hz (75% PRP) 79
Sound power level guaranteed (Lwa) 50Hz (75% PRP) 96
Dimensions DW compact version

M138 - Dimensions DW soundproofed version

M138 - Dimensions DW 48h soundproofed version

* dimensions and weight without options
50 Hz
Basic It is used as a basic terminal block for connecting a control unit. Offers the
following functions:
terminal block - emergency stop button
- customer connection terminal block
- CE certified
The M80 is a dual-function control panel. It can be used as a basic terminal block
M80 for connecting a control unit and as an instrument panel with a direct read
facility, with displays giving a global view of your generating set's basic
parameters. Offers the following functions:
- Engine parameters: tachometer, working hours counter, coolant
temperature indicator, oil pressure indicator
- emergency stop button
- customer connection terminal block
- CE certified
The APM303 is a versatile unit which can be operated in manual or automatic

APM303 mode. It offers the following features:
- Measurements: phase-to-neutral and phase-to-phase voltages, fuel
level (In option : active power currents, effective power, power factors,
Kw/h energy meter, oil pressure and coolant temperature levels)
- Supervision: Modbus RTU communication on RS485
- Reports: (In option : 2 configurable reports)
- Safety features: Overspeed, oil pressure, coolant temperatures,
minimum and maximum voltage, minimum and maximum frequency
(Maximum active power P<66kVA)
- Traceability: Stack of 12 stored events
For further information, please refer to the data sheet for the APM303
BASIC GENERATING SET AND POWER PLANT CONTROL

The APM403 is a versatile control unit which allows operation in manual or
APM403 automatic mode
- Measurements : voltage and current
- kW/kWh/kVA power meters
- Standard specifications: Voltmeter, Frequency meter.
- Optional : Battery ammeter.
- J1939 CAN ECU engine control
- Alarms and faults: Oil pressure, Coolant temperature, Overspeed, Start-
up failure, alternator min/max, Emergency stop button.
- Engine parameters: Fuel level, hour counter, battery voltage.
- Optional (standard at 24V): Oil pressure, water temperature.
- Event log/ Management of the last 300 genset events.
- Mains and genset protection
- Clock management
- USB connections, USB Host and PC,
- Communications : RS485 INTERFACE
- ModBUS protocol /SNMP
- Optional : Ethernet, GPRS, remote control, 3G, 4G,
- Websupervisor, SMS, E-mails
50 Hz
STANDARD SCOPE OF SUPPLY

All our gensets are fitted with:
- Industrial water cooled DIESEL engine

- Electric starter & charge alternator
- Standard air filter
- Schneider or ABB electric circuit breaker, adapted to the short-circuit current of the generating set
- Single bearing alternator IP 23 T° rise/ insulation to class H/H
- Welded steel base frame with 85% vibration attenuation mounts
- 4 lifting points on the chassis, lifting bar on the top included from 165 kVA ESP or optional
- highly durable QUALICOAT certified epoxy paint
- frame height optimized to allow it to be moved safely by forklift
- enclosure made of new high-quality European steel with enhanced corrosion resistance
- IP 64 locks, made from stainless materials
- enclosures and base frames tested and analyzed by the French Corrosion Institut
- 100% of tanks tested for permeability
- Personal protection ensured by protective grilles on hot and rotating parts
- Separate 9 dB(A) silencer
- Fuel tank welded inside the genset frame
- Retention bund included for gensets up to 110 kVA ESP
- Charged DC starting battery with electrolyte
- Emergency stop button on the outside
- Flexible fuel lines & lub oil drain cock
- Exhaust outlet with flexible and flanges
- User’s manual (1 copy)
- Packing under plastic film
- Delivered with oil and antifreeze liquid
CODES AND STANDARDS

Engine-generators set is designed and manufactured in facilities certified to standards ISO9001:2015 & ISO14001:2015. The generator sets and
its components are prototype-tested, factory built and production tested and are in compliance with the relevant standards:
- Machinery Directive 2006/42/EC of May 17th 2006

- EMC Directive2014/30/UE
- Safety objectives set out in the Low Voltage Directive 2014/35/UE
- EN ISO 8528-13, EN 60034-1, EN 61000-6-1, EN 61000-6-2, EN 61000-6-3, EN 55011, EN 1679-1 et EN 60204-1
POWER RATINGS DEFINITION according to ISO8528-1 (2018-02 edition) and ISO-3046-1
Emergency Standby Power (ESP): The standby rating is applicable to varying loads for the duration of a power outage. There is no overload
capability for this rating. Average load factor per 24 hours of operation is <70%.
Prime Power (PRP): At varying load, the number of generator set operating hours is unlimited. A 10% overload capacity is available for one
hour within 12 hour of operation. Average load factor per 24 hours of operation is <70%.
50 Hz
TERMS OF USE
According to the standard, the nominal power assigned by the genset is given for 25°C Air Intlet Temperature, of a barometric pressure of 100
kPA (100 m A.S.L), and 30% relative humidity. For particular conditions in your installation, refer to the derating table.
WARRANTY INFORMATIONS
Standard Warranty Period:
- for Products in "back-up" service

o 30 months from the date the Product leaves the plant
o 24 months from the Product’s commissioning date
o 1,000 running hours
The warranty expires when one of the above conditions is met.
- for Products in “prime” or "continuous" service (continuous supply of electricity, either in the absence of any normal electricity grid
or to complement the grid),
o 18 months from the date the Product leaves the plant
o 12 months from the Product’s commissioning date
o 2,500 running hours
The warranty expires when one of the above conditions is met.
For more details regarding conditions of application and scope of the warranty please refer to our General “terms & conditions of sales”.
General and safety manual
Generating set
General-Safety-Installation
Supplied by
33532000201_11_1
IZIDOC-1194_EN-08/08/2023
Introduction
Contents
CONTENTS .............................................................................................................................................................................. 1
SECTION 1. INTRODUCTION ................................................................................................................................................... 4
1.1 Organization of the documentation ................................................................................................................................... 4
1.2 Warnings regarding all operations on the generating set .................................................................................................. 4
1.3 Contact your authorized Kohler distributor/dealer for service ........................................................................................... 4
SECTION 2. MEANING OF THE PICTOGRAMS ON THE GENERATING SET ....................................................................... 5
SECTION 3. EQUIPMENT DESCRIPTION ................................................................................................................................ 6
3.1 Identification plates ........................................................................................................................................................... 6
3.1.1 Location of plates on generating sets with and without an enclosure .................................................................... 6
3.1.2 Location of plates on containerized generating sets .............................................................................................. 6
3.1.3 Identifying sets ...................................................................................................................................................... 7
3.1.4 Identifying generating set components .................................................................................................................. 7
3.2 Generating sets with and without an enclosure ................................................................................................................ 8
3.2.1 Enclosed generating set ........................................................................................................................................ 8
3.2.2 Generating set without enclosure .......................................................................................................................... 9
3.3 Containerised generating sets ........................................................................................................................................ 10
3.3.1 ISO 20 and ISO 40 containers ............................................................................................................................. 10
3.3.2 CPU 40 containers .............................................................................................................................................. 11
3.3.3 CIR 20 containers ................................................................................................................................................ 11
SECTION 4. HANDLING ......................................................................................................................................................... 12
4.1 Safety instructions for handling ....................................................................................................................................... 12
4.2 Preparing for unloading .................................................................................................................................................. 12
4.3 Moving the generating set by lifting ................................................................................................................................ 12
4.3.1 Preparing for handling ......................................................................................................................................... 12
4.3.2 Positioning of the lifting points ............................................................................................................................. 13
4.3.3 Handling .............................................................................................................................................................. 14
4.4 Moving the generating set by fork lift .............................................................................................................................. 14
4.5 Moving the generating set on rollers ............................................................................................................................... 14
SECTION 5. TRANSPORT ...................................................................................................................................................... 15
5.1 Preparing for transport .................................................................................................................................................... 15
5.2 Preparing for unloading .................................................................................................................................................. 15
5.3 Road transport ................................................................................................................................................................ 16
5.3.1 Anchoring enclosed generating sets.................................................................................................................... 16
5.3.1.1 Flatbed truck, road truck ........................................................................................................................ 16
5.3.1.2 Lorry with trailer truck or semi-trailer truck............................................................................................. 16
5.3.2 Transporting a generating set with its fuel (ADR) ................................................................................................ 17
5.4 Rail transport .................................................................................................................................................................. 17
5.5 Shipping .......................................................................................................................................................................... 17
5.5.1 Sea transportation of generating sets .................................................................................................................. 17
5.5.2 Sea transportation of generating sets in containers ............................................................................................ 17
5.5.3 Sea transportation of accessories and spare parts ............................................................................................. 18
5.6 Air transport .................................................................................................................................................................... 18
SECTION 6. STUDIES TO BE PERFORMED FOR INSTALLATION ..................................................................................... 18
6.1 Requirements to be observed to install a generating set ................................................................................................ 18
6.2 Installing a generating set indoors .................................................................................................................................. 19
6.2.1 Reduce noise and vibrations ............................................................................................................................... 19
6.2.2 Venting the exhaust gas ...................................................................................................................................... 20
6.2.3 Planning the fuel supply ...................................................................................................................................... 21
6.2.4 Ensuring cooling .................................................................................................................................................. 22
6.2.5 Ventilate the room ............................................................................................................................................... 23
6.3 Installing an enclosed generating set.............................................................................................................................. 23
6.4 Installing a containerised generating set ......................................................................................................................... 24
6.5 Specific context of seismic installation (IBC) .................................................................................................................. 24
SECTION 7. INITIAL COMMISSIONING ................................................................................................................................. 25
7.1 Electrically connecting a generating set .......................................................................................................................... 25
7.1.1 Risk of electrocution ............................................................................................................................................ 25
7.1.1.1 Safety precautions in case of electrical shock ....................................................................................... 26
7.1.2 Low voltage installations...................................................................................................................................... 26
7.1.2.1 Low-voltage wiring ................................................................................................................................. 26
7.1.2.1.1 Low voltage earthing diagrams ................................................................................................................ 30
1194_EN 2023-08-08 1
Introduction
7.1.3 High voltage installations ..................................................................................................................................... 30

7.1.3.1 High-voltage installation ........................................................................................................................ 30
7.1.3.2 High voltage earthing diagrams ............................................................................................................. 31
7.1.4 Temporary power supply of an installation without Automatic Transfer Switch ................................................... 31
7.2 Fluids: fuels, oils, coolants, DEF ..................................................................................................................................... 32
7.2.1 Fuel specifications ............................................................................................................................................... 32
7.2.2 Oil grades ............................................................................................................................................................ 34
7.2.3 Coolant specifications.......................................................................................................................................... 34
7.2.4 DEF specifications ............................................................................................................................................... 34
7.2.5 Transportation and storage of the fluids .............................................................................................................. 35
7.3 Commissioning, first use of the generating set ............................................................................................................... 35
7.3.1 Checking the electrical connections .................................................................................................................... 35
7.3.2 Checking the mechanical components ................................................................................................................ 35
7.3.3 Operation of the generating set ........................................................................................................................... 35
7.3.4 Preparing the generating set for starting ............................................................................................................. 36
7.3.5 Performing the relevant tests and checks............................................................................................................ 36
7.3.5.1 Starting test ........................................................................................................................................... 36
7.3.5.2 ON load test .......................................................................................................................................... 36
SECTION 8. OPERATION ....................................................................................................................................................... 37
8.1 Safety instructions for the operation of the generating set .............................................................................................. 37
8.1.1 Risk of Electromagnetic interference ................................................................................................................... 37
8.1.2 Risk of electrocution ............................................................................................................................................ 37
8.1.3 Serious risks of intoxication ................................................................................................................................. 37
8.1.4 Risks of crushing, shearing or catching ............................................................................................................... 38
8.1.5 Risks of burns ...................................................................................................................................................... 38
8.1.6 Risks of fire and explosion ................................................................................................................................... 38
8.1.7 Risks relating to noise ......................................................................................................................................... 39
8.1.8 Specificity of gas operation .................................................................................................................................. 39
8.2 Preparing the generating set for starting ......................................................................................................................... 39
8.3 Starting the generating set .............................................................................................................................................. 39
8.4 Checking the generating set after startup ....................................................................................................................... 40
8.5 Minimizing operation at no load and below load ............................................................................................................. 40
8.5.1 Conscious Care™ maintenance program with KD series .................................................................................... 40
8.5.2 Low Load operation with all other models (not KD series)................................................................................... 41
8.5.3 Conscious Care™, No-Load and Low-Load Exercise ......................................................................................... 42
8.6 Switching the generating set off ...................................................................................................................................... 42
8.6.1 Normal shutdown ................................................................................................................................................ 42
8.6.2 Emergency stop .................................................................................................................................................. 42
SECTION 9. MAINTENANCE .................................................................................................................................................. 43
9.1 Maintenance safety instructions...................................................................................................................................... 43
9.1.1 Protecting personnel............................................................................................................................................ 43
9.1.2 Preserving the equipment.................................................................................................................................... 44
9.2 Planning maintenance .................................................................................................................................................... 44
9.2.1 Designing a suitable maintenance schedule ....................................................................................................... 44
9.2.2 Example maintenance schedule .......................................................................................................................... 45
9.3 Performing maintenance ................................................................................................................................................. 46
9.3.1 Checking the good condition and cleanliness of the entire installation ................................................................ 46
9.3.2 Performing the relevant tests and checks............................................................................................................ 47
9.3.2.1 Start test ................................................................................................................................................ 47
9.3.2.1.1 Start test with Conscious Care™ maintenance program (KD series only) ................................................ 47
9.3.2.1.2 Start test with all other models (not KD series) ........................................................................................ 48
9.3.2.2 Emergency Stop Test ............................................................................................................................ 48
9.3.2.3 ON Load Test ........................................................................................................................................ 48
9.3.2.3.1 ON load test with Conscious Care™ maintenance plan (KD series generator sets only) .......................... 48
9.3.2.3.2 ON load test with all other models (not KD series) ................................................................................... 49
9.3.3 Fuel System ........................................................................................................................................................ 49
9.3.3.1 Topping up the fuel ................................................................................................................................ 49
9.3.3.2 Fuel pre-filters ....................................................................................................................................... 50
9.3.3.2.1 Pre-filter maintenance interval ................................................................................................................. 50
9.3.3.2.2 Draining water ......................................................................................................................................... 51
9.3.3.2.3 Replace the filter ..................................................................................................................................... 51
9.3.4 Oil circuit.............................................................................................................................................................. 52
9.3.4.1 Draining the oil ...................................................................................................................................... 52
9.3.4.2 Topping up the oil .................................................................................................................................. 53
9.3.5 Cooling system .................................................................................................................................................... 53
9.3.5.1 Draining the coolant .............................................................................................................................. 54
9.3.5.2 Topping up the coolant .......................................................................................................................... 54
2 1194_EN 2023-08-08
Introduction
9.3.6 Starter batteries ................................................................................................................................................... 55

9.3.6.1 Cleaning the starter battery ................................................................................................................... 55
9.3.6.2 Adjusting the electrolyte level ................................................................................................................ 55
9.3.6.3 Charging the starter battery ................................................................................................................... 56
9.3.6.4 Battery charger (option) ......................................................................................................................... 56
9.3.7 Air filter for dusty atmosphere (option)................................................................................................................. 56
9.3.7.1 Maintenance indicator (option) .............................................................................................................. 57
9.3.7.2 Replacing the filter element ................................................................................................................... 57
9.3.8 Air coolers (according to the generating set model) ............................................................................................ 58
9.3.9 Cleaning the external panels ............................................................................................................................... 59
9.3.10 View of the drainage holes .................................................................................................................................. 60
9.3.11 Hoses .................................................................................................................................................................. 61
9.3.12 Exhaust mufflers .................................................................................................................................................. 61
9.3.13 Fluid recovery and retention tanks (option) ......................................................................................................... 62
SECTION 10. RAPID IDENTIFICATION OF MINOR MALFUNCTIONS ................................................................................... 63
10.1 Generating set verifications ............................................................................................................................................ 63
10.2 Starter batteries (option) ................................................................................................................................................. 64
10.3 Manual pump (option) ..................................................................................................................................................... 64
10.4 Electric pump (option) ..................................................................................................................................................... 65
SECTION 11. STORAGE/REMOVAL FROM STORAGE .......................................................................................................... 65
11.1 Preserving the equipment ............................................................................................................................................... 65
11.2 Depreserving the equipment ........................................................................................................................................... 65
11.3 Transportation and storage of the fluids ......................................................................................................................... 66
SECTION 12. DECOMMISSIONED GENERATING SET .......................................................................................................... 66
SECTION 13. GLOSSARY ........................................................................................................................................................ 66
SECTION 14. TABLE OF ILLUSTRATIONS ............................................................................................................................. 71
1194_EN 2023-08-08 3
Introduction
Section 1. Introduction
1.1 Organization of the documentation

This general and safety manual is made up of the following elements:
• Safety instructions for personal protection,
• Description of the main components of generator sets,
• Instructions regarding:
o the transport and handling of generator sets;
o the installation of generator sets;
o preparing generator sets prior to their commissioning;
o the fuels, oils and coolants to be used;
o maintenance of the electrical generator set;
o maintenance of the most common optional equipment.
Documentation about the engines fitted in the generator sets is from the original manufacturer. Sometimes this original
manufacturer documentation includes information about the control units: As our generator sets are fitted with control units that
are specific to the generator sets, only the information that appears in the documentation for the generator set control units should
be taken into consideration.
In this general and safety manual, warning messages are used in the following manner:
DANGER RISK TO THE HEALTH OF THOSE CONCERNED

DANGER OF DEATH (if appropriate)
Indicates an imminent danger which may result in death or serious injury. Failure to follow
[Appropriate pictogram(s)]
the instruction shown may pose serious risks to the health and life of those concerned.
IMPORTANT Material damage

[At-risk equipment]
Indicates an at-risk situation. Failure to follow the instructions provided may result in minor
injuries to those concerned or material damage.
The information contained in this documentation is taken from technical data available at the time of print. This information is
subject to change without warning. Furthermore, the photos shown in this manual have no contractual value.
Words followed by the ⃰ symbol are defined in the glossary at the end of the manual.
1.2 Warnings regarding all operations on the generating set

• Observe the applicable standards, local regulations and legislation regarding the use of the generating set.
• Control operations, monitoring and maintenance must only be carried out on the equipment by qualified, authorized
professional personnel.
• Read the generating set user and maintenance manual carefully.
• Observe the safety instructions supplied in the operating and maintenance manual for the generating set.
• Be qualified and authorized to perform the different operations described in the operating and maintenance manual for
the generating set.
• Ensure that no setting is changed unless explicitly indicated in the operating and maintenance manual for the generating set.
• Provide the necessary instructions to anyone who is required to carry out operations on the generating set.
• Ensure that no child may come near the generating set, even when it is stopped.
DANGER RISK TO THE HEALTH OF THOSE CONCERNED

DANGER OF DEATH
Read and follow the guidelines given in the documentation supplied.
Keep the documents provided and make them accessible at any time to anyone who must
work on the equipment or on the installation.
1.3 Contact your authorized Kohler distributor/dealer for service

If you have any doubts regarding the instructions or the operations to be performed, use the information provided on the nameplate
of the generator set and contact your nearest authorized Kohler distributor/dealer for service.
Our qualified authorized Kohler distributor/dealer for service can:
• Answer any questions regarding the operations to be performed;
• Supply spare parts and retrofitting parts;
• Ensure preventive and corrective maintenance of the generator set;
• Ensure all repairs on the generator set.
4 1194_EN 2023-08-08
Meaning of the pictograms on the generating set
Section 2. Meaning of the pictograms on the generating set
Reading the
DANGER: manual for the DANGER:
equipment is diesel fuel fill with oil fill with coolant
general panel electricity
compulsory
DANGER:
DANGER: DANGER:
rotating or moving drain the fuel drain the oil drain the coolant
high temperature Automatic starting
parts
DANGER: DANGER:
external fuel drain the retention retention
explosive corrosive ground container high
connections container
materials, risk of materials level
explosion
PROHIBITED: PROHIBITED:
DANGER:
Water spray Naked flames
Flammable fill up with coolant
prohibited, jet prohibited, inspection flap
products fuel supply selection before preheating
washing smoking
valve
prohibited prohibited
DANGER:
Compulsory: Compulsory: Compulsory: Important:
Do not open the
sight and hearing battery isolating
Consult the sight protection doors when the open the doors before
protection starting the generator set switch
information guide compulsory generator set is
compulsory operating
Lashing:
Compulsory: Compulsory: transport bracket, Point for passing through refilling the
CLASS 3 DANGER:
compulsory lifting forklift required for to be removed transport straps and diesel exhaust
Flammable liquid
point lifting before installation anchorages for generator fluid (DEF)
sets
Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain
how to act safely. The decals are shown throughout this publication to improve operator recognition. Replace missing or damaged
decals.
1194_EN 2023-08-08 5
Equipment description
Section 3. Equipment description
3.1 Identification plates

3.1.1 Location of plates on generating sets with and without an enclosure
The nameplate for generator sets with and without enclosures is affixed to the lower section of the skid.
Figure 1: Position of the nameplate for generator sets with and without enclosures
3.1.2 Location of plates on containerized generating sets
The nameplate for containers is affixed next to the emergency stop pushbutton.
Figure 2: Position of the nameplate for generator sets in a container
6 1194_EN 2023-08-08
3.1.3 Identifying sets
Generator sets and their components are identified by means of Nameplates.
Before contacting our authorized Kohler distributor/dealer for service, you must be familiar with the information shown on the
Nameplates of the generator sets. Please make a note of all of this information.
The exact identification rules for each major component (engine, alternator, etc.) are described in each manufacturer's own
documentation.
Figure 3: Example of a generator set Nameplate
C:
- rated voltage (V)
- rated frequency (Hz)
- equipment rotation speed (RPM)
- rated power factor (Cos Phi ⃰)
B:
- number of phases
manufacturer name
A: - rated power (kVA and kW)
model
type of equipment - PRP = main power ⃰
version
- ESP = emergency power ⃰
weight (kg)
- rated current (A)
- maximum ambient temperature for the rated power (°C)
- maximum altitude of the site above sea level (m) for the rated
power
- performance class⃰
E:
D:
Non-CE standard marking F: G:
year of manufacture
(example: EAC for Russia) sound pressure sound power
serial number
CE marking
3.1.4 Identifying generating set components
Each component of a generator set (engine, alternator) is equipped with a nameplate. For detailed information about these
nameplates, please see the manufacturer's documentation.
1194_EN 2023-08-08 7
3.2 Generating sets with and without an enclosure

The views in this sub-section are advisory only. The layout of the components (engine, alternator, etc.) may vary from one
generator set to the other.
3.2.1 Enclosed generating set
6
3
5
15
13
14
10
12
11
Figure 4: General description of a generator set with enclosure
1 Lifting eye 6 Engine 11 Skid

2 Air filter 7 Protective grille for rotating parts 12 Nameplate
3 Alternator 8 Exhaust 13 Circuit breaker
4 Vibromounts 9 Radiator 14 Console
5 Starter battery 10 Enclosure 15 Control unit
8 1194_EN 2023-08-08
3.2.2 Generating set without enclosure
5 2
8
12
11
10
Figure 5: General description of a generator set without enclosure
1 Air filter 5 Engine 9 Frame

2 Alternator 6 Protective grille for rotating parts 10 Nameplate
3 Vibromounts 7 Control unit 11 Circuit breaker
4 Starter battery 8 Radiator 12 Console
1194_EN 2023-08-08 9
3.3 Containerised generating sets

The views in this sub-section are advisory only. The layout of our containers may vary. Refer to the overall plans for the installation.
3.3.1 ISO 20 and ISO 40 containers

• Compliant with ISO/CT 104 standards and certified to C.S.C ⃰.
• Approved for sea transportation.
silencer console
AIPR ⃰
sound traps
soundproof air
inlet grille
radiator
Figure 6: Example of an ISO 20 container
fuel tank
silencer
sound traps
soundproof air inlet AIPR ⃰

grille radiator
Figure 7: Example of an ISO 40 container
10 1194_EN 2023-08-08
3.3.2 CPU 40 containers

• Compact, designed for low noise level and exceptional accessibility.
• Dimensions and ISO ⃰ corners.
• Possibility of transportation and handling using ISO equipment.
sound traps
air inlet grille

radiator
Figure 8: Example of a CPU 40 container
3.3.3 CIR 20 containers

• Not certified to C.S.C ⃰.
• On request, compliant with ISO/CT 104.
• Low noise level.
• Well suited to mobile and rental applications.
radiator
silencer
soundproof air
inlet grille
tank drainage hole
non-retention zone
Figure 9: Example of a CIR 20 container
1194_EN 2023-08-08 11
Handling
Section 4. Handling
DANGER HANDLING PHASE – RISK OF DROPPING

DANGER OF DEATH
Failure to observe the safety instructions during handling phases can result in significant
material damage, or even put the health and life of those concerned at risk.
4.1 Safety instructions for handling

• Equipment handling operations must be carried out by qualified and authorized professional personnel.
• Select the appropriate handling equipment and accessories according to the type of equipment being handled.
• For handling equipment and accessories, check:
o the handling capacity (maximum authorized weight);
o good working order.
• Ensure that the handling area is completely clear.
• Observe the handling instructions described in this manual.
• Observe the safety instructions corresponding to the pictograms shown on the equipment to be handled.
4.2 Preparing for unloading

1. Select the generator set unloading site according to the following criteria:
a. Proximity between the generator set unloading site and its final position of use;
b. Ease of movement between the generator set unloading site and its final position of use.
2. If necessary, mount beams or distribution plates that are strong enough to support the load of the assembly.
3. Always follow the handling instructions in the "Handling" chapter of this manual.
4. If the transportation equipment needs to be moved to make unloading easier, ensure that the generator set to be handled
is properly secured to it.
4.3 Moving the generating set by lifting

Lifting ring – Generating sets
• Always check the condition of the lifting ring and the sheet metal around the ring
before each use: the ring and sheet metal must be clean and free of rust. If in
doubt, do not use and involve one of our authorized Kohler distributor/dealer for
service.
• The lifting rings are dimensioned to handle the generating set only: drain any high
capacity tanks, do not use the lifting rings to lift a generating set fitted with a trailer
or any other complementary equipment.
• The lifting rings are designed to lift vertically only: the angle between the enclosure
and the lifting accessories must be at a right angle (90°).
4.3.1 Preparing for handling
1. Be qualified and authorized and use suitable personal protection equipment (gloves, helmets, shoes,
etc.).
2. If fitted, remove the transport brackets of the generator set.
3. Prepare the lifting device (lanyards, suction cups or other equipment), ensuring that the maximum
working load is adapted to the weight of the load.
4. Secure the lifting accessories only to the generator set's lifting points marked by a pictogram.
5. Without lifting the generator set, slightly tension the lifting device and check:
a. the good condition of the lifting points and correct locking of the attachment points;
b. the good condition and secure attachment of the lifting device;
c. the absence of friction or constraints which could damage the generator set (in particular for
generator sets without enclosures).
In the event of a fault, immediately interrupt the lifting procedure and resolve the problem
encountered.
6. Perform the handling once all checks have been completed.
12 1194_EN 2023-08-08
Handling
4.3.2 Positioning of the lifting points

GENERATOR SET WITHOUT ENCLOSURE:
Generator set with 4 lifting holes Generator set with 4 lifting brackets
GENERATOR SET WITH ENCLOSURE:
Enclosure with 1 lifting ring Enclosure with 2 lifting brackets Enclosure with 4 lifting brackets
ENCLOSURES M137/M138 CONTAINER:

Option
Central upper lifting point is an option.

Lifting via the ISO ⃰ corners must be carried out with a spreader
Possibility to sling by the frame with a spreader
1194_EN 2023-08-08 13
Handling
4.3.3 Handling

Slings
• The maximum opening angle of the slings is 30° for generating sets with enclosure
and lifting brackets.
• The slings must be 2 times longer than the width of the generating set enclosure.
1. Ensure that the handling area is clear (no people or objects).

2. Lift the generating set carefully and without jerking, taking care to avoid any impacts.
3. Minimizing the swing of the generating set, direct it towards the chosen site.
4. Carefully set down the generating set while continuing to position it.
5. Release the tension on the lifting device before detaching it from the lifting points.
4.4 Moving the generating set by fork lift

IMPORTANT
Material damage
Generator sets in containers
• Handle containers whose fork lift zones are marked with a safety pictogram.
1. Be qualified and authorized to perform this operation.

2. Position the forks of the handling equipment:
a. either under the generator set frame;
b. or, if fitted, in the fork lift zones marked by the safety pictograms.
2. Ensure that:
a. only the frame structure is resting on the forks;
b. the forks of the handling equipment are longer than the width of the frame.
3. Lift and handle the generator set carefully.
4. Set the generator set down in its unloading position.
M137 ENCLOSURE
65 mm
Height of forklift pockets is limited

at à 65 mm.
Figure 10 : Exemples de manutention par passage de fourche
4.5 Moving the generating set on rollers

2. If fitted, the transport brackets of the generator set must be removed.
3. Ensure that the rollers are suited to the weight of the generator set or container to be handled.
4. Ensure that the frame of the generator set or container supported by the rollers is not deformed.
5. If using a hand winch, use an adequate braking system.
14 1194_EN 2023-08-08
Transport
Section 5. Transport

Transport
• Strictly follow the instructions given in this section.
• Never operate a generator set while it is being transported.
5.1 Preparing for transport

CHECKS BEFORE TRANSPORT:
Before transporting the generator set (with or without enclosure, in container):

1. Check the overall condition of the generator set and ensure that all threaded fasteners are tight.
2. Check that all valves on the generator set are correctly closed (drain valve, fuel valve, etc.).
3. Check that the doors or access panels of the generator set are correctly closed and cannot open unexpectedly.
4. Check for leaks.
5. Remove additional equipment.
a. If necessary, contact your authorized Kohler distributor/dealer for service.
6. Block the air inlets and outlets.
PROTECTING THE GENERATOR SET:
For generator sets with and without enclosure, observe the following instructions.
1. Use adhesive edges (1), adhesive buffers (2) and transparent stretch film.
2. Beginning at the base of the generator set, cover it with an initial layer of transparent stretch film.
3. Ensuring that you never stick the adhesive edges directly onto the paintwork, secure them to each corner, beginning
at the top of the generator set.
4. Ensuring that you never stick the adhesive buffers directly onto the paintwork, secure them to the doors of the
generator set, protected by the transparent stretch film.
5. Beginning at the base of the generator set, cover it with a second layer of transparent stretch film.
6. If you have any doubt, contact your authorized Kohler distributor/dealer for service'.
Figure 11: Example of generator set with adhesive edges and buffers (with enclosure)
Some elements of the generator set (exhaust shaft, spark arrester, exhaust extension, air conditioning, air cooler, etc.) must be
removed for transport and refitted afterwards: consult one of our authorized Kohler distributor/dealer for service.
After transport, check that the generator sets and its elements are in good condition and clean them if necessary.
5.2 Preparing for unloading

1. Select the generator set unloading site according to the following criteria:
o Proximity between the generator set unloading site and its final position of use;
o Ease of movement between the generator set unloading site and its final position of use.
2. If necessary, mount beams or distribution plates that are strong enough to support the load of the assembly.
3. Always follow the handling instructions in the "Handling" chapter of this manual.
4. If the transportation equipment needs to be moved to make unloading easier, ensure that the generator set to be handled
is properly secured to it.
1194_EN 2023-08-08 15
Transport
5.3 Road transport

• Select suitable transport equipment according to:
o its capacity to support the weight of the generator set and its container;
o the securing devices fitted on the transport equipment.
• Select an itinerary that ensures that the passable roads are of sufficient quality to prevent damage to the generator set
and its container.
• Check that the height of the load does not exceed the height:
o of the means of transport;
o of the roads used.
• Before any transport, check that the loads are correctly distributed and carefully secured to the transport means.
5.3.1 Anchoring enclosed generating sets

5.3.1.1 Flatbed truck, road truck
ENCLOSURE WITH ONE ENCLOSURE WITH TWO
ENCLOSURE WITH NO ENCLOSURE WITH
PAIR OF LIFTING PAIRS OF LIFTING
LIFTING RING/BRACKET SINGLE LIFTING RING
BRACKETS BRACKETS
1. Fit and attach the straps in accordance with the corresponding diagram.
2. Ensure that the

straps are centered 2. Ensure that the attachment angle is between 20° and 30°.
on the frame.
20 - 30° 20 - 30° 20 -
30°
= =
3. Place chocks around the generator set and secure them to the deck of the transport equipment, or fit the corners of
the generator set with non-slip transport pads.
5.3.1.2 Lorry with trailer truck or semi-trailer truck
Flat bed truck with body :

1. Prepare for transport.
2. Place the generator set in the transport equipment in such a way that the available space is optimized:
a. M1xx enclosures: width-ways;
b. M2xx / M3xx / M4xx enclosures: length-ways.
3. Place chocks around the generator set and secure them to the deck of the transport equipment, or fit the four corners of
the generator set with non-slip transport pads.
16 1194_EN 2023-08-08
Transport
5.3.2 Transporting a generating set with its fuel (ADR)
Regulation ADR⃰-363 2017:

• Concerns generator sets for which the fuel tank contains fuel so that they can be operational without having to first fill
their fuel tank.
• Concerns any terrestrial transport of dangerous goods, including loading and unloading operations carried out before or
after road transport of dangerous goods in the territory of the European Union.
APPLY ADR PROVISION 363:
For road transport of a generator set with a full fuel tank in the territory of the European Union, please observe the following
instructions.
• If the machine contains more than 60 liters of liquid fuel for a capacity between 450 liters and
3000 liters, a plaque label must be fixed to it on two opposite sides;
• If the machine contains more than 60 liters of liquid fuel for a capacity greater than 3000 liters, a
plaque label must be fixed to it on two opposite sides;
• A shipping document containing the following note: "Carriage in accordance with special provision
363" is only required when the machine contains more than 1000 liters of liquid fuel.
ADR signatory countries (alphabetic order):
Albania, Germany, Andorra, Austria, Azerbaijan, Belarus, Belgium, Bosnia and Herzegovina, Bulgaria, Cyprus, Croatia, Denmark,
Spain, Estonia, Republic of Macedonia, Russia, Finland, France, Greece, Hungary, Ireland, Italy, Kazakhstan, Latvia,
Liechtenstein, Lithuania, Luxembourg, Malta, Morocco, Moldova, Montenegro, Netherlands, Norway, Poland, Portugal, Czech
Republic, Romania, United Kingdom, Serbia, Slovakia, Slovenia, Switzerland, Tunisia, Turkey and Ukraine.
5.4 Rail transport

Rail transport of generator sets is subject to specific standards and regulations. Please note those in force in the country
concerned.
o its capacity to support the weight of the generator set;
5.5 Shipping
5.5.1 Sea transportation of generating sets
Transport the generator sets inside a shipping container.

o its capacity to support the weight of the generator set;
• In the case of an LCL (less-than-container-load) container, elements must be packed in SEI crates.
• After sea transportation, clean the external panels.
5.5.2 Sea transportation of generating sets in containers
BEFORE SEA TRANSPORTATION:

1. Determine whether the container to be transported has valid C.S.C ⃰ approval or not.
2. Refer to the nameplate of the container to determine the maximum stacking load ⃰.
3. Ensure that the container is properly sealed by plugging all holes (air inlets and outlets, exhaust, etc.).
CONTAINERS WITH C.S.C ⃰ APPROVAL:

• Can be transported as maritime containers.
• Can be stacked ⃰ in a container carrier and can be gripped from above.
NON-APPROVED CONTAINERS:
• Must be transported in tankers.
• Ensure that the container is properly sealed by plugging all holes (air inlets and outlets, exhaust, etc.).
AFTER SEA TRANSPORTATION:

• Clean the external panels.
1194_EN 2023-08-08 17
Studies to be performed for installation
5.5.3 Sea transportation of accessories and spare parts

Transportation of certain components of the generator set or installation must often be organized separately. Ensure that the
packaging protect the components from any damage that could occur during transport. For electrical equipment, use SEI 4C or
SEI 3C crates.
5.6 Air transport

According to UN regulations, generator sets are classified as “dangerous goods” as per code UN 3528 – class 3 – 378 “Machinery,
international combustion flammable liquid powered”.
1. A prior declaration to the air freight company responsible for transporting the generator set must be made.
2. Observe the instructions provided by the air freight company concerned (marking, draining, etc.).
3. Pack the electrical equipment (cabinets, etc.) in SEI 4C crates.
Section 6. Studies to be performed for installation
DANGER INSTALLATION - MULTIPLE RISKS

DANGER OF DEATH
In the absence of qualified personnel trained to implement installation of a generator set,
one of our authorized Kohler distributor/dealer for service must be contacted.
Incorrect installation may pose serious risks to the health and safety of those concerned. A correct and safe installation must:
• include the necessary safety and emergency stop devices, which should always be easy to access;
• be performed by a qualified and authorized professional;
• be suitable for the particular features of the operating site, and thus be implemented on a case by case basis.
This chapter does not provide detailed installation instructions for a generator set but is a reminder of the main principles. For
more information, contact your authorized Kohler distributor/dealer for service.
6.1 Requirements to be observed to install a generating set

When installing a generator set, observe the following instructions.
• Install the generator set in an open area to limit the risk of fire.
• Install the generator set on a flat, level surface strong enough to support its weight and the vibrations occurring during
operation.
• Create a document describing the modifications made to the generator set (configuration, settings, connections, etc.)
and ensure that it is handed over to the operating manager.
• Use appropriate ventilation to allow the equipment to cool correctly and ensure sufficient air renewal.
• Correctly evacuate all of the exhaust gases: risk of poisoning and significant material damage.
• Ensure that the doors and access panels of the generator set can open fully.
• If fitted, remove the transport brackets from the generator set.
• If necessary, ensure that engine fluids are stored under optimal conditions and in the appropriate quantity.
• When installing the equipment on a vehicle or other mobile equipment, a study must be conducted beforehand to take
into account the various specific uses of the generator set.
18 1194_EN 2023-08-08
6.2 Installing a generating set indoors

To achieve correct and safe installation in a room, several elements are required:
ensure that the engine is vent the exhaust gases

cooled
supply the generator set

with fuel
ventilate the room
reduce noise and vibrations
6.2.1 Reduce noise and vibrations

• Refer to the applicable standards and legislation in the country affected by the installation of the generator set regarding
the limitation of sound ⃰ at property boundaries.
• Determine the sound pressure level and the sound power level of the complete installation.
• If you have any doubt, contact your authorized Kohler distributor/dealer for service.
To reduce the noise and vibrations associated with the operation of the generator set:
• Adapt the generator set installation plan.
• Install flexible parts that enable the absorption of vibrations on all of the exhaust and cooling pipes (suspension mounts,
compensators, etc.).
• Install one or more silencers on the exhaust circuit.
• Install sound traps and a system of chicanes in the air inlet and outlet ducts.
• Increase the bulk of the walls to limit the noise transmitted through the walls of the room.
• Add an absorbent material to limit the reverberation of sound and vibrations.
• In case of doubt regarding the limitation of noise and vibrations, contact your authorized Kohler distributor/dealer for
service.
1194_EN 2023-08-08 19
6.2.2 Venting the exhaust gas

Exhaust gases contain carbon monoxide and can lead to death. Ensure that all exhaust gases are vented correctly and check the
exhaust system periodically.
• Refer to the applicable standards and legislation in the country of installation of the generator set regarding exhaust
emissions, shaft heights, ejection speed and distances between exhaust shafts and buildings.
• Determine the cross-sections of the generator set exhaust pipes using calculations.
• Install monoxide detectors (test and replace them regularly according to the manufacturer’s instructions).
flue
Flue
exhaust silencer
compensator
column base
manifold
Manifold
condensate drainage
dsqdsqdsqdsq
Scsqdsq
Figure 12: Example of an exhaust system

To properly vent the exhaust gas of the generator set, conduct a study taking into account the following criteria:
• pressure drops caused by the exhaust;
• thermal insulation;
• suspension and dilatation of the exhaust pipes;
• sound level;
• air pollution.
20 1194_EN 2023-08-08
6.2.3 Planning the fuel supply

• Refer to the applicable standards and legislation in the country of installation of the generator set regarding the fuel,
pipework, tanks and breaking components.
• Determine the dimensions of the connection pipes using calculations.
• Install fire detectors and extinguishers (test and replace them periodically according to the manufacturer’s instructions).

Fuel quality
• Always ensure that the available fuel quality is compatible with the engine
technologies, in particular with the high-pressure injectors.
o If necessary, refer to the "Fuel specifications" section of the "Commissioning"
chapter of this manual.
FUEL STORAGE IN TANK AND CONTAINER:

• Fit the tank air vent at a sufficient height.
• Use a solenoid valve or an anti-siphon valve to prevent putting a container on a daily service tank or on a skid fuel tank
under pressure.
• If the fuel tank is installed in a flood zone, ensure that the safety guidelines specific to this situation are observed.
Ensure that fuel leaks or drainages are collected in suitable containers, never allow them to flow onto the floor.

Electric pump
Possibility of using an electric pump for the automatic filling device.
• Never allow the pump to run idle.
• Before starting an electric pump, the discharge tap or gun must be closed. The by-
pass allows the pump to operate with the discharge opening closed for a limited
period.
CONNECTING PIPES:
Use single or double skin pipes made of:

• black steel;
• stainless steel;
• polyethylene.
The use of any other material (galvanized steel, brass, etc.) could cause material damage and is prohibited.
1194_EN 2023-08-08 21
6.2.4 Ensuring cooling

• Refer to the applicable standards and legislation in the country of installation of the generator set with regard to the
cooling circuit.
• Use calculations to determine the level of cooling required and the dimensions of the cooling circuit pipes.
To determine the appropriate cooling system, carry out a study taking into account the following elements:
• the cooling type allowed by the engine;
• the number of cooling circuits;
• the thermal output to be vented;
• the temperatures at the engine inlet and outlet;
• the ambient temperature;
• the cooling circuit flows;
• the pressure drops in cooling circuits outside of the engine;
• the desired sound level.
ENGINES:
• The engines have 1 or 2 cooling circuits:
• 1 HV circuit, for cooling the engine block;
• 1 LV circuit, for cooling the combustion air after it passes through the turbo.
• Circulation of the coolant between the engine and the cooler is ensured by pumps (attached or electric).
• In case of doubt regarding the engine configuration, contact your authorized Kohler distributor/dealer for service.

Cooling via radiator or internal air cooler
• Board up the air outlet at the cut-out for the room's air outlet.
• Ensure that the cut-out for the room's air outlet is sufficient to vent the generator
set's air and thus obtain an adequate thermal balance.
COOLING TYPES:
• radiator;
• air cooler; air outlet
• water loss.
Figure 13: Air outlet of a generator set with radiator
22 1194_EN 2023-08-08
6.2.5 Ventilate the room

During operation, the engine consumes oxygen and releases carbon monoxid: lack of air renewal could result in important material
damages and even fainting or death to those concerned.
• Refer to the applicable standards and legislation in the country of installation of the generator set with regard to room
ventilation.
• Use calculations to determine the level of ventilation required and the cross-sections of the air inlets and outlets.
• Pour limiter la perte de charge et la nuisance sonore, dimensionner les sections d’entrées et de sortie d’air afin d’avoir
une vitesse de passage raisonnable.
• To limit the pressure drop and the noise disturbance, ensure that the cross-sections of the air inlets and outlets allow a
reasonable passage speed.
Air outlet
The aim of ventilation is:
• to route fresh air to the engine;
• to vent the radiation of the generator set (see
diagram);
• to cool the engine if the cooling system is in
the room.
Ventilation can be ensured by: Air inlet

• an engine radiator (air flow enforced by the
radiator);
• an air cooler in the room (air flow enforced by
the air cooler);
• an electric fan (calculated air flow).
Air inlet
Figure 14: Good venting of the radiation from the generator sets
6.3 Installing an enclosed generating set

When running, the engine consumes oxygen and emits carbon monoxide: failure to renew the air could cause major damage
to the equipment, or cause illness or even the death of those concerned.
• Refer to the overall plans of the generating set.
• Install the generating set in an open area to limit the risk of fire.
• Clear sufficient space for the operator to carry out the maintenance operations.
• Ensure that air and exhaust gases are properly vented and cannot be recirculated.
• If installation is carried out in a room:
o install fire detectors, extinguishers and carbon monoxide detectors inside the room (test and replace them
periodically according to the manufacturer’s instructions);
o ensure that the dimensions of the entrance to the room are big enough for the generating set to be transported
into the room;
o ensure that the doors and access panels of the generating set can be opened fully;
o observe the instructions in the previous paragraphs.
• In case of doubt regarding the installation of an enclosed generating set, contact your distributor or approved Kohler
dealer.
exhaust gas
outlet
air outlet
Figure 15: Installation in a room and good venting of exhaust gas and air
1194_EN 2023-08-08 23
6.4 Installing a containerised generating set
2 meters
2 meters minimum Air inlet
minimum
Air
outlet
Air inlet
Figure 16: Example of installation of a generator set in a container
When installing a generator set in a container, consider the following elements:

• Install the container in a space sufficiently clear to allow:
o the container access doors to be opened fully;
o the generator set to be removed from the container if necessary;
o the risk of fire due to the high temperature of the exhaust gas to be reduced.
• Plan the foundation of the container (see diagrams below):
o the container must sit on stable and level ground along the full length of the side beams;
o the ISO ⃰ corners of the container must be clear;
o the container must never rest on its ISO ⃰ corners.
• Ensure that the air inlets are clear and that air can circulate freely.
• Ensure that air and exhaust gases are properly vented and cannot be recirculated.
• Install fire detectors, extinguishers and carbon monoxide detectors inside the room (test and replace them
periodically according to the manufacturer’s instructions).
• If the container is installed near a building, ensure that sound reverberation is limited.
• If the container is installed inside a room, observe the instructions in the previous paragraphs.
• In case of doubt regarding the installation of a generator set in a container, contact your authorized Kohler
distributor/dealer for service.
Correct installation
Incorrect installation Incorrect installation
6.5 Specific context of seismic installation (IBC)

Generator sets installed in the specific context of seismic installation are specially designed to meet the requirements of the
International Building Code (IBC). Seismic installations of the International Building Code (IBC) involve additional assembly and
installation considerations: refer to the corresponding seismic installation diagram(s) to find out the seismic insulation
requirements.
24 1194_EN 2023-08-08
Initial commissioning
Section 7. Initial commissioning
DANGER ELECTRICAL EQUIPMENT - RISK OF ELECTRIC SHOCKS

DANGER OF DEATH
Failure to observe the safety instructions could result in serious injuries or the death of those
concerned.
For commissioning of a generating set, observe the following safety instructions.

1. Be a qualified professional authorized to commission a generating set.
2. Wear suitable personal protection equipment (gloves, goggles, clothing, etc.).
3. Read the supplied documentation carefully.
4. Ensure that the output of the generating set is suitable for the requirements of the installation.
5. Check that the configuration (settings and parameters) of the generating set is suitable for the requirements of the
installation.
6. Ensure that the installation has been implemented correctly by qualified and authorized personnel (correct maintenance,
regular checks of the installation, cleanliness, no cloths or other materials near the engine-alternator).
7. Adapt and/or complete the checks mentioned in this chapter according to the actual starting conditions.
7.1 Electrically connecting a generating set

Tight sealing of the installation
• While connecting, ensure that the cable passageways on the installation have
been properly sealed (notably concerning generator sets with enclosures).
ENCLOSURE M1xx/M2xx/M4xx
Enclosures are designed with a special sheet metal that is to be
drilled to allow the cables to exit.
1. Drill the sheet metal according to the needs.
2. Install one or several cable gland.
3. Install one or several cables.
Unfitted and forbidden
ENCLOSURE M137 ONLY Second drilling

First drilling to be to be performed
1. Drill the rubber seal. performed on the on the
2. Drill the aluminium sheet metal. rubber seal aluminium sheet
metal
3. Install one or several cable gland.
4. Install one or several cables.
7.1.1 Risk of electrocution

• Read the nameplate located on the generator set (or container) carefully:
1. Note the voltage, output, current and frequency values;
2. Check that these values match the installation being supplied with electricity.
• The electrical connections must be made in accordance with the applicable standards and regulations in the country of
use and the grounding system of the equipment.
• Connection of the equipment to an existing electrical network must be carried out by an electrician.
• Disconnect the power to the equipment (equipment voltage, battery voltage and network voltage) before performing any
installation or maintenance operation.
• Connect the equipment wires by respecting the wiring diagram supplied by the manufacturer.
• Always handle the equipment with dry hands and feet.
• Take all the necessary precautions to avoid touching stripped cables or disconnected connectors.
• Use cables that are in good condition, well insulated and are correctly and securely connected, and keep these cables
in good condition.
• Only replace equipment that provides protection against electric shock with identical equipment (specifications and
nominal values).
• Only use flexible cables with a rubber covering, which conform to CEI 245-4.
• Refit the protective plates (blanking covers) on the generator set after each maintenance operation.
1194_EN 2023-08-08 25
7.1.1.1 Safety precautions in case of electrical shock

In the event of electric shock, follow the instructions below.
1. Avoid direct contact with the victim's body or with the live conductor.
2. Activate the nearest emergency stop.
3. If it is not possible to access the equipment: move the victim away from the live conductor using
an insulated pole, a piece of dry wood, dry clothing or any other non-conductive material.
4. Move the victim away from any situations where there is a DANGER OF DEATH.
5. Contact the emergency services.
6. If breathing has stopped, begin artificial respiration at once.
7. In the event of cardiac arrest, carry out cardiac massage.
7.1.2 Low voltage installations

7.1.2.1 Low-voltage wiring
• Low voltage electrical installations are subject to the regulations set out in standard NFC 15.100 (France) or the
standards in the countries concerned based on international standard IEC 60364.
• Low voltage electrical installations must also adhere to the regulations in the NFC 15.401 application guide (France) or
to the regulations and standards in the relevant country.
• Cable routing must comply with NFC 15.100, paragraph 528 “Electromagnetic disturbances” or IEC 60364-4-44
“Protection against voltage disturbances and electromagnetic disturbances”.
POWER CABLES:
Depending on the output of the generator set, the power cables may be single pole cables⃰ or multi pole cables⃰.
1. Depending on the type of cables and the standards to be observed in the country of installation of the generator set,
ensure that you:
a. determine the number of cables and the cross-section;
b. select electrical conductors that comply with the international standard IEC 30364-5-52.
2. Power cables should preferably be installed:
a. either in ducts;
b. or on a cable tray for this purpose.
Three phase - Calculation assumption (data is indicative only): Fitting method = wiring in cable runs or non-perforated trays / Permissible voltage
drop = 5% / Multiconductors or single conductor joined when precision 4X…(1) / Cable type PVC 70°C (e.g. H07RNF) / Ambient temperature = 30°C.
cable sizes
circuit breaker rating
(A) 0 to 50 m 51 to 100 m 101 to 150 m
mm²/AWG mm²/AWG mm²/AWG
10 1.5 / 14 2.5 / 12 4 / 10
16 2.5 / 12 4 / 10 6/9
20 2.5 / 12 4 / 10 6/9
25 4 / 10 6/9 10 / 7
32 6/9 6/9 10 / 7
40 10 / 7 10 / 7 16 / 5
50 10 / 7 10 / 7 16 / 5
63 16 / 5 16 / 5 25 / 3
80 25 / 3 25 / 3 35 / 2
100 35 / 2 35 / 2 4 x (1 x 50) / 0
125 (1) 4 x (1 x 50) / 0 4 x (1 x 50) / 0 4 x (1 x 70) / 2/0
160 (1) 4 x (1 x 70) / 2/0 4 x (1 x 70) / 2/0 4 x (1 x 95) / 4/0
250 (1) 4 x (1 x 95) / 4/0 4 x (1 x 150) / 2350MCM 4 x (1 x 150) / 2350MCM
400 (1) 4 x (1 x 185) / 0400MCM 4 x (1 x 185) / 0400MCM 4 x (1 x 185) / 0400MCM
630 (1) 4 x (2 x 1 x 150) / 2x 2350MCM 4 x (2 x 1 x 150) / 2x 2350MCM 4 x(2x1x150) / 2x 2350MCM
Single phase* - Calculation assumption (data is indicative only): Fitting method = wiring in cable runs or non-perforated trays / Permissible
voltage drop = 5% / Multiconductors / Cable type PVC 70°C (e.g. H07RNF) / Ambient temperature = 30°C
cable sizes
circuit breaker rating 0 to 50 m 51 to 100 m 101 to 150 m
(A) mm²/AWG mm²/AWG mm²/AWG
4 / 10 10 / 7 10 / 7
16 6/9 10 / 7 16 / 5
20 10 / 7 16 / 5 25 / 3
25 10 / 7 16 / 5 25 / 3
32 10 / 7 25 / 3 35 / 2
40 16 / 5 35 / 2 50 / 0
50 16 / 5 35 / 2 50 / 0
63 25 / 3 50 / 0 70 / 2/0
80 35 / 2 50 / 0 95 / 4/0
100 35 / 2 70 / 2/0 95 / 4/0
125 50 / 0 95 / 4/0 120 / 2250MCM
26 1194_EN 2023-08-08
BATTERY CABLES:
1. Connect the battery terminal cables to the starter terminals.
2. Ensure that the polarity of the battery corresponds to the polarity of the starter.
GENERAL RESIDUAL CURRENT PROTECTION DEVICE:
In order to ensure that staff are protected against electric shocks, generator sets are equipped with a general residual current
protection device which is configured by default in the factory to be triggered instantly with a sensitivity of 30 mA.
If, to meet the requirements of the installation, this value has to be changed on the generator set, ensure that the installation
complies with the personal safety standards in force.
As soon as the generator set is disconnected from the installation, return to the "factory" settings by default: instant triggering and
a sensitivity of 30 mA.
GROUNDING THE GENERATOR SET:
Grounding the generator set = ensuring effective protection against electric shock
1. Make the ground connection:
a. either with an grounding rod;
b. or directly to the installation, in compliance with the electrical diagram.
2. Use a copper cable with a suitable cross-section (see below).
3. Connect the copper cable to the grounding terminal⃰ of the generator set.
4. Connect the copper cable to a galvanized steel grounding rod embedded vertically into the floor.
Ul
RA =
a) The maximum resistance value of the ground connection ⃰ is calculated using the following formula:
I n
R A (Ω) = resistance of the ground connection. The maximum value must be less than that corresponding to this value.
I n
(A) = rated residual current at highest RCD of the installation to be protected. The selected value must be that of the highest
differential setting of the RCD for the installation to be protected.
Ul
(V) = the maximum permissible contact voltage.
As a guideline, Table1 : Maximum value of the ground connection as a function of the rated current of the RCD ⃰indicates the
maximum value of the ground connection resistance R A for the different normal values of rated differential current for operation
of the RCDs⃰,.
In practice, the value to be taken into consideration for the resistance of the grounding connection must take possible seasonal
variations into account.
If it is not possible to measure the resistance of the ground connection, ensure that the impedance of the fault loop is not greater
than the value indicated in the table.
Ul
This table is given for a maximum contact voltage = 50 VAC:
I n
maximum rated residual differential current of the highest R A (Ω) maximum resistance value of the ground
RCD ⃰ of the installation connection of the grounds in Ohms
20 A 2.5
10 A 5
Low sensitivity
5A 10
3A 17
1A 50
500 mA 100
Average sensitivity
300 mA 167
100 mA 500
High sensitivity ≤ 30 mA > 500
Table1 : Maximum value of the ground connection as a function of the rated current of the RCD ⃰
1194_EN 2023-08-08 27
GROUNDING CABLE CROSS-SECTION:
The cross-section of the copper grounding cable must:

• if the cable is in the open air, have a minimum cross-section of:
o insulated conductors = 2.5 mm2 Cu minimum;
o bare conductors = 4 mm2 Cu minimum.
• if the cable is buried, have a minimum cross-section of:
o insulated conductors = 16 mm2 Cu minimum;
o bare conductors = 25 mm2 Cu minimum.
• in addition, be selected in compliance with the table below or be calculated (refer to the standard):
Cross-section of the phase conductors of Minimum cross-section of the protective conductors (mm2)
the installation S (mm2) Protective conductor of the same kind as the phase conductor
S ≤ 16 S
16 < S ≤ 500 16
S > 35 S / 2/
Table 2: Minimum cross-section of the protective conductors
b) Grounding rod specifications
The resistance of an ground connection depends on its dimensions, its shape and the resistance of the ground in which it is
established. This resistance is often variable from one place in the ground to another, and also varies according to depth.
The resistance (in Ohms) of the ground connection made up of a vertical hot-dip galvanized steel rod is approximately equal to:
 
RA = The minimum length of the grounding rod would therefore be L=
L RA
RA (Ω) = maximum resistance of the ground connection
 (Ω.m) = Resistance of the ground
L (m) = Length of the grounding rod
If there is a risk of frost or drought, increase the lengths by 1 m or 2 m.
It is possible to reduce the resistance value of the ground connection by using several vertical rods connected in parallel and set
apart by at least their length in the case of two rods and more if there are more than two.
Remember that, for very long rods, the ground is rarely homogeneous; very long rods can be used to reach low resistance layers,
if they exist.
28 1194_EN 2023-08-08
SUMMARY TABLES FOR INFORMATION ONLY:
According to the information supplied in the table below:

• If the length is less than 1 m, use an grounding rod with a minimum length of 1 m.
• If the length is greater than 1 m, use several grounding rods connected in parallel and set apart by at least their length
to obtain an equivalent length.
Example: for a minimum length of 3.6 m, use 4 rods of 1 m connected to each other and each positioned 1 m apart from each other.
For a contact voltage Ul = 50 VAC
L (m)
R A (Ω)
I n Minimum length of the grounding rod as a function of the
average resistance value of the ground
Maximum
Maximum rated residual differential resistance value of Thick arable land, Thin arable land, Bare stony soils,
current of the highest RCD ⃰ of the the ground damp compact gravel, rough dry sand,
installation connection of the backfill backfill impermeable rock
grounds in Ohms
 = 50 Ω.m  = 500 Ω.m  = 3000 Ω.m
20 A 2.5 20 200 1200
10 A 5 10 100 600
Low sensitivity
5A 10 5 50 300
3A 17 3 29.4 176.5
1A 50 1 10 60
500 mA 100 0.5 5 30
Average sensitivity
300 mA 167 0.30 3 18
100 mA 500 0.10 1 6
30 mA 1667 0.03 0.3 1.8
High sensitivity
≤ 30 mA > 500 >1 >1 > 1.8
Table 3: Minimum length of the grounding rod with Ul = 50 VAC
For a contact voltage Ul = 25 VAC
L (m)
R A (Ω) Minimum length of the grounding rod as a function of the

I n Maximum average resistance value of the ground
Maximum rated residual differential resistance value of
Thick arable land, Lean arable land, Bare stony soils,
current of the highest RCD ⃰ of the the ground
moist compact Gravel, coarse dry sand,
installation connection of the
ballast ballast impermeable rock
grounds in Ohms
 = 50 Ω.m  = 500 Ω.m  = 3000 Ω.m
20 A 1.25 40 400 2400
10 A 2.5 20 200 1200
Low sensitivity
5A 5 10 100 600
3A 8 6 60 360
1A 25 2 20 120
500 mA 50 1 10 60
Average sensitivity
300 mA 83 0.6 6 36
100 mA 250 0.2 2 12
30 mA 833 0.1 0.6 3.6
High sensitivity
≤ 30 mA > 500 >1 >1 > 3.6
Table 4: Minimum length of the grounding rod with Ul = 25 VAC
Note: For the United States (National Electrical Code reference NFPA-70). The generator set must be earthed. To do this, use a
copper wire with a minimum cross-section of 13.3 mm² (or AWG 6, at most) connected to the generator set earth socket and a
galvanized steel grounding rod embedded vertically and fully into the ground. This grounding rod embedded fully in the ground
must have a minimum length of 2.5 m.
1194_EN 2023-08-08 29
7.1.2.1.1 Low voltage earthing diagrams

The ground connection diagram, or SLT ⃰ (also called the grounding system ⃰) of the electrical installation defines:
• the neutral connection of the generator set in relation to earth;
• the ground connection of the electrical installation by the user.
The purpose of the grounding systems is to protect personnel and equipment by managing the risks posed by insulation defects.
For safety reasons, any live conducting part of a facility must be insulated from the earth.
Always ensure that the installation and the generator set are correctly earthed. The SLT is a system of letters, each with their own
precise meaning.
CODIFICATION OF GROUND CONNECTION DIAGRAMS:

1st letter: defines the connection to neutral 2nd letter: defines the earth situation
I Insulated neutral or earthed via an impedance device⃰ T Earth connected to earth
T Neutral connected to earth N Earth connected to neutral
Number of
Speed Detection Note
conductors
TT 4 poles Measurement of residual current Triggered by RCD upon 1st fault (see Glossary)
C 3 poles
TN No measurement of residual current Triggered by overcurrent protection upon 1st fault
S 4 poles
IT SN 3 poles Insulation resistance measurement Triggered upon 2nd fault by overcurrent protection
TT = neutral and earth to earth

TNC = combined earth and neutral
TNS = separate earth and neutral
ITSN = Insulated earth without neutral
7.1.3 High voltage installations

7.1.3.1 High-voltage installation
• "High voltage electrical installations" (HVA) are defined as installations with a voltage level of between 1 kV and 50 kV.
• These high voltage electrical installations are subject to the rules of standard NFC 13.100, and, in particular, NFC 13.200
(France, voltage level from 1 kV to 33 kV) or the standards of the relevant country, based on international standard
IEC 62271.
• Cable routing must comply with NFC 13.200, paragraph 451 "Electromagnetic disturbances" or IEC 62271-1 and
IEC 62271-200.
EQUIPMENT:
Example:
The operating voltage must be below the rated voltage.
Voltage • Operating voltage: 20 kV
This operating voltage shall define the isolation voltage.
• Rated voltage: 24 kV
Short-time withstand current Example: 12.5 kA / 1 s
Current
Continuous-duty current Example: 400 A
POWER CABLES:
The power cables for high voltage installations must be high voltage cables, in order to ensure the protection of people and
equipment.
The cross-section shall be selected following the study of overcurrents and protections implemented.
30 1194_EN 2023-08-08
SAFETY GUIDELINES:
• Provide all safety and operating equipment (gloves, pole, stool, etc.) in every room containing HVA equipment.
• Protection against direct contact:
o Ensure that live parts are out of reach;
o It is imperative to use HVA equipment that is compliant with current standards;
o Respect the manufacturer's implementation requirements.
• Protection against indirect contact:
o All grounding and conductive elements must be interconnected by means of equipotential systems connected to the
grounding connection of the installation;
o Ensure that the cross-section of the protective conductor is suitable to transmit fault currents (calculation required) ;
o Ensure that the cross-section of this protective conductor is at least 25 mm² in copper or 35 mm² in aluminum.
7.1.3.2 High voltage earthing diagrams

PROTECTION AGAINST OVERCURRENTS:
For an HVA installation, it is necessary to:

1. Protect against overloads.
2. Protect against short-circuits: The protective device must disconnect the power supply of the components in a sufficiently
short time to prevent damage.
3. In the event of any modifications to the installation, check that the different elements of the installation are correctly
protected against overcurrent.
7.1.4 Temporary power supply of an installation without Automatic Transfer Switch
SUPPLYING AN INSTALLATION WITHOUT SOURCE INVERTER:

2. The generator set must be separated from the electrical distribution grid.
3. Ensure that the disconnect device allows you to guarantee the disconnection (e.g.: manual opening of the main circuit
breaker).
4. During operation of the generator set, ensure that the disconnection point is kept open:
a. either by a blocking device;
b. or by a lock-out panel.
Fixed
installation
Head disconnect point

open
Grid
Generator set
1194_EN 2023-08-08 31
7.2 Fluids: fuels, oils, coolants, DEF
DANGER
ENGINE FLUIDS: TOXIC, FLAMMABLE, PRESSURIZED PRODUCTS - MULTIPLE
RISKS
DANGER OF DEATH
Failure to observe the safety instructions could result in serious injuries or the death of
those concerned.
When handling engine fluids, follow the safety instructions below.

• Only use the engine fluids (fuels, oils, coolants, DEF*, etc.) listed in the "Specifications" sections.
• Comply with the orders, standards and legislation in force int he country of use.
• Each time you purchase a fluid, ask the supplier for the safety data sheets.
• Use suitable personal protective equipment (gloves, goggles, etc.) and ensure that an extinguisher is provided nearby.
• Before any operation, ensure that the engine fluids are not pressurized.
• Never inhale or ingest.
• Avoid all contact with the skin and eyes.
7.2.1 Fuel specifications
QUALITY REQUIREMENTS:
• Only use fuel that complies with the applicable international and national legislation and standards in the country
concerned.
• To improve engine performance, take into account these fuel specifications:
o capacity to meet legal requirements regarding pollutant emissions;
o output supplied;
o consumption;
o service life;
o technical performance.
• Consult the local fuel distributor to find out the specifications of the fuels available in the area.

Water and contaminants
Water and its contaminants (bacteria, residue, fungus, etc.) can cause significant material
damage, notably to the engine and its fuel filters.
• Use only clean fuel without any water.
32 1194_EN 2023-08-08
APPROVED FUELS: For details, see the engine user and maintenance manual.
FOR INFORMATION:
The certification measures confirming that the legal emission value limits are respected are performed with certified fuels which
conform to the standards and requirements stated below.
Fuels Designation Details Restrictions

0.0015% sulfur max HFRR 460 µm
ASTM D975 1D
ASTM D975 (Road) 0.05% sulfur max HFRR 460 µm;
ASTM D975 2D Without EATS
0.5% sulfur
Paraffinic diesel fuel from synthesis

EN15940 EN15940 Max HFRR 460 µm
(Hydrotreated Vegetable Oil)
road diesel CSR 4.0.05

EN590 EN590 biodiesel ratio < 7%
non road diesel CSR 4.1.03
BS2869 2010
BS2869 2010 non road diesel 0.001% sulfur biodiesel ratio < 10%
classA2
without EATS
Improve the storage conditions by using fuel pre-treated in a
FOD available in CSR 4.4.06 refinery in order to stabilize it (prevent oxidation, the
FOD
France DIN 51603 development of bacteria and corrosion).
Add a water separator pre-filter between the storage tank and
the daily service tank.
Bio Fuel max 7% biodiesel EN12214 mixed without EATS

EN 12214 with diesel ASTM D975 or FOD Improve the storage conditions by using fuel pre-treated in a
Biodiesel
Bio Fuel max 7% biodiesel ASTM D6751 refinery in order to stabilize it (prevent oxidation, the
ASTM D6751 mixed with fuel ASTM D975 or FOD development of bacteria and corrosion).
NATO F-54
identical to EN590 CSR 4.0.05 Biodiesel ratio < 10 %
(Road)
XF-51 (Non identical to EN590 Non Road
Biodiesel ratio < 10 %
Road) CSR 4.1.02 to CSR 4.1.03
NATO F-63 or NATO F34 or F35 or F44
XF-63 + Additive S1750
In general, kerosene is damaging to a diesel engine:
1. Viscosity too low = seizing and wear of the injection system.
Military fuels
2. Cetane index too low = difficulty starting or failure to start (forbidden for emergency use).
3. Negative impact on engine maintenance.
4. Negative impact on fuel consumption.
5. Negative impact on pollutant emissions.
6. Negative impact on output.
The version of the kerosene-based military fuel containing additives (Nato F-63 or XF-63) is best suited to our generating
sets although it still maintains the negative impacts listed in points (3 to 6).
Operation with a NATO F-63 or XF-63 fuel is a substitution choice for which the user of the generating set must assume
the impacts on the entire service life of the engine and the performance of the generating set.
Definition of the terms used in the table above:

• 0.5% sulfur = 5000 ppm.
• EATS (Exhaust After Treatment System).
• HFRR (High Frequency Reciprocating Rig): test method to check the lubricating performance of diesel fuels.
• FOD (Fuel Oil Domestic): domestic heating oil
RESISTANCE TO LOW TEMPERATURES:

• Consult the national standards and/or regulations to find out the requirements to be respected during the different
seasons (winter/summer) according to the various geographical regions.
• If using diesel at a low outside temperature, use diesel fuels that are sufficient fluid in cold conditions in order to avoid
malfunctions associated with paraffin deposits (clogged filters, etc.).
• Give preference to fuels with additives added in the refinery over fuels modified in a storage tank.
1194_EN 2023-08-08 33
7.2.2 Oil grades
• Use only synthetic engine oils in accordance with the applicable national and international standards and regulations in
the country of use.
• A quality oil is indispensable for the proper operation of the engine and should:
o effectively lubricate;
o cool certain parts;
o protect metal parts against corrosion;
o clean the parts and remove impurities (to the filter).
APPROVED OILS:
• The quality and type of the oil must be chosen according to several important parameters such as:
o the engine technology,
o how the generator set is used (number of hours per year),
o the conditions of use (outside temperatures, etc.),
o if the generator set is equipped with an exhaust aftertreatment system.
• For details, see user and maintenance engine manual.
• KOHLER oil on sale at our authorized Kohler distributor/dealer for service.
RESISTANCE TO TEMPERATURES:
Adapt the oil viscosity index when cold (SAE) according to outside temperatures. Always use a multi-viscosity oil of high quality.
For details, see user and maintenance engine manual.
If you have any doubt, please contact your authorized Kohler distributor/dealer for service.
7.2.3 Coolant specifications

The engine's internal cooling system allows the engine to operate at a precise temperature. KOHLER coolant is a ready-to-use
cooling fluid which provides a high level of protection and is produced from an approved antifreeze (Power Cooling concentrated
antifreeze).
RECOMMENDED COOLANT (all engines): KOHLER
7.2.4 DEF specifications
Certain engines are equipped with an exhaust gas post-treatment system (SCR*). For details, see the engine user and
maintenance manual.
• High quality DEF is essential to ensure proper operation of the engine, as it guarantees:
o correct emissions performance;
o protection against malfunctioning of the SCR* system and associated damage.
• Only use DEF* (exhaust fluid) which is clean and free from water, in accordance with the legislation and international
and national standards in force in the country concerned.
AUTHORIZED DEF*: For details, see the engine user and maintenance manual.
If you have any questions, contact your authorized Kohler distributor/dealer for service'.
34 1194_EN 2023-08-08
7.2.5 Transportation and storage of the fluids

The engine fluids are toxic products which are harmful to humans and the environment: the engine fluids are stored and
transported in line with strict regulations. Refer to the orders, regulations, standards and legislation in force in the country in which
the engine fluids are transported and stored.
Moreover, storing engine fluids in unsuitable conditions causes the engine fluids to deteriorate and results in material damage
during use. Store the engine fluids under optimal conditions that preserve their qualities.
• Each time you purchase a fluid, as the supplier for the safety data sheets and make them available for staff permanently
exposed to them;
• Find out the appropriate storage conditions (temperature resistance, authorized storage period, etc.) and apply them.
• Make first-response fire equipment (extinguishers, hydrants) available to staff.
• Ensure that only qualified and authorized staff using the necessary PPE* handle the engine fluids.
• Correctly mark the storage tanks with clearly visible, legible labels resistant to hydrocarbons.
• Use appropriate storage tanks which are: clean, made from material suitable for the content, sealed, sufficiently strong
and equipped with a perfectly sealed fastening device, etc.
• Position storage tanks on retention containers, away from light and moisture and at a constant temperature
recommended by the supplier.
• In any case, ensure that all measures intended to safeguard staff and the environment are implemented and that the
orders, regulations, standards and legislation in force are complied with.
7.3 Commissioning, first use of the generating set

Before any commissioning operation on a generator set, observe the following instructions.
1. Remove the protective caps, plugs and adhesive tapes from the generator set.
2. If fitted, remove the desiccant bags from the electrical components (cabinet, central control console, alternator, etc.).
3. Remove any element blocking the air inlets and outlets of the generator set (radiator, fan, etc.).
4. Keep all flammable or explosive materials (petrol, oil, fabric, etc.) out of the way.
5. Check that the equipment is well protected against any fluid splashes and bad weather.
7.3.1 Checking the electrical connections

1. Be qualified and authorized to perform electrical checks.
2. Check that the residual current devices are operating correctly.
3. Check the electrical connections:
a. grounding;
b. electrical control and power connections;
c. if fitted, the voltage and caliber of the starter battery charging system.
d. If necessary, refer to paragraph "Electrical connection of a generator set" of the "Commissioning" chapter in this manual.
7.3.2 Checking the mechanical components

1. Be qualified and authorized to perform mechanical checks.
2. Check that the installation has been implemented in accordance with the instructions in this manual.
3. Check whether the engine documentation specifies a required run-in period.
4. If fitted, check that the rotor on the engine radiator is centered in relation to the volute (see diagram).
5. If fitted, check that the starter batteries are well charged.
6. If equipped, ensure that the oil breather connection does not have a low point: the hose must have
a continuous downward slope.
7.3.3 Operation of the generating set

INFORMING THE GENERATOR SET OPERATING STAFF:
• Ask the operations manager to make all of the documentation supplied with the equipment available to the operating
staff, if possible directly at the operating site of the generator set.
• Contact your authorized Kohler distributor/dealer for service if you have any questions about the equipment or any staff
training requirements.
• Regularly remind the operating staff of the safety and operating instructions for the generator set.
• Never start a generator set positioned on a vehicle in operation.
• Even when the generator set is stopped, keep any unauthorized persons (unqualified employees, children, etc.) and
animals away from it.
BEFORE OPERATING THE GENERATOR SET:
1. Be qualified and authorized to operate a generator set.
2. Take note of the equipment documentation, in particular the safety sections.
3. Create a maintenance schedule adapted to the configuration of the installation and the generator set.
a. If necessary, refer to the "Maintenance schedules" section of the "Maintenance" chapter.
4. Familiarize yourself with the operation of the generator set.
5. Take note of the fluid specifications and top up if necessary.
a. If necessary, refer to section "Fuels, oils and coolants" of the "Commissioning" chapter of this manual, or refer to
the maintenance manual.
b. If necessary, refer to the "Maintenance" manual to read the fluid top-up procedures.
1194_EN 2023-08-08 35
7.3.4 Preparing the generating set for starting
1. Be a qualified professional authorized to start a generating set and strictly follow safety rules.
2. Wear suitable clothing (fitted, not loose, etc.) and remove any personal belongings that may hinder the operation (watch,
bracelet, scarf, etc.)
3. Wear suitable personal protection equipment (gloves, safety goggles, shoes, helmet, etc.).
4. Ensure that the generating set and the installation are in good condition, and that the air inlets and outlets and drainage
holes are clear.
5. Check the fuel, oil and coolant levels.
6. If fitted, open the top-up valves (oil, fuel, etc.).
7. If fitted, close the drain valves.
8. If necessary, drain the air from the fuel system (prime it at initial commissioning if necessary).
a. If necessary, refer to the engine maintenance manual supplied with the equipment.
9. Select the fuel supply mode (generating set tank or external tank).
10. Close all the access doors and ensure that the enclosure panels (if fitted) are properly secured
7.3.5 Performing the relevant tests and checks

7.3.5.1 Starting test
Perform a start-up test once a month if required by local regulations.
The starting test only allows you to check the engine starting and its safety features. It does not allow you to check that the
generator set is working properly. To check whether the generator set is working properly, refer to paragraph "ON load tests".
To perform a starting test, follow the instructions below.

1. Making sure not to exceed 10 minutes of operation, begin the starting test.
2. Check that the safety devices are working properly, in particular the emergency stop and, if fitted, the differential
protection.
3. If faults are indicated, correct and acknowledge them, referring to the control unit documentation.
4. If fitted, check that the pre-heating system is working properly.
5. It is essential to perform the monthly ON load test of the generator set as well as the associated checks.
6. If you have any doubt, contact your authorized Kohler distributor/dealer for service.

No load and below load tests
No load and below load tests damage the equipment, in particular the engine:
• never exceed 10 minutes of no load test or below load test;
• limit the frequency of no load tests to a maximum of once per month.
7.3.5.2 ON load test

To perform an ON load test and the associated checks, follow the instructions below.
1. Only when the generator set is stopped, check the correct operation of the fuel circuit shut-off valve.
2. Plan a load greater than 50% of the nominal output, ideally 80%.
3. Apply voltage and check immediately that there are no alarms or faults on the displays and/or control unit.
4. Ensure that there are no leaks, vibrations or abnormal noises.
5. Ensure that the color of the exhaust gas is normal.
6. Check the engine parameters (oil pressure, coolant temperature).
7. Check the electrical parameters (voltage, frequency, current, rotating magnetic field⃰).
8. If fitted, check the correct operation of the automatic filling devices (fuel and/or oil).
36 1194_EN 2023-08-08
Operation
Section 8. Operation
8.1 Safety instructions for the operation of the generating set

8.1.1 Risk of Electromagnetic interference
DANGER RISK OF ADVERSE EFFECTS: WEARERS OF A PACEMAKER

DANGER OF DEATH
The electromagnetic fields generated when the electrical generating set is running could
affect the operation of pacemakers.
concerned.
Before any operation on the electrical generating set, seek medical advice.
8.1.2 Risk of electrocution
DANGER ELECTRICAL EQUIPMENT - RISK OF ELECTRIC SHOCKS

DANGER OF DEATH
concerned.
• Read the Nameplate located on the generator set (or container) carefully:
1. Note the voltage, output, current and frequency values;
2. Check that these values match the installation being supplied with electricity.
• Always handle the equipment with dry hands and feet.
• Take all the necessary precautions to avoid touching stripped cables or disconnected connectors.
• For wearers of a Pacemaker or of an implanted defibrillator, it is strongly recommended not to access to the installation
or work near a generating.
• Stay away from the generator set while it is in operation.
In the event of electric shock, follow the instructions below.

1. Avoid direct contact with the victim's body or with the live conductor.
2. Activate the nearest emergency stop.
3. If it is not possible to access the equipment: move the victim away from the live conductor using
an insulated pole, a piece of dry wood, dry clothing or any other non-conductive material.
4. Move the victim away from any situations where there is a DANGER OF DEATH.
5. Contact the emergency services.
6. If breathing has stopped, begin artificial respiration at once.
7. In the event of cardiac arrest, carry out cardiac massage.
8.1.3 Serious risks of intoxication
DANGER EXHAUST GASES, CARBON MONOXIDE – RISK OF INTOXICATION.

DANGER OF DEATH
concerned.
Generator set operation. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is an odorless,
colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Avoid breathing exhaust fumes when
working on or near the generator set. Never operate the generator set inside a building unless the exhaust gas is piped safely
outside. Never operate the generator set where exhaust gas could accumulate and seep back inside a potentially occupied
building.
1194_EN 2023-08-08 37
Operation
8.1.4 Risks of crushing, shearing or catching
DANGER RISK OF SERIOUS ACCIDENT – RISK OF SERIOUS INJURY: SHEARING,

ENTANGLEMENT, CRUSHING
DANGER OF DEATH
concerned.
• Before starting up the electrical generating set, check that the safety features guarding the rotating parts have been
refitted after the maintenance work
• Keep away from the engine when it is in operation.
8.1.5 Risks of burns
DANGER RISK OF SERIOUS ACCIDENT – RISK OF SERIOUS BURNS

DANGER OF DEATH
concerned.
During its operation and for several hours after it is stopped, the generator set remains hot:
• Keep away from the engine when it is in operation or right after it is stopped. Avoid all contact with hot parts of the
equipment.
• Use appropriate ventilation to allow the equipment to cool correctly.
8.1.6 Risks of fire and explosion
DANGER RISK OF SERIOUS ACCIDENT--– RISK OF FIRE AND EXPLOSION

DANGER OF DEATH
concerned.
During operation, engine fluids are hot and, if leaking, could result in a fire or an explosion. Moreover, the high temperature of the
gas at the exhaust or sparks that may be produced during operation pose a real risk if there are flammable materials in the vicinity.
During operation:
• Regularly monitor the generator set and its installation.
• Clear a large enough area around the generator set.
• Keep all flammable or explosive materials (cloths, petrol, oil, plants, etc.) out of the way.
• Train the operating staff in fire safety and, if necessary, install fire detectors and extinguishers in the room.
38 1194_EN 2023-08-08
Operation
8.1.7 Risks relating to noise
DANGER
HIGH SOUND LEVEL - RISK OF HEARING LOSS
Failure to observe the safety instructions could cause serious injuries to those concerned.
• Note the sound pressure level measured at 1 m, which is indicated on the nameplate of the generator set (or container).
• When working in close proximity to a generator set which is in operation, always wear suitable ear protection.
8.1.8 Specificity of gas operation
DANGER
FLAMMABLE PRODUCTS – RISKS OF FIRE AND EXPLOSION.

DANGER OF DEATH.
concerned.
Before any operation on a generator set running on gas, follow the safety instructions below.
• A qualified specialist must be consulted regarding any operations on a gas installation.
• Request the technical operating notes and LPG ⃰ or NG ⃰ safety data sheets from the gas supplier.
• All of the safety instructions in this manual must be observed.
• Gas supply procedures must be carried out in the open air (outside) in accordance with local regulations, in an area well
away from fires, people or animals.
• Check the gas supply circuit for leaks:
o either using soapy water with the circuit pressurized;
o or using a leak detector.
• It is forbidden to smoke, bring flames near or create sparks when the tank is being filled, and near to the generator set.
8.2 Preparing the generating set for starting

1. Be a qualified professional authorized to start a generating set and strictly follow safety rules.
3. Wear suitable personal protection equipment (gloves, safety goggles, shoes, helmet, etc.).
4. Ensure that the generating set and the installation are in good condition, and that the air inlets and outlets and drainage
holes are clear.
5. Check the fuel, oil and coolant levels.
6. If fitted, open the top-up valves (oil, fuel, etc.).
7. If fitted, close the drain valves.
8. If necessary, drain the air from the fuel system (prime it at initial commissioning if necessary).
a. If necessary, refer to the engine maintenance manual supplied with the equipment.
9. Select the fuel supply mode (generating set tank or external tank).
10. Close all the access doors and ensure that the enclosure panels (if fitted) are properly secured
8.3 Starting the generating set

1. Follow the instructions about preparing the generator set for starting.
a. For ISO20 and ISO40 containers, open the doors of the sound traps
2. Check that the load corresponds to the capacity of the generator set.
3. Observe the instructions in the user manual for the generator set control unit.
a. The starting procedure differs according to the configuration of the generator set and the installation characteristics.
4. Stay away from the generator set while it is in operation and keep panels or side doors shut.
1194_EN 2023-08-08 39
Operation
8.4 Checking the generating set after startup

protection.
3. Check the mechanical parameters of the engine (oil pressure, coolant temperature).
4. Check the following elements:
a. absence of leaks;
b. tightness of the exhaust circuit;
c. absence of abnormal vibrations;
d. absence of abnormal noises.
5. Check the following electrical parameters:
a. voltage, frequency and phase rotation direction.
8.5 Minimizing operation at no load and below load

NOTICE
For generator sets with exhaust aftertreatment systems (EATS), never operate under no-load or low-load conditions. To
prevent hydrocarbon buildup in the EATS components, use a load bank or the building design to maintain the minimum load
and minimum exhaust temperature. For operation and requirements, refer to the Exhaust Aftertreatment System Installation
and Application Manual.
Operation of the generator set at no load or low load (0-30% of nominal output) deteriorates the engine and reduces its service
life.
nominal output of the generator set

less than 33%.
• Clogging of the engine (segmentation, valves, loss of
tightness, etc.)
engine does not warm up sufficiently, • Increase in engine crankcase gas flow rates
it is too cold.
• Clogging of the oil
• Possible dilution of the oil with fuel
degraded combustion, production of
carbon particles.
Hydrocarbon buildup and deposits typically occur when regularly operating the engine at no load or low load for extended periods
of time, which is intensified by operation at low ambient temperatures. High exhaust temperatures burn off these hydrocarbons
and deposits. When proper operation and maintenance procedures are followed, no-load and low-load operation can be used
without hydrocarbon buildup or engine damage.
For more information about no load and low load operation and on how to take the necessary precautions, refer to the following
information and consult with your Kohler distributor or dealer. Refer to maintenance section for more details in the on-load test
and no- and low-load start test instructions.
8.5.1 Conscious Care™ maintenance program with KD series
KD series generator sets qualify for the Conscious Care™ maintenance program, which reduces fuel consumption and carbon
emissions through no- or low-load exercise. Generator set exercise is typically performed under loaded operation conditions (33%
or greater load); however, for some facilities, no-load (0% load) and low load (0–33% load) operation may be needed to prevent
interruption of facility services.
Two options are available with the Conscious Care™ maintenance program:
• Monthly exercise at no load or low load
• Extended exercise at no load or low load, exercise every 4 months.
Important:
Conscious Care maintenance program is not available for generator sets with exhaust aftertreament systems (EATS).
The Conscious Care™ maintenance program requires a service agreement to ensure that proper operation and maintenance
procedures are followed. Contact an authorized Kohler distributor or dealer to sign up for a service agreement.
40 1194_EN 2023-08-08
Operation
Monthly Exercise with Conscious Care™
• Exercise under no-load or low load for a minimum of 10 minutes. Refer to the maintenance procedure Start Test to check
generator set operation.
o Period between exercise intervals must not exceed 1 month.
• Reduce the test intervals of the engine components, particularly the crankcase breather oil circuit.
• Perform maintenance operations more often, particularly the exhaust drainage operations.
• Analyze the oil, if necessary.
• Regularly perform annual loaded exercise for a minimum duration of 30–60 minutes.
o Maintain the exhaust temperature at the rated kW stated on the generator set specification sheet for a minimum of
30 minutes.
o Perform loaded exercise after 12 hours of cumulative no-load and low-load operation. Refer to the maintenance
procedure, On-Load Test, to check generator set operation.
Extended Exercise (4-month intervals) with Conscious Care™
Exercising the generator set every four months further reduces fuel emissions and fuel consumption; however, additional
preparation and requirements must be taken to ensure reliable starts. In addition to the previous list, see the following list of
requirements and recommendations for extended exercise with Conscious Care™:
Required:
• Period between exercise intervals must not exceed 4 months.
• No biofuels or biofuel blends
• Alternator heater
• With engine models KD62V12, KD83V16, KD103V20, idle start at point of exercise is required.
Note:
APM802 controller must be updated to firmware version 1.11 or greater. Contact your authorized distributor or dealer to
verify idle start availability.
Recommended:
• Monthly cranking to lubricate components
• Redundant starters (if available)
• Redundant batteries
• Redundant battery chargers
• With engine models KD18L06, KD27V12, KD36V16, KD45V20, idle start at point of exercise is recommended but not
required.
8.5.2 Low Load operation with all other models (not KD series)

Operation at no load and below load
• Never exceed 10 minutes.
• Limit the frequency of operation at no load or below load to a maximum of once
per month.
In the event of operation at no load or below load (0-30% of nominal output), limit the material damage by:
• adding a ballast resistor
• regularly performing ON load tests (70-100% of nominal output) for a minimum duration of 1 hour to clear the
equipment
• reducing the test intervals of the engine components, in particular the engine breather oil circuit
• reducing the intervals of the maintenance operations, in particular the intervals between 2 drainage operations
• analyzing the oil, if necessary
1194_EN 2023-08-08 41
Operation
8.5.3 Conscious Care™, No-Load and Low-Load Exercise
NOTICE
Over time, hydrocarbon buildup can damage the engine and reduce engine performance.
• After 12 hours of cumulative low-load operation or at a minimum of once annually, the generator set must operate
under load for 30-60 minutes and maintain the exhaust temperature at rated kW listed on generator set specification
sheet for 30 minutes minimum.
• Generator sets with exhaust aftertreatment systems (EATS) should never operate under no-load or low-load
conditions because of exhaust temperature requirements.
KD series generator sets qualify for the Conscious Care™ maintenance program, which reduces fuel consumption and carbon
emissions through no- or low-load exercise.
Hydrocarbon buildup and deposits typically occur when regularly operating the engine at no load or low load for extended periods
of time, which is intensified by operation at low ambient temperatures. High exhaust temperatures, obtained during loaded
operation, burn off these hydrocarbons and deposits. When combined with an annual loaded operation and proper maintenance
procedures, no-load and low-load operation can be used without hydrocarbon buildup or engine damage.
Two options are available with the Conscious Care™ maintenance program:
• Monthly exercise at no load or low load
• Extended exercise at no load or low load, exercise every 4 months
Important:
Conscious Care maintenance program is not available for generator sets with exhaust aftertreament systems (EATS).
procedures are followed. Contact an authorized Kohler distributor or dealer to sign up for a service agreement.
8.6 Switching the generating set off

8.6.1 Normal shutdown
The procedure for stopping a generator set differs according to the configuration of the generator set and the installation
characteristics.
2. For a generator set equipped with a control unit, follow the instructions in the user manual of the control unit supplied
with the generator set.
3. Gradually reduced the load applied to the generator set and allow it to idle (0% load) for ten or so minutes before stopping
it.
DISCONNECTING FROM THE INSTALLATION, CHECK THE FACTORY SETTINGS:
In order to ensure that staff are protected against electric shocks, generator sets are equipped with a general residual current
protection device which is configured in the factory to be triggered instantly with a sensitivity of 30mA. If, to meet the installation
requirements, this value has been modified on the generator set, ensure that it returns to the factory safety settings each time the
generator set is disconnected from the installation :
2. Return the general residual current protection device to the factory settings: instant triggering and sensitivity of 30 mA.
3. Check that the return to factory settings has been taken into account.
8.6.2 Emergency stop

Emergency stopping of the generator set is recommended only in the event of a dangerous situation. Sudden stopping during ON
load operation of the generator set could cause damage to the equipment.
1. Only press the emergency stop push-button to immediately stop the generator set if necessary.
2. Before any attempt to restart, resolve the fault which required the emergency stop button to be pressed.
3. "RESET" the faults.
4. If necessary, refer to the control unit operating manual.
42 1194_EN 2023-08-08
Maintenance
Section 9. Maintenance
As a safety precaution, maintenance of the generating set and its installation must be carried out regularly and diligently by
qualified, authorized professional personnel equipped with suitable tools, in compliance with the applicable standards and
legislation.
The maintenance operations to be performed are described in the maintenance schedule in this chapter:
• The maintenance schedule in this manual is not exhaustive. Complete it using the technical documentation of the
components supplied with this manual (engine, alternator and, if fitted, other components).
• The frequency of the maintenance operations is indicative only and should be reduced according to the actual usage
conditions of the equipment and requirements.
• The frequency of the maintenance operations is calculated for equipment operating with fluids that are in compliance
with the specifications stated in this manual.
Always give priority to the specifications in the technical documentation supplied with this manual (engine, alternator, etc.) rather
than the instructions in this manual.
Warranties are excluded if the equipment has not been properly maintained.
9.1 Maintenance safety instructions
DANGER MAINTENANCE OPERATIONS - MULTIPLE RISKS

DANGER OF DEATH
concerned.
During maintenance operations on the generator set take any necessary measure to protect
personnel against the risks involved by maintenance operations, in particular protect
personnel against:
• electrocution,
• elevated areas,
• catching, shearing or crushing,
• burns,
• fires or explosions,
• carbon monoxide poisoning.
The electrical generator set may also be equipped with a cranking system which is
programmed and automatic, or controlled remotely, which can pose a real risk to
maintenance operators.
9.1.1 Protecting personnel

1. Control operations, monitoring and maintenance must only be carried out on the equipment by qualified, authorized
professional personnel.
2. All the safety instructions set out in the documentation provided must be carefully read and strictly followed.
3. Ensure that the lighting conditions are sufficient throughout the operation.
5. Wear suitable personal protection equipment (gloves, safety goggles, helmet, etc.).
6. Lock out the installation (activate the equipment's emergency stop, open the circuit breaker, actuate the battery isolating
switch (if equipped), disconnect the battery (if equipped) starting with the negative terminal (-), disconnect the pneumatic
starter (if equipped) and place a sign on the equipment controls prohibiting any start-up attempts).
7. Before handling the equipment, ensure that the engine of the generating set is stopped and cold (risk of serious burns).
8. Before removing or disconnecting any fittings, pipes or connected components, depressurize the air, oil and cooling
circuits.
9. It is essential to collect the fluids in containers intended for this purpose, never allow the fluids to flow onto the floor.
10. During maintenance operations, certain protective grilles or panels must be removed: refit these carefully once the
operations have been completed. During operation, any missing panel or grille will cause major damage to the equipment
and could also cause serious bodily injuries (risk of getting caught in the machinery, shearing or cutting).
1194_EN 2023-08-08 43
Maintenance
PPE* MANDATORY - IF ENGINE FLUIDS COME INTO CONTACT WITH THE SKIN AND/OR EYES ACCIDENTALLY:
The generator sets contain toxic, corrosive and flammable substances (fuel, oil, coolant, battery electrolyte, etc.) which are likely
to cause serious harm to health. Avoid all contact with these substances by wearing suitable personal protection equipment
(goggles, gloves, etc.).
In the event of accidental contact with the skin:
1. Wash thoroughly with water and soap.
2. Consult a doctor immediately.
In the event of accidental contact with the eyes:
1. Rinse immediately with running water or, if possible, with a solution of 10% diluted boric acid for at least 15 minutes.
2. Consult a doctor immediately.
9.1.2 Preserving the equipment

1. Before any operation, read the relevant chapters and ensure you have understood them properly.
o If you have any doubt, contact your authorized Kohler distributor/dealer for service.
2. It is essential to make a note of any modifications made to the generator set (configuration, settings, connections, etc.)
in the descriptive document sent by the operations manager.
3. Use tools with insulated handles, in good condition and suited to the work to be done.
o For parts fitted with captive bolts, use screwdrivers (the use of electric or pneumatic screwdrivers to unscrew captive
bolts causes strong material damages and is formally prohibited).
4. The maintenance products recommended in this documentation must be used.
5. Check that the spare parts fitted on the equipment are supplied only by our authorized Kohler distributor/dealer for
service.
6. Note the maintenance to be performed and the associated deadlines.
7. Throughout the generator set's service life, regularly check that the maintenance deadlines are respected.
9.2 Planning maintenance

The maintenance operations are intended to preserve the integrity of the generator set and that of the generator set's installation.
To ensure good maintenance:

1. Create a maintenance schedule listing the maintenance operations to be performed (refer to the example maintenance
schedule shown in the following section).
2. Create a service history indicating:
a. the frequency of the maintenance operations;
b. the nature of the maintenance operations;
c. the inspections and/or tests performed;
d. the date and time at which the maintenance operation was performed;
e. an account of the maintenance operation;
f. the name and signature of the operator.
9.2.1 Designing a suitable maintenance schedule

• The maintenance schedules are defined in the respective maintenance manuals of the engines, alternators and certain
complementary components.
• The maintenance schedules generally distinguish:
o use in continuous operation;
o use in emergency operation.
To design a suitable maintenance schedule:
1. Consider the specifics of the installation, such as the quality of the engine fluids (sulfur content of the fuel, quality of
oil, etc.), harsh operating conditions, a dusty environment, etc.
2. Adapt the maintenance schedule of the generator set and the maintenance schedules of all its complementary
equipment.
3. Refer to the instructions of the maintenance manuals for the components of the generator set (engine, alternator and, if
fitted, other components) rather than to the instructions of this manual.
44 1194_EN 2023-08-08
Maintenance
9.2.2 Example maintenance schedule
Create a maintenance schedule based on the following model (non-exhaustive list of operations to be performed), adapting it to
the specifics of the installation and the technical documentation supplied (engine, alternator and, if fitted, other components).
INTERVAL* OPERATIONS
When the 1st of the two deadlines is non-exhaustive list, refer to the technical documentation supplied (engine, alternator and, if fitted, other
reached components)
Check that the entire installation is in good condition and is clean

Check the fluid levels and, if fitted, that the automatic fluid filling device is working properly
every 100 operating hours Perform a starting test followed by an ON load test and carry out the associated checks
OR Check the condition of the various fuel filters on generating set and drain if necessary
every month
Visually check the load resistors, if fitted
If fitted, check that the ballast insulation is clean and in good condition and clean the insulation
with a cloth soaked with quick-drying thinner or, if necessary, replace the insulation
If fitted, have the fire safety systems checked by a certified organization.

every 3 months
If fitted, have the carbon monoxide detection systems checked by a certified organization.
Check for leaks

Check the charging system and the charge status of the batteries
Grease the earth strap nuts with conductive grease
Clean the panels of the generating set
If fitted, check that the safety elements are in good condition and tightened securely (guard
every 500 operating hours rails, ladders, walkways, etc.)
OR If fitted, replace the various fuel filters on the generating set
every six months
If fitted, check the electrical connections, including in the control cabinets or power cabinets
If fitted, check the clogging indicator on the air filter(s)
If fitted with air coolers, drain engines equipped with drain holes
If fitted, drain condensates from the exhaust system
If fitted, check the retention container level and, if necessary, drain it
Check for abnormal engine wear, signs of overheating

Check the condition of the suspension mounts for the engine-alternator beam, and replace
them if necessary
every 1000 operating hours If fitted, service the starter batteries
OR If fitted, check the catalytic converters of the silencers
every year If fitted, manually check the operation of the rain grilles and lubricate them
If fitted, check the pressure gage and replace the filter element(s) on the oil breather, if
necessary
If fitted, clean the lights with a cloth
every 2000 hours Drain the cooling system

OR Have general maintenance performed by one of our authorized Kohler distributor/dealer for
every two years service.
Check that the cooling radiator fins are in good condition, clean them by blowing compressed
every 4000 hours air in the opposite direction to the normal air flow.
OR Perform a thorough, meticulous check of the condition of the fluid hoses and replace them if
every four years necessary
If a fuel tank is fitted, employ a specialist company to check its condition
Refer to the technical documentation supplied with this manual. Depending on the models of
engine, alternator and other
the generating set components, the maintenance intervals and the maintenance operations to
components
be performed may vary.
* information is given as a guideline to be adapted according to the technical documentation supplied (engine, alternator and, if
fitted, other components) and the specifics of the installation.
1194_EN 2023-08-08 45
Maintenance
9.3 Performing maintenance
DANGER MAINTENANCE OPERATIONS - MULTIPLE RISKS

DANGER OF DEATH
concerned.
During maintenance operations on the generator set take any necessary measure to protect
personnel against the risks involved by maintenance operations, in particular protect
personnel against:
• electrocution,
• elevated areas,
• catching, shearing or crushing,
• burns,
• fires or explosions,
• carbon monoxide poisoning.
The electrical generator set may also be equipped with a cranking system which is
programmed and automatic, or controlled remotely, which can pose a real risk to
maintenance operators.
9.3.1 Checking the good condition and cleanliness of the entire installation
1. Remove any waste (decomposing leaves, etc.) and, if fitted, drain the fluid retention container.
2. Check the condition and/or cleanliness of the following equipments and, if necessary, carefully brush and/or replace the
defective elements:
a. of the fan;
b. of the cooling circuit honey combs;
c. of the air inlet and outlet elements;
d. of the panels (corrosion);
e. of the drive belts;
f. of the electrical equipment and their connections;
g. of the exhaust circuit components (mechanical hold, alteration of the materials, etc.) ;
h. of the hoses and pressure lines and their connections;
i. of the protective grilles;
j. if fitted, of the manual pump,
k. if fitted, of the bird guards;
l. if fitted, of the spark arrestor;
m. if fitted, of the cooling batteries;
n. if fitted, of the radiators and sound levels.
3. Check and retighten the fastenings on all of the installation.
4. Check the fluid levels and, if fitted, that the automatic fuel and/or oil filling device is working properly.
5. Replace any missing or illegible safety pictograms on the equipment.
46 1194_EN 2023-08-08
Maintenance
9.3.2 Performing the relevant tests and checks

9.3.2.1 Start test
Start tests are performed under no-load and low-load conditions. The start test allows you to check the engine starting and its
safety features. The start test does not allow you to check whether the generator set is working properly under load. To check the
generator set under load, refer to the "ON load test.”
NOTICE
For generator sets with exhaust aftertreatment systems (EATS), never operate under no-load or low-load conditions. To
prevent hydrocarbon buildup in the EATS components, use a load bank or the building design to maintain the minimum load
and minimum exhaust temperature. For operation and requirements, refer to the Exhaust Aftertreatment System Installation
and Application Manual.
9.3.2.1.1 Start test with Conscious Care™ maintenance program (KD series only)
NOTICE
Over time, hydrocarbon buildup can damage the engine and reduce engine performance.
• After 12 hours of cumulative low-load operation or at a minimum of once annually, the generator set must operate
under load for 30-60 minutes and maintain the exhaust temperature at rated kW listed on generator set specification
sheet for 30 minutes minimum.
• Generator sets with exhaust aftertreatment systems (EATS) should never operate under no-load or low-load
conditions because of exhaust temperature requirements.
To perform a start test for the Conscious Care™ maintenance program, operate the generator set for a minimum of 10 minutes
under no-load or low-load conditions. Check local and state statutes and codes for requirements. Use the following instructions
and perform the associated checks:
1. If faults are indicated, correct and acknowledge them.
2. If fitted, check that the pre-heating system works properly.
3. Check for leaks, vibrations, or abnormal noises.
6. Check the electrical parameters (voltage, frequency, current, rotating magnetic field).
7. If fitted, check the correct operation of the automatic filling devices (fuel or oil).
procedures are followed. Contact an authorized Kohler distributor or dealer to sign up for a service agreement and for questions
and information related to no-load or low-load operation.
1194_EN 2023-08-08 47
Maintenance
9.3.2.1.2 Start test with all other models (not KD series)
Perform a start-up test once a month if required by local regulations.
The starting test only allows you to check the engine starting and its safety features. It does not allow you to check that the
generator set is working properly. To check whether the generator set is working properly, refer to paragraph "ON load tests".
To perform a starting test, follow the instructions below.

1. Making sure not to exceed 10 minutes of operation, begin the starting test.
protection.
3. If faults are indicated, correct and acknowledge them, referring to the control unit documentation.
4. If fitted, check that the pre-heating system is working properly.
5. It is essential to perform the monthly ON load test of the generator set as well as the associated checks.

No load and below load tests
No load and below load tests damage the equipment, in particular the engine:
• never exceed 10 minutes of no load test or below load test;
• limit the frequency of no load tests to a maximum of once per month.
9.3.2.2 Emergency Stop Test
NOTICE
Testing the emergency stop button under load or low-load can damage the engine or alternator. Only perform an emergency
stop test under no-load operation.
The emergency stop test is a monthly test that may be required for installation compliance (such as NFE-37312 in France). Check
local and state statutes and codes for requirements. Never perform an emergency stop test under loaded or low-load operation.
Use the following instructions and perform the associated checks:
1. Start the generator set under no-load operation.
2. Allow the engine to warm up and run for approximate 10 minutes.
3. Press the emergency stop button to stop the generator set.
4. Reset the emergency stop button.
9.3.2.3 ON Load Test
The ON load test of the generator set allows you to check that it is operating properly and to guarantee that the engine is clear.
The following procedures vary slightly between KD series generator sets and for all other generator set models.
9.3.2.3.1 ON load test with Conscious Care™ maintenance plan (KD series generator sets only)
To perform an on-load test, use the following instructions and perform the associated checks:
1. Operate the generator set under load for 30–60 minutes while maintaining the exhaust temperature at rated kW listed
on the generator set specification sheet to remove hydrocarbon buildup.
2. Apply voltage and check for alarms or faults.
3. Check for leaks, vibrations, or abnormal noises.
6. Check the electrical parameters (voltage, frequency, current, rotating magnetic field).
7. If fitted, check the correct operation of the automatic filling devices (fuel or oil).
48 1194_EN 2023-08-08
Maintenance
9.3.2.3.2 ON load test with all other models (not KD series)
The ON load test of the generator set allows you to check that it is operating properly and to guarantee that the engine is clear.
Perform an ON load test:

• once per month for 1 hour after stabilization of the parameters;
• with a load greater than 50% of the nominal output, ideally 80%.
To perform an ON load test and the associated checks, follow the instructions below.
1. Only when the generator set is stopped, check the correct operation of the fuel circuit shut-off valve.
2. Plan a load greater than 50% of the nominal output, ideally 80%.
3. Apply voltage and check immediately that there are no alarms or faults on the displays and/or control unit.
4. Ensure that there are no leaks, vibrations or abnormal noises.
7. Check the electrical parameters (voltage, frequency, current, rotating magnetic field⃰).
8. If fitted, check the correct operation of the automatic filling devices (fuel and/or oil).
9.3.3 Fuel System
DANGER
ENGINE FLUIDS: TOXIC, FLAMMABLE, PRESSURIZED PRODUCTS - MULTIPLE
RISKS
DANGER OF DEATH
Failure to observe the safety instructions could result in serious injuries or the death of
those concerned.
When handling the fuel, always observe the following safety instructions.
• Be qualified and authorized to perform any operation.
• Wear suitable personal protection equipment (gloves, goggles, helmet, etc.).
• Before any operation, ensure that the engine is stopped and cold.
• Before any operation, ensure that the pressure in the fuel circuit has fallen.
• Ensure that the generator set room has suitable fire-fighting equipment.
• Only bleed the supply circuit at the fuel filters.
• Replace the hoses as soon as their condition demands it.
• It is essential to use fuel that meets the technical requirements of this manual.
• Respect current local regulations regarding the equipment and fuel used (petrol, diesel and gas).
• In case of contact with the skin, rinse immediately and thoroughly.
• Never smoke, bring a flame near or create sparks while the fuel tank is being filled.
9.3.3.1 Topping up the fuel
DANGER
ENGINE FLUIDS: FLAMMABLE, TOXIC PRODUCTS - MULTIPLE RISKS
DANGER OF DEATH
Fuel is highly flammable, handle it with caution. Keep away from any flames or any source
of sparks. Always switch off the generator set before filling with fuel.
1. Identify the fuel tank cap. It is always indicated by a pictogram (see figure below).
2. Open the fuel tank cap.
3. Top up the tank with fuel.
4. Carefully close the fuel tank cap.
5. All traces of fuel should be wiped off with a clean cloth.
Figure 17: Example of fuel tank cap and pictogram.
1194_EN 2023-08-08 49
Maintenance
9.3.3.2 Fuel pre-filters

• Additional fuel filters, fitted on certain generator sets.
• Priority should be given to the instructions in the engine maintenance manuals (filters fitted by the engine manufacturers).
• In addition to the instructions in the engine maintenance manuals, perform the operations described in this paragraph.
A: filter
B: seal
C: water bleed screw D B
D: air bleed screw
E: priming pump E
F: water presence sensor A
B isolation valves
D
A
A
B
B
B
A
B
C
C
F C
Figure 18: Examples of pre-filters (change of filter via the bowl)
D isolation valve
B
Figure 19: Examples of pre-filters (change of filter via the cover)
9.3.3.2.1 Pre-filter maintenance interval

Allow for 2 types of maintenance on the fuel pre-filters:
• Drain the water:
o if the generator set loses power;
o as often as necessary according to the visual indicator.
• Replace the filter element:
o at the same time as you replace the main fuel filter.
The frequency of maintenance on the fuel pre-filters varies according to the quality and the level of contaminants in the fuel used.
Water has a higher density than fuel, and so it is easy to check for the presence of water in the pre-filter since it appears in a
different color at the bottom of the transparent bowl.
50 1194_EN 2023-08-08
Maintenance
9.3.3.2.2 Draining water

1. Stop the generator set and wait until the engine is cold.
2. Alternatively, if the filters fitted in series are equipped with an isolating valve, isolate the filter to be bled.
3. Place a container at the water bleed screw.
4. Unscrew (approximately 2 turns) the water bleed screw on the bowl and, if fitted, the filter air bleed screw.
5. Drain the water.
6. Close the water bleed screw and the air bleed screw.
7. Ensure that the bleed screws are not leaking.
9.3.3.2.3 Replace the filter
BEFORE ANY FILTER REPLACEMENT:

1. Stop the generator set and wait until the engine is cold to avoid any risk of fire.
2. If fitted, close the isolating valve between the tank and the filter.
3. Alternatively, if the filters fitted in series are equipped with an isolating valve, isolate the filter to be replaced.
FILTER FOR REMOVAL VIA THE BOWL:

1. If fitted, open the air bleed screw.
2. Place an appropriate container at the water bleed screw to collect the fuel.
3. Unscrew (approximately 2 turns) the water bleed screw on the bowl and drain the fuel.
4. Remove, by hand if possible, the elements required to access the filter element then scrap the used filter element.
5. Ensure the integrity and cleanliness of the elements (filter support, bowl, seals, etc.) and replace the damaged elements.
6. Close the bleed screws.
7. Lubricate the seals with oil or fuel and fit the new filter element.
8. Fill the elements to be refitted with clean fuel.
9. Hand-tighten the assembly onto the filter support.
10. If necessary, bleed the fuel supply circuit.
FILTER FOR REMOVAL VIA THE COVER:
If necessary, after replacing the filter, bleed the fuel supply circuit.
1194_EN 2023-08-08 51
Maintenance
9.3.4 Oil circuit
DANGER HOT OIL - RISK OF BURNS AND POISONING

DANGER OF DEATH
The oil may contain toxic combustion residue.
concerned.
When handling the oil, always observe the following safety instructions.
• Be qualified and authorized to perform all maintenance operations.
• Suitable personal protection equipment (gloves, goggles, etc.) must be worn.
• Before any operation, wait until the engine has come to a complete stop and has cooled fully.
• Before starting the engine, refit the oil filler cap.
• Never mix different types of oil.
• Avoid all contact with hot oil.
• Ensure proper ventilation.
9.3.4.1 Draining the oil
1. Ensure that the engine is stopped and

cold.
2. If fitted, close the tap on the oil top up
tank.
3. Place an appropriate container under
the oil sump drainage valve to collect
the oil.
4. Open the oil sump drainage valve.
5. Operate the lever of the manual pump
until the oil sump is drained.
6. Close the oil sump valve.
7. If necessary, replace the oil filter.
a. Refer to the engine maintenance
manual.
Figure 20: Oil drainage pump Figure 21: Examples of oil sump drainage valve
52 1194_EN 2023-08-08
Maintenance
9.3.4.2 Topping up the oil
To top up the oil, follow the instructions below:

1. Ensure that the engine is stopped and cold.
2. Remove the dipstick from the guide tube and clean it.
3. Insert the dipstick into the guide tube until it stops.
4. After 10 seconds, remove the dipstick and check the oil
level.
5. If the oil level is not between the "min." and "max." marks,
top it up:
a. open the filling port;
b. top up with oil that meets the technical requirements up
to the "max." mark;
c. close the filler cap.
6. Insert the dipstick into the guide tube until it stops.
7. Close the guide tube.
8. Check for leaks in the oil circuit using the following
procedure.
To check for leaks in the oil circuit, follow the instructions below:
1. If fitted, open the tap on the oil top up tank.
2. If fitted, start the pre-lubrication system.
3. Start the generator set.
4. Check the engine oil pressure and the tightness of the oil
filter.
5. Stop the engine and wait for 10 minutes to check the oil level
again.
Figure 22: Example guide tube and dipstick
9.3.5 Cooling system
DANGER
COOLANT - RISK OF SERIOUS CHEMICAL BURNS
The corrosion inhibitor present in the coolant contains alkali, a substance which is very toxic
to the health and to the environment.
Failure to observe the safety instructions could result in serious injuries to those concerned.

Coolant
• Never mix different types of coolant.
• Before proceeding with filling, ensure that you have enough new coolant for all of
the circuit (engine, pipes, radiator, etc.).
• After draining the cooling circuit, several successful top ups are required to
completely fill the circuit.
When handling the coolant, always observe the following safety instructions.
• Suitable personal protection equipment (gloves, goggles, helmet, etc.) must be worn.
• Only remove the filler cap when it is cold. Turn the cap to the first notch to release the pressure then remove it completely.
• Read the instructions on the coolant packaging.
• Avoid all contact with the skin and eyes.
1194_EN 2023-08-08 53
Maintenance
9.3.5.1 Draining the coolant

To drain the coolant, follow the instructions below.
1. Ensure that the engine is stopped and cold.
2. Place an appropriate container under the air bleeding valves and drain plugs to collect the coolant.
3. If fitted, stop the pre-heating system.
4. Turn the expansion tank cap to the first notch to eliminate any pressure, then remove it completely.
5. Open all the drainage points and allow the coolant to flow at the following locations (to be adapted according to the
configurations):
a. radiator drain valve;
b. engine block;
c. pre-heating unit;
d. cooling pump body;
e. injection pump;
f. thermostat case;
g. cooling circuit pipes fitted with bleed screws.
6. Close all open drainage points.
7. Fit the expansion tank cap, then close it.
9.3.5.2 Topping up the coolant

FILLING WITH A PUMP:
1. Filling should preferably be performed with a pump.
2. Using a flexible hose, connect a suitable pump to the lowest drainage point.
3. Loosen the permanent venting points and the air bleeding points.
a. If necessary, also drain at the pump body and the thermostat casing.
5. Open the drain valve and fill the coolant circuit with the pump, ensuring that the pressure is greater than 0.5 bar.
6. As filling progresses, when liquid free from air bubbles runs out, close the permanent venting points and the air bleeding
points in succession.
7. Fill the coolant circuit until the level in the expansion tank is at the maximum.
8. Close the drainage valve.
9. If necessary, clean the sealing surfaces.
10. Check that the expansion tank cap is in good condition, refit it and then close it.
11. Remove the pump and flexible hose used for drainage.
12. Cut the fuel supply then restart the generator set for 10 minutes (maximum).
13. Check for leaks in the cooling circuit assembly.
15. Top up the coolant to the maximum level.
a. If necessary, repeat the engine starting and refilling processes as shown in the previous steps of this procedure.
17. Remove and clean the pump and flexible hose.
FILLING VIA EXPANSION TANK ⃰:
If it is not possible to follow the filling method with a pump, perform filling via the expansion tank.
2. Loosen the permanent venting points and the air bleeding points.
a. If necessary, also drain at the pump body and the thermostat casing.
3. Pour the coolant into the expansion tank.
4. As filling progresses, when liquid free from air bubbles runs out, close the permanent venting points and the air bleeding
points in succession.
5. Fill the coolant circuit until the level in the expansion tank is at the maximum.
6. If necessary, clean the sealing surfaces.
7. Check that the expansion tank cap is in good condition, refit it and then close it.
8. Cut the fuel supply, then start the engine for 10 minutes (maximum).
9. Check for leaks in the cooling circuit assembly.
11. Top up the coolant to the maximum level.
a. If necessary, repeat the engine starting and refilling processes as shown in the previous steps of this procedure until
there is no further need to add more coolant.
54 1194_EN 2023-08-08
Maintenance
9.3.6 Starter batteries
DANGER
STARTER BATTERIES - RISK OF CHEMICAL BURNS, FIRE AND EXPLOSION

DANGER OF DEATH
concerned.
When handling the starter batteries, always observe the following safety instructions.
• Wear suitable personal protection equipment (gloves, goggles, clothing, etc.), use tools with insulated handles.
• Avoid all contact with the skin and eyes (the electrolyte in the starter batteries is extremely corrosive).
• Vent the room, never smoke, bring a naked flame near or create sparks near a starter battery, especially when it is
charging.
• When fitting a starter battery, never invert the polarities.
• Never short-circuit the starter battery terminals with a tool or a metal object and remove any jewelry before servicing.
9.3.6.1 Cleaning the starter battery
DANGER CABLE TERMINALS - RISK OF EXPLOSION

DANGER OF DEATH
A cable terminal which is not secured correctly may cause sparks and therefore lead to an
explosion.
• Cable terminals must be tightened securely.
The presence of impurities and rust on the starter battery and its terminals may cause the current jumps, voltage drops and the
battery to discharge, particularly in humid weather. Clean the starter battery regularly to prevent damaging the equipment.
1. Starting with the black cable (-), disconnect the battery.
2. Using a brass brush, clean any signs of oxidation on the cable terminals as well as on the starter battery terminals.
3. Fully tighten the cable terminals.
4. Using grease for starter battery terminals or Vaseline, grease the cable terminals to delay oxidation of the battery.
5. Starting with the red cable (+), reconnect the battery.
9.3.6.2 Adjusting the electrolyte level

BATTERY WITHOUT FILLER CAP:
• No operation required, charge or replace the starter battery if needed (not possible to adjust the electrolyte).
BATTERY WITH FILLER CAP:

1. Remove the starter battery and place it on a leveled ground, in a clean and ventilated area.
2. Using a clean cloth slightly moistened with a baking soda paste, clean the top of the battery and around the battery
terminals.
3. Check that the battery case is in a good state and do not have any cracks (replace the starter battery if necessary).
4. Open the filler caps, and with a clean and dry cloth, clean and be careful to prevent anything from entering the starter
battery.
5. Using a flashlight, check electrolyt level: the plates should be covered with about 1 cm of electrolyte.
6. If the level is too low, use a pipette distilled water. Proceed slowly and with a lot of care, frequently checking the level
(do not overfill).
7. With a clean and dry cloth, clean any splash, close the filling caps and clean again if necessary.
8. Charge the starter battery for at least 30 minutes.
1194_EN 2023-08-08 55
Maintenance
9.3.6.3 Charging the starter battery
Every 6 months, perform the following checks:

1. Check the voltage when idle.
2. Define the charge status of the starter battery using the table below.
3. If the charge status of the starter battery is less than 60%, the battery must be recharged.
a. The power of the charger must be suitable for the starter battery and the charging time available.
4. Stop the charge before disconnecting the cables from the battery when the starter battery voltage and the acid density
stop increasing.
State of charge Voltage when idle Observation / action
100% Above 12.60 V
80% 12.54 V
60 % 12.36 V From 60%, recharge the battery
40% 12.18 V Risk of sulfating, replace the battery
20% Below 11.88 V Unusable, replace the battery
If several batteries connected together are being recharged, the following points must be checked:
• Are the starter batteries connected in series?
• Is the voltage chosen exact? 1 starter battery x 12 V, 3 x 36 V starter batteries.
• Adjust the charge current to the lowest starter battery.
• The power difference between the starter batteries must be as low as possible.
EXAMPLE OF CHARGE:
• Starter battery 12 V, 60 Ah (ampere-hours) = charging current 6 A.
• State of charge: 50% (acid density = 1.19; voltage when idle = 12.30 V).
• The starter battery must have an additional 30 Ah, or it must be recharged.
• Charging current: 6 A, approximately 6 hours of charging are required; the charging current must always be 1/10th of the
nominal capacity of the battery.
9.3.6.4 Battery charger (option)

The battery chargers supply the permanent equipment (surveillance, signaling, control unit) and keep the batteries charged, thus
safeguarding all of the systems during electrical power faults.
The battery chargers are well suited to:

• systems with electrical current requirements (relays, motors, solenoid valves, PLCs, audible alarm devices, etc.);
• permanent equipment (surveillance, signaling, control unit);
• equipment intended for charging accumulator batteries.
9.3.7 Air filter for dusty atmosphere (option)

Air filter
Cleaning can cause damage to the filter element, the accidental introduction of dust to the
engine or even diminished efficiency of filtration.
• To ensure the correct operation of the engine, never clean the filter element but
replace the air cleaners as frequently as necessary.
When handling the air cleaner, always observe the following safety instructions.
• Refer to the manufacturer's maintenance manual and/or the procedures in the paragraphs below.
• Never assess the condition of an air cleaner based on its visual appearance.
• If there is no maintenance indicator or complementary instructions in the engine maintenance manual, replace the air
cleaners as often as necessary and at least once a year.
56 1194_EN 2023-08-08
Maintenance
9.3.7.1 Maintenance indicator (option)

• The maintenance indicator indicates that maintenance of the air cleaner is
required through cleaning and/or replacement.
• If fitted, the maintenance indicator can be mounted directly on the filter.
• If fitted with a sensor, information concerning the clogging of the filter can be
reported on the control unit.
Refer to the control unit operating manual.

Figure 23: Example of a
maintenance indicator
CHECK THE MAINTENANCE INDICATOR:

1. If the air cleaner is fitted with a dust control valve (A), press the tip of the valve
to release any accumulated dust particles.
2. Check the maintenance indicator (B):
a. if it is green: No maintenance operation required.
b. if it is red:
i. if indicated, clean the air cleaner as many times as permitted before
replacement (in case of conflicting information, observe the shortest
maintenance deadline);
ii. if nothing is indicated, replace the filter element each time it becomes
clogged.
3. Reset the maintenance indicator.
9.3.7.2 Replacing the filter element

To replace the filter element, follow the instructions below.
1. Be qualified and authorized to maintain generator sets.
2. Ensure that the generator set is stopped and that starting is not possible.
3. Remove the filter element carefully.
4. Thoroughly clean the inside of the filter and the parts in contact with the gaskets using a clean, damp cloth.
5. Check that the gaskets on the new filter cartridge are in good condition and check the elasticity.
6. Refit the new filter cartridge and close the cover carefully.
7. Check the entire circuit for leaks.
8. If fitted, reset the maintenance indicator after replacing the filter element.
1194_EN 2023-08-08 57
Maintenance
9.3.8 Air coolers (according to the generating set model)
DANGER
AIR COOLERS - RISKS OF SERIOUS ACCIDENTS
Be qualified and authorized to handle air coolers.
To maintain air coolers, observe the safety instructions below.

• Regularly check that the harness fins are not clogged and clean as often as the actual installation conditions require.
o The cleanliness of the device is a factor which will determine its performance and length of service life.
• For engines fitted with an oil vapor recirculation system, ensure that the harness is not greasy.
• To clean the harness, use compressed air directed parallel to the fins.
o Perform cleaning with care, in order not to damage the fins.
MAINTENANCE OF AIR COOLERS:
1. Ensure that the personal protection measures and equipment preservation

measures are applied. drainage
2. Drain the high temperature (HT) and low temperature (LT) cooling circuits via point drainage
tapping points in the lower section of the air cooler (drain boss and vents on the LV point
circuit on the HV
provided on the manifolds or pipes).
3. Remove the flexible pipes connected to the engine circuit
4. Having made the power supply safe, disconnect the wiring on all of the
extractor fans then remove the fans, beginning at the top of the air cooler.
5. Carry out the same procedure for the other fans.
6. Remove the fan support panels.
7. Disconnect the servomotors from the motorized ventilation flap.

servomotor
connection unit
for the
servomotor
8. Remove the motorized ventilation flap to gain access to the harness.

electrovalve
58 1194_EN 2023-08-08
Maintenance
9.3.9 Cleaning the external panels

Clean the generator set or container:
• after sea transportation;
• at least every 6 months.
Clean more frequently if:
• the generator set or container is installed in a wooded area or in a corrosive atmosphere;
• the generator set or container is soiled with dust or organic matter (decomposing leaves, moss, debris, etc.).

Cleaning the panels
• Take care not to remove insulating foam.
• Never clean the inside of the enclosures or containers with water.
1. Remove any caps plugging the drainage holes.

a. If necessary, refer to the views of the drainage holes in the following section.
2. Ensure that the generator set or container is not leaking (check the seals).
3. If fitted, close the access doors, ensuring that they cannot open unexpectedly, and refit the mobile panels.
4. Wash the panels with detergent (water + gentle detergent).
5. Rinse the panels thoroughly with clear water.
a. If using a high pressure cleaner, never exceed a pressure of 120 bars, maintain a distance of 30 cm between the
surface to be cleaned and the nozzle of the high pressure cleaner.
6. If necessary, remove stains or stubborn soiling using a suitable solvent (white spirit or equivalent).
a. In the event of significant scratches or bumps, contact a skilled professional for curative treatment.
7. Wipe the panels with a clean, soft and absorbent cloth.
1194_EN 2023-08-08 59
Maintenance
9.3.10 View of the drainage holes

Drainage holes
• Ensure that it is always possible for engine fluids to drain through the drainage holes in all
circumstances.
DRAINAGE HOLES ON ENCLOSED GENERATOR SETS:

M1xx enclosures
removable panel drainage holes

M2xx enclosures
removable panel drainage holes
drainage holes
removable panel
M3xx enclosures
removable panel
drainage holes air intakes
drainage holes
removable panel
M4xx enclosures
removable panel drainage hole

Figure 24: Drainage holes on enclosed generator sets
60 1194_EN 2023-08-08
Maintenance
CONTAINER DRAINAGE HOLES:
CPU40: drainage holes (9 in total)
9.3.11 Hoses
The service life of a hose and/or pressure line essentially depends on the internal and external stresses to which it is subjected.
The service life of a hose or pressure line:
• varies generally from 1 to 10 years depending on the constraints. Check the date of manufacture marked on the hose or
pressure line;
• can be determined based on previous experience, a regulatory requirement, analysis of the resistance of the hose and/or
pressure line in relation to specific constraints, and can influence the maintenance schedule.
As often as necessary, and at least every 6 months, visually check for:
• the absence of significant permanent or local deformation (denting, crushing, blistering, elbows, etc.),
• the absence of external cracking or downgrading of the external texture,
• the absence of damage to the external layer through its entire thickness,
• the absence of cuts rendering the structure or reinforcement visible,
• the absence of slippage of the connection on the tube,
• the absence of traces of leakage or sweating.
• the absence of incorrect operation of connectors or obvious loss of tightness;
• If necessary, replace the hose and/or pressure line.
9.3.12 Exhaust mufflers

Once a year, or more frequently if required by the actual installation and/or usage conditions, perform maintenance on the exhaust
silencer:
1. Be qualified and authorized to perform this maintenance operation.
2. Ensure that the installation, including the generator set, is at a complete stop and that the engine and its components
are cold.
3. Check the mechanical performance of the components.
4. Check the tightness of the various fastenings.
5. Check the correct operation of the drainage system.
6. If fitted on the silencer, clean the spark arresters periodically.
7. If fitted on the silencer, check the catalytic converters periodically (efficiency and condition).
1194_EN 2023-08-08 61
Maintenance
9.3.13 Fluid recovery and retention tanks (option)

These containers prevent the engine fluids contained in the generator set from flowing onto the floor, in compliance with the
environment protection laws. Engine fluids collected in this way include the fuel, oil and coolant of the generator set, as well as
rainwater and condensation.
RECOVERY CONTAINERS: RETENTION CONTAINERS:
assembly 1: assembly 2: assembly 3:

- Integrated in the subbase tank of the - Integrated in the frame of the - Removable option, to be positioned
generator set generator set, with the fuel tank below the subbase tank of the generator
- Sometimes without integrated drain positioned above set
plugs, in which case drainage should be - Integrated drain plugs - Integrated drain plugs
carried out from the top - Top level indicator
- Fork lift zone
To drain a recovery or retention container, follow the instructions below.

1. Regularly check the level of the engine fluids contained in the recovery or retention container.
2. Collect the engine fluids in suitable retention containers, never allow engine fluids to flow onto the floor.
3. If necessary, drain the engine fluids,
a. or by succion (M137/M138 enclosures),
b. or via the drainage hole,
c. or using the drain pump (for containers equipped with this pump).
62 1194_EN 2023-08-08
Rapid identification of minor malfunctions
Section 10. Rapid identification of minor malfunctions
10.1 Generating set verifications

In the event of a malfunction, check the display on the control unit (if the generator set is equipped with one) and refer to the
meaning of the alarms, faults and fault codes as required. The following points can be checked:
The generator set… Check that: Solutions to be applied:

resume installation and commissioning,
has a mechanical problem: the installation and the commissioning
contact your authorized Kohler
does not start or operates in an were carried out correctly. NO distributor/dealer for service if necessary.
abnormal manner.
YES
the pre-start checks were performed
re-check prior to start-up.
correctly. NO
YES
the battery is correctly connected and perform minor troubleshooting on the batteries
charged. NO and battery chargers.
YES
the control unit parameters are correct, it
does not display a fault and is not in “out of refer to the control unit operating manual.
service” mode. NO
YES
the maintenance operations were perform the required maintenance operations;
performed correctly, in keeping with the contact your authorized Kohler
established schedule. NO distributor/dealer for service if necessary.
YES
eliminate the cause of the triggering before
the damper valve is open.
NO resetting it.
YES
have the generator set and the installation
checked by an authorized Kohler
has an electrical problem: resume installation and commissioning,

the installation and the commissioning
does not deliver current, the contact your authorized Kohler
were carried out correctly. NO
installation is not supplied with distributor/dealer for service if necessary.
power. YES
the electrical connections were made in follow the instructions in the diagrams
compliance with the diagrams provided. NO provided.
YES
the control unit parameters are correct, it
does not display a fault and is not in “out of refer to the control unit operating manual.
service” mode. NO
YES
the generator set is in compliance with the
Contact your authorized Kohler
installation, in terms of power and
NO distributor/dealer for service.
configuration.
YES
the maintenance operations were perform the required maintenance operations;
performed correctly, in keeping with the Contact your authorized Kohler
established schedule. NO distributor/dealer for service if necessary.
YES
tripped circuit breaker(s).
NO distributor/dealer for service.
YES
the alternator delivers voltage.
NO
YES
have the generator set and the installation
checked by an authorized Kohler
If the problem persists, contact your authorized Kohler distributor/dealer for service. The serial numbers of the generator set,
engine, alternator and possibly the control unit (if fitted) will be required.
1194_EN 2023-08-08 63
Rapid identification of minor malfunctions
10.2 Starter batteries (option)
fault observed probable origin measurements or observations

- incorrect composition - cool
- the acid heats up when a new
- incorrect storage - charge the battery
battery is filled
- prolonged storage in a damp place - check the acid density
- the acid escapes through the
- the battery is too full - reduce the battery fluid level
filler holes
- battery tray not leaktight
- replace the battery
- acid level too low - considerable formation of gas due to a very high
- check the charger and repair if necessary
charging voltage
- acid level too low - insufficient charge
- recharge the battery
- incorrect operation from start- - short circuit in the power circuit
- check the electrical installation
up - consumption fault
- the battery has been filled with acid instead of - reduce the acid level and fill with distilled
- acid density too high
water water, repeating the operation if necessary
- battery empty - recharge the battery
- starting problems - battery exhausted or faulty
- starting test incorrect - capacity too low
- replace the battery
- battery sulfated
- tighten the ends of the battery cables or
- incorrect electrical connection
- battery terminals melted replace them if necessary and replace the
- battery cabling incorrect
battery
- one or two cells release a lot of
- faulty cell(s) - replace the battery
gas at high charge
- charge status too low - check the load
- short circuit in the power circuit
- the battery discharges very
- high self-discharge (for example: through
quickly - replace the battery
electrolyte contamination)
- sulfation (storage of discharged battery)
- define the correct battery part reference for
- incorrect battery part reference
the recommended use
- short service life
- repeated deep discharging - it is recommended to charge the battery
- battery stored too long without charge using a regulator
- overload
- high water consumption - check the charger (voltage regulator)
- charging voltage too high
- sparks after battery charging
- short-circuit
- the battery explodes - connection or disconnection during charging - replace the battery
- internal fault (for example: interruption) and low
electrolyte level
10.3 Manual pump (option)

• The pump no longer provides suction or is draining:
o Air intake: check all the seals and the suction pipes.
o The foot valve (suction valve) no longer works: probably dirt or some waste under the valve; check the valve.
o There are impurities inside the pump blocking the valves: remove the cover, clean the inside, check the free play of
the valves.
• Leaks from the cable gland:
o Tighten the two nuts of the cable gland bracket by one or two turns alternately. If necessary, remove this bracket,
remove the cable gland inside its housing. Clean this housing by removing the residues on the lining. Replace the
lining with a graphite strap.
o In the case of a pump without a cable gland, model 254, remove the cover, replace the O-ring, ensuring that the
piston axis is not oxidized. In this case, clean it thoroughly. Also refit the trim on the graphite grease neck.
64 1194_EN 2023-08-08
Storage/Removal from storage
10.4 Electric pump (option)

The electric pumps do not have any particular maintenance requirements. Check for leaks around the seals if necessary.
possible causes actions
the motor
no electric current check the connections
does not
work remove the pump from the motor
impeller jammed
look for any foreign bodies
possible causes actions
suction height too high bring the electric pump closer to the fluid to be pumped
foot valve jammed clean or replace the valve
no flow rate
filter clogged clean the filter
or
significant load loss increase the diameter of the pipes
insufficient
pressure bypass valve blocked clean or replace the valve
air in the suction pipes check the seal
check the pipe connections
fluid leak
replace the seals
Section 11. Storage/Removal from storage
Failure to use the equipment may have a damaging effect on it, particularly the engine and alternator.
• If a generator set is only used on an occasional basis (emergency back-up, rental, etc.), it is recommended that starting
tests and ON load tests are performed each month to check that the equipment remains in good working order at all
times.
• If the delivered equipment is not to be used for a period of 6 to 18 months (if construction of the building is not complete,
for example), it will be necessary to protect the equipment.
11.1 Preserving the equipment

1. Ensure the generator set is stored:
• on a flat, leveled ground strong enough to support its weight,
• in a clean, dry and frost-free place, and ensure constant temperature and constant hygrometry.
2. Follow the engine preservation recommendations given in the engine user and maintenance manual.
o Use high quality engine fluids specially dedicated for preservation operations.
3. Check that the equipment is in good conditions, clean panels and external sheet metal.
4. Check that the exhaust system is mounted and fitted with a draining system.
5. Block the air inlets with a clean and dry cloth, and block the other openings of the engine with nonabsorbent adhesive
tape.
6. Mask the engine ECU, the alternator, the controller and all the electrical connections.
7. Disconnect and remove the batteries, store them in a clean clean, dry and frost-free place protected agains the sun.
• To prevent any risk of acid spillage, transport and store batteries in a vertical position.
• Place the terminal cover on the positive terminal.
• Check the battery charge level every month and charge them if necessary.
8. At the end of the preservation period (18 months maximum), proceed to depreservation.
o If the preservation is still needed, depreserve, perform the starting test and on-load test during 2 hours before
preserving the generator set again.
9. In case of doubt, contact your authorized Kohler distributor/dealer for service.
11.2 Depreserving the equipment

1. Follow the engine depreservation recommendations given in the engine user and maintenance manual
2. Remove the protections and check that every part of the equipment is in good conditions.
3. Check the rotor and stator winding insulation, resistance and continuity.
4. If the alternator is fitted with regreasable bearings, grease the bearings.
o See alternator user and maintenance manual.
5. Perform the starter battery maintenance and connect them.
6. Perform the starting test and on-load test.
7. In case of doubt, contact your authorized Kohler distributor/dealer for service.
1194_EN 2023-08-08 65
Decommissioned generating set
11.3 Transportation and storage of the fluids

The engine fluids are toxic products which are harmful to humans and the environment: the engine fluids are stored and
transported in line with strict regulations. Refer to the orders, regulations, standards and legislation in force in the country in which
the engine fluids are transported and stored.
Moreover, storing engine fluids in unsuitable conditions causes the engine fluids to deteriorate and results in material damage
during use. Store the engine fluids under optimal conditions that preserve their qualities.
• Each time you purchase a fluid, as the supplier for the safety data sheets and make them available for staff permanently
exposed to them;
• Find out the appropriate storage conditions (temperature resistance, authorized storage period, etc.) and apply them.
• Make first-response fire equipment (extinguishers, hydrants) available to staff.
• Ensure that only qualified and authorized staff using the necessary PPE* handle the engine fluids.
• Correctly mark the storage tanks with clearly visible, legible labels resistant to hydrocarbons.
• Use appropriate storage tanks which are: clean, made from material suitable for the content, sealed, sufficiently strong
and equipped with a perfectly sealed fastening device, etc.
• Position storage tanks on retention containers, away from light and moisture and at a constant temperature
recommended by the supplier.
• In any case, ensure that all measures intended to safeguard staff and the environment are implemented and that the
orders, regulations, standards and legislation in force are complied with.
Section 12. Decommissioned generating set
End-of-life management of a generator set:

1. Collect the engine fluids from the generator set (fuel, oil, coolant, DEF*) in suitable retention containers, never allow
engine fluids to flow onto the floor.
2. Take the waste fluid as well as the generator set to a waste collection point. Never dispose of them in the countryside.
Section 13. Glossary
The active power P of a generator set is the real power, measured in kW, supplied by this generator
set to an installation. It is the mechanical power of the internal combustion engine converted into
electrical power by the alternator. It is related to the apparent power (S) (kVA) and the power factor
Active power (PF) through the relationship: P (kW) = S (kVA) x PF.
(kW) • The rated active power (kW) which appears on the nameplate of the generator set is the
maximum power that the generator set is capable of providing under the operating
conditions defined by the output class (COP, PRP, LTP or ESP) assigned by the
manufacturer to the generator set and indicated on the nameplate.
European Agreement Concerning the International Carriage of Dangerous Goods by Road: this
agreement stipulates the conditions for the materials involved, notably their packaging and labels,
ADR
and the conditions notably for the construction, equipment and use of the vehicle transporting the
materials involved.
AIPR designates electrical equipment (cabinet or box) which houses the main circuit breaker
AIPR (downstream from the power alternator) and the auxiliary outgoing feeders. The AIPR is generally
mounted on the generator set skid. It is used for housing circuit breakers of 800 A or more.
The apparent power S provided by a generator set to an installation is the power calculated in kVA
from the current (I) per phase and the voltage (U) between phases independently of the power factor
(PF) of the installation. The apparent power is calculated using the following formulas:
• Single-phase generator set: S (kVA) = U (V) x I (kA) I (kA) = I (A) / 1000
• Three-phase generator set: S (kVA) = U (V) x I (kA) x √3
• Example: a three-phase generator set supplies 400 V between phases and 100 A per
phase to an installation. The apparent power S (kVA) = 400 x 0.100 x 1.732 = 69.28 kVA.
Apparent power A three-phase generator set is designed and protected (circuit breaker setting) to be able to provide
(kVA) its nominal active power (kW) to an installation whose power factor (PF) can vary from 1 to 0.8.
The nominal apparent power (kVA) indicated on the nameplate of a three-phase generator set is
determined for a nominal power factor (PF) of 0.8 and is therefore equal to the nominal active power
(kW) divided by 0.8.
Example: If the rated active power of a three-phase generator set is 80 kW, the rated apparent power
in kVA is: 80 / 0.8 = 100 kVA.
When the rated power factor (PF) indicated on the nameplate of a single-phase generator set is 1,
the rated apparent power (kVA) is equal to the rated active power (kW).
66 1194_EN 2023-08-08
Glossary
Auxiliaries
The electrical auxiliaries of a generator set comprise the electrical equipment which ensures the
(auxiliary electrical
correct operation of the generator set, in particular that of the heat engine: battery charger, heat
equipment of a generator
engine preheating, electric fuel supply pump, etc.
set)
Application (or performance) classes: G1, G2, G3 and G4.
Standardized performance classes for generator sets defined by standard ISO 8528-1:
They define the particular requirements concerning precision and stability for the voltage and
frequency of a generator set during load variations in the installation to be supplied.
. Class G1: for an application requiring minor voltage and frequency constraints;
Classes of application
. Class G2: for an application whose constraints are approximately the same as those of the public
(or performance)
network;
. Class G3: for an application imposing severe requirements for stable voltages, frequencies and
waveforms (for example: telecommunications and thyristor-controlled loads;
. Class G4: for an application imposing particularly severe requirements for stable voltages,
frequencies and waveforms (for example: data processing).
Maximum power in kW that a generator set is capable of supplying continuously under a constant
load for an unlimited number of hours per year, under the agreed operating conditions, provided that
the maintenance intervals and operating modes are performed according to the manufacturer's
requirements.
legend:
Continuous Power t time
COP P power
a continuous power (100%)
Container Safety Convention.

International convention governing container safety (or CSC convention), which was rendered in
France by Decree no. 80-837 of 20 October 1980 and the orders issued for its application.
These orders define the process for obtaining CSC approval, and list the bodies authorized to issue
this approval. This approval, which comes in the form of a standardized plate permanently fixed on
each approved container, is obligatory for authorization of sea transportation. The stacked load that
the container can bear is indicated on this plate.
This approval is obtained by the manufacturer, for each container model, by submitting a technical
file, subject to validation of standard tests by the approved body.
CSC
Differential circuit Differential device cutting off the supply to an electrical circuit when a fault current to earth has been
breaker detected or in the event of an overload or short circuit.
Differential device which only detects the fault current to earth in an electrical circuit. It is designed
Ground fault relay (GFR) to be connected to the control of a circuit breaker which it opens in order to cut off the electrical
supply when a fault current is detected.
Differential device cutting off the supply to an electrical circuit when a fault current to earth has been
Differential switch detected. Unlike the differential circuit breaker, the differential switch does not provide protection
against overloads or short circuits.
DT Day tank
Conductive current element embedded in the ground to establish an electrical contact with the local
Ground
earth (for example: grounding rod, grounding electrodes).
Generator set connection terminal identified by a PE marking or by a standardized "Earth" symbol
Ground (GND)
and provided to enable the generator set to be earthed. This terminal is internally connected to the
(of a generator set)
earths of the generator set and, according to the grounding system (SLT), to the alternator neutral.
1194_EN 2023-08-08 67
Glossary
Grounding The generator set grounding consists of establishing an electrical connection between the generator
set ground (GND) and an Ground or a local ground (GND) of an installation using a cable (green &
(of a generator set) yellow earth conductor which has a cross-section appropriate to the generator set output).
Grounding system Expression designating the grounding system (SLT) of an installation.
Emergence Difference between the sound pressure level (sound level) measured at a given location near an
(acoustic) operating generator set and the level measured when this generator set is switched off.
Maximum power available in kW, for a variable power sequence, under the operating conditions
specified, that a generator set is capable of supplying up to 200 hours per year if the network energy
is interrupted or under test conditions, provided that the maintenance intervals and operating modes
are observed according to the manufacturer's requirements.
The mean admissible power (Ppp) over a 24-hour period must not exceed 70% of the emergency
standby power, unless otherwise agreed by the manufacturer of the heat engine.
legend:
t time
Emergency Standby
P power
Power: ESP
a emergency standby power (100%)
b mean admissible power over 24 hrs (Ppp)
c actual mean power over 24 hrs (Ppa)
d stop
note: t1+t2+t3+ … +tn = 24h
Exhaust head loss When fluid is flowing in a pipe and energy is lost due to friction, we talk about head loss.
This is used for compensating for volume variations to which the mass of a fluid in the facility is
Expansion bottle
subjected due to temperature fluctuations.
Engine fluids Fuel, oil (lubricant) and coolant
GNR Off road diesel
High Voltage:
HV A: 1000 V < HVA < 50 000 V alternating current
B: 50 000 V < HTB alternating current
IMD Insulation Monitoring Device
Electrical impedance measures the opposition of an electrical circuit to the passage of a sinusoidal
Impedance alternating current.
The concept of impedance is a generalization of Ohm's law in the study of alternating current circuits.
Standardised fitting on all 8 corners of ISO containers enabling containers to be handled and
ISO corner
transported.
Maximum power in kW that a generator set is capable of supplying up to 500 hours per year, under
the agreed operating conditions, provided that the maintenance intervals and operating modes are
observed according to the manufacturer's requirements.
Note: The limited running time power (100%) is limited to a maximum value of 500 hours per year.
legend:
t time
Limited Time Running P power
a limited running time power (100%)
Power: LTP
68 1194_EN 2023-08-08
Glossary
Sound pressure level (of a generator set).

The sound pressure level LpA (commonly called "sound level") of a generator set is expressed in
dBA and is measured using a standardized method at a given distance from the generator set. It
represents the sound intensity emitted by the generator set and detected by the human ear at this
point. The sound pressure level depends on the sound power level LWA of the generator set and
LpA
the distance from the measuring point to the generator set; this distance should therefore always be
specified when a sound level is indicated.
• The sound pressure level indicated in the instruction manual for the generator set is
measured in an unobstructed spaced 1 m away from the generator set, in accordance with
the applicable European Directives.
LPG Liquefied petroleum gas
Low Voltage:
LV A: 50 V <LVA < 500 V alternating current
B: 500 V <LVB < 1000 V alternating current
Low Voltage Central Control Panel
LVCCP This is the low voltage electric panel of large electrical installations. This panel forms the link between
the supplier's incoming line and the customer network.
Guaranteed sound power level (of a generator set).
Sound emission level in dB(A) characterizing the acoustic energy radiated by a generator set. The
sound power level is a characteristic of the generator set which does not change; it must not be
LWA confused with the sound pressure level LpA (sound level).
The marking of the guaranteed sound power level LWA on the nameplate of generator sets designed
for use outside buildings in countries within the European Union meets a requirement of European
Directive 2000/14/CE.
Power given by multiplying the current and the voltage that the generator set is capable of supplying
over at least 5 minutes within the following voltage and frequency limits.
Note 1 re the article: The prescribed output voltage must be ± 10% of the rated voltage and the output frequency
Maximum power: MAX must be ± 8% of the nominal frequency.
Note 2 re the article: The protective device must not be activated for 5 minutes and the overload conditions must
meet the requirements of paragraph 6.4 Overload conditions of ISO 8528-8. The minimum ratio between the
rated power (COP) and the maximum power (MAX) must be Pnominal/Pmax ≥ 0.75.
Mean effective pressure.

The MEP* is the pressure which, if it was applied constantly to the piston of a spark ignition engine
throughout its power stroke, would make it possible to obtain the same level of work to that which is
actually created. This is therefore a false measurement which is used to compare various engines
and to determine the application class of the generator set according to standard ISO 8528 (class
MEP G1, G2 or G3). The MEP is indicated in Bar or KPa in the technical specifications of fuel engine
manufacturers.
* in English: BMEP (Brake Mean Effective Pressure).
SCR (Selective Catalytic Reduction)
DEF (Diesel exhaust fluid)
Multipolar cable Cable comprising more than one insulated conductor
NG Natural gas
. Output class: COP, PRP, LTP, ESP, DCP and MAX
Output class
. Standard output class of a generator set defined by standard ISO 8528-1 and ISO 8528-8.
PAB Public access building
Phase-to-neutral voltage Voltage between neutral and any one phase of a three-phase system with neutral
Phase-to-phase voltage Voltage between any two phases of a three-phase system
Parameter specific to an electrical installation at a given moment obtained by dividing the active
power P (kW) by the apparent power S (kVA) at this moment. The power factor varies according to
the nature of the devices being supplied at a given moment (for example: when powerful electric
motors are switched on, the power factor reduces).
In an installation, the active power P (kW) and the apparent power S (KVA) are related to the power
Power factor: factor PF by the relationship: FP = P / S. In an installation comprising various devices in operation
cos φ * (lights, computers, electric heating, lifts, etc.) the power factor is between 0.8 and 1 on average.
* the power factor of an installation is sometimes referred to as the cos PHI (cos φ) of this
installation.
SCR (Selective Catalytic Reduction)
DEF (Diesel exhaust fluid)
PPE Personal Protection Equipment (gloves, glasses, shoes, etc.)
1194_EN 2023-08-08 69
Glossary
Maximum power in kW that a generator set is capable of supplying continuously under a variable load for
an unlimited number of hours per year, under the agreed operating conditions, provided that the
maintenance intervals and operating modes are observed according to the manufacturer's requirements.
The mean admissible power (Ppp) over a 24-hour period must not exceed 70% of the main power,
unless otherwise agreed by the manufacturer of the heat engine.
legend
t time
Prime Power: P power
PRP
a main power (100%)
b mean admissible power over 24 hrs (Ppp)
c actual mean power over 24 hrs (Ppa)
d stop
note: t1+t2+t3+ … +tn = 24h
Residual current device. Device protecting against the risks of an electric shock based on detecting
an abnormal earth-leakage current resulting from an insulation fault in an electrical installation.
This device is designed to cut off the power supply to the faulty electric circuit when the earth-leakage
current becomes greater than the maximum allocated residual current (sensitivity) of the device. The
sensitivity and the activation time may be fixed or adjustable depending on the model of the residual
current device.
They can be distinguished according to their sensitivity:
RCD • high sensitivity (≤ 30 mA);
• average sensitivity (100 mA to 1 A);
• low sensitivity (3 A to 20 A).
There are three types of differential device:

• differential circuit breaker
• differential switch
• ground fault relay (GFR)
Checking the rotating magnetic field on a three-phase installation involves checking the direction of
rotation of the phases using a device (phase rotation tester or indicator): when the device pins
Rotating field
marked phase 1, phase 2, phase 3, are connected to the corresponding phases of the network being
(rotating field check)
checked, the display on the device makes it possible to check whether the order 1-2-3 indicated by
the markings on the tested conductors (terminals, cables) is correct or not.
Single phase
A single phase generator set (or an alternator), supplies the electrical current with a single phase
(generator set or
and a neutral (2 poles).
alternator)
Single pole cable Cable comprising a single insulated conductor
SLT Grounding system
Also called "container clamp". Handling device making it possible to lift a container from anchorage
Spreader points located in the corners of the containers. There are different sizes of spreaders, which can be
adapted to the standardized dimensions: choose from containers of 16, 20 or 40 feet.
Stack of containers Stacking of containers
Three-phase
A three-phase generator set (or an alternator), supplies the electrical current with three phases (3
(generator set or
poles) or with three phases and a neutral (4 poles).
alternator)
Tracking Electric system (example: heater band) installed on the pipework or the fuel tanks to ensure they
(fuel circuit) are protected from frost.
Tripolar cable Multipolar cable comprising three insulated conductors
Unit Common name given to an ISO container
Very Low Voltage
VLV VLV < 50 V alternating current
VLV < 120 V alternating current
Metal part of electrical equipment likely to be touched and which is not normally supplied with voltage
Weight but could be in the event of an insulation fault. All the earths of the generator set are connected to
an earth busbar equipped with a generator set ground (GND).
Welding seam Weld bead
70 1194_EN 2023-08-08
Table of illustrations
Section 14. Table of illustrations
Figure 1: Position of the nameplate for generator sets with and without enclosures ...................................................................... 6
Figure 2: Position of the nameplate for generator sets in a container ............................................................................................ 6
Figure 3: Example of a generator set Nameplate........................................................................................................................... 7
Figure 4: General description of a generator set with enclosure .................................................................................................... 8
Figure 5: General description of a generator set without enclosure ............................................................................................... 9
Figure 6: Example of an ISO 20 container ................................................................................................................................... 10
Figure 7: Example of an ISO 40 container ................................................................................................................................... 10
Figure 8: Example of a CPU 40 container .................................................................................................................................... 11
Figure 9: Example of a CIR 20 container ..................................................................................................................................... 11
Figure 10 : Exemples de manutention par passage de fourche ................................................................................................... 14
Figure 11: Example of generator set with adhesive edges and buffers (with enclosure) ............................................................. 15
Figure 12: Example of an exhaust system ................................................................................................................................... 20
Figure 13: Air outlet of a generator set with radiator .................................................................................................................... 22
Figure 14: Good venting of the radiation from the generator sets ................................................................................................ 23
Figure 15: Installation in a room and good venting of exhaust gas and air .................................................................................. 23
Figure 16: Example of installation of a generator set in a container............................................................................................. 24
Figure 17: Example of fuel tank cap and pictogram. .................................................................................................................... 49
Figure 18: Examples of pre-filters (change of filter via the bowl) .................................................................................................. 50
Figure 19: Examples of pre-filters (change of filter via the cover) ................................................................................................ 50
Figure 20: Oil drainage pump....................................................................................................................................................... 52
Figure 21: Examples of oil sump drainage valve.......................................................................................................................... 52
Figure 22: Example guide tube and dipstick ................................................................................................................................ 53
Figure 23: Example of a maintenance indicator ........................................................................................................................... 57
Figure 24: Drainage holes on enclosed generator sets ................................................................................................................ 60
1194_EN 2023-08-08 71
User Manual
User Level
Controller
APM303
33502030901_1_1
Soft version : 1.1.0 - 23/01/2015
 The "user level" user manual is designed for users who are qualified to set up an
installation (generating set and environment). These users must be able to monitor
that the generating set is operating correctly (start, stop, basic settings), to interpret
any indications (mechanical, electrical) and may be required to check one or more
parameters.
 The "operator level" user manual is designed for those who – in addition to the skills
required for users – have the skills required to modify one or more parameters, to
change the operation of an installation (generating set and environment). To do this,
the operator will have completed training provided by the manufacturer beforehand.
 The "specialist level" user manual is designed for those who – in addition to the
skills required for operators – have the skills required to make any special or complex
modification to an installation (generating set and environment). To do this, the
specialist will have completed training provided by the manufacturer beforehand.
APM303 - QUICK START GUIDE page 1/2
abbreviations used: GS = Generating Set 5 - Operation in MANUAL mode: GS off
ATS = Automatic Transfer Switch  Manually open the GS circuit breaker (the power is cut
1 - Safety instructions off).
Read the safety instructions on starting up Allow the engine to cool down for 3 minutes.
a GS. Press the STOP button, the RUN LED goes off, the engine
(see General and Safety Manual) stops.
When the GS is off, the control unit may be powered by a
dangerous voltage (preheating, battery charger). 6 - Operation in AUTO mode
When on, the APM303 is powered by a dangerous voltage.
The APM303 has been factory preconfigured; modifying its The AUTO mode is active only if the AUTO LED is fixed.
parameters may make the generating set unstable.
Check that the GS circuit breaker is closed.
Press the AUTO button, the AUTO LED lights up, AUTO mode
2 - Powering on is selected.
Close the battery isolator (if fitted), Start up is possible if the ALARM! LED is off.
Turn the switch on the front of the central console ON (if fitted). Start-up is launched on activation of the remote start/stop,
input, which must be a () potential-free contact (no AC or DC
3 - Checks before starting voltage).
Battery voltage, () e.g. coming from a self-regulating ATS.
Engine oil level,
Coolant level, On activation of the input, the RUN LED flashes and the GS
GS circuit breaker open. starts.
If the ALARM! LED is flashing, refer to section 7. When the voltage and frequency have stabilised, the RUN
4 - Front panel, buttons and LEDs LED becomes fixed and the GS takes over.
On deactivation of the remote start/stop input, the RUN LED
 STOP button flashes.
stops the GS and After a cooling period (3 minutes) (), the GS stops and the
acknowledges the fault (if RUN LED goes off.
ALARM! is flashing) The AUTO LED remains on, the GS is on standby, ready for
 AUTO button another start.
selects AUTO or MANUAL () If an ATS is fitted, the total number of cooling periods
mode must be correctly adjusted.
 START button
starts the GS MANUAL mode takes priority over active AUTO mode:
- pressing the START button activates MANUAL mode,
LED off - pressing the STOP button stops the GS.
 other buttons
LED on access to screens 7 - Appearance of an anomaly
LED flashing (see section 13) If the ALARM! LED flashes (see section 13), this means that
an anomaly (alarm or fault) has been detected.
ALARM! alarm = GS not stopped fault = GS stopped
no anomaly (alarm or fault) To view the anomaly, press or to show the screen
fault detected but cleared below:
anomaly detected (alarm or fault) A C
AUTO
MANUAL mode by default B D
AUTO mode selected
remote start/stop on/engine cooling E
RUN
GS stopped A The anomaly appears with an order number
GS started (MANUAL mode) Pictogram symbolising the anomaly (see sections 9 and
B 11)
start or stop in progress
C Anomaly status (fault only, see section 10)
5 - Operation in MANUAL mode: GS on Number of hours GS has been operating when anomaly
D appeared
MANUAL mode inhibits AUTO mode.
If the ALARM! LED is off (no fault present), it is possible to E See section 13 when  flashes
start the GS.
Press the START button, the RUN LED flashes, the GS starts. Note: this screen also shows the events (see section 12).
When the voltage and frequency have stabilised, the RUN LED
8 - Active and inactive alarm
becomes fixed.
active
 Manually close the GS circuit breaker; the GS takes load
or is ready to take load.
Check the electrical and mechanical values on the APM303 inactive
screens (see section 13).
An alarm cannot be cleared: it becomes inactive even after
intervention from the user.
APM303 - QUICK START GUIDE page 2/2
9 - List of alarms 13 - Displaying the different screens
Automatic scrolling through 7 screens ( 1 to 6 + INIT).
Battery voltage low or charging alternator not working
1
Manual scrolling through 6 screens ( 1 to 6 ), by pressing
flat battery repeatedly on or .
low fuel level INIT

GS overload
1
alternator phase rotation

alarm input no. x (x=1, 2 or 3)
GS maintenance to be carried out (non-contractual) INIT
activation conditions, see user manual, operator level
1
10 - Active and inactive faults - Clearing
active, not cleared
inactive, not
cleared main ()
active, cleared 2
after pressing
inactive, cleared
after pressing
currents & voltages ()

11 - List of faults
emergency stop
3
1
low fuel level

low oil pressure
1
coolant temperature high

power levels ()
speed too high
4
speed too low
max. alternator voltage (59)
min. alternator voltage (27)
max. alternator frequency (81H)
mechanical values ()
min. alternator frequency (81L)
5
alternator short circuit (50/51)
GS failure to start
GS failure to stop
fault input no. x (x=1, 2 or 3)
counters ()()
Circ. breaker pos. inconsistent
activation conditions, see user manual, operator level 6 
 visible in automatic
12 - Events list possible if 
scrolling if:
-alarm active is flashing
The APM303 is powered on
-fault active
start up in MANUAL mode -fault not acknowledged 12 - Events and anomalies
1
start up in AUTO mode When  is fixed (after 4 seconds), the list of events and
anomalies can be viewed by pressing .
stop in MANUAL mode
stop in AUTO mode
1
AUTO mode is activated

AUTO mode is deactivated etc.
GS stabilised When the no. 12 appears at the bottom of the screen, pressing
again displays screen 1 .
automatic start when battery low
automatic stop after battery recharge () non-contractual indications () RESET not possible
Modbus order received (see Modbus manual) 14 - Dual output report pack (optional)
"general alarm and fault" and "GS ready to take load"
Operation and maintenance manual
Engine
4045HF120
4045HSG20
4045HSG21
4045TF120
4045TF220
4045TSG20
6068HF120-153
6068HF120-183
6068HFG20-153
6068HFG20-183
6068HFG20-202
6068HSG22
6068TF220
JOHN DEERE
Supplied by
33521042101_4_1
OMRG25204_en - 15/08/2022
*DCT*
PowerTech™ 4.5 L and 6.8 L
Non-Certified and Tier
1 Certified OEM Diesel
Engines
OPERATOR'S MANUAL
*OMRG25204*
PowerTech™ 4.5 L and 6.8 L

Non-Certified and Tier 1 Certified
OEM Diesel Engines
OMRG25204 ISSUE 15AUG22 (ENGLISH)
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents

are known to the State of California to cause cancer,
birth defects, and other reproductive harm.
If this product contains a gasoline engine:
WARNING
The engine exhaust from this product contains

chemicals known to the State of California to cause
cancer, birth defects or other reproductive harm.
*omrg25204*
The State of California requires the above two warnings.
John Deere Power Systems

Worldwide Edition
PRINTED IN U.S.A.
Introduction
OEM Engine and Drivetrain Warranty Registration
RG24614 —UN—21OCT13
Scan this code to register your OEM engine or drive-

train product online. You can also visit us directly at
http://jdpswarrantyreg.deere.com/WarrantyReg.
Why registering your OEM engine or drivetrain

product is a really smart idea:
• OEM Engines: 2-year/2,000-hour warranty, with
unlimited hours in the first year.
• Get faster service. Registering your engine or • Drivetrain Products: 12-month/2000-hour warranty. In
drivetrain product gives us the information we need to the absence of a functional hour meter, hours of use
meet your service needs promptly and completely. will be determined on the basis of 12 hours of use per
• Protect your investment. You’ll be kept up-to-date on calendar day.
engine or drivetrain product updates. These warranties take effect the date the engine or
• Extend your warranty. You’ll be given the option to drivetrain product is delivered to the first retail purchaser.
extend your coverage before your standard warranty Be sure to register your engine or drivetrain product and
term expires. take full advantage of the John Deere service and support
• Stay informed. Be the first to know about new products network.
and money-saving offers from John Deere.
In addition, engine extended warranties are available
under certain conditions. John Deere offers a variety of
You’re Covered purchased warranties to extend the warranty period for
your engine. You'll be given the option to extend your
When you buy a John Deere engine or drivetrain product coverage before your standard warranty term expires.
you aren’t just buying pistons and crankshafts and gear
drives. You’re buying the ability to get work done. Without Obtaining Warranty Service
downtime, without worries, and without hassles. And Warranty service must be requested through an
you’re buying the assurance that if you do need help, a authorized John Deere service outlet before the expiration
strong support network will be there — ready to step in. of the warranty. Evidence of the engine’s or drivetrain
product’s delivery date to the first retail purchaser must be
presented when requesting warranty service. Authorized
Confidence. That's what John Deere engines, John service outlets include:
Deere drivetrains, and John Deere Warranties are all
about. • John Deere distributor
• John Deere OEM service dealer
Long durations. Warranties designed to give you • John Deere equipment dealer
confidence in your engine or drivetrain product. • John Deere marine dealer
Worldwide support. Get service when and where
you need it. John Deere has 4,000+ service locations
worldwide. Worldwide Support Network
Genuine John Deere parts and service. Authorized Visit https://dealerlocator.deere.com/ or

service outlets will use only new or remanufactured parts https://dealerlocator.deere.ca/to find the au-
or components furnished by John Deere. thorized engine or drivetrain service location
nearest you. For complete warranty details visit
https://www.deere.com/en/parts-and-service/war-
Warranty Duration ranty-and-protection-plans/warranties/warranty-state-
ments or https://www.deere.ca/en/parts-and-service/war-
Equipment operators can’t afford downtime or unexpected ranty-and-protection-plans/warranties/warranty-state-
repairs. That’s why we offer comprehensive warranties mentsto view, download, or print the warranty statement
on our OEM industrial engines, marine engines, and for your engine or drivetrain product.
drivetrain products.
GM52594,0000996 -19-26MAY22-1/1
081922
PN=3
Introduction
Foreword
This manual contains information to operate and service WRITE ENGINE SERIAL NUMBERS and option codes
PowerTech 4.5 L & 6.8 L non-certified and Tier 11 emission in the spaces indicated in the Record Keeping Section.
certified OEM engines built at Dubuque Iowa (T0), Saran Accurately record all the numbers. Your dealer also
France (CD) and Torreon Mexico (PE) from 1996 on. needs these numbers when you order parts. File the
These engines have mechanically-controlled fuel systems. identification numbers in a secure place off the engine.
READ THIS MANUAL carefully to learn how to operate SETTING FUEL DELIVERY beyond published factory
and service your engine correctly. Failure to do so could specifications or otherwise overpowering will result in loss
result in personal injury or equipment damage. of warranty protection for this engine.
THIS MANUAL SHOULD BE CONSIDERED a permanent CERTAIN ENGINE ACCESSORIES such as radiator,
part of your engine and should remain with the engine air cleaner, and instruments are optional equipment on
when you sell it. John Deere OEM Engines. These accessories may be
MEASUREMENTS IN THIS MANUAL are given in both provided by the equipment manufacturer instead of John
metric and customary U.S. unit equivalents. Use only Deere. This operator's manual applies only to the engine
correct replacement parts and fasteners. Metric and inch and those options available through the John Deere
fasteners may require a specific metric or inch wrench. distribution network.
RIGHT-HAND AND LEFT-HAND sides are determined by NOTE: This operators manual covers only engines
standing at the drive or flywheel end (rear) of the engine provided to OEM (Outside Equipment
and facing toward the front of the engine. Manufacturers). For engines in Deere machines,
refer to the machine operators manual.
1
Emission certified for United States as EPA Tier 1 and
European Union as Stage 1.
OURGP11,0000004 -19-20AUG15-1/1
Engine Owner
John Deere Engine Owner: http://www.johndeere.com/enginewarranty Your John
Deere Engine Distributor or local John Deere Service
It is important for you to register your new engine for Dealer will also be happy to provide this service. If you
factory warranty. Registering your engine will allow your would like to view the John Deere Service Dealer network
Service Dealer to verify your warranty status should or locate your nearest Dealer, use the following URL:
a repair be needed. The easiest way to register your http://www.johndeere.com/dealer
engine is via the internet. To register your engine for
warranty via the internet, please use the following URL:
OURGP11,0000251 -19-24OCT11-1/1
081922
PN=4
Introduction
Identification View — 4.5 L Engines
RG7998 —UN—19JUN00
RG7999 —UN—19JUN00 4045D Engine
4045D Engine
RG7997 —UN—19JUN00
RG7996 —UN—19JUN00
4045T Engine
4045T Engine
RG,RG34710,5501 -19-20AUG15-1/1
081922
PN=5
Introduction
Identification View — 6.8 L Engines
RG8002 —UN—19JUN00
RG8003 —UN—19JUN00
6068D Engine
6068D Engine
RG8000 —UN—19JUN00
RG8001 —UN—19JUN00
6068T Engine
6068T Engine
RG,RG34710,5503 -19-20AUG15-1/1
081922
PN=6
Introduction
Trademarks
Trademarks
AdBlue is a trademark of VDA, the German Association of the
AdBlue®
Automotive Industry.
AMP® AMP is a trademark of Tyco Electronics
BIO-GREASE-GARD™ BIO-GREASE-GARD is a trademark of Deere & Company
Bio Hy-Gard™ Bio Hy-Gard is a trademark of Deere & Company
Bluetooth® Bluetooth is a trademark of Bluetooth SIG
Break-In™ Plus Break-In is a trademark of Deere & Company
CINCH® CINCH is a trademark of Cinch Inc.
COOL-GARD™ PLUS COOL-GARD is a trademark of Deere & Company
CoolScan™ CoolScan is a trademark of Deere & Company
COOLSCAN™ PLUS COOLSCAN is a trademark of Deere & Company
Custom Performance™ Custom Performance is a trademark of Deere & Company
Deere™ Deere is a trademark of Deere & Company
DENSO® DENSO is a trademark of DENSO Corporation
DEUTSCH® DEUTSCH is a trademark of TE Connectivity
DieselScan™ DieselScan is a trademark of Deere & Company
DuPont® DuPont is a trademark of E.I. DuPont de Nemours and Company
EXTREME-GARD™ EXTREME-GARD is a trademark of Deere & Company
FleetGard™ FleetGard is a trademark of Deere & Company
Fuelscan™ Fuelscan is a trademark of Deere & Company
Funk™ Funk is a trademark of Deere & Company
GREASE-GARD™ GREASE-GARD is a trademark of Deere & Company
Hy-Gard™ Hy-Gard is a trademark of Deere & Company
JDLink™ JDLink is a trademark of Deere & Company
JDParts™ JDParts is a trademark of Deere & Company
JDPoint™ JDPoint is a trademark of Deere & Company
John Deere™ John Deere is a trademark of Deere & Company
Loctite® Loctite is a trademark of Henkel Corporation
Metri-Pack® Metri-Pack is a trademark of Delphi Connection Systems
OILSCAN PLUS™ OILSCAN PLUS is a trademark of Deere & Company
Oilscan™ Oilscan is a trademark of Deere & Company
Permatex® Permatex is a trademark of Illinois Tool Works Inc.
Phoenix™ Phoenix is a trademark of Deere & Company
Plastigage® Plastigage is a trademark of Perfect Circle Corporation
Plus-50™ II Plus-50 is a trademark of Deere & Company
PowerSight™ PowerSight is a trademark of Deere & Company
PowerTech™ PowerTech is a trademark of Deere & Company
PowerTech™ E PowerTech is a trademark of Deere & Company
PowerTech™ M PowerTech is a trademark of Deere & Company
PowerTech™ Plus PowerTech is a trademark of Deere & Company
Restore® Restore is a trademark of "Restore, Inc."
Continued on next page ZE59858,0000006 -19-12APR21-1/2
081922
PN=7
Introduction
Scotch-Brite® Scotch-Brite is a trademark of 3M Co.

Scotch-Grip® Scotch-Grip is a trademark of 3M Co.
Service ADVISOR™ Service ADVISOR is a trademark of Deere & Company
SERVICEGARD™ SERVICEGARD is a trademark of Deere & Company
SPEEDI-SLEEVE® SPEEDI-SLEEVE is a registered trademark of the SKF Group.
SWEDA™ SWEDA is a trademark of Deere & Company
Swagelok® Swagelok is a registered trademark of Swagelok Company.
TACH-N-TIME is a trademark of Bosch Automotive Service Solutions
TACH-N-TIME™
Inc.
TeamMate™ TeamMate is a trademark of Deere & Company
TEFLON® TEFLON is a trademark of Du Pont Co.
Torq-Gard™ Torq-Gard is a trademark of Deere & Company
TORX® TORX is a registered trademark of Acument Intellectual Properties, LLC
Vari-Cool™ Vari-Cool is a trademark of Deere & Company
WEATHER PACK® WEATHER PACK is a trademark of Packard Electric
WINDOWS® WINDOWS is a trademark of Microsoft Corporation
ZE59858,0000006 -19-12APR21-2/2
081922
PN=8
Contents
Page
Page
Record Keeping
PowerTech Medallion .........................................01-1 Handling and Storing Diesel Fuel .......................10-2
Engine Serial Number Plate ...............................01-1 Biodiesel Fuel .....................................................10-3
Record Engine Serial Number............................01-2 Testing Diesel Fuel .............................................10-4
Engine Option Codes .........................................01-3 Aviation (Jet) Fuels.............................................10-4
Record Fuel Injection Pump Model Number.......01-5 Burner Fuels .......................................................10-4
Fuel Filters..........................................................10-5
Minimizing the Effect of Cold Weather
Safety on Diesel Engines ..........................................10-6
Recognize Safety Information ............................05-1 Diesel Engine Break-In Oil —
Understand Signal Words...................................05-1 Non-Emissions Certified and
Follow Safety Instructions...................................05-1 Certified Tier 1, Tier 2, Tier 3, Stage
Replace Safety Signs .........................................05-2 I, Stage II, and Stage III .................................10-7
Illuminate Work Area Safely ...............................05-2 Diesel Engine Oil — Non-Emissions
Work in Clean Area ............................................05-2 Certified and Certified Tier 1 and
Use Proper Tools ................................................05-3 Stage I............................................................10-8
Live With Safety..................................................05-3 Extended Diesel Engine Oil Service
Prevent Machine Runaway.................................05-3 Intervals — Non-Emissions Certified
Handle Fuel Safely—Avoid Fires........................05-4 and Certified Tier 1 and Stage I .....................10-9
Prepare for Emergencies....................................05-4 Mixing of Lubricants............................................10-9
Handle Starting Fluid Safely ...............................05-4 Alternative and Synthetic Lubricants ..................10-9
In Case of Fire ....................................................05-5 Lubricant Storage .............................................10-10
Handle Fluids Safely—Avoid Fires .....................05-5 Oil Filters ..........................................................10-10
Avoid Static Electricity Risk When Refueling......05-6 Diesel Engine Coolant (engine with
Service Machines Safely ....................................05-6 wet sleeve cylinder liners) ............................ 10-11
Wear Protective Clothing....................................05-6 Water Quality for Mixing with Coolant
Protect Against Noise .........................................05-7 Concentrate..................................................10-12
Handling Batteries Safely ...................................05-7 Operating in Warm Temperature Climates .......10-12
Prevent Acid Burns.............................................05-8 Testing Coolant Freeze Point ...........................10-13
Stay Clear of Rotating Drivelines........................05-8 Disposing of Coolant ........................................10-13
Install All Guards ................................................05-9
Practice Safe Maintenance.................................05-9
Remove Paint Before Welding or Heating........05-10 Engine Operating Guidelines
Avoid Heating Near Pressurized Fluid Lines ....05-10 Instrument (Gauge) Panels ................................15-1
Avoid High-Pressure Fluids ..............................05-10 Instrument (Gauge) Panel (North America)........15-2
Do Not Open High-Pressure Fuel System........ 05-11 VDO Instrument (Gauge) Panel
Protect Against High Pressure Spray ............... 05-11 (Except North America)..................................15-3
Prevent Battery Explosions .............................. 05-11 Engine Break-In Service.....................................15-4
Avoid Hot Exhaust ............................................05-12 Auxiliary Gear Drive Limitations .........................15-6
Work In Ventilated Area....................................05-12 Generator Set (Standby) Applications ................15-6
Service Cooling System Safely ........................05-12 Starting the Engine .............................................15-6
Decommissioning — Proper Recycling Warming Engine .................................................15-8
and Disposal of Fluids and Components .....05-13 Normal Engine Operation ...................................15-8
Cold Weather Operation.....................................15-9
Changing Engine Speed...................................15-10
Fuels, Lubricants, and Coolant Avoid Excessive Engine Idling..........................15-10
Diesel Fuel..........................................................10-1 Stopping the Engine ......................................... 15-11
Supplemental Diesel Fuel Additives ...................10-2 Using a Booster Battery or Charger .................15-12
Lubricity of Diesel Fuel .......................................10-2
Continued on next page
Original Instructions. All information, illustrations and specifications in this

manual are based on the latest information available at the time of publication.
The right is reserved to make changes at any time without notice.
COPYRIGHT © 2022
DEERE & COMPANY
Moline, Illinois
All rights reserved.
A John Deere ILLUSTRUCTION ™ Manual
Previous Editions
Copyright © 1996, 2000, 2002, 2004, 2006, 2011, 2014, 2015, 2016, 2017, 2018, 2019, 2020
i PN=1
081922
Contents
Page Page
Pre-Start Cleaning Guide ...................................45-3

Lubrication and Maintenance Replacing Single Stage Air Cleaner ...................45-4
Required Emission-Related Information.............20-1 Replacing Axial Seal Air Cleaner Filter
Observe Service Intervals ..................................20-1 Element ..........................................................45-5
Use Correct Fuels, Lubricants, and Coolant.......20-1 Replacing Radial Seal Air Cleaner
Lubrication and Maintenance Service Filter Element .................................................45-6
Interval Chart..................................................20-2 Replacing Fan and Alternator Belts....................45-7
Checking Fuses In Instrument Panels................45-8
Lubrication & Maintenance — Daily Checking Air Compressors.................................45-9
Daily Prestarting Checks ....................................25-1 Bleeding the Fuel System...................................45-9
Lubrication & Maintenance — 250 Hours/6 Troubleshooting

Months General Troubleshooting Information .................50-1
Servicing Fire Extinguisher.................................30-1 Engine Wiring Diagram Legend
Changing Engine Oil and Replacing Filter..........30-1 (Standard Instrument Panel For
Checking Engine Mounts....................................30-3 North America) ...............................................50-3
Servicing Battery ................................................30-3 Wiring Diagram (Standard Instrument
Manual Belt Tensioner Adjustment .....................30-5 Panel For North America) ..............................50-4
Manual Belt Tensioner Adjustment Engine Wiring Diagram—VDO
Using Belt Tension Tool (Alternate Instrument Panel (Except North America)......50-5
Method For Engines Without Engine Wiring Diagram Legend—VDO
Auxiliary Drive) ...............................................30-6 Instrument Panel (Except North America)......50-6
Engine Troubleshooting......................................50-7
Lubrication & Maintenance — 500 Hours/12
Months Storage
Cleaning Crankcase Vent Tube..........................35-1 Engine Storage Guidelines.................................55-1
Checking Air Intake System ...............................35-1 Preparing Engine for Long-Term Storage...........55-2
Replacing Fuel Filter Element (Single Filter) ......35-2 Removing Engine from Long Term Storage .......55-3
Replacing Fuel Filter Elements (Dual Filters) .....35-3
Checking Belt Tensioner Spring Specifications
Tension and Belt Wear (Automatic General OEM Engine Specifications —
Tensioner) ......................................................35-4 4.5 L Engines .................................................60-1
Checking Engine Speeds ...................................35-6 General OEM Engine Specifications —
Checking Engine Electrical Ground 6.8 L Engines .................................................60-1
Connections ...................................................35-6 Engine Power Ratings And Fuel
Checking Cooling System ..................................35-6 Injection Pump Specifications — 4.5
Replenishing Supplemental Coolant L Engines .......................................................60-2
Additives (SCAs) Between Coolant Engine Power Ratings And Fuel
Changes.........................................................35-7 Injection Pump Specifications — 6.8
Testing Diesel Engine Coolant............................35-8 L Engines .......................................................60-7
Pressure Testing Cooling System.......................35-9 Engine Power Ratings And Fuel
Injection Pump Specifications ......................60-10
Lubrication & Maintenance — 2000 Hours/24 Engine Crankcase Oil Fill Quantities ................60-19
Months Unified Inch Bolt and Screw Torque Values......60-20
Adjusting Variable Speed (Droop) on Metric Bolt and Screw Torque Values...............60-21
Generator Set Engines...................................40-1
Checking Crankshaft Vibration Damper Lubrication and Maintenance Records
(6-Cylinder Engine Only)................................40-3 Using Lubrication and Maintenance Records.....65-1
Flushing and Refilling Cooling System ...............40-4 Daily (Prestarting) Service..................................65-1
Testing Thermostats Opening Temperature .......40-6 250 Hour/6 Month Service..................................65-1
Check and Adjust Valve Clearance ....................40-9 500 Hour/12 Month Service................................65-2
2000 Hour/24 Month Service..............................65-3
Service as Required Service as Required ...........................................65-4
Additional Service Information............................45-1
Do Not Modify Fuel System................................45-1 Warranty
Adding Coolant ...................................................45-2 John Deere Warranty in OEM Applications ........70-1
ii 081922
PN=2
Contents
Page
Emissions Control System Certification Label....70-4

EPA Non-road Emissions Control
Warranty Statement—Compression Ignition ..70-5
CARB Non-road Emissions Control
Warranty Statement—Compression Ignition ..70-7
John Deere Service Literature Available

Technical Information..........................................75-1
iii 081922
PN=3
Contents
iv 081922
PN=4
Record Keeping
POWERTECH® Medallion
A medallion is located on the rocker arm cover which
identifies each engine as a John Deere POWERTECH®
engine.
RG11608 —UN—17OCT01
RG11609 —UN—17OCT01
POWERTECH is a trademark of Deere & Company.
RG,RG34710,5505 -19-04JAN02-1/1
Engine Serial Number Plate

Each engine has a 13-digit John Deere engine serial
number. The first two digits identify the factory that
produced the engine:
• “T0” indicates the engine was built in Dubuque, Iowa
RG8007 —UN—15JAN99
• “CD” indicates the engine was built in Saran, France
• “PE” indicates the engine was built in Torreon, Mexico
• “J0” indicates the engine was built in Rosario, Argentina
Your engine's serial number plate (A) is located on the
right-hand side of cylinder block behind the fuel filter.
13-Digit Engine Serial Number Plate
RG,RG34710,5506 -19-04JAN02-1/1
01-1 081922
PN=13
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.
RG7936 —UN—13NOV97
This information is very important for repair parts or
warranty information.
Engine Serial Number (B)
Dubuque Engine Serial Number Plate

Engine Model Number (C)
RG7935 —UN—13NOV97
Coefficient of Absorption Value (D)
(Saran Engines Only)
Saran Engine Serial Number Plate
RG9062 —UN—16MAR98
Torreon Engine Serial Number Plate
RG,RG34710,5507 -19-04JAN02-1/1
01-2 081922
PN=14
Record Keeping
Engine Option Codes
JOHN DEERE Number PE6068U000094
A
6068HFC09 6.8 L 2732F
1111 1399 1425 1524 1606 1708 1928 2002 2699 2815 2909 3008 3512 3914 4026
RG24026 —UN—05AUG13
4391 4607 4702 4803 4903 5002 5103 5215 5407 5511 5615 5709 5927 6543 6801
6901 72F3 7306 7703 7897 8422 8911 9805
Customer No. OPTION CODES
Option Code Label Example

A—Engine Base Code (example)
OEM engines have an engine option code label affixed to An additional option code label may also be delivered (in
the rocker arm cover. These codes indicate which of the a plastic bag attached to the engine or inserted in the
engine options were installed on your engine at the factory. machine documentation). It is recommended to place this
When in need of parts or service, furnish your authorized label either on this page of the operator’s manual or in the
servicing dealer or engine distributor with these numbers. Engine Owner's Warranty booklet under Option Codes.
The engine option code label includes an engine base The machine manufacturer may have placed the label in a
code (A). This base code must also be recorded along specific accessible area (inside the enclosure or close to
with the option codes. At times it will be necessary to a maintenance area).
furnish this base code to differentiate two identical option
codes for the same engine model. Your engine option code label may not contain all option
codes if an option has been added after the engine left
The first two digits of each code identify a specific group, the producing factory.
such as alternators. The last two digits of each code
identify one specific option provided on your engine, such If option code label is lost or destroyed, consult your
as a 24 volt, 120 amp alternator. servicing dealer or engine distributor selling the engine for
a replacement.
If an engine is ordered without a particular component, the
last two digits of that functional group option code will be Record your engine Base Code (A) in the spaces provided
99, 00, or XX. The following list shows only the first two below for easy reference.
digits of the code numbers. For future reference such as
ordering repair parts, it is important to have these code Engine Base Code (A):
numbers available. To ensure this availability, enter the
third and fourth digits shown on your engine option code
label in the spaces provided on the following page.
Option Codes Description Option Codes Description
10 Paint Protection 56 Paint

11 Rocker Arm Cover 57 Water Pump Inlet
12 Oil Filler 58 Power Take Off
13 Crankshaft Pulley 59 Oil Cooler/Oil Filter
14 Flywheel Housing 60 Add-On Fan Drive Pulley
15 Flywheel 61 After Treatment Device/Muffler
16 Fuel Injection System 62 Alternator Mounting
17 Air Inlet 63 Low-Pressure Fuel Lines
18 Air Cleaner 64 Exhaust Elbow
19 Oil Pan 65 Turbocharger
20 Water Pump 66 Temperature Switch
21 Thermostat Cover 67 Engine Sensors
Continued on next page RG,RG34710,5004 -19-16AUG21-1/2
01-3 081922
PN=15
Record Keeping
Option Codes Description Option Codes Description

22 Thermostat 68 Damper
23 Fan Drive 69 Engine Serial Number Plate
24 Fan Belt 70 Decomposition Tube (OEM)
25 Fan 71 SCR (OEM)
26 Block Heater 72 Performance Software and Labels
27 Radiator/Heat Exchanger 7A Performance Software and Labels
28 Exhaust Manifold 73 After Treatment Dosing System
29 Ventilator System 74 Air Conditioning
30 Starting Motor 75 Restriction Indicator
31 Alternator 76 Oil Pressure Switch
32 DEF Lines, Pressure (OEM) 77 Timing Gear Cover (S450/S650)
33 DEF Lines, Supply/Return to Tank (OEM) 78 Air Compressor
34 DEF Tank and Header (OEM) 79 Certification
35 Final Fuel Filter 80 Sea Water Pump (Marine)
36 Front Plate and Idler Shafts 81 Primary Fuel Filter/Water Separator
37 Fuel Transfer Pump 82 Ignition System (Natural Gas)
38 Operator Manual 83 Vehicle Performance Software
39 Thermostat Housing 84 Wiring Harness
40 Dipstick and Tube 85 Fuel System (Natural Gas)
41 Belt Driven Auxiliary Drive (Add-On Crank Pulley) 86 Fan Pulley
42 DEF Line, Supply Module to Injector (OEM) 87 Belt Tensioner
43 Starting Aid 88 Oil Filter
44 Timing Gear Cover (S350) 89 EGR System
44 Tachometer Drive Sensors (S450/S650) 90 Trim Software (OEM)
45 Secondary Balancers 91 Engine Installation Kit (S350)
46 Cylinder Block with Camshaft 92 Engine Test Certificate/Engine Accessories
(S350)
47 Crankshaft/Main Bearings 92 Engine Installation Kit (S450)
48 Connecting Rods/Pistons/Liners 93 Emission Label
49 Valve Actuating Mechanism 94 Custom Software
50 Oil Pump 95 Parts Installed at Factory
51 Cylinder Head with Valves 96 Engine Installation Kit/Ship With (S450/S650)
52 Gear Driven Auxiliary Drive 96 ECU Wiring Harness (6125/6135)
53 Fuel Heater 97 Field Installed Items
54 Turbo Air Intake 98 Engine Lift Strap
55 Shipping Stand 99 Service Only Parts
NOTE: This is a complete option code list based on at any time without notice. Your engine will not
the latest information available at the time of contain all option codes listed.
publication. The right is reserved to make changes
RG,RG34710,5004 -19-16AUG21-2/2
01-4 081922
PN=16
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. RPM
RG8008A —UN—13JUN00
Manufacturer's No.
Serial No.
A—Serial Number Plate

Record Injection Pump Serial Number
RG,RG34710,5511 -19-20MAY96-1/1
01-5 081922
PN=17
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
T81389 —UN—28JUN13
practices.
DX,ALERT -19-29SEP98-1/1
Understand Signal Words

DANGER; The signal word DANGER indicates a
hazardous situation which, if not avoided, will result in
death or serious injury.
WARNING; The signal word WARNING indicates a
hazardous situation which, if not avoided, could result in
TS187 —19—30SEP88
death or serious injury.
CAUTION; The signal word CAUTION indicates a
hazardous situation which, if not avoided, could result in
minor or moderate injury. CAUTION may also be used
to alert against unsafe practices associated with events
which could lead to personal injury.
A signal word—DANGER, WARNING, or CAUTION—is precautions are listed on CAUTION safety signs.
used with the safety-alert symbol. DANGER identifies CAUTION also calls attention to safety messages in this
the most serious hazards. DANGER or WARNING manual.
safety signs are located near specific hazards. General
DX,SIGNAL -19-05OCT16-1/1
Follow Safety Instructions

Carefully read all safety messages in this manual and on
your machine safety signs. Keep safety signs in good
condition. Replace missing or damaged safety signs. Be
sure new equipment components and repair parts include
the current safety signs. Replacement safety signs are
TS201 —UN—15APR13
available from your John Deere dealer.
There can be additional safety information contained on
parts and components sourced from suppliers that is not
reproduced in this operator's manual.
Learn how to operate the machine and how to use controls
properly. Do not let anyone operate without instruction.
Keep your machine in proper working condition.
If you do not understand any part of this manual and need
Unauthorized modifications to the machine may impair the
assistance, contact your John Deere dealer.
function and/or safety and affect machine life.
DX,READ -19-01AUG22-1/1
05-1 081922
PN=18
Safety
Replace Safety Signs

Replace missing or damaged safety signs. Use this
operator’s manual for correct safety sign placement.
There can be additional safety information contained on
parts and components sourced from suppliers that is not
reproduced in this operator's manual.
DX,SIGNS -19-18AUG09-1/1
Illuminate Work Area Safely

Illuminate your work area adequately but safely. Use
a portable safety light for working inside or under the
machine. Make sure the bulb is enclosed by a wire cage.
The hot filament of an accidentally broken bulb can ignite
spilled fuel or oil.
TS223 —UN—23AUG88
DX,LIGHT -19-04JUN90-1/1
Work in Clean Area

Before starting a job:
• Clean work area and machine.
• Make sure you have all necessary tools to do your job.
• Have the right parts on hand.
T6642EJ —UN—18OCT88
• Read all instructions thoroughly; do not attempt
shortcuts.
DX,CLEAN -19-04JUN90-1/1
05-2 081922
PN=19
Safety
Use Proper Tools

Use tools appropriate to the work. Makeshift tools and
procedures can create safety hazards.
Use power tools only to loosen threaded parts and
fasteners.
TS779 —UN—08NOV89
For loosening and tightening hardware, use the correct
size tools. DO NOT use U.S. measurement tools on
metric fasteners. Avoid bodily injury caused by slipping
wrenches.
Use only service parts meeting John Deere specifications.
DX,REPAIR -19-17FEB99-1/1
Live With Safety

Before returning machine to customer, make sure
machine is functioning properly, especially the safety
systems. Install all guards and shields.
TS231 —19—07OCT88
DX,LIVE -19-25SEP92-1/1
Prevent Machine Runaway

Avoid possible injury or death from machinery runaway.
Do not start engine by shorting across starter terminals.
Machine will start in gear if normal circuitry is bypassed.
NEVER start engine while standing on ground. Start
TS177 —UN—11JAN89
engine only from operator’s seat, with transmission in
neutral or park.
DX,BYPAS1 -19-29SEP98-1/1
05-3 081922
PN=20
Safety
Handle Fuel Safely—Avoid Fires

Handle fuel with care: it is highly flammable. Do not refuel
the machine while smoking or when near open flame or
sparks.
Always stop engine before refueling machine. Fill fuel
tank outdoors.
Prevent fires by keeping machine clean of accumulated
trash, grease, and debris. Always clean up spilled fuel.
Use only an approved fuel container for transporting
flammable liquids.
Never fill fuel container in pickup truck with plastic bed
liner. Always place fuel container on ground before
refueling. Touch fuel container with fuel dispenser nozzle Do not store fuel container where there is an open flame,
before removing can lid. Keep fuel dispenser nozzle in spark, or pilot light such as within a water heater or other
contact with fuel container inlet when filling. appliance.
DX,FIRE1 -19-12OCT11-1/1
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. Keep
starting fluid away from batteries and cables.
To prevent accidental discharge when storing the
TS1356 —UN—18MAR92
pressurized can, keep the cap on the container, and store
in a cool, protected location.
Do not incinerate or puncture a starting fluid container.
Do not use starting fluid on an engine equipped with glow
plugs or an air intake heater.
DX,FIRE3 -19-14MAR14-1/1
05-4 081922
PN=21
Safety
In Case of Fire
CAUTION: Avoid personal injury.
Stop machine immediately at the first sign of fire. Fire

may be identified by the smell of smoke or sight of flames.
Because fire grows and spreads rapidly, get off the
machine immediately and move safely away from the fire.
Do not return to the machine! The number one priority
is safety.
Call the fire department. A portable fire extinguisher can
put out a small fire or contain it until the fire department
arrives; but portable extinguishers have limitations.
Always put the safety of the operator and bystanders first.
If attempting to extinguish a fire, keep your back to the 1. Pull the pin. Hold the extinguisher with the nozzle
wind with an unobstructed escape path so you can move pointing away from you, and release the locking
away quickly if the fire cannot be extinguished. mechanism.
Read the fire extinguisher instructions and become familiar 2. Aim low. Point the extinguisher at the base of the fire.
with their location, parts, and operation before a fire starts.
Local fire departments or fire equipment distributors may 3. Squeeze the lever slowly and evenly.
offer fire extinguisher training and recommendations.
4. Sweep the nozzle from side-to-side.
If your extinguisher does not have instructions, follow
these general guidelines:
DX,FIRE4 -19-22AUG13-1/1
Handle Fluids Safely—Avoid Fires

When you work around fuel, do not smoke or work near
heaters or other fire hazards.
Store flammable fluids away from fire hazards. Do not
incinerate or puncture pressurized containers.
Make sure machine is clean of trash, grease, and debris.
Do not store oily rags; they can ignite and burn
spontaneously.
DX,FLAME -19-29SEP98-1/1
05-5 081922
PN=22
Safety
Avoid Static Electricity Risk When Refueling

The removal of sulfur and other compounds in Ultra-Low
Sulfur Diesel (ULSD) fuel decreases its conductivity and
increases its ability to store a static charge.
Refineries may have treated the fuel with a static
RG22142 —UN—17MAR14
dissipating additive. However, there are many factors that
can reduce the effectiveness of the additive over time.
Static charges can build up in ULSD fuel while it is flowing
through fuel delivery systems. Static electricity discharge
when combustible vapors are present could result in a
fire or explosion.
Therefore, it is important to ensure that the entire system
used to refuel your machine (fuel supply tank, transfer
pump, transfer hose, nozzle, and others) is properly
grounded and bonded. Consult with your fuel or fuel
system supplier to ensure that the delivery system is in
compliance with fueling standards for proper grounding
RG21992 —UN—21AUG13
and bonding practices.
DX,FUEL,STATIC,ELEC -19-12JUL13-1/1
Service Machines Safely

Tie long hair behind your head. Do not wear a necktie,
scarf, loose clothing, or necklace when you work near
machine 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.
DX,LOOSE -19-04JUN90-1/1
Wear Protective Clothing

Wear close fitting clothing and safety equipment
appropriate to the job.
Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones
while operating machine.
DX,WEAR2 -19-03MAR93-1/1
05-6 081922
PN=23
Safety
Protect Against Noise

There are many variables that affect the sound level
range, including machine configuration, condition and
maintenance level of the machine, ground surface,
operating environmental, duty cycles, ambient noise, and
attachments.
Exposure to loud noise can cause impairment or loss of
hearing.
Always wear hearing protection. Wear a suitable
hearing protective device such as earmuffs or earplugs
to protect against objectionable or uncomfortable loud
noises.
DX,NOISE -19-03OCT17-1/1
Handling Batteries Safely

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.
Always remove grounded (-) battery clamp first and
replace grounded clamp last.
Sulfuric acid in battery electrolyte is poisonous and strong
enough to burn skin, eat holes in clothing, and cause
blindness if splashed into eyes.
Avoid hazards by:
• Filling batteries in a well-ventilated area
• Wearing eye protection and rubber gloves
• Avoiding use of air pressure to clean batteries
• Avoiding breathing fumes when electrolyte is added
• Avoiding spilling or dripping electrolyte
• Using correct battery booster or charger procedure.
If acid is spilled on skin or in eyes:
1. Flush skin with water.
2. Apply baking soda or lime to help neutralize the acid.
3. Flush eyes with water for 15—30 minutes. Get
medical attention immediately.
If acid is swallowed:
1. Do not induce vomiting.
2. Drink large amounts of water or milk, but do not
exceed 2 L (2 qt.).
3. Get medical attention immediately.
WARNING: Battery posts, terminals, and related
accessories contain lead and lead compounds, chemicals

known to the State of California to cause cancer and
reproductive harm. Wash hands after handling.
DX,WW,BATTERIES -19-02DEC10-1/1
05-7 081922
PN=24
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. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is added.
4. Avoiding spilling or dripping electrolyte.
5. Use proper jump start procedure.
If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize the acid.
3. Flush your eyes with water for 15—30 minutes. Get
medical attention immediately.
1. Do not induce vomiting.
2. Drink large amounts of water or milk, but do not
exceed 2 L (2 quarts).
DX,POISON -19-21APR93-1/1
Stay Clear of Rotating Drivelines

Entanglement in rotating driveline can cause serious
injury or death.
Keep all shields in place at all times. Make sure rotating
shields turn freely.
TS1644 —UN—22AUG95
Wear close-fitting clothing. Stop the engine and be sure
that all rotating parts and drivelines are stopped before
making adjustments, connections, or performing any type
of service on engine or machine driven equipment.
DX,ROTATING -19-18AUG09-1/1
05-8 081922
PN=25
Safety
Install All Guards

Rotating cooling system fans, belts, pulleys, and drives
can cause serious injury.
Keep all guards in place at all times during engine
operation.
TS677 —UN—21SEP89
Wear close-fitting clothes. Stop the engine and be sure
fans, belts, pulleys, and drives are stopped before making
adjustments, connections, or cleaning near fans and their
drive components.
DX,GUARDS -19-18AUG09-1/1
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 away from
power-driven parts. Disengage all power and operate
controls to relieve pressure. Lower equipment to the
ground. Stop the engine. Remove the key. Allow machine
to cool.
Securely support any machine elements that must be
raised for service work.
Keep all parts in good condition and properly installed.
Fix damage immediately. Replace worn or broken parts.
Remove any buildup of grease, oil, or debris.
On self-propelled equipment, disconnect battery ground
cable (-) before making adjustments on electrical systems
or welding on machine.
On towed implements, disconnect wiring harnesses from
tractor before servicing electrical system components or
welding on machine.
Falling while cleaning or working at height can cause
serious injury. Use a ladder or platform to easily reach
each location. Use sturdy and secure footholds and
handholds.
DX,SERV -19-28FEB17-1/1
05-9 081922
PN=26
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 100 mm (4 in.) from area
to be affected by heating. If paint cannot be removed,
wear an approved respirator before heating or welding.
• If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
• If you use solvent or paint stripper, remove stripper with
soap and water before welding. Remove solvent or
paint stripper containers and other flammable material
Do all work in an area that is well ventilated to carry toxic
from area. Allow fumes to disperse at least 15 minutes
fumes and dust away.
before welding or heating.
Do not use a chlorinated solvent in areas where welding Dispose of paint and solvent properly.
will take place.
DX,PAINT -19-24JUL02-1/1
Avoid Heating Near Pressurized Fluid Lines

Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to yourself
and bystanders. Do not heat by welding, soldering,
or using a torch near pressurized fluid lines or other
flammable materials. Pressurized lines can accidentally
TS953 —UN—15MAY90
burst when heat goes beyond the immediate flame area.
DX,TORCH -19-10DEC04-1/1
Avoid High-Pressure Fluids

Inspect hydraulic hoses periodically – at least once
per year – for leakage, kinking, cuts, cracks, abrasion,
blisters, corrosion, exposed wire braid or any other signs
of wear or damage.
X9811 —UN—23AUG88
Replace worn or damaged hose assemblies immediately
with John Deere approved replacement parts.
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.
a few hours or gangrene may result. Doctors unfamiliar
Search for leaks with a piece of cardboard. Protect hands with this type of injury should reference a knowledgeable
and body from high-pressure fluids. medical source. Such information is available in
English from Deere & Company Medical Department in
If an accident occurs, see a doctor immediately. Any fluid Moline, Illinois, U.S.A., by calling 1-800-822-8262 or +1
injected into the skin must be surgically removed within 309-748-5636.
DX,FLUID -19-12OCT11-1/1
05-10 081922
PN=27
Safety
Do Not Open High-Pressure Fuel System

High-pressure fluid remaining in fuel lines can cause
serious injury. Do not disconnect or attempt repair of fuel
lines, sensors, or any other components between the
high-pressure fuel pump and nozzles on engines with
High Pressure Common Rail (HPCR) fuel system.
TS1343 —UN—18MAR92
Only technicians familiar with this type of system can
perform repairs. (See your John Deere dealer.)
DX,WW,HPCR1 -19-07JAN03-1/1
Protect Against High Pressure Spray

Spray from high pressure nozzles can penetrate the skin
and cause serious injury. Keep spray from contacting
hands or body.
If an accident occurs, see a doctor immediately. Any high
TS1343 —UN—18MAR92
pressure spray injected into the skin must be surgically
removed within a few hours or gangrene may result.
Doctors unfamiliar with this type of injury should reference
a knowledgeable medical source. Such information is
available from Deere & Company Medical Department in
Moline, Illinois, U.S.A.
DX,SPRAY -19-16APR92-1/1
Prevent Battery Explosions

Keep sparks, lighted matches, and open flame away from
the top of battery. Battery gas can explode.
Never check battery charge by placing a metal object
across the posts. Use a volt-meter or hydrometer.
Do not charge a frozen battery; it may explode. Warm
battery to 16°C (60°F).
DX,SPARKS -19-03MAR93-1/1
05-11 081922
PN=28
Safety
Avoid Hot Exhaust

Servicing machine or attachments with engine running
can result in serious personal injury. Avoid exposure and
skin contact with hot exhaust gases and components.
Exhaust parts and streams become very hot during
RG17488 —UN—21AUG09
operation. Exhaust gases and components reach
temperatures hot enough to burn people, ignite, or melt
common materials.
DX,EXHAUST -19-20AUG09-1/1
Work In Ventilated Area

Engine exhaust fumes can cause sickness or death. If
it is necessary to run an engine in an enclosed area,
remove the exhaust fumes from the area with an exhaust
pipe extension.
If you do not have an exhaust pipe extension, open the
doors and get outside air into the area.
DX,AIR -19-17FEB99-1/1
Service Cooling System Safely

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.
DX,WW,COOLING -19-19AUG09-1/1TS281 —UN—15APR13
05-12 081922
PN=29
Safety
Decommissioning — Proper Recycling and

Disposal of Fluids and Components
Safety and environmental stewardship measures must
be taken into account when decommissioning a machine
and/or component. These measures include the following:
TS1133 —UN—15APR13
• Use appropriate tools and personal protective
equipment such as clothing, gloves, face shields or
glasses, during the removal or handling of objects and
materials.
• Follow instructions for specialized components.
• Release stored energy by lowering suspended machine
elements, relaxing springs, disconnecting the battery
or other electrical power, and releasing pressure in
hydraulic components, accumulators, and other similar filters; batteries; and, other substances or parts.
systems. Burning of flammable fluids or components in other than
• Minimize exposure to components which may have specially designed incinerators may be prohibited by law
residue from agricultural chemicals, such as fertilizers and could result in exposure to harmful fumes or ashes.
and pesticides. Handle and dispose of these • Service and dispose of air conditioning systems
components appropriately. appropriately. Government regulations may require
• Carefully drain engines, fuel tanks, radiators, hydraulic a certified service center to recover and recycle air
cylinders, reservoirs, and lines before recycling conditioning refrigerants which could damage the
components. Use leak-proof containers when draining atmosphere if allowed to escape.
fluids. Do not use food or beverage containers. • Evaluate recycling options for tires, metal, plastic,
• Do not pour waste fluids onto the ground, down a drain, glass, rubber, and electronic components which may be
or into any water source. recyclable, in part or completely.
• Observe all national, state, and local laws, regulations, • Contact your local environmental or recycling center, or
or ordinances governing the handling or disposal of your John Deere dealer for information on the proper
waste fluids (example: oil, fuel, coolant, brake fluid); way to recycle or dispose of waste.
DX,DRAIN -19-01JUN15-1/1
05-13 081922
PN=30
Fuels, Lubricants, and Coolant
Diesel Fuel
Consult your local fuel distributor for properties of the
Sulfur Content for Interim Tier 4, Final Tier 4, Stage III
diesel fuel available in your area.
A and B, Stage IV, and Stage V Engines Above 560 kW
In general, diesel fuels are blended to satisfy the low
temperature requirements of the geographical area in • Use ONLY diesel fuel with a maximum of 500 mg/kg
which they are marketed. (500 ppm) sulfur content.
Diesel fuels specified to EN 590 or ASTM D975 are Sulfur Content for Interim Tier 4, Final Tier 4, Stage
recommended. Renewable diesel fuel produced by III B, Stage IV Engines, and Stage V Engines
hydrotreating animal fats and vegetable oils is basically
identical to petroleum diesel fuel. Renewable diesel that
• Use ONLY ultra low sulfur diesel (ULSD) fuel with a
maximum of 15 mg/kg (15 ppm) sulfur content.
meets EN 590, ASTM D975, or EN 15940 is acceptable
for use at all percentage mixture levels. Sulfur Content for Tier 3 and Stage III A Engines
Required Fuel Properties • Use of diesel fuel with sulfur content less than 1000
mg/kg (1000 ppm) is RECOMMENDED.
In all cases, the fuel shall meet the following properties:
• Use of diesel fuel with sulfur content 1000—2000 mg/kg
Cetane number of 40 minimum. Cetane number greater (1000—2000 ppm) REDUCES the oil and filter change
than 47 is preferred, especially for temperatures below interval.
–20 °C (–4 °F) or elevations above 1675 m (5500 ft.).
• BEFORE using diesel fuel with sulfur content greater
Cloud Point should be below the expected lowest ambient than 2000 mg/kg (2000 ppm), contact your John Deere
temperature or Cold Filter Plugging Point (CFPP) should dealer.
be a maximum 10°C (18°F) below the fuel cloud point.
Sulfur Content for Tier 2 and Stage II Engines
Fuel lubricity should pass a maximum scar diameter of
0.52 mm as measured by ASTM D6079 or ISO 12156-1. • Use of diesel fuel with sulfur content less than 2000
A maximum scar diameter of 0.45 mm is preferred. mg/kg (2000 ppm) is RECOMMENDED.
• Use of diesel fuel with sulfur content 2000—5000 mg/kg
Diesel fuel quality and sulfur content must comply with (2000—5000 ppm) REDUCES the oil and filter change
all existing emissions regulations for the area in which interval.1
the engine operates. DO NOT use diesel fuel with sulfur • BEFORE using diesel fuel with sulfur content greater
content greater than 10 000 mg/kg (10 000 ppm). than 5000 mg/kg (5000 ppm), contact your John Deere
dealer.
Materials such as copper, lead, zinc, tin, brass and
bronze should be avoided in fuel handling, distribution Sulfur Content for Other Engines
and storage equipment as these metals can catalyze fuel
oxidation reactions which can lead to fuel system deposits • Use of diesel fuel with sulfur content less than 5000
and plugged fuel filters. mg/kg (5000 ppm) is RECOMMENDED.
• Use of diesel fuel with sulfur content greater than 5000
E-Diesel fuel mg/kg (5000 ppm) REDUCES the oil and filter change
interval.
DO NOT use E-Diesel (Diesel fuel and ethanol blend).
Use of E-Diesel fuel in any John Deere machine may void IMPORTANT: Do not mix used diesel engine oil or any
the machine warranty. other type of lubricating oil with diesel fuel.
Improper fuel additive usage may cause damage
CAUTION: Avoid severe injury or death due to the on fuel injection equipment of diesel engines.
fire and explosion risk from using E-Diesel fuel.
1
See DX,ENOIL12,OEM, DX,ENOIL12,T2,STD, or DX,ENOIL12,T2,EXT
for more information on Engine Oil and Filter Service Intervals.
DX,FUEL1 -19-13JUL20-1/1
10-1 081922
PN=31
Supplemental Diesel Fuel Additives

Diesel fuel can be the source of performance or other
operational problems for many reasons. Some causes To further aid in maintaining performance and reliability of
include poor lubricity, contaminants, low cetane number, the engine's fuel system, John Deere has developed a
and a variety of properties that cause fuel system family of fuel additive products for most global markets.
deposits. These and others are referenced in other The primary products include Fuel-Protect Diesel Fuel
sections of this Operator's Manual. Conditioner (full feature conditioner in winter and summer
formulas) and Fuel-Protect Keep Clean (fuel injector
To optimize engine performance and reliability, closely deposit removal and prevention). Availability of these and
follow recommendations on fuel quality, storage, and other products varies by market. See your local John
handling, which are found elsewhere in this Operator's Deere dealer for availability and additional information
Manual. about fuel additives that might be right for your needs.
DX,FUEL13 -19-07FEB14-1/1
Lubricity of Diesel Fuel

Most diesel fuels manufactured in the United States, If fuel of low or unknown lubricity is used, add John Deere
Canada, and the European Union have adequate lubricity Fuel-Protect Diesel Fuel Conditioner (or equivalent) at
to ensure proper operation and durability of fuel injection the specified concentration.
system components. However, diesel fuels manufactured
in some areas of the world may lack the necessary lubricity. Lubricity of BioDiesel Fuel
IMPORTANT: Make sure the diesel fuel used Fuel lubricity can improve significantly with BioDiesel
in your machine demonstrates good blends up to B20 (20% BioDiesel). Further increase in
lubricity characteristics. lubricity is limited for BioDiesel blends greater than B20.
Fuel lubricity should pass a maximum scar diameter of

0.52 mm as measured by ASTM D6079 or ISO 12156-1.
A maximum scar diameter of 0.45 mm is preferred.
DX,FUEL5 -19-07FEB14-1/1
Handling and Storing Diesel Fuel
CAUTION: Reduce the risk of fire. Handle fuel Check engine oil level daily prior to starting engine. A
carefully. DO NOT fill the fuel tank when engine rising oil level may indicate fuel dilution of the engine oil.
is running. DO NOT smoke while you fill the
IMPORTANT: The fuel tank is vented through the
fuel tank or service the fuel system.
filler cap. If a new filler cap is required, always
replace it with an original vented cap.
Fill the fuel tank at the end of each day's operation to
prevent water condensation and freezing during cold
When fuel is stored for an extended period or if there is
weather.
a slow turnover of fuel, add a fuel conditioner to stabilize
Keep all storage tanks as full as practical to minimize the fuel. Keeping the free water drained and treating the
condensation. bulk fuel storage tank quarterly with a maintenance dose
of a biocide will prevent microbial growth. Contact your
Ensure that all fuel tank caps and covers are installed fuel supplier or John Deere dealer for recommendations.
properly to prevent moisture from entering. Monitor water
content of the fuel regularly.
When using biodiesel fuel, the fuel filter may require more
frequent replacement due to premature plugging.
DX,FUEL4 -19-13JAN18-1/1
10-2 081922
PN=32
Biodiesel Fuel
Biodiesel fuel is comprised of monoalkyl esters of long
Biodiesel Use Requirements and Recommendations
chain fatty acids derived from vegetable oils or animal
fats. Biodiesel blends are biodiesel mixed with petroleum The petroleum diesel portion of all biodiesel blends must
diesel fuel on a volume basis. meet the requirements of ASTM D975 (US) or EN 590
Before using fuel containing biodiesel, review the (EU) commercial standard.
Biodiesel Use Requirements and Recommendations in Biodiesel users in the U.S. are strongly encouraged to
this Operator’s Manual. purchase biodiesel blends from a BQ-9000 Certified
Environmental laws and regulations can encourage or Marketer and sourced from a BQ-9000 Accredited
prohibit the use of biofuels. Operators should consult Producer (as certified by the National biodiesel Board).
with appropriate governmental authorities prior to using Certified Marketers and Accredited Producers can be
biofuels. found at the following website: http://www.bq9000.org.
Biodiesel contains residual ash. Ash levels exceeding the
John Deere Stage V Engines Operating in
maximums allowed in either ASTM D6751 or EN14214
the European Union
can result in more rapid ash loading and require more
Where the engine is to be operated within the Union on frequent cleaning of the Exhaust Filter (if present).
diesel or non-road gas-oil, a fuel with a FAME content not The fuel filter can require more frequent replacement
greater than 8% volume/volume (B8) shall be used. when using biodiesel fuel, particularly if switching from
John Deere Engines with Exhaust Filter Except Stage diesel. Check engine oil level daily prior to starting engine.
V Engines Operating in the European Union A rising oil level can indicate fuel dilution of the engine oil.
Biodiesel blends up to B20 must be used within 90 days
Biodiesel blends up to B20 can be used ONLY if the of the date of biodiesel manufacture. Biodiesel blends
biodiesel (100% biodiesel or B100) meets ASTM D6751, above B20 must be used within 45 days from the date of
EN 14214, or equivalent specification. Expect a 2% biodiesel manufacture.
reduction in power and a 3% reduction in fuel economy
when using B20. When using biodiesel blends up to B20, the following
must be considered:
Biodiesel concentrations above B20 can harm the
engine’s emission control systems and should not be • Cold-weather flow degradation
used. Risks include, but are not limited to, more frequent • Stability and storage issues (moisture absorption,
stationary regeneration, soot accumulation, and increased microbial growth)
intervals for ash removal. • Possible filter restriction and plugging (usually a problem
when first switching to biodiesel on used engines)
John Deere Fuel conditioners or equivalent, which • Possible fuel leakage through seals and hoses
contain detergent and dispersant additives, are required (primarily an issue with older engines)
when using biodiesel blends from B10 to B20, and are • Possible reduction of service life of engine components
recommended when using lower biodiesel blends.
Request a certificate of analysis from your fuel distributor
John Deere Engines Without Exhaust Filter to ensure that the fuel is compliant with the specifications
provided in this Operator’s Manual.
Biodiesel blends up to B20 can be used ONLY if the
biodiesel (100% biodiesel or B100) meets ASTM D6751, Consult your John Deere dealer for John Deere fuel
EN 14214, or equivalent specification. Expect a 2% products to improve storage and performance with
reduction in power and a 3% reduction in fuel economy biodiesel fuels.
when using B20. The following must also be considered if using biodiesel
These John Deere engines can operate on biodiesel blends above B20:
blends above B20 (up to 100% biodiesel). Operate at
levels above B20 ONLY if the biodiesel is permitted by law
• Possible coking or blocked injector nozzles, resulting
in power loss and engine misfire if John Deere fuel
and meets the EN 14214 specification (primarily available additives and conditioners or equivalent containing
in Europe). Engines operating on biodiesel blends above detergent/dispersants are not used
B20 might not fully comply with or be permitted by all
applicable emissions regulations. Expect up to a 12%
• Possible crankcase oil dilution (requiring more frequent
oil changes)
reduction in power and an 18% reduction in fuel economy
when using 100% biodiesel.
• Possible lacquering or seizure of internal components
• Possible formation of sludge and sediments
John Deere fuel conditioners or equivalent, which contain • Possible thermal oxidation of fuel at elevated
detergent and dispersant additives, are required when temperatures
using biodiesel blends from B10 to B100, and are
recommended when using lower biodiesel blends.
Continued on next page DX,FUEL7 -19-13JAN18-1/2
10-3 081922
PN=33
• Possible compatibility issues with other materials • Because biodiesel blends above B20 contain more
(including copper, lead, zinc, tin, brass, and bronze) ash, using blends above B20 can result in more rapid
used in fuel handling, distribution, and storage ash loading and require more frequent cleaning of the
equipment Exhaust Filter (if present)
• Possible reduction in water separator efficiency
IMPORTANT: Raw pressed vegetable oils are
• Possible damage to paint if exposed to biodiesel
NOT acceptable for use as fuel in any
• Possible corrosion of fuel injection equipment
concentration in John Deere engines. Their
• Possible elastomeric seal and gasket material
use could cause engine failure.
degradation (primarily an issue with older engines)
• Possible high acid levels within fuel system
DX,FUEL7 -19-13JAN18-2/2
Testing Diesel Fuel operations, bacteria, cloud point, acid number, particulate
contamination, and whether the fuel meets ASTM D975
A fuel analysis program can help to monitor the quality or equivalent specification.
of diesel fuel. The fuel analysis can provide critical data
such as calculated cetane index, fuel type, sulfur content, Contact your John Deere dealer for more information on
water content, appearance, suitability for cold weather diesel fuel analysis.
DX,FUEL6 -19-13JAN18-1/1
Aviation (Jet) Fuels Type Comments

Jet A Not Recommended.Lower viscosity and density than
IMPORTANT: Not all fuels should be considered for base No. 2-D diesel fuel. Power loss up to 10% can
regular use. Some fuels that can be used in be expected.
this engine are for emergency only and can
cause premature engine and component wear Jet A-1 Not Recommended.Lower viscosity and density than
base No. 2-D diesel fuel. Power loss up to 10% can
if used long term. Unless your engine has be expected. May be used as an emergency fuel only,
been specifically designed for prolonged use with the addition of John Deere PREMIUM DIESEL
of aviation fuel, the following fuels should be FUEL CONDITIONER (or equivalent) at the specified
used for an emergency only fuel alternative. concentration.
Jet B Not Recommended.Lower density and extremely
Aviation (jet) fuels may be used with the following low viscosity compared to base No. 2-D diesel fuel.
restrictions. Power loss up to 14% can be expected. May be used
as an emergency fuel only, with the addition of John
Deere PREMIUM DIESEL FUEL CONDITIONER (or
equivalent) at the specified concentration.
JP-4 Not Recommended.Lower density and extremely
low viscosity compared to base No. 2-D diesel fuel.
Power loss up to 14% can be expected. May be used
as an emergency fuel only, with the addition of John
Deere PREMIUM DIESEL FUEL CONDITIONER (or
equivalent) at the specified concentration.
JP-5 Not Recommended.Lower viscosity and density than
be expected.
be expected.
be expected.
OURGP12,000003F -19-16AUG11-1/1
Burner Fuels Type Comments

No.2 Higher density and specific gravity than base No. 2-D
Burner fuels, like kerosene, may be used with the diesel fuel. Power increase up to 3% can be expected.
following restrictions.
No.1 Lower viscosity than base No. 2-D diesel fuel. Power
loss up to 2% can be expected.
OURGP12,0000040 -19-07JUL04-1/1
10-4 081922
PN=34
Fuel Filters manufacturing tolerances have significantly reduced

capacities for debris and water.
The importance of fuel filtration cannot be overemphasized
with modern fuel systems. The combination of increasingly John Deere brand fuel filters have been designed and
restrictive emission regulations and more efficient engines produced specifically for John Deere engines.
requires fuel system to operate at much higher pressures.
Higher pressures can only be achieved using fuel injection To protect the engine from debris and water, always
components with very close tolerances. These close change engine fuel filters as specified in this manual.
DX,FILT2 -19-14APR11-1/1
10-5 081922
PN=35
Minimizing the Effect of Cold Weather on Diesel Engines

John Deere diesel engines are designed to operate
Diesel Fuel Cold Flow Additive
effectively in cold weather.
However, for effective starting and cold-weather Use John Deere Fuel-Protect Diesel Fuel Conditioner
operation, a little extra care is necessary. The following (winter formula), which contains anti-gel chemistry, or
information outlines steps that can minimize the effect equivalent fuel conditioner to treat non-winter grade fuel
that cold weather may have on starting and operation of (No. 2-D in North America) during the cold-weather
your engine. See your John Deere dealer for additional season. This generally extends operability to about 10°C
information and local availability of cold-weather aids. (18°F) below the fuel cloud point. For operability at even
lower temperatures, use winter grade fuel.
Use Winter Grade Fuel
IMPORTANT: Treat fuel when outside temperature
When temperatures fall below 0°C (32°F), winter grade drops below 0°C (32°F). For best results, use
fuel (No. 1-D in North America) is best suited for with untreated fuel. Follow all recommended
cold-weather operation. Winter grade fuel has a lower instructions on label.
cloud point and a lower pour point.
Biodiesel
Cloud point is the temperature at which wax begins to
form in the fuel. This wax causes fuel filters to plug. Pour When operating with biodiesel blends, wax formation can
point is the lowest temperature at which movement of occur at warmer temperatures. Begin using John Deere
the fuel is observed. Fuel-Protect Diesel Fuel Conditioner (winter formula) or
equivalent at 5°C (41°F) to treat biodiesel fuels during
NOTE: On average, winter grade diesel fuel has a lower the cold-weather season. Use B5 or lower blends at
Btu (heat content) rating. Using winter grade fuel temperatures below 0°C (32°F). Use only winter grade
may reduce power and fuel efficiency, but should not petroleum diesel fuel at temperatures below -10°C (14°F).
cause any other engine performance effects. Check
the grade of fuel being used before troubleshooting Winterfronts
for low-power complaints in cold-weather operation.
Use of fabric, cardboard, or solid winterfronts is not
Air Intake Heater recommended with any John Deere engine. Their use
can result in excessive engine coolant, oil, and charge
An air intake heater is an available option for some air temperatures. This can lead to reduced engine life,
engines to aid cold weather starting. loss of power and poor fuel economy. Winterfronts may
also put abnormal stress on fan and fan drive components
Ether potentially causing premature failures.
An ether port on the intake is available to aid cold weather If winterfronts are used, they should never totally close
starting. off the grill frontal area. Approximately 25% area in the
center of the grill should remain open at all times. At no
CAUTION: Ether is highly flammable. Do not time should the air blockage device be applied directly
use ether when starting an engine equipped to the radiator core.
with glow plugs or an air intake heater.
Radiator Shutters
Coolant Heater If equipped with a thermostatically controlled radiator
An engine block heater (coolant heater) is an available shutter system, this system should be regulated in such a
option to aid cold weather starting. way that the shutters are completely open by the time the
coolant reaches 93°C (200°F) to prevent excessive intake
Seasonal Viscosity Oil and Proper Coolant manifold temperatures. Manually controlled systems are
Concentration not recommended.
Use seasonal grade viscosity engine oil based on the If air-to-air aftercooling is used, the shutters must be
expected air temperature range between oil changes completely open by the time the intake manifold air
and a proper concentration of low silicate antifreeze as temperature reaches the maximum allowable temperature
recommended. (See DIESEL ENGINE OIL and ENGINE out of the charge air cooler.
COOLANT requirements in this section.) For more information, see your John Deere dealer.
DX,FUEL10 -19-13JAN18-1/1
10-6 081922
PN=36
Diesel Engine Break-In Oil — Non-Emissions Certified and Certified Tier 1, Tier 2, Tier
3, Stage I, Stage II, and Stage III
New engines are filled at the factory with either John • ACEA Oil Sequence E1
Deere Break-In™ or John Deere Break-In Plus™
Engine Oil. During the break-in period, add John Deere IMPORTANT: Do not use Plus-50™ II, Plus-50™, or
Break-In™ or Break-In Plus™ Engine Oil, respectively, as engine oils meeting any of the following for the
needed to maintain the specified oil level. initial break-in of a new or rebuilt engine:
API CK-4 ACEA E9
Operate the engine under various conditions, particularly
heavy loads with minimal idling, to help seat engine API CJ-4 ACEA E7
components properly.
API CI-4 PLUS ACEA E6
If John Deere Break-In™ Engine Oil is used during the API CI-4 ACEA E5
initial operation of a new or rebuilt engine, change the oil
and filter at a maximum of 100 hours. API CH-4 ACEA E4
API CG-4 ACEA E3
If John Deere Break-In Plus™ Engine Oil is used, change
the oil and filter at a minimum of 100 hours and a API CF-4
maximum equal to the interval specified for John Deere API CF-2
Plus-50™ II or Plus-50™ oil.
API CF
After engine overhaul, fill the engine with either John
Deere Break-In™ or Break-In Plus™ Engine Oil. These oils do not allow the engine to
If John Deere Break-In™ or Break-In Plus™ Engine Oil is break in properly.
not available, use an SAE 10W-30 viscosity grade diesel
engine oil meeting one of the following and change the oil John Deere Break-In Plus™ Engine Oil can be used for
and filter at a maximum of 100 hours of operation: all John Deere diesel engines at all emission certification
levels.
• API Service Classification CE After the break-in period, use John Deere Plus-50™
• API Service Classification CD II, John Deere Plus-50™, or other diesel engine oil as
• API Service Classification CC recommended in this manual.
• ACEA Oil Sequence E2
Break-In is a trademark of Deere & Company.
Break-In Plus is a trademark of Deere & Company
Plus-50 is a trademark of Deere & Company.
DX,ENOIL4 -19-02NOV16-1/1
10-7 081922
PN=37
Diesel Engine Oil — Non-Emissions Certified and Certified Tier 1 and Stage I
Failure to follow applicable oil standards and drain
intervals can result in severe engine damage that might 50oC 122oF
not be covered under warranty. Warranties, including the
emissions warranty, are not conditioned on the use of 40oC 104oF
John Deere oils, parts, or service.
SAE 40
30oC 86oF
Use oil viscosity based on the expected air temperature
SAE 15W-40
SAE 30
range during the period between oil changes.
SAE 10W-40
20oC 68oF
SAE 10W-30
John Deere Plus-50™ II oil is preferred.
SAE 5W-30
SAE 5W-40
SAE 0W-40
10oC 50oF
John Deere Plus-50™ is also recommended.
0oC 32oF
SAE 10W
John Deere Torq-Gard™ is also allowed.
Other oils may be used if they meet one or more of the -10oC 14oF
following standards:
-20oC -4oF
TS1743 —UN—25APR19
• API Service Category CK-4
• API Service Category CJ-4 -30oC -22oF
• API Service Category CI-4 PLUS
• API Service Category CI-4 -40oC -40oF
• API Service Category CH-4
• API Service Category CG-4
• API Service Category CF-4 Oil Viscosities for Air Temperature Ranges
• ACEA Oil Sequence E6 Diesel fuel quality and fuel sulfur content must comply
• ACEA Oil Sequence E5 with all existing emissions regulations for the area in
• ACEA Oil Sequence E4 which the engine operates.
• ACEA Oil Sequence E3 If diesel fuel with sulfur content greater than 5000 mg/kg
• ACEA Oil Sequence E2 (5000 ppm) is used, reduce the service interval by 50%.
If oils meeting API CG-4, API CF-4, or ACEA E2 are used,
DO NOT use diesel fuel with sulfur content greater than
reduce the service interval by 50%.
10 000 mg/kg (10 000 ppm).
Multi-viscosity diesel engine oils are preferred.
Plus-50 is a trademark of Deere & Company
Torq-Gard is a trademark of Deere & Company
DX,ENOIL -19-23APR19-1/1
10-8 081922
PN=38
Extended Diesel Engine Oil Service Intervals — Non-Emissions Certified and Certified Tier
1 and Stage I
When John Deere Plus-50™ II or John Deere Plus-50™
is used with the specified John Deere filter, the service If John Deere Plus-50™ II or John Deere Plus-50™,
interval for engine oil and filter changes may be increased ACEA E9, ACEA E7, ACEA E6, ACEA E5, or ACEA E4
by 50% but not to exceed a maximum of 500 hours. oils are used with other than the specified John Deere
filter, change the engine oil and filter at the normal service
Use oil analysis to evaluate the condition of the oil and to interval.
aid in selection of the proper oil and filter service interval.
Contact your John Deere dealer or other qualified service If John Deere Torq-Gard™, API CK-4, API CJ-4, API CI-4
provider for more information on engine oil analysis. PLUS, API CI-4, API CH-4, or ACEA E3 oils are used,
change the engine oil and filter at the normal service
Change the oil and oil filter at least once every 12 months interval.
even if the hours of operation are fewer than the otherwise
recommended service interval. If API CG-4, API CF-4, or ACEA E2 oils are used, change
the engine oil and filter at 50% of the normal service
When ACEA E9, ACEA E7, ACEA E6, ACEA E5, or interval.
ACEA E4 oils are used with specified John Deere filter,
use engine oil analysis to determine if the service interval IMPORTANT: To avoid engine damage:
for engine oil and filter changes may be increased by • Reduce oil and filter service intervals by 50%
a maximum of 50%, but not to exceed 500 hours. Oil when using biodiesel blends greater than B20.
analysis means taking a series of oil samples at 50 hour Oil analysis may allow longer service intervals
increments beyond the normal service interval until either • Use only approved oil types
the data indicates the end of useful oil life or the maximum
service interval is reached.
Plus-50 is a trademark of Deere & Company

Torq-Gard is a trademark of Deere & Company
DX,ENOIL6 -19-13JAN18-1/1
Mixing of Lubricants
In general, avoid mixing different brands or types of oil. Consult your John Deere dealer to obtain specific
Oil manufacturers blend additives in their oils to meet
information and recommendations.
certain specifications and performance requirements.
Mixing different oils can interfere with the proper
functioning of these additives and degrade lubricant
performance.
DX,LUBMIX -19-18MAR96-1/1
Alternative and Synthetic Lubricants
Conditions in certain geographical areas may require The temperature limits and service intervals shown in this
lubricant recommendations different from those printed in manual apply to John Deere branded fluids or fluids that
this manual. have been tested and/or approved for use in John Deere
Some John Deere brand coolants and lubricants may not equipment.
be available in your location. Re-refined base stock products may be used if the
Consult your John Deere dealer to obtain information and finished lubricant meets the performance requirements.
recommendations.
Synthetic lubricants may be used if they meet the
performance requirements as shown in this manual.
DX,ALTER -19-13JAN18-1/1
10-9 081922
PN=39
Lubricant Storage
Your equipment can operate at top efficiency only when
clean lubricants are used. Make certain that all containers are properly marked to
identify their contents.
Use clean containers to handle all lubricants.
Properly dispose of all old containers and any residual
Store lubricants and containers in an area protected from lubricant they may contain.
dust, moisture, and other contamination. Store containers
on their side to avoid water and dirt accumulation.
DX,LUBST -19-11APR11-1/1
Oil Filters Use filters meeting John Deere performance

Filtration of oils is critical to proper operation and specifications.
lubrication.
Always change filters regularly as specified in this manual.
DX,FILT -19-18MAR96-1/1
10-10 081922
PN=40
Diesel Engine Coolant (engine with wet sleeve cylinder liners)

Failure to follow applicable coolant standards and drain
intervals can result in severe engine damage that may
• Pre-mix coolant meeting ASTM D6210 requirements
not be covered under warranty. Warranties, including the
• Is formulated with a 2-ethylhexanoic acid (2-EHA) free
additive package
emissions warranty, are not conditioned on the use of
John Deere coolants, parts, or service.
• Coolant concentrate meeting ASTM D6210
requirements in a 40—60% mixture of concentrate with
Preferred Coolants quality water
The following pre-mix engine coolants are preferred: If coolant meeting one of these specifications is
unavailable, use a coolant concentrate or pre-mix coolant
• John Deere COOL-GARD™II that has a minimum of the following chemical and physical
• John Deere COOL-GARD II PG properties:
COOL-GARD II pre-mix coolant is available in several • Provides cylinder liner cavitation protection according to
concentrations with different freeze protection limits as either the John Deere Cavitation Test Method or a fleet
shown in the following table. study run at or above 60% load capacity
COOL-GARD II Pre-Mix Freeze Protection Limit
• Is formulated with a nitrite-free additive package
• Is formulated with a 2-ethylhexanoic acid (2-EHA) free
COOL-GARD II 20/80 -9°C (16°F) additive package
COOL-GARD II 30/70 -16°C (3°F)
• Protects the cooling system metals (cast iron, aluminum
alloys, and copper alloys such as brass) from corrosion
COOL-GARD II 50/50 -37°C (-34°F)
Water Quality
COOL-GARD II 55/45 -45°C (-49°F)
COOL-GARD II PG 60/40 -49°C (-56°F)
Water quality is important to the performance of the
cooling system. Deionized or demineralized water
COOL-GARD II 60/40 -52°C (-62°F) is recommended for mixing with ethylene glycol and
propylene glycol base engine coolant concentrate.
Not all COOL-GARD II pre-mix products are available in
all countries. Coolant Drain Intervals
Use COOL-GARD II PG when a non-toxic coolant Drain and flush the cooling system and refill with fresh
formulation is required. coolant at the indicated interval, which varies with the
coolant used.
Additional Recommended Coolants
When COOL-GARD II or COOL-GARD II PG is used, the
The following engine coolant is also recommended: drain interval is 6 years or 6000 hours of operation.
• John Deere COOL-GARD II Concentrate in a 40—60% If a coolant other than COOL-GARD II or COOL-GARD II
mixture of concentrate with quality water. PG is used, reduce the drain interval to 2 years or 2000
hours of operation.1
IMPORTANT: When mixing coolant concentrate with
water, do not use less than 40% or greater IMPORTANT: Do not use cooling system sealing
than 60% concentration of coolant. Less than additives or antifreeze that contains
40% gives inadequate additives for corrosion sealing additives.
protection. Greater than 60% can result in
coolant gelation and cooling system problems. Do not mix ethylene glycol and propylene
glycol base coolants.
Other Coolants Do not use coolants that contain nitrites.
Other ethylene glycol or propylene glycol base coolants
may be used if they meet the following specification:
COOL-GARD is a trademark of Deere & Company

1
Coolant analysis may extend the service interval of other "Coolants"
to a maximum not to exceed the interval of Cool-Gard II coolants.
Coolant analysis means taking a series of coolant samples at 1000
hour increments beyond the normal service interval until either
the data indicate the end of useful coolant life or the maximum
service interval of Cool-Gard II is reached.
DX,COOL3 -19-25AUG20-1/1
10-11 081922
PN=41
Water Quality for Mixing with Coolant Concentrate

Engine coolants are a combination of three chemical
components: ethylene glycol (EG) or propylene glycol Freeze Protection
(PG) antifreeze, inhibiting coolant additives, and quality The relative concentrations of glycol and water in the
water. engine coolant determine its freeze protection limit.
Water quality is important to the performance of the Ethylene Glycol Freeze Protection Limit
cooling system. Deionized or demineralized water
is recommended for mixing with ethylene glycol and 40% -24°C (-12°F)
propylene glycol base engine coolant concentrate. 50% -37°C (-34°F)
All water used in the cooling system should meet the 60% -52°C (-62°F)
following minimum specifications for quality:
Propylene Glycol Freeze Protection Limit
Chlorides <40 mg/L
40% -21°C (-6°F)
Sulfates <100 mg/L
50% -33°C (-27°F)
Total solids <340 mg/L
60% -49°C (-56°F)
Total dissolved I hardness <170 mg/L
pH 5.5—9.0
DO NOT use a coolant-water mixture greater than 60%
ethylene glycol or 60% propylene glycol.
IMPORTANT: Do not use bottled drinking water
because it often contains higher concentrations
of total dissolved solids.
DX,COOL19 -19-13JAN18-1/1
Operating in Warm Temperature Climates

John Deere engines are designed to operate using Foaming, hot surface aluminum and iron
recommended engine coolants. corrosion, scaling, and cavitation occur when
Always use a recommended engine coolant, even when water is used as the coolant, even when
operating in geographical areas where freeze protection coolant conditioners are added.
is not required. Drain cooling system and refill with
IMPORTANT: Water may be used as coolant in recommended engine coolant as soon
emergency situations only. as possible.
DX,COOL6 -19-17FEB20-1/1
10-12 081922
PN=42
Testing Coolant Freeze Point

The use of a handheld coolant refractometer is the
quickest, easiest, and most accurate method to determine
coolant freeze point. This method is more accurate than
a test strip or a float-type hydrometer which can produce
poor results.
TS1732 —UN—04SEP13
A coolant refractometer is available through your
John Deere dealer under the SERVICEGARD™ tool
program. Part number 75240 provides an economical
solution to accurate freeze point determination in the field.
To use this tool:
SERVICEGARD™ Part Number 75240
1. Allow cooling system to cool to ambient temperatures.
2. Open radiator cap to expose coolant.
3. With the included dropper, collect a small coolant
sample.
4. Open the lid of the refractometer, place one drop of
coolant on the window and close the lid.
5. Look through the eyepiece and focus as necessary.
6. Record the listed freeze point for the type of coolant
(ethylene glycol coolant or propylene glycol) being
tested.
TS1733 —UN—04SEP13
Image with a Drop of 50/50 Coolant Placed on the Refractometer Window
SERVICEGARD is a trademark of Deere & Company

DX,COOL,TEST -19-13JUN13-1/1
Disposing of Coolant
Improperly disposing of engine coolant can threaten the
environment and ecology.
Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone TS1133 —UN—15APR13
into drinking from them.

Do not pour waste onto the ground, down a drain, or into
any water source.
Inquire on the proper way to recycle or dispose of waste
from your local environmental or recycling center, or from
your John Deere engine distributor or servicing dealer. Recycle Waste
RG,RG34710,7543 -19-26APR18-1/1
10-13 081922
PN=43
Engine Operating Guidelines
Instrument (Gauge) Panels
All controls and gauges are optional equipment for John
Deere OEM Engines. They may be provided by the
equipment manufacturer instead of John Deere. The
following information applies only to those controls and
gauges provided by John Deere.
IMPORTANT: Any time an electric gauge or meter
does not register correctly, replace it with a
new one. Do not attempt to repair it.
Two types of instrument panels are offered on 4.5 L and
RG11299 —UN—12SEP00
6.8 L engines, as shown on this page. See following for
complete information on each type of instrument panel.
North American Instrument Panel
VDO Instrument Panel (Except North America)
DPSG,RG34710,107 -19-10JAN02-1/1
15-1 081922
PN=44
Instrument (Gauge) Panel (North America)

Following is a brief description of the components on the

instrument (gauge) panel:
A—Oil Pressure Gauge - This gauge indicates oil
RG11299B —UN—17AUG00
pressure. It also has an adjustable electrical contact
which activates the safety switch when oil pressure goes
below the pressure set point. This will automatically stop
the engine.
B—Coolant Temperature Gauge - This gauge
indicates coolant temperature. It also has an electrical
contact which activates the safety switch when coolant North American Instrument Panel
temperature goes above the temperature set point. This
will automatically stop the engine.
C—Key Switch - The key switch is used to start and stop
the engine. A key is required to operate the switch so as
to prevent unauthorized operation of the engine.
D—Tachometer - The tachometer indicates engine speed
in hundreds of revolutions per minute (rpm).
RG10607 —UN—19OCT99
E—Safety Switch (Reset Button) - The safety switch
de-energizes the fuel shut-off solenoid or injection rack
puller to stop the engine, if one or more conditions are met:
• Low or no oil pressure
• High coolant temperature
• Low crankcase oil level (if equipped with engine oil level Hour Meter And Tachometer Codes
switch)
• High crankcase oil level (if equipped with engine oil
A—Oil Pressure Gauge F— Fuse Holder (14 Amp Fuse)
level switch) B—Coolant Temperature G—Ammeter
Gauge H—Hourmeter
The reset button has to be held in when starting the C—Key Switch I— Hand Throttle
engine. The button allows the safety switch to override D—Tachometer J— Tachometer Binary Code
the shut-down circuits until safe engine oil pressure E—Reset (Safety) Switch
is maintained. Once engine oil pressure is within
specifications, the safety switch will latch and the reset
button can be released. held in while the key switch is in the ON position. The
accumulated hours are displayed in hours and tenths of
F—Fuse Holder - Contains 14 amp fuse.
hours. On some panels, the hourmeter may be separate
G—Ammeter - The ammeter indicates the rate of charge from the tachometer.
(+) or discharge (—) of the battery. When the engine is
I—Hand Throttle - The hand throttle is used to manually
first started, the ammeter will usually indicate a charge
control engine speed. If the hand throttle is electronic (as
rate of approximately 30 amps. After a short period of
shown), turn the knob clockwise or counterclockwise to
operation, the ammeter needle will point slightly to the
change engine speed. If the hand throttle is mechanical
right of “0”, indicating the charging system is operating
(not shown), turning the handle, either clockwise or
normally. A problem with the charging system is indicated
counterclockwise, will lock the throttle position. Turn the
if the ammeter needle points to the left of “0” during
handle half way between the two lock positions to unlock
engine operation.
the throttle.
H—Hour Meter - The hour meter operates when the
engine is operating, or when the reset button is manually
Continued on next page DPSG,RG34710,108 -19-08JAN02-1/2
15-2 081922
PN=45
tachometer and must be set at “10110011” to operate at

J—Tachometer Binary Code - The tachometer is 30 pulses per revolution.
calibrated to the number of flywheel gear teeth read. The
dip switch to set the binary code is located in back of
DPSG,RG34710,108 -19-08JAN02-2/2
VDO Instrument (Gauge) Panel (Except North

America)
RG10606B —UN—20OCT99
Following is a brief description of the components on the

instrument (gauge) panel: VDO Instrument Panel
A—Oil Pressure Gauge - The oil pressure gauge

indicates engine oil pressure. A—Oil Pressure Gauge G—Battery Light
B—Coolant Temperature H—Oil Pressure Light
B—Coolant Temperature Gauge - The coolant Gauge I— Coolant Temperature Light
C—Tachometer J— Key/Start Switch
temperature gauge indicates coolant temperature. D—Engine Control Light K—Hour Meter
E—Preheater Light
C—Tachometer - The tachometer indicates engine speed F— Fuel Level Light
in hundreds of revolutions per minute (rpm).
The engine control system consists of the following:
(position I). The light will remain on until the engine is
D—Engine Control Light - The engine control light started and the specified oil pressure is reached. If oil
illuminates after the engine has started and oil pressure pressure is lost during engine operation, the light will
is up to specification. The light indicates that the engine illuminate and protection circuitry will stop the engine. The
protection circuitry is activated. oil pressure light will remain on, indicating that the engine
was stopped due to a low oil pressure condition.
E—Preheater Light - The preheater light illuminates
when the key is turned to the bulb test position (position I—Coolant Temperature Light - The coolant temperature
I). It should go off after approximately five seconds. When light illuminates when the key is turned to the bulb test
the key switch is held in position II, the engine preheater position (position I). It should go off after approximately
is energized and the preheater light illuminates. five seconds. After the engine is running, if the engine
overheats, the light will illuminate and protection circuitry
F—Fuel Level Light - The fuel level light illuminates when
will stop the engine. The coolant temperature light will
the key is turned to the bulb test position (position I). It
remain on indicating the engine was stopped due to the
should go off after approximately five seconds. After the
engine overheating.
engine is running, if the engine runs out of fuel, the light
will illuminate and protection circuitry will stop the engine. Other components on the instrument panel:
The fuel level light will remain on indicating the engine
was stopped due to the fuel tank being empty. J—Key/Start Switch - The four-position key start switch
controls the electrical system.
G—Battery Light - The battery light illuminates when the
key is turned to the bulb test position (position I). It should K—Hour Meter - The hour meter is an integral part of the
go off after approximately five seconds. After the engine tachometer. It shows the accumulated hours of engine
is running, if the alternator stops charging, the light will service. The hour meter operates when the engine is
illuminate and protection circuitry will stop the engine. running and accumulated hours are displayed in hours
The battery light will remain on indicating the engine was and tenths of hours.
stopped due to the alternator not charging.
H—Oil Pressure Light - The oil pressure light illuminates
when the key switch is turned to the bulb test position
DPSG,RG34710,109 -19-08JAN02-1/1
15-3 081922
PN=46
Engine Break-In Service

The engine is ready for normal operation. However, extra
care during the first 250 hours of operation will result in
more satisfactory long-term engine performance and life.
DO NOT exceed 250 hours of operation with break-in oil.
RG8009 —UN—06JAN99
1. This engine is factory-filled with John Deere ENGINE
BREAK-IN OIL. Operate the engine at heavy loads
with minimal idling during the break-in period.
2. If the engine has significant operating time at idle,
constant speeds, and/or light load usage, or makeup
oil is required in the first 250 hour period, a longer
break-in period may be required. In these situations, an Check Engine Oil
additional 250 hour break-in period is recommended
using a new change of John Deere ENGINE
BREAK-IN OIL and a new John Deere oil filter.
OURGP12,0000076 -19-09SEP04-1/4
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 break-in period.
Crosshatch Pattern On Oil Dipstick
3. Check engine oil level more frequently during engine
break-in period. If oil must be added during this period,
John Deere ENGINE BREAK-IN OIL is preferred. See A—Crosshatch Pattern On Oil
ENGINE BREAK-IN OIL, in Fuels, Lubricants, and Dipstick
Coolant Section.
IMPORTANT: DO NOT use PLUS-50® Engine Oil
Specification
during the break-in period of a new engine or 1
Engine —Oil Pressure at
engine that has had a major overhaul. PLUS-50®
Full Load Rated Speed...... 345 ± 103 kPa (3.45 ± 1.03 bar) (50 ± 15 psi)
oil will not allow a new or overhauled engine to
Minimum Oil Pressure at
properly wear during this break-in period.
Rated Speed.........................................................275 (2.75 bar) (40 psi)
DO NOT fill above the crosshatch pattern (A) or Minimum Oil Pressure at
the FULL mark, whichever is present. Oil levels 850 rpm ........................................................ 105 kPa (1.05 bar) (15 psi)
anywhere within the crosshatch are considered Coolant Temperature
in the acceptable operating range. Range ................................................................ 82°–94°C (180°–202°F)
PLUS-50 is a trademark of Deere & Company.

1
At normal operating temperature of 115°C (240°F) sump.
Continued on next page OURGP12,0000076 -19-09SEP04-2/4
15-4 PN=47
081922
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 250 hours (maximum), change engine
oil and replace engine oil filter. (See CHANGING
ENGINE OIL AND REPLACING OIL FILTER in
RG7961B —UN—22JAN99
Lubrication and Maintenance/250 Hour/6 Month
Section.) Fill crankcase with the normal seasonal
viscosity grade oil. (See DIESEL ENGINE OIL, in
Fuels, Lubricants, and Coolant Section.)
NOTE: Some increase in oil consumption may be
expected when low viscosity oils are used.
Check oil levels more frequently. Changing Oil And Oil Filter Before First 250 Hours
If air temperature is below -10°C (14°F), use

an engine block heater.
OURGP12,0000076 -19-09SEP04-3/4
6. Watch coolant temperature gauge (A) closely. If

coolant temperature rises above 112°C (234°F),
reduce load on engine. Unless temperature drops
quickly, stop the engine and determine the cause
before resuming operation.
NOTE: When the coolant temperature gauge reads
approximately 115°C (239°F), the engine
will shutdown automatically, if equipped
with safety controls.
7. Check poly-vee belt for proper alignment and seating

in pulley grooves.
A—Coolant Temperature
RG11299F —UN—17AUG00
Gauge
North American (1999— ) Instrument Panel Shown
OURGP12,0000076 -19-09SEP04-4/4
15-5 081922
PN=48
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:
• 30 kW (40 hp) Continuous Operation at 2500 rpm

• 37 kW (50 hp) Intermittent Operation at 2500 rpm
A—Auxiliary Gear Drive
Auxiliary Gear Drive
RG,RG34710,5555 -19-27JUL06-1/1
Generator Set (Standby) Applications speed (with 50%—70% load) for 30 minutes every 2
weeks. DO NOT allow engine to run extended period of
To assure that your engine will deliver efficient standby time with no load.
operation when needed, start engine and run at rated
RG,RG34710,5556 -19-27JUL06-1/1
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. Always use safety approved
fuel storage and piping.
NOTE: If temperature is below 0°C (32°F), it may be Use Proper Ventilation

necessary to use cold weather starting aids (See
COLD WEATHER OPERATION, later in this section).
NOTE: Electronically controlled governor applications
1. Perform all prestarting checks outlined in Lubrication & may be equipped with a rotary speed potentiometer
Maintenance/Daily Section later in this manual. on the throttle (A) on the instrument panel.
2. Open the fuel supply shut-off valve, if equipped.
3. Disengage clutch (if equipped) controlling any engine
drivelines.
Continued on next page RG,RG34710,5557 -19-07JAN02-1/2
15-6 081922
PN=49
4. On mechanical governor (7-10% regulation) engines,

pull hand throttle (A) 1/3 of the way out. Turn the handle
in either direction to lock it in place.
5. If equipped, depress and hold reset button (B) while
starting.
IMPORTANT: Do not operate the starter for more
than 30 seconds at a time. To do so may
overheat the starter. If the engine does not start
RG11299X —UN—18OCT01
the first time, wait at least 2 minutes before
trying again. If engine does not start after four
attempts, see Troubleshooting Section.
6. Turn the key switch (C) clockwise to crank the engine.

When the engine starts, release the key so that it returns
to the "ON" position.
North American Standard Instrument Panel (1999— ) Shown
IMPORTANT: If the key switch is released before
the engine starts, wait until the starter and
the engine stop turning before trying again.
RG11610 —UN—17OCT01
This will prevent possible damage to the
starter and/or flywheel.
7. After the engine starts, continue to hold the reset

button in until the oil pressure gauge (D) reads at least
105 kPa (1.05 bar) (15 psi). The safety controls will not
allow the engine to run at a lower oil pressure unless the
reset button is held in. VDO Standard Instrument Panel (Except North America)
IMPORTANT: Should the engine die when operating

A—Hand Throttle C—Key Start Switch
under load, immediately disengage PTO B—Reset Button D—Oil Pressure Gauge
clutch and restart the engine. Overheating
of turbocharger parts may occur when
oil flow is stopped.
8. Check all gauges for normal engine operation. If

operation is not normal, stop the engine and determine
the cause.
RG,RG34710,5557 -19-07JAN02-2/2
15-7 081922
PN=50
Warming Engine
IMPORTANT: To assure proper lubrication, operate
engine at or below 1200 rpm with no load for 1–2
minutes. Extend this period 2–4 minutes when
operating at temperatures below freezing.
RG11612 —UN—17OCT01
Engines used in generator set applications
where the governor is locked at a specified speed
may not have a slow idle function. Operate these
engines at high idle for 1 to 2 minutes before
applying the load. This procedure does not apply
to standby generator sets where the engine is
loaded immediately upon reaching rated speed.
Standard North American Instrument Panel
1. Check oil pressure gauge (A) as soon as engine
starts. If gauge needle does not rise above minimum
oil pressure specification of 105 kPa (1.05 bar) (15.0
psi) within 5 seconds, stop the engine and determine
the cause. Normal engine oil pressure is 345 kPa
(3.45 bar) (50 psi) at rated full load speed (1800–2500
rpm) with oil at normal operating temperature of 115°C
RG10613 —UN—21OCT99
(240°F).
NOTE: On certain engines, the oil pressure and
coolant temperature gauges are replaced by
indicator warning lights. The lights must be
"OFF" when engine is running.
2. Watch coolant temperature gauge (B). Do not place Standard VDO Instrument Panel (Except North America)
engine under full load until it is properly warmed up.
The normal engine coolant temperature range is A—Oil Pressure Gauge B—Coolant Temperature
82°—94°C (180°—202°F). Gauge
NOTE: It is a good practice to operate the engine under

a lighter load and at lower speeds than normal
for the first few minutes after start-up.
RG,RG34710,5560 -19-08JAN02-1/1
Normal Engine Operation

Observe engine coolant temperature and engine the engine. Overheating of the turbocharger
oil pressure. Temperatures and pressures will vary parts may occur when oil flow is stopped.
between engines and with changing operating conditions,
temperatures, and loads. Stop engine immediately if there are any signs of part
failure. Symptoms that may be early signs of engine
Normal engine coolant operating temperature range is problems are:
82°—94°C (180°—202°F). If coolant temperature rises
above 112°C (234°F), reduce load on engine. Unless • Sudden drop in oil pressure
temperature drops quickly, stop engine and determine • Abnormal coolant temperatures
cause before resuming operation. • Unusual noise or vibration
Operate the engine under a lighter load and at slower
• Sudden loss of power
than normal speed for first 15 minutes after start-up. DO
• Excessive black exhaust
NOT run engine at slow idle.
• Excessive fuel consumption
• Excessive oil consumption
IMPORTANT: Should the engine die while operating • Fluid leaks
under load, immediately remove load and restart
RG,RG34710,5552 -19-20MAY96-1/1
15-8 081922
PN=51
Cold Weather Operation
CAUTION: Ether injector starting fluid is highly

flammable. DO NOT use starting fluid on engines
equipped with air intake heaters.
TS1356 —UN—18MAR92
DO NOT use starting fluid near fire, sparks,
or flames. DO NOT incinerate or puncture
a starting fluid container.
Engines may be equipped with intake air heaters, coolant

heaters, or ether injectors as a cold weather starting aid.
Starting aids are required below 32°F (0°C). They will Handle Starting Fluid with Care
enhance starting performance above these temperatures
and may be needed to start applications that have high
parasitic loads during cranking and/or start acceleration
to idle.
Using correct grade of oil (per engine and machine
operator's manual) is critical to achieving adequate cold
weather cranking speed.
Other cold weather starting aids are required at
temperatures below -22°F (-30°C) or at altitudes above
1500 m (5000 ft).
1. Follow steps 1—4 as listed under , then proceed as
follows according to the instrument (gauge) panel on
your engine.
RG11521 —19—10JAN01
2. Switch on the air intake heater for 30 seconds
or activate ether injector by following suppliers
instructions.
3. Follow remaining steps 5—8 as listed under earlier
in this section.
Additional information on cold weather operation is Cold Weather Starting Guidelines
available from your authorized servicing dealer.
RG,RG34710,5050 -19-08JAN02-1/1
15-9 081922
PN=52
Changing Engine Speed

To increase engine speed, turn throttle handle (A), if
equipped, to the horizontal position and pull out until
desired engine speed is obtained. Turn the handle in
either direction to lock throttle position. The handle is
pushed inward to decrease engine speed.
NOTE: On engines without handle, use throttle lever
to control engine speed.
A—Throttle Handle
RG11299I —UN—11SEP00
North American Standard Instrument Panel Shown
RG,RG34710,5561 -19-07JAN02-1/1
Avoid Excessive Engine Idling

Prolonged idling may cause the engine coolant Slow idle speed for this engine is 850 rpm at factory. If an
temperature to fall below its normal range. This, in turn, engine will be idling for more than 5 minutes, stop and
causes crankcase oil dilution, due to incomplete fuel restart later.
combustion, and permits formation of gummy deposits on
valves, pistons, and piston rings. It also promotes rapid NOTE: Generator set applications where the governor
accumulation of engine sludge and unburned fuel in the is locked at a specified speed may not have a
exhaust system. slow idle function. These engines will idle at no
load governed speed (high idle).
Once an engine is warmed to normal operating
temperatures, engine should be idled at slow idle speed.
RG,RG34710,5562 -19-27JUL06-1/1
15-10 081922
PN=53
Stopping the Engine

1. Disengage clutch (if equipped) controlling engine
drivelines.
2. Move the throttle (A) to slow idle on standard
(mechanical) governor engines.
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.
For engines in generator set applications, where
the governor is locked at a specified speed and
no slow idle function is available, run engine for
RG11299J —UN—11SEP00
at least 2 minutes at fast idle and no load.
3. Turn key switch (B) to "OFF" position to stop the

engine. Remove ignition key.
IMPORTANT: Make sure that exhaust stack cap (rain
cap) is installed when engine is not running. This
will prevent water and dirt from entering engine. North American Standard Instrument Panel Shown
A—Throttle B—Key Switch
RG10616 —UN—16JUN00
Exhaust Stack Rain Cap
RG,RG34710,5563 -19-07JAN02-1/1
15-11 081922
PN=54
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.
Before connecting or disconnecting a battery
charger, turn charger off. Make last connection
and first disconnection at a point away from
battery. Always connect NEGATIVE (–) cable
last and disconnect this cable first.
Exploding Battery
WARNING: Battery posts, terminals, and related
reproductive harm. Wash hands after handling.
RG4678 —UN—14DEC88
IMPORTANT: Be sure polarity is correct before
making connections. Reversed polarity will
damage electrical system. Always connect
positive to positive and negative to ground.
Always use 12-volt booster battery for 12-volt
electrical systems and 24-volt booster battery
(ies) for 24-volt electrical systems. 12-Volt System
1. Connect booster battery or batteries to produce the

required system voltage for your engine application.
NOTE: To avoid sparks, DO NOT allow the free ends
of jumper cables to touch the engine.
2. Connect one end of jumper cable to the POSITIVE (+)
RG4698 —UN—14DEC88
post of the booster battery.
3. Connect the other end of the jumper cable to the
POSITIVE (+) post of battery connected to starter.
4. Connect one end of the other jumper cable to the
NEGATIVE (–) post of the booster battery.
5. ALWAYS complete the hookup by making the last 24-Volt System
connection of the NEGATIVE (–) cable to a good
ground on the engine frame and away from the battery A—12-Volt Machine Battery C—Booster Cable
(ies). (ies) D—Cable to Starting Motor
B—12-Volt Booster Battery
6. Start the engine. Disconnect jumper cables (ies)
immediately after engine starts. Disconnect
NEGATIVE (–) cable first.
RG,RG34710,5564 -19-27JUL06-1/1
15-12 081922
PN=55
Lubrication and Maintenance
Required Emission-Related Information
Service Provider
A qualified repair shop or person of the owner's choosing may maintain, replace, or repair emission control devices and systems with original or
equivalent replacement parts. However, warranty, recall, and all other services paid for by John Deere must be performed at an authorized John
Deere service center.
DX,EMISSIONS,REQINFO -19-12JUN15-1/1
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.
IMPORTANT: Recommended service intervals are for
normal operating conditions. Service MORE
OFTEN if engine is operated under adverse
conditions. Neglecting maintenance can result
in failures or permanent damage to the engine.
RG11299A —UN—17AUG00
A—Hour Meter
North American Instrument Panel Hour Meter Shown

DPSG,OUOE003,20 -19-07JAN02-1/1
Use Correct Fuels, Lubricants, and Coolant

IMPORTANT: Use only fuels, lubricants, and
coolants meeting specifications outlined in
Fuels, Lubricants, and Coolant Section when
servicing your John Deere Engine.
Consult your John Deere engine distributor, servicing
dealer or your nearest John Deere Parts Network for
recommended fuels, lubricants, and coolant. Also
available are necessary additives for use when operating
engines in tropical, arctic, or any other adverse conditions.
DPSG,OUOE003,20 -19-09OCT07-1/1
20-1 081922
PN=56
Lubrication and Maintenance
Lubrication and Maintenance Service Interval

Chart
Lubrication and Maintenance Service Intervals
250 Hour/ 500 Hour/ 2000 Hour/
Item Dailya 6 Month 12 Month 24 Month As Required
Check Engine Oil and Coolant Level •
Check Fuel Filter(s)/Water Separator Bowl •
Check Air Cleaner Dust Unloader Valve & Indicator b •
Perform Visual Walkaround Inspection •
Service Fire Extinguisher •
Change Engine Oil And Replace Oil Filterc ,d •
Check Engine Mounts •
Service Battery •
Check Manual Belt Tensioner and Belt Wear •
Check Automatic Belt Tensioner and Belt Wear •
Clean Crankcase Vent Tube •
Check Air Intake Hoses, Connections, & System •
Replace Single or Dual Fuel Filter Elements •
Check Engine Speeds •
Check Engine Electrical Ground Connection •
Coolant Solution Analysis-Add SCAs as required •
Pressure Test Cooling System •
Check Cooling System •
Test Thermostats •
Check Crankshaft Vibration Damper (6.8 L Engines)e •
Flush Cooling Systemf •
Check and Adjust Engine Valve Clearance •
Check Variable Speed (Droop) (Genset Only) •
Add Coolant •
Replace Air Cleaner Elements •
Replace Poly-Vee Belt •
Check Fuses •
Check Air Compressor (If Equipped) •
Bleed Fuel System •

a
Standby generator applications may allow intervals up to every 2 weeks.
b
Replace primary air cleaner element when restriction indicator shows a vacuum of 625 mm (25 in) H2O.
c
During engine break in, change the oil and filter for the first time before 100 hours of operation.
d
Service intervals depend on sulfur content of the diesel fuel, oil pan capacity, and the oil and filter used, which means that intervals may be
REDUCED. (See DIESEL ENGINE OIL AND FILTER SERVICE INTERVALS in Fuels, Lubricants, and Coolant Section.)
e
Replace crankshaft damper every 4500 hours or 60 months, whichever occurs first.
f
If John Deere Cool-Gard is used, the flushing interval may be extended to 3000 hours or 36 months. If John Deere Cool-Gard is
used and the coolant is tested annually AND additives are replenished as needed by adding a supplemental coolant additive, the
flushing interval may be extended to 5000 hours or 60 months, whichever occurs first.
OURGP11,0000006 -19-20AUG15-1/1
20-2 081922
PN=57
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 add mark.
A—Left Side Oil Filler Cap C—Cover Oil Filler Cap
B—Right Side Oil Filler Cap D—Crosshatch On Dipstick
Left Side Oil Filler Cap
Right Side Oil Filler Cap
RG8025B —UN—16JUN00
Rocker Arm Cover Filler Cap
Crosshatch on Dipstick
Continued on next page OURGP12,0000048 -19-13OCT06-1/4
25-1 081922
PN=58
1. Check engine oil level on dipstick. Add as required,

using seasonal viscosity grade oil. (See DIESEL
ENGINE OIL in Fuels, Lubricants, and Coolant
Section for oil specifications.)
Depending on application, oil may be added at left
(A) or right (B) side oil filler cap and rocker arm
cover filler cap (C) locations.
IMPORTANT: DO NOT fill above the top mark on
the dipstick. Oil levels anywhere within
crosshatch (D) are considered in the
acceptable operating range.
High-Pressure Fluids
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.
2. Check the coolant level when engine is cold.

Coolant level should be at bottom of filler neck.
Fill radiator (A) with proper coolant solution if level
is low. (See ADDING COOLANT in Service As
Required Section.) Check overall cooling system
for leaks.
NOTE: Refer to your vehicle's operator's manual
RG4675 —UN—14DEC88
for recommendations for non-John Deere
supplied accessories.
Fill Radiator
A—Fill Radiator
25-2 081922
PN=59
3. Check the single or dual fuel filters for water or

debris. If filter is fitted with a see-through water
separator bowl, drain as needed based on a daily
visual inspection.
IMPORTANT: Drain water into a suitable container
RG13542 —UN—20JUL04
and dispose of properly.
a. Loosen drain plugs (B) at bottom of each fuel filter

or bowl, if equipped, two or three turns.
b. Loosen air bleed plugs (A) two full turns on fuel filter
mountings and drain water from bottom until fuel
starts to drain out. Drain Fuel Filters (Dual Filters Shown)
c. When fuel starts to drain out, tighten drain plugs
securely.
After draining water from the fuel filter, the filter must be
primed by bleeding all air from the fuel system.
a. Operate primer lever of the fuel supply pump (C)
until fuel flow is free from air bubbles.
b. Tighten bleed plugs securely, and continue
operating hand primer until pumping action is not
felt. Primer lever is spring-loaded, and will return
to normal position.
If the fuel system needs further bleeding of air, see Priming At Fuel Supply Pump
BLEEDING FUEL SYSTEM in Service As Required
Section, later in this manual.
A—Air Bleed Plugs C—Fuel Supply Pump Primer

B—Drain Plugs Lever
25-3 081922
PN=60
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.
IMPORTANT: Maximum air intake restriction is 6.25
kPa (0.06 bar) (1.0 psi) (25 in. H2O). A clogged
air cleaner element will cause excessive intake
restriction and a reduced air supply to the engine.
5. Make a thorough inspection of the engine

compartment. Look for oil or coolant leaks, worn fan Dust Unloader Valve and Indicator Gauge
and accessory drive belts, loose connections and
trash build-up. Remove trash buildup and have repairs A—Dust Unloader Valve B—Air Restriction Indicator
made as needed if leaks are found.
NOTE: Wipe all fittings, caps, and plugs before
performing any maintenance to reduce the
• Water pump for coolant leaks.
chance of system contamination. NOTE: It is normal for a small amount of leakage to
occur as the engine cools down and parts contract.
Inspect: Excessive coolant leakage may indicate the need to
replace the water pump seal. Contact your engine
• Radiator for leaks and trash build-up. distributor or servicing dealer for repairs.
• Air intake system hoses and connections for cracks
and loose clamps.
• Fan, alternator, and accessory drive belts for cracks,
breaks or other damage.
OURGP12,0000048 -19-13OCT06-4/4
25-4 081922
PN=61
Lubrication & Maintenance — 250 Hours/6 Months
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
RW4918 —UN—15DEC88
250 hours of engine operation or once a month. Once
extinguisher is operated, no matter how long, it must be
recharged. Keep record of inspections on the tag which
comes with the extinguisher instruction booklet.
A—Fire Extinguisher
Fire Extinguisher
RG,RG34710,5567 -19-20MAY96-1/1
Changing Engine Oil and Replacing Filter

NOTE: Change engine oil and oil filter for the first
time after 100 hours maximum of operation,
then every 250 hours thereafter.
RG11616 —UN—24OCT01
If John Deere PLUS-50® or ACEA E4 or E5 engine oil
and a John Deere oil filter are used, the oil and filter
change interval may be extended by 50 percent.
OILSCAN® or OILSCAN PLUS®is a John Deere sampling
program to help you monitor machine performance and
identify potential problems before they cause serious
damage. OILSCAN® and OILSCAN PLUS®kits are Oil Filter
available from your John Deere engine distributor or
servicing dealer. Oil samples should be taken prior to the
oil change. Refer to instructions provided with kit.
To change engine oil and oil filter:
1. Run engine approximately 5 minutes to warm up oil.
Shut engine off.
RG4881 —UN—29NOV88
2. Remove oil pan drain plug (arrow).
3. Drain crankcase oil from engine while warm.
NOTE: Drain plug location may vary, depending
on the application.
Oil Pan Drain Plug
A—Oil Filter Element
PLUS-50 is a trademark of Deere & Company.

OILSCAN is a trademark of Deere & Company.
OILSCAN PLUS is a trademark of Deere & Company.
30-1 081922
PN=62
4. Turn filter element (A) counterclockwise 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.
5. Remove oil filter packing and clean filter mounting pad.
IMPORTANT: Filtration of oils is critical to
proper lubrication. Always change filter
regularly. Use filter meeting John Deere
performance specifications.
6. Oil new packing and install new filter element. Hand Removing Oil Filter Element
tighten element according to values printed on filter
element. If values are not provided, tighten element A—Oil Filter Element
approximately 3/4 — 1-1/4 turn after packing contacts
filter housing. DO NOT overtighten filter element.
7. Install oil pan drain plug with O-ring or copper washer. Specification
If copper washer is used, install with raised center Oil Pan Drain
against plug. If O-ring or washer is damaged, replace Plug With Copper
it. Washer—Torque............................................................. 70 N·m (52 lb ft)
Oil Pan Drain Plug With
8. Tighten drain plug to specifications. O-Ring—Torque............................................................. 50 N·m (37 lb ft)
OURGP12,0000078 -19-31OCT06-2/3
9. Fill engine crankcase with correct John Deere engine

oil through rocker arm cover opening (B) or either
side oil filler (C) 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
the Specifications Section of this manual.
IMPORTANT: Immediately after completing any
oil change, crank engine for 30 seconds
without permitting engine to start. This will
help insure adequate lubrication to engine
components before engine starts. Rocker Arm Cover Oil Filler
NOTE: Crankcase oil capacity may vary slightly. ALWAYS

fill crankcase to full mark or within crosshatch on
dipstick, whichever is present. DO NOT overfill.
10. Start engine and run to check for possible leaks.

RG8054B —UN—19JUN00
11. Stop engine and check oil level after 10 minutes. Oil
level reading should be within crosshatch of dipstick.
B—Rocker Arm Cover Oil Filler C—Side Oil Filler
Side Oil Filler

OURGP12,0000078 -19-31OCT06-3/3
30-2 PN=63
081922
Checking Engine Mounts 1. Check the engine mounting bracket, vibration

Engine mounting is the responsibility of the vehicle or isolators, and mounting bolts on support frame and
generator manufacturer. Follow manufacturer's guidelines engine block for tightness. Tighten as necessary.
for mounting specifications. 2. Inspect overall condition of vibration isolators, if
IMPORTANT: Use only Grade SAE 8 or higher grade equipped. Replace isolators if rubber has deteriorated
of hardware for engine mounting. or mounts have collapsed, as necessary.
DPSG,RG34710,111 -19-07JAN02-1/1
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.
Always remove grounded NEGATIVE (–) battery
clamp first and replace it last.
WARNING: Battery posts, terminals, and related Exploding Battery

reproductive harm. Wash hands after handling. any corrosion, and wash terminals with a solution
of 1 part baking soda and 4 parts water. Tighten all
1. On regular batteries, check electrolyte level. Fill each connections securely.
cell to bottom of filler neck with distilled water.
NOTE: Coat battery terminals and connectors
NOTE: Low-maintenance or maintenance-free batteries with a mixture of petroleum jelly and baking
should require little additional service. However, soda to retard corrosion.
electrolyte level can be checked by cutting the
center section of decal on dash-line, and removing 3. Keep battery fully charged, especially during cold
cell plugs. If necessary, add clean, soft water weather. If a battery charger is used, turn charger
to bring level to bottom of filler neck. off before connecting charger to battery(ies). Attach
POSITIVE (+) battery charger lead to POSITIVE (+)
2. Keep batteries clean by wiping them with a damp battery post. Then attach NEGATIVE (–) battery
cloth. Keep all connections clean and tight. Remove charger lead to a good ground.
Continued on next page RG,RG34710,5568 -19-27JUL06-1/2
30-3 081922
PN=64
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. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when
electrolyte is added.
4. Avoiding spilling or dripping electrolyte.
5. Use proper jump start procedure.
If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to help
neutralize the acid.
3. Flush your eyes with water for 10–15 minutes.
Get medical attention immediately.
1. Drink large amounts of water or milk.
2. Then drink milk of magnesia, beaten
eggs, or vegetable oil.
In freezing weather, run engine at least 30 minutes to

assure thorough mixing after adding water to battery. Sulfuric Acid
If necessary to replace battery(ies), replacements must
meet or exceed the following recommended capacities at 24 Volt Standard Duty
-18°C (0°F): Starter—Cold Cranking
Amps.................................................................................................. 570
Specification
12 Volt Standard Duty
Starter—Cold Cranking
Amps.................................................................................................. 640
12 Volt Heavy Duty
Starter—Cold Cranking
Amps.................................................................................................. 800
RG,RG34710,5568 -19-27JUL06-2/2
30-4 PN=65
081922
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
RG10556 —UN—21DEC99
254—305 mm (10—12 in.) span with two fingers. A
properly tensioned belt will turn 75—85 degrees.
If belt turns more, it needs to be tightened. If belt
turns less, it needs to be loosened.
NOTE: If timing gear cover or alternator bracket interfere

with installation/centering of belt tension gauge
(A), install gauge with face toward engine. Check Belt Tension
1. Install JDG1341 Belt Tension Gauge (A) on belt,

halfway between pulleys as shown. (JDG1341 Belt
Tension Gauge available from local John Deere Dealer
or Distributor.)
RG10557 —UN—21DEC99
2. Loosen cap screws (B) and (C).
3. Slide alternator or tensioner bracket (D) in slot by hand
to remove all excess slack in belt.
IMPORTANT: Do not pry against alternator rear frame.
4. Stretch belt by prying outward on alternator front

frame or tensioner bracket. Observing tension gauge, Adjust Belt Tension
stretch the belt until specified tension is achieved.
Specification A—Belt Tension Gauge C—Cap Screw
B—Cap Screw D—Tensioner Bracket
New Belt—Tension................................ 470—650 N (105—145 lb-force)
Used Belt—Tension................................. 400—580 N (90—130 lb-force)
6. Run engine for ten minutes and immediately re-check

5. Tighten cap screws (B) and (C). belt tension per used belt specification above.
NOTE: After ten minutes run-in, new belts are considered 7. Reset belt tension as necessary.
used. Belt tension must then be rechecked
per used belt specifications.
OURGP11,0000008 -19-24JUN04-1/1
30-5 081922
PN=66
Manual Belt Tensioner Adjustment Using

Belt Tension Tool (Alternate Method For
Engines Without Auxiliary Drive)
NOTE: The JDG1520 Belt Tension Tool may not be
compatible with all alternators. In that case, use
RG11812 —UN—31OCT01
the preceding method for belt tensioning.
NOTE: Inspect belts for cracks, fraying, or stretched-out

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. Alternator Bracket and Cap Screws
If belt turns more, it needs to be tightened. If belt
turns less, it needs to be loosened.
1. Loosen upper (A) and lower (B) alternator bracket cap

screws. Lower cap screw must remain tight enough to
prevent excessive alternator play but allow alternator
to pivot by hand.
RG11813 —UN—31OCT01
2. Insert JDG1520 Belt Tension Tool (C) behind belt (D)
and over alternator mounting screw.
A—Upper Alternator Bracket C—JDG1520 Belt Tension Tool

Cap Screw D—Belt
B—Lower Alternator Bracket
Cap Screw Belt Tension Tool
Continued on next page OURGP11,0000009 -19-24JUN04-1/2
30-6 081922
PN=67
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)
RG11814 —UN—31OCT01
Used Belt—Tension................................. 400—580 N (90—130 lb-force)
JDG1520 Belt Tensioning Tool Torque Table

Desired Belt Tension Applied Torque On Tool
N (lb-force) N·m (lb-ft)
445 (100) 108 (90)
489 (110) 115 (85) Belt Tension Tool and Torque Wrench
534 (120) 122 (90)

623 (140) 135 (100)
4. While holding tension with torque wrench (B), scribe a

reference mark (D) on alternator in line with notch (E)
on upper alternator bracket.
5. Continue to hold tension with torque wrench and
tighten upper alternator bracket cap screw.
6. Check position of reference mark to see if alternator
moved while tightening. If alternator moved, loosen
upper alternator bracket cap screw and repeat the
tension adjustment procedure.
RG11815 —UN—31OCT01
7. Remove belt tension tool and tighten lower alternator
bracket cap screw.
A—Alternator D—Reference Mark

B—Belt Tensioning Tool E—Alternator Upper Bracket
C—Torque Wrench Notch
Scribe Reference Mark

OURGP11,0000009 -19-24JUN04-2/2
30-7 081922
PN=68
Cleaning Crankcase Vent Tube

If you operate the engine in dusty conditions, clean the
tube at shorter intervals.
1. Remove and clean crankcase vent tube (A).
2. Install the vent tube. Be sure the O-ring fits correctly
in the rocker arm cover for elbow adapter. Tighten
hose clamp securely.
A—Crankcase Vent Tube
Crankcase Vent Tube

RG,RG34710,5574 -19-08JAN02-1/1
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.
RG4689 —UN—20DEC88
1. Inspect all intake hoses (piping) for cracks. Replace
as necessary.
2. Check clamps (A) on piping which connect the air
cleaner, engine and, if present, turbocharger. Tighten
clamps as necessary. This will help prevent dirt
from entering the air intake system through loose
Check Clamps
connections causing internal engine damage.
3. If engine has a rubber dust unloader valve (B), inspect
the valve on bottom of air cleaner for cracks or
plugging. Replace as necessary.
IMPORTANT: ALWAYS REPLACE primary air
cleaner element when air restriction indicator
shows a vacuum of 625 mm (25 in.) H2O,
is torn, or visibly dirty.
4. Test air restriction indicator (C) for proper operation.

Replace indicator as necessary.
IMPORTANT: If not equipped with air restriction
indicator, replace air cleaner elements at 500 Unloader Valve and Air Restriction Indicator
Hours or 12 Months, whichever occurs first.
A—Clamps C—Air Restriction Indicator
B—Dust Unloader Valve
RG,RG34710,5575 -19-07JAN02-1/1
35-1 081922
PN=69
Replacing Fuel Filter Element (Single Filter)
CAUTION: Escaping fluid under pressure can

penetrate the skin causing serious injury. Relieve
pressure before disconnecting fuel or other lines.
Tighten all connections before applying pressure.
Keep hands and body away from pinholes and
nozzles which eject fluids under high pressure.
X9811 —UN—23AUG88
Use a piece of cardboard or paper to search
for leaks. Do not use your hand.
If any fluid is injected into the skin, it must
be surgically removed within a few hours
by a doctor familiar with this type injury or
gangrene may result. Doctors unfamiliar with High-Pressure Fluids
this type of injury may call the Deere & Company
Medical Department in Moline, Illinois, or other
knowledgeable medical source.
1. Close fuel shut-off valve, if equipped.

2. Thoroughly clean fuel filter assembly and surrounding
area.
RG7721 —UN—15JAN99
3. Loosen drain plug (C) and drain fuel into a suitable
container.
NOTE: Lifting up on retaining ring as it is rotated helps
to get it past raised locators.
4. Firmly grasp the retaining ring (A) and rotate it Fuel Filter
clockwise 1/4 turn (when viewed from top). Remove
ring with filter element (B). A—Retaining Ring C—Drain Plug
B—Filter Element D—Bleed Plug
5. Inspect filter mounting base for cleanliness. Clean as
required.
NOTE: Raised locators on fuel filter canister must ring (about 1/3 turn) until it “snaps” into the detent. DO
be indexed properly with slots in mounting NOT overtighten retaining ring.
base for correct installation. NOTE: The proper installation is indicated when a "click"
is heard and a release of the retaining ring is felt.
6. Install new filter element onto mounting base. Be
sure element is properly indexed and firmly seated on A plug is provided with the new element for
base. It may be necessary to rotate filter for correct plugging the used element.
alignment.
9. Open fuel shut-off valve and bleed the fuel system.
7. Align keys on filter element with slots in filter base. (See BLEEDING FUEL SYSTEM in Service As
8. Install retaining ring onto mounting base making Required Section.) Tighten bleed plug (D).
certain dust seal is in place on filter base. Hand tighten
OURGP11,000000A -19-24JUN04-1/1
35-2 081922
PN=70
Replacing Fuel Filter Elements (Dual Filters)

X9811 —UN—23AUG88
If any fluid is injected into the skin, it must
be surgically removed within a few hours
gangrene may result. Doctors unfamiliar with High-Pressure Fluids
this type of injury may call the Deere & Company
1. Close fuel shut-off valve, if equipped.

2. Thoroughly clean fuel filter assemblies and
RG13543 —UN—21JUL04
surrounding area.
NOTE: Perform the following steps on each fuel filter.
3. Loosen drain plug (C) and drain fuel into a suitable

container.
NOTE: Lifting up on retaining ring as it is rotated helps
to get it past raised locators. Dual Fuel Filters (Final Filter at Left, Primary Filter with Bowl at Right)
4. Firmly grasp the retaining ring (A) and rotate it A—Retaining Ring C—Drain Plug
clockwise 1/4 turn (when viewed from top). Remove B—Filter Element D—Bleed Plug
ring with filter element (B).
5. Inspect filter mounting base for cleanliness. Clean as
required. 9. Install retaining ring onto mounting base making
certain dust seal is in place on filter base. Hand tighten
6. On primary filter with water separator, remove filter ring (about 1/3 turn) until it “snaps” into the detent. DO
element from water separator bowl. Drain and clean NOT overtighten retaining ring.
separator bowl. Dry with compressed air. Install water
separator bowl onto new element. Tighten securely. NOTE: The proper installation is indicated when a "click"
is heard and a release of the retaining ring is felt.
NOTE: Raised locators on fuel filter canister must
be indexed properly with slots in mounting A plug is provided with the new element for
base for correct installation. plugging the used element.
7. Install new filter element onto mounting base. Be 10. Open fuel shut-off valve and bleed the fuel system.
sure element is properly indexed and firmly seated on (See BLEEDING FUEL SYSTEM in Service As
base. It may be necessary to rotate filter for correct Required Section.) Tighten bleed plug (D).
alignment.
8. Align keys on filter element with slots in filter base.
OURGP12,000004B -19-13OCT06-1/1
35-3 PN=71
081922
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. If tensioner spring tension is not
RG8098 —UN—18NOV97
within specification, replace tensioner assembly.
Checking Belt Wear
The belt tensioner is designed to operate within the limit of
arm movement provided by the cast stops (A and B) when
correct belt length and geometry is used.
Cast Stops
Visually inspect cast stops (A and B) on belt tensioner
assembly. A—Cast Stops B—Cast Stop
If the tensioner stop on swing arm (A) is hitting the
fixed stop (B), check mounting brackets (alternator,
belt tensioner, idler pulley, etc.) and the belt length.
Replace belt as needed (see REPLACING FAN AND
ALTERNATOR BELTS in Service As Required Section).
Continued on next page OURGP12,000004A -19-28JUL04-1/2
35-4 081922
PN=72
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:
RG7977 —UN—14NOV97
NOTE: Later engines have a 12.7 mm (1/2 in.) square
drive hole in tensioner, so no socket drive is required.
1. Release tension on belt using a breaker bar and socket

(if required) on tension arm. Remove belt from pulleys.
2. Release tension on tension arm and remove breaker
bar. Marks on Tensioner
3. Put a mark (A) on swing arm of tensioner as shown.

4. Measure 21 mm (0.83 in.) from (A) and put a mark (B)
on tensioner mounting base.
5. Install torque wrench (C) so that it is aligned with center
RG12054 —UN—08JAN02
of pulley and tensioner. Rotate the swing arm with the
torque wrench until marks (A and B) are aligned.
6. Record torque wrench measurement and compare
with specification below. Replace tensioner assembly
as required.
Specification
Spring Tension—Torque.......................................18-22 N·m (13-16 lb-ft) Align Marks
NOTE: Threads on earlier belt tensioner roller cap

screw are LEFT-HAND threads.
A—Mark On Swing Arm C—Torque Wrench

B—Mark On Tensioner
Mounting Base
RG12065 —UN—28JAN02
Align Torque Wrench With Pulley And Tensioner
OURGP12,000004A -19-28JUL04-2/2
35-5 081922
PN=73
Checking Engine Speeds

Observe tachometer (A) reading on the instrument panel
to verify engine speeds while running engine. (Refer
to Specifications section later in this manual for engine
speed specifications.) If engine speeds need adjustment,
contact your engine dealer or distributor.
A—Tachometer
RG11299A —UN—17AUG00
Check Engine Speed On Tachometer
OURGP11,000000B -19-24JUN04-1/1
Checking Engine Electrical Ground

Connections
Keep all engine ground connections clean and tight to
prevent electrical arcing which can damage electronic
components.
OUOD002,0000169 -19-08OCT01-1/1
Checking Cooling System

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
IMPORTANT: Air must be expelled from cooling

system when system is refilled. Loosen
temperature sending unit fitting at rear High-Pressure Fluids
of cylinder head or plug in thermostat
housing to allow air to escape when filling
system. Retighten fitting or plug when all 2. Thoroughly inspect all cooling system hoses for hard,
the air has been expelled. flimsy, or cracked condition. Replace hoses if any of
the above conditions are found.
1. Visually check entire cooling system for leaks. Tighten
all clamps securely.
RG,RG34710,5580 -19-20MAY96-1/1
35-6 081922
PN=74
Replenishing Supplemental Coolant Additives (SCAs) Between Coolant Changes
RG6261 —UN—08DEC97
RG6262 —UN—05DEC97
Radiator Coolant Check JT07298 Coolant/Battery Tester
IMPORTANT: Do not add supplemental coolant available, recharge the system per instructions printed on
additives when the cooling system is drained label of John Deere Liquid Coolant Conditioner.
and refilled with John Deere COOL-GARD®
IMPORTANT: ALWAYS maintain coolant at correct
NOTE: If system is to be filled with coolant that does not level and concentration. DO NOT operate engine
contain SCAs, the coolant must be precharged. without coolant even for a few minutes.
Determine the total system capacity and premix If frequent coolant makeup is required, the
with 3% John Deere Coolant Conditioner. glycol concentration should be checked with
JTO7298 Coolant/Battery Tester to ensure
Through time and use, the concentration of coolant that the desired freeze point is maintained.
additives is gradually depleted during engine operation. Follow manufacturer's instructions provided
Periodic replenishment of inhibitors is required, even when with Coolant/Battery Tester.
John Deere COOL-GARD® is used. The cooling system
must be recharged with additional supplemental coolant Add the manufacturer's recommended concentration of
additives available in the form of liquid coolant conditioner. supplemental coolant additive. DO NOT add more than
Maintaining the correct coolant conditioner concentration the recommended amount.
(SCAs) and freeze point is essential in your cooling The use of non-recommended supplemental coolant
system to protect against rust, liner pitting and corrosion, additives may result in additive drop-out and gelation of
and freeze-ups due to incorrect coolant dilution. the coolant.
John Deere LIQUID COOLANT CONDITIONER is If other coolants are used, consult the coolant supplier
recommended as a supplemental coolant additive in and follow the manufacturer's recommendation for use of
John Deere engines. supplemental coolant additives.
DO NOT mix one brand of SCA with a different brand. See DIESEL ENGINE COOLANTS AND
Test the coolant solution every 500 hours or 12 months of SUPPLEMENTAL ADDITIVE INFORMATION for
operation using either John Deere coolant test strips or a proper mixing of coolant ingredients before adding to the
COOLSCAN® analysis. If a COOLSCAN® analysis is not cooling system.
COOL-GARD is a registered trademark of Deere & Company

COOLSCAN is a registered trademark of Deere & Company
DPSG,OUOD002,1921 -19-07JAN02-1/1
35-7 081922
PN=75
Testing Diesel Engine Coolant

Maintaining adequate concentrations of glycol and
inhibiting additives in the coolant is critical to protect the Add only the recommended concentration of John Deere
engine and cooling system against freezing, corrosion, COOL-GARD II Coolant Extender. DO NOT add more
and cylinder liner erosion and pitting. than the recommended amount.
Test the coolant solution at intervals of 12 months or less When Using Nitrite-Containing Coolants
and whenever excessive coolant is lost through leaks or Compare the test strip results to the supplemental coolant
overheating. additive (SCA) chart to determine the amount of inhibiting
Coolant Test Strips additives in your coolant and whether more John Deere
Liquid Coolant Conditioner should be added.
Coolant test strips are available from your John Deere
dealer. These test strips provide a simple, effective Add only the recommended concentration of John Deere
method to check the freeze point and additive levels of Liquid Coolant Conditioner. DO NOT add more than the
your engine coolant. recommended amount.
When Using John Deere COOL-GARD II Coolant Analysis
John Deere COOL-GARD II Premix™ , COOL-GARD For a more thorough evaluation of your coolant, perform a
II PG Premix and COOL-GARD II Concentrate are coolant analysis. The coolant analysis can provide critical
maintenance free coolants for up to six years or 6000 data such as freezing point, antifreeze level, pH, alkalinity,
hours of operation, provided that the cooling system is nitrite content (cavitation control additive), molybdate
topped off using only John Deere COOL-GARD II Premix content (rust inhibitor additive), silicate content, corrosion
or COOL-GARD II PG premix. Test the coolant condition metals, and visual assessment.
annually with coolant test strips designed for use with Contact your John Deere dealer for more information on
John Deere COOL-GARD II coolants. If the test strip coolant analysis.
chart indicates that additive is required, add John Deere
COOL-GARD II Coolant Extender as directed.
COOL-GARD is a trademark of Deere & Company
DX,COOL9 -19-11APR11-1/1
35-8 081922
PN=76
Pressure Testing Cooling System
RG6557 —UN—20JAN93
RG6558 —UN—20JAN93
Test Radiator Cap
Test Cooling System
CAUTION: Explosive release of fluids from Test Cooling System

serious burns. NOTE: Engine should be warmed up to test
overall cooling system.
cool enough to touch with bare hands. Slowly 1. Allow engine to cool, then carefully remove radiator
loosen cap to first stop to relieve pressure cap.
2. Fill radiator with coolant to the normal operating level.
Test Radiator Cap
IMPORTANT: DO NOT apply excessive pressure
1. Remove radiator cap and attach to D05104ST Tester to cooling system, doing so may damage
as shown. radiator and hoses.
2. Pressurize cap to specification listed. Gauge should 3. Connect gauge and adapter to radiator filler neck.
hold pressure for 10 seconds within the normal range Pressurize cooling system to specification listed for
if cap is acceptable. radiator cap.
If gauge does not hold pressure, replace radiator cap. 4. With pressure applied, check all cooling system hose
Specification connections, radiator, and overall engine for leaks.
Radiator Cap Holding If leakage is detected, correct as necessary and
Pressure (Not pressure test system again.
Opening For 10
Seconds)—Pressure.......................... 70 kPa (0.7 bar) (10 psi) minimum If no leakage is detected, but the gauge indicated a
drop in pressure, coolant may be leaking internally
3. Remove the cap from gauge, turn it 180°, and retest within the system or at the block-to-head gasket. Have
cap. This will verify that the first measurement was your engine distributor or servicing dealer correct this
accurate. problem immediately.
RG,RG34710,5586 -19-07JAN02-1/1
35-9 081922
PN=77
Adjusting Variable Speed (Droop) on

Generator Set Engines
Stanadyne Mechanical Injection Pumps Only
1. Warm engine to normal operating temperature.
2. When necessary, disconnect throttle linkage or cable.
3. Adjust slow idle (C) and adjust fast idle (B) speed
when necessary.
4. Run engine at fast idle, then apply load until reaching
rated speed.
RG12066 —UN—29JAN02
5. Check power. Adjust with the screw (A) if needed.
6. Remove load from engine.
7. Again check and adjust fast idle if screw (A) has been
turned.
8. Repeat procedure until both the engine power and the Droop Adjustment Screw
fast idle speed are correct.
9. Reinstall throttle linkage if previously removed. A—Adjustment Screw C—Slow Idle Adjustment
B—Fast Idle Adjustment
Continued on next page RG,RG34710,5583 -19-28JAN02-1/2
40-1 081922
PN=78
DENSO In-Line Injection Pumps Only

1. Check for specified no-load (frequency). If governor
regulation is within 5–7% range, no adjustment is
necessary.
2. If governor regulation is above 7% or below 5%, stop
engine and remove cap nuts from adjusting screws
before making adjustments.
3. Remove droop adjusting screw access plug (B, shown
removed) from top of governor housing.
4. Back out slow idle (adjusting) screw (D) and bumper
screw. Pull back on throttle lever (F, toward rear of
governor housing) by hand until the droop adjusting
screw (C) inside housing can be adjusted through the
access plug hole.
5. Screw the droop screw in (clockwise), counting the
turns until screw bottoms out. Then, return screw to
RG5752 —UN—03NOV97
original setting.
NOTE: A noticeable click will occur at each 1/4 turn of
droop adjusting screw. One click clockwise will
increase no-load speed approximately 10 rpm,
counterclockwise will reduce speed by 10 rpm.
6. Screw in the droop screw (clockwise) no more than 1/2 DENSO In-Line Injection Pump
turn (two clicks) at a time to reduce governor droop.
Turn counterclockwise no more than two clicks at a
time to increase governor droop (to reduce governor A—Fast Idle (Stop) Screw E—Idle (Bumper) Spring
B—Droop Adjusting Screw F— Throttle Lever
sensitivity). Access Plug Location G—Mechanical Shutoff Lever
C—Droop Adjusting Screw
7. Replace access plug in top of governor housing. Start D—Slow Idle (Adjusting) Screw
engine, apply full (100%) load, and readjust high idle
adjusting screw until 1500 rpm is obtained at the
specified power.
Delphi (Lucas) Injection Pumps Only
8. Screw in idle (bumper) spring until engine speed
increases 5–10 rpm. See your authorized Delphi (Lucas) Repair Station for
speed droop adjustment. This service requires that an
9. Repeat steps 4 through 7 until governor regulation is internal pump adjustment be made.
within the 5–7% range.
10. Replace all cap nuts onto adjusting screws and tighten
lock nuts securely.
RG,RG34710,5583 -19-28JAN02-2/2
40-2 081922
PN=79
Checking Crankshaft Vibration Damper

(6-Cylinder Engine Only)
IMPORTANT: Crankshaft vibration damper assembly
is not repairable and should be replaced every
4500 hours or 60 months, whichever occurs first.
RG8018 —UN—15JAN99
1. Remove belts (shown removed).
2. Grasp crankshaft vibration damper with both hands
and attempt to turn it in both directions. If rotation
is felt, crankshaft vibration damper is defective and
should be replaced.
3. Check crankshaft vibration damper radial runout by Grasp Vibration Damper
positioning dial indicator so probe contacts crankshaft
vibration damper outer diameter.
4. With engine at operating temperature, rotate
crankshaft using JDE83 or JD81-1 flywheel turning
tool.
RG7508 —UN—23NOV97
5. Note dial indicator reading. If runout exceeds
specification, replace crankshaft vibration damper.
Specification
Crankshaft Vibration
Damper—Maximum
Radial Runout............................................................. 1.50 mm (0.060 in)
Check Runout
RG,RG34710,5585 -19-27OCT15-1/1
40-3 081922
PN=80
Flushing and Refilling Cooling System

serious burns.
NOTE: When John Deere COOL-GARD is used, the

drain interval is 3000 hours or 36 months. The
drain interval may be extended to 5000 hours High-Pressure Fluids
or 60 months of operation, provided that the
coolant is tested annually AND additives
are replenished, as needed, by adding a
supplemental coolant additive (SCA).
If COOL-GARD is not used, the flushing interval
is 2000 hours or 24 months of operation.
Drain old coolant, flush the entire cooling system, test

thermostats, and fill with recommended clean coolant per
the following procedure.
1. Pressure test entire cooling system and pressure
cap if not previously done. (See PRESSURE
TESTING COOLING SYSTEM, in the Lubrication and
Maintenance/500 Hour/12 Month Section.)
RG12833 —UN—13FEB03
2. Slowly open the engine cooling system filler cap or
radiator cap (A) to relieve pressure and allow coolant
to drain faster.
Radiator Cap
Continued on next page OURGP11,000000C -19-24JUN04-1/2
40-4 081922
PN=81
3. Open engine block drain valve (A) on left side of

engine. Drain all coolant from engine block.
NOTE: These engines use several different oil filter
adapters. Use either drain plug (B) or (C) to
drain coolant, whichever is more accessible for
the oil filter adapter on your engine.
4. Open radiator drain valve. Drain all coolant from
radiator.
5. Remove thermostats at this time, if not previously
done. Install cover (without thermostats) using old
gasket and tighten cap screws to 47 N·m (35 lb-ft).
Engine Block Drain Valve
6. Test thermostat opening temperature. (See Inspecting
Thermostats And Testing Opening Temperature in
A—Engine Block Drain Valve C—Engine Block Drain Plug
Service As Required Section.) B—Engine Block Drain Plug
7. Close all drain valves after coolant has drained.
temperature sending unit fitting at rear
CAUTION: Do not run engine longer than
of cylinder head or plug in thermostat
10 minutes. Doing so may cause engine
housing to allow air to escape when filling
to overheat which may cause burns when
system. Retighten fitting or plug after
radiator water is draining.
filling cooling system.
8. Fill the cooling system with clean water. Run the engine
NOTE: Coolant capacity may vary depending
about 10 minutes to stir up possible rust or sediment.
on application.
9. Stop engine, pull off lower radiator hose and remove
radiator cap. Immediately drain the water from system 13. Add coolant to radiator until coolant touches bottom
before rust and sediment settle. of filler neck. (See specification for capacity.) Install
radiator cap.
10. After draining water, close drain valves. Reinstall
radiator cap and radiator hose and clamp. Fill Specification
the cooling system with clean water and a heavy 4.5 L Engine— Coolant
duty cooling system cleaner such as Fleetguard® Capacity..................................................................................8.5 L (9 qt)
RESTORE™ and RESTORE PLUS™. Follow 6.8 L Engine—Coolant
manufacturer's directions on label. Capacity.............................................................................. 11.3 L (12 qt)
11. After cleaning the cooling system, drain cleaner and fill 14. Run engine until it reaches operating temperature.
with water to flush the system. Run the engine about This mixes the solution uniformly and circulates it
10 minutes, remove radiator cap and pull off lower through the entire system. The normal engine coolant
radiator hose to drain out flushing water. temperature range is 82°—94°C (180° — 202°F).
12. Close all drain valves on engine and radiator. Reinstall 15. After running engine, check coolant level and entire
radiator hose and tighten clamps securely. Install cooling system for leaks.
thermostats using a new gasket. (See TESTING 16. Inspect the fan belt for wear and check belt tension.
THERMOSTATS OPENING TEMPERATURE later in (See Checking Belt Tensioner Spring Tension and Belt
this section.) Wear in Lubrication and Maintenance 500 Hour/12
IMPORTANT: Air must be expelled from cooling Month section.
system when system is refilled. Loosen
Fleetguard is a trademark of Cummins Engine Company, Inc.
RESTORE is a trademark of Fleetguard.
RESTORE PLUS is a trademark of Fleetguard.
OURGP11,000000C -19-24JUN04-2/2
40-5 PN=82
081922
Testing Thermostats Opening Temperature

To Remove Thermostat(s)
NOTE: On some engines, the coolant manifold/thermostat
housing is an integral part of the cylinder head.
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.
High Pressure Fluids
1. Visually inspect area around thermostat housing for
leaks.
2. Remove radiator pressure cap and partially drain
cooling system.
3. Remove thermostat cover-to-water pump tube (A) and
seal.
A—Cover-To-Coolant Pump
Tube
Thermostat Cover-to-Water Pump Tube

DPSG,RG34710,112 -19-07JAN02-1/5
4. Remove thermostat cover (B) with gasket.

5. Remove thermostat(s)
6. Remove and discard all gasket material. Clean gasket
surfaces.
RG7921A —UN—13NOV97
7. Clean and check cover for cracks or damage.
B—Thermostat Cover
Thermostat Cover
40-6 081922
PN=83
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. Either
may rupture if overheated.
3. Suspend thermostat and a thermometer in a container

of water.
4. Stir the water as it heats. Observe opening action
RG5971 —UN—23NOV97
of thermostat and compare temperatures with the
specification given in chart below.
NOTE: Due to varying tolerances of different suppliers,
initial opening and full open temperatures may
vary slightly from specified temperatures.
THERMOSTAT TEST SPECIFICATIONS Testing Thermostat Opening Temperature

Rating Initial Opening (Range) Full Open
(Nominal)
5. Remove thermostat and observe its closing action as
71°C (160°F) 69—72°C (156—162°F) 84°C (182°F) it cools. In ambient air the thermostat should close
77°C (170°F) 74—78°C (166—172°F) 89°C (192°F) completely. Closing action should be smooth and slow.
82°C (180°F) 80—84°C (175—182°F) 94°C (202°F) 6. Replace any defective thermostat. On a dual
thermostat engine, replace both thermostats.
89°C (192°F) 86—90°C (187—194°F) 101°C (214°F)
90°C (195°F) 89—93°C (192—199°F) 103°C (218°F)
92°C (197°F) 89—93°C (193—200°F) 105°C (221°F)
96°C (205°F) 94—97°C (201—207°F) 100°C (213°F)
99°C (210°F) 96—100°C (205—212°F) 111°C (232°F)
40-7 081922
PN=84
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).
RG7614A —UN—06NOV97
1. Clean all gasket material from thermostat cover and
housing mounting surfaces.
2. Using guide studs (A) to keep gasket in place, install a
new gasket on cylinder head.
3. Install thermostat(s) with jiggle wire facing up in the
12 o'clock position.
Installing Thermostat Cover
4. Using a screwdriver to hold thermostat(s) in place,
install thermostat(s) and water manifold/thermostat
cover.
5. Tighten cover cap screws to 70 N·m (52 lb-ft).
6. Lubricate new O-ring with PT507 Multi-Purpose
RG7921B —UN—13NOV97
Grease. Install seal (B) in thermostat cover.
A—Guide Studs B—Seal
Thermostat Cover Seal

DPSG,RG34710,112 -19-07JAN02-4/5
7. Install coolant manifold/thermostat cover-to-coolant

pump tube (C). Tighten clamps.
8. If not already done, fill cooling system and check for
leaks.
IMPORTANT: Air must be expelled from cooling
system when filling. Loosen temperature
sending unit fitting at rear of cylinder head
or plug in thermostat housing to allow air to
escape when filling system. Tighten fitting or
plug when all air has been expelled.
C—Cover-To-Coolant Pump
Tube Cover-To-Coolant Pump Tube
DPSG,RG34710,112 -19-07JAN02-5/5
40-8 081922
PN=85
Check and Adjust Valve Clearance
CAUTION: To prevent accidental starting of engine

while performing valve adjustments, always
disconnect NEGATIVE (—) battery terminal.
RG7408 —UN—06AUG96
IMPORTANT: Valve clearance MUST BE checked
and adjusted with engine COLD.
1. Remove rocker arm cover and crankcase ventilator

tube.
IMPORTANT: Visually inspect contact surfaces of
valve tips and rocker arm wear pads. Check all Flywheel Housing Timing Holes
parts for excessive wear, breakage, or cracks.
Replace parts that show visible damage. A—Timing/Rotation Hole B—Timing Pin Hole
Rocker arms that exhibit excessive valve
clearance should be inspected more thoroughly
to identify damaged parts. 4. With engine lock-pinned at TDC of No. 1 piston's
compression stroke, check valve clearance to
2. Remove plastic plugs or cover plate from engine following specifications. (Use sequence for 4-cylinder
timing/rotation hole (A) and timing pin hole (B). or 6-cylinder engines as outlined on next page.)
NOTE: Some engines are equipped with flywheel Specification
housings which do not allow use of an engine Intake Valve Clearance
flywheel rotation tool. These engines may be For Checking (Rocker
rotated from front nose of engine, using JDG966 Arm-to-Valve Tip) (Engine
Crankshaft Front/Rear Rotation Adapter. Cold)—Clearance.............................................................0.31—0.38 mm
(0.012—0.015 in.)
3. Using JDE83 or JD81-1 Flywheel Turning Tool, rotate Exhaust Valve Clearance
engine flywheel in running direction (clockwise viewed For Checking (Rocker
from front) until No. 1 cylinder is at TDC compression Arm-to-Valve Tip) (Engine
stroke. Insert JDG1571 or JDE81-4 Timing Pin in Cold)—Clearance.............................................................0.41—0.48 mm
flywheel. (0.016—0.019 in.)
If No.1 cylinder rocker arms are loose, the engine is at

No. 1 TDC compression.
If No. 1 cylinder rocker arms are not loose, rotate
engine one full revolution (360°) to No. 1 TDC
compression.
Continued on next page DPSG,RG41165,137 -19-18FEB21-1/10
40-9 PN=86
081922
5. If valves need adjusting, use the appropriate valve

clearance adjustment procedure on the next page
and adjust to specifications below. Loosen the jam
nut (A) on rocker arm adjusting screw. Turn adjusting
screw until feeler gauge slips with a slight drag. Hold
the adjusting screw from turning with screwdriver and
tighten jam nut to specifications. Recheck clearance
RG7409 —UN—06AUG96
again after tightening jam nut. Readjust clearance as
necessary.
Specification
Intake Valve Clearance
For Adjusting (Rocker
Arm-to-Valve Tip) (Engine
Adjusting Valves
Cold)—Clearance...................................................... 0.36 mm (0.014 in.)
Exhaust Valve Clearance
For Adjusting (Rocker A—Adjusting Screw Jam Nut
Arm-to-Valve Tip) (Engine
Cold)—Clearance...................................................... 0.46 mm (0.018 in.)
Rocker Arm Adjusting
Screw Jam Nut—Torque................................................. 27 N·m (20 lb-ft)
DPSG,RG41165,137 -19-18FEB21-2/10
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).
RG4776 —UN—31OCT97
2. Adjust valve clearance on No. 1 and 3 exhaust valves
and No. 1 and 2 intake valves.
3. Turn crankshaft 360°. Lock No. 4 piston at TDC
compression stroke (C).
4. Adjust valve clearance on No. 2 and 4 exhaust valves
and No. 3 and 4 intake valves.
4-Cylinder Engine Valve Adjustment
A—Front of Engine E—Exhaust Valve

B—No. 1 Piston TDC I— Intake Valve
Compression
C—No. 4 Piston TDC
Compression
40-10 081922
PN=87
6-Cylinder Engine:
NOTE: Firing order is 1-5-3-6-2-4.
1. Lock No. 1 piston at TDC compression stroke (B).

2. Adjust valve clearance on No. 1, 3 and 5 exhaust
RG4777 —UN—31OCT97
valves and No. 1, 2, and 4 intake valves.
3. Turn crankshaft 360°. Lock No. 6 piston at TDC
compression stroke (C).
4. Adjust valve clearance on No. 2, 4 and 6 exhaust
valves and No. 3, 5, and 6 intake valves.
6-Cylinder Engine Valve Adjustment
The Following Steps Are to Install the Rocker
Arm Cover Gasket
A—Front of Engine E—Exhaust Valve
IMPORTANT: Replace rocker arm cover gasket every B—No. 1 Piston TDC I— Intake Valve
time the rocker arm cover is removed. Compression
C—No. 6 Piston TDC
Compression
NOTE: The procedure shown is for the 4045 engine.
The 6068 engine is similar.
NOTE: This procedure is to install a standard or a NOTE: Extended high temperature rocker arm cover
high-temperature rocker arm cover gasket. Use gasket (optional) is designed for non-High Pressure
the appropriate procedure. Common Rail (HPCR) engines.
NOTE: For extended high temperature operations, the • Carefully remove the old gasket from rocker arm cover.
optional high temperature gasket kit is available Do not use any cutting tool that could damage the cover.
to prevent oil leakage between valve cover • Clean the groove with acetone. Dry with compressed air.
and head, in the area above the exhaust ports • Clean the mating surface of cylinder head.
and/or directly beneath the turbo.
DPSG,RG41165,137 -19-18FEB21-4/10
Rocker Arm Cover Gap Adjustment for

High-Temperature Gasket
IMPORTANT: Installation of the high-temperature
rocker arm cover gasket requires the
measurement/adjustment of the gap between
the rocker arm cover and the cylinder head.
1. Install rocker arm cover (D) without gasket (E) or

O-rings (C).
A—Plug (4 used) D—Rocker Arm Cover

B—Flanged Head Nut (4 used) E—Rocker Arm Cover Gasket
C—O-Ring (4 used)
RG27005 —UN—08APR15
Rocker Arm Cover Assembly

40-11 081922
PN=88
2. Install flanged head nuts (B) and tighten in sequence

shown to specification.
Specification
Rocker Arm Cover
Nuts—Torque................................................................. 35 N·m (26 lb·ft)
RG33390 —UN—27JAN21
Tightening Sequence
DPSG,RG41165,137 -19-18FEB21-6/10
3. Use a feeler gauge to measure the gap (B) between

the rocker arm cover (A) and the cylinder head (C).
4. Remove rocker arm cover from an engine.
A—Rocker Arm Cover C—Cylinder Head

B—Gap
A
RG27006 —UN—08APR15
B
Rocker Cover Gap

DPSG,RG41165,137 -19-18FEB21-7/10
5. If gap (B) measured in Step 3 is less than 1.5 mm

(0.059 in), install one shim (E) onto each rocker arm
cover hold down stud (D).
6. If the gap measured in Step 3 is greater than 1.5 mm
(0.059 in), do not install any shims.
RG27007 —UN—08APR15
D—Hold-Down Stud E—Shim
40-12 081922
PN=89
Rocker Arm Cover Gasket Installation

1. Install a new rocker arm cover gasket (E) in the groove
at the base of rocker arm cover (D). Start at the ends
and work toward the center of the cover. Do not use
sealant on the gasket (E).
IMPORTANT: Prevent damage to engine components.
ALWAYS discard O-rings when removed. Reuse
of O-rings can cause leakage.
2. Install rocker arm cover (D) onto the cylinder head

over the studs of the rocker arm shaft retaining cap
screws. Install O-rings (C) onto the studs.
RG27005 —UN—08APR15
A—Plug (4 or 6 used) D—Rocker Arm Cover
B—Flanged Head Nut (4 or 6 E—Rocker Arm Cover Gasket
used)
C—O-Ring (4 or 6 used)
Rocker Arm Cover Assembly

DPSG,RG41165,137 -19-18FEB21-9/10
IMPORTANT: The Non-High Pressure Common

Rail (HPCR) engines require a different
tightening specification. Use the appropriate
torque value for the engine.
3. Install flanged head nuts (B) onto the studs of the
RG33390 —UN—27JAN21
rocker arm shaft retaining cap screws. Tighten in
sequence shown to specification.
Rocker Arm Cover Nuts—Specification
Non-HPCR Engines with
2-Valve Head—Torque................................................... 35 N·m (26 lb·ft)
HPCR Engines with
2-Valve Head—Torque................................................... 11 N·m (97 lb·in)
Tightening Sequence 4045 Engine
4. Install plugs (A).
RG33483 —UN—18FEB21
Tightening Sequence 6068 Engine

DPSG,RG41165,137 -19-18FEB21-10/10
40-13 081922
PN=90
Service as Required
Additional Service Information
This is not a detailed service manual. If you want more
detailed service information, use the form in the back of
this manual to order a component technical manual.
RG4624 —UN—15DEC88
Component Technical Manual
RG,RG34710,5591 -19-20MAY96-1/1
Do Not Modify Fuel System

IMPORTANT: Modification or alteration of the injection
pump (arrow), the injection pump timing, or
the fuel injectors in ways not recommended by
the manufacturer will terminate the warranty
obligation to the purchaser.
In addition, tampering with fuel system which
alters emission-related equipment on engines
may result in fines or other penalties, per EPA
regulations or other local emission laws.
Do not attempt to service injection pump or
fuel injectors yourself. Special training and Fuel Injection Pump
special tools are required. (See your authorized
servicing dealer or engine distributor.)
Never steam clean or pour cold water on an
injection pump while it is still warm. To do so
may cause seizure of pump parts.
OURGP12,000004D -19-03AUG04-1/1
45-1 081922
PN=91
Service as Required
Adding Coolant

serious burns.
IMPORTANT: Never pour cold liquid into a hot

engine, as it may crack cylinder head or
block. DO NOT operate engine without High-Pressure Fluids
coolant for even a few minutes.
John Deere TY15161 Cooling System Sealer may
be added to the radiator to stop leaks. DO NOT
use any other stop-leak additives in the system.
Air must be expelled from cooling system
when coolant is added.
1. Loosen temperature sending unit fitting at rear of

cylinder head or plug in side of thermostat housing to
allow air to escape when filling system.
IMPORTANT: When adding coolant to the system,
use the appropriate coolant solution. (
See ENGINE COOLANT SPECIFICATIONS
in Fuels, Lubricants, and Coolant Section
RG12833 —UN—13FEB03
for mixing of coolant ingredients before
adding to cooling system.)
Do not overfill cooling system. A pressurized
system needs space for heat expansion without
overflowing at top of radiator.
2. Remove radiator cap (A) and fill until coolant level Radiator Filler Cap
touches bottom of radiator filler neck.
3. Tighten plugs and fittings when air has been expelled A—Radiator Filler Cap
from system.
4. Run engine until it reaches operating temperature.
OURGP12,0000049 -19-22JUL04-1/1
45-2 081922
PN=92
Service as Required
Pre-Start Cleaning Guide residue that blocks airflow may degrade machine
performance and requires more frequent cleaning
CAUTION: Avoid injury. Before cleaning machine, depending on environmental conditions.
allow ample time for hot surfaces to cool. • Inspect difficult to observe areas daily as conditions
may require additional cleaning care to remove debris.
IMPORTANT: Avoid machine damage. Do not direct • Check for oil and fuel leaks daily. Replace or repair
high-pressure spray from hose output directly at sources of leaks, including gaskets, seals, breather
or close to electrical connections and sensors. tubes, fittings, and fluid lines.
Maintenance and Service Reminders
Cleaning as needed is recommended. Clean more
frequently during heavy machine use, and when weather • Keep surfaces free of grease and oil.
conditions are dry. • Clean up hydraulic and other fluid leaks.
• Check enclosed areas daily. Clean the engine and • Fuel Lines — Check for leaks, cracks, and kinks.
other enclosed areas of equipment to remove debris • Fuel Pumps — Check fittings, especially compression
ring couplings, for cracks and leaks.
and any buildup of oil and grease. Keep the engine and
engine compartment free of combustible material. • Fuel Injectors — Check pressure and return lines for
signs of leaks.
• Check for debris buildup daily on and around intake
• When servicing fuel filter or draining water separator,
systems, exhaust systems, and intercooler piping
avoid fuel spills. Immediately clean up any fuel spill.
systems. Verify that there are no holes or leaks in intake
or exhaust systems. Do not allow debris to build up • Check for transmission case venting system seepage,
transmission case leakage, power steering cylinder
near hot exhaust components. Verify that hot exhaust
leakage, or power steering line leakage.
components are cleaned as often as environmental
conditions require. • Check for loose electrical connectors, damaged wiring,
corrosion, or poor connections.
• Inspect cooling system daily to determine whether
cooling system needs cleaning. Visible buildup of
ZE59858,0000009 -19-07JUL20-1/1
45-3 081922
PN=93
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.) H2O, is torn, or visibly dirty.
RG11319A —UN—06SEP00
NOTE: This procedure applies to John Deere single stage
air cleaner kits. Refer to manufacturers' instructions
for servicing air cleaners not supplied by John Deere.
1. If equipped, loosen body clamp.

2. Loosen clamp around outlet neck (A).
Single Stage Air Filter
3. Remove air cleaner.
4. Install new filter so that overlap (B) of air cleaner outlet
neck and engine intake pipe is to specification below.
Specification
Air Cleaner Neck to
Engine Intake—Overlap.................................................... 38 mm (1.5 in)
RG11320 —UN—07SEP00
5. Tighten neck clamp (A) to specification below.
Specification
Air Cleaner Neck
Clamp—Torque........................................................... 6.8 N·m (60 lb-in.)
Installation of Single Stage Air Cleaner

IMPORTANT: Do NOT overtighten body clamp.
Overtightening may cause crushing of air cleaner A—Outlet Neck Clamp B—Filter to Engine Overlap
body. Tighten body clamp only until snug.
6. If equipped, tighten body clamp until snug. 7. If equipped, fully depress air restriction indicator reset
IMPORTANT: Whenever the air cleaner has been button and release to reset indicator.
serviced or removed, ALWAYS fully depress
the air restriction indicator reset button (if
equipped) to assure accurate readings.
RG,RG34710,5594 -19-07JAN02-1/1
45-4 081922
PN=94
Service as Required
Replacing Axial Seal Air Cleaner Filter

Element
RG4686 —UN—20DEC88
NOTE: This procedure applies to John Deere 2-stage

axial seal air cleaner kits. Refer to manufacturers'
instructions for servicing air cleaners not
supplied by John Deere.
1. Remove wing nut and remove canister cover shown Wing Nut and Primary Element
in small illustration inset.
2. Remove wing nut (A) and remove primary element
(B) from canister.
3. Thoroughly clean all dirt from inside canister.
NOTE: Some engines may have a dust unloader valve
RG4687 —UN—20DEC88
(C) on the air cleaner. If equipped, squeeze valve
tip to release any trapped dirt particles.
IMPORTANT: Remove secondary (safety) element (E)

ONLY for replacement. DO NOT attempt to clean,
wash, or reuse secondary element. Replacement
of secondary element is usually necessary Dust Unloader Valve
ONLY when primary element has a hole in it.
4. To replace secondary element, remove retaining nut

(D) and secondary element (E). Immediately replace
secondary element with new element to prevent dust
from entering air intake system.
RG11068 —UN—26JUN00
5. Install new primary element and tighten wing nut
securely. Install cover assembly and tighten retaining
wing nut securely.
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. Retaining Nut and Secondary Element
6. If equipped, fully depress air restriction indicator reset A—Wing Nut D—Retaining Nut
button and release to reset indicator. B—Primary Element E—Secondary Element
C—Dust Unloader Valve
RG41165,000008A -19-12NOV01-1/1
45-5 081922
PN=95
Service as Required
Replacing Radial Seal Air Cleaner Filter

Element
NOTE: This procedure applies to John Deere 2-stage

radial seal air cleaner kits. Refer to manufacturers'
instructions for servicing air cleaners not
supplied by John Deere.
1. Unlatch and remove dust cap/cover (A) of air cleaner. Dust Cap/Cover
2. Move end of filter (B) back and forth gently to break

seal.
3. Pull filter (B) off outlet tube and out of housing.
4. Thoroughly clean all dirt from inside housing and from
outlet bore.
IMPORTANT: Remove secondary (safety) element (C)
ONLY for replacement. DO NOT attempt to clean,
wash, or reuse secondary element. Replacement
of secondary element is usually necessary
ONLY when primary element has a hole in it.
Primary Filter Element
5. To replace secondary element (C), pull filter element
out gently. Immediately replace secondary element
with new element to prevent dust from entering air
intake system.
6. Install new primary filter element. Apply pressure by
hand at outer rim of filter.
IMPORTANT: Do NOT use latches on cover to force
filter into air cleaner. Using cover to force
filter will damage cleaner housing.
7. Close housing with dust unloader valve aimed down

and latch latches.
Secondary Filter Element
IMPORTANT: Whenever the air cleaner has been
serviced or cover has been removed, ALWAYS A—Dust Cap/Cover C—Secondary Filter Element
fully depress the air restriction indicator reset B—Primary Filter Element
button (if equipped) to assure accurate readings.
8. If equipped, fully depress air restriction indicator reset

button and release to reset indicator.
RG41165,000008B -19-07OCT10-1/1
45-6 081922
PN=96
Service as Required
Replacing Fan and Alternator Belts

Refer to CHECKING BELT TENSIONER SPRING
TENSION AND BELT WEAR in Lubrication and
Maintenance/250 Hour/6 Month Section for additional
information on the belt tensioner.
1. Inspect belts for cracks, fraying, or stretched out
RG11950 —UN—07NOV01
2. To replace belt with automatic tensioner, release
tension on belt using a breaker bar and socket (if
required) on tension arm.
To replace belt with manual tensioner, release tension
at belt tensioner (See MANUAL BELT TENSIONER
290 mm (11.4 in.) Fan Height and Lower*
ADJUSTMENT in Lubrication and Maintenance/250
Hour/6 Month Section.)
3. Remove poly-vee belt from pulleys and discard belt.
4. Install new belt, making sure belt is correctly seated
in all pulley grooves. Refer to belt routing at right for
your application.
RG11951 —UN—07NOV01
5. Apply tension to belt with tensioner. Remove socket.
6. Start engine and check belt alignment.
*Measured from crank centerline to fan drive center.
A—Alternator I— Idler Pulley

CSP—Crankshaft Pulley T— Tensioner
FC—Freon (A/C) Compressor CP—Coolant Pump 338 mm (13.3 in.) Fan Height and Higher Without Freon Compressor*
FD—Fan Drive
RG11952 —UN—07NOV01
402 mm (15.8 in.) Fan Height With Freon Compressor*
OURGP12,000004C -19-29JUL04-1/1
45-7 081922
PN=97
Service as Required
Checking Fuses In Instrument Panels

The following instructions apply to engines equipped with
John Deere instrument panels.
1. On Engines With The North American Standard
Instrument Panel ( —1998), check the fuse (A)
RG4493 —UN—14DEC88
between the ammeter (B) and key switch (C) located
on back side of instrument panel. If defective, replace
with an equivalent 25-amp fuse.
Also check the fuse (D) mounted on the bottom of
the magnetic safety switch. If defective, install an
equivalent 14-amp fuse.
North American ( —1998) Standard Instrument Panel Shown
2. On later (1999— ) North American Standard
Instrument Panels, check the fuse in fuse holder
(E) on front face of instrument panel. Replace as
necessary with an equivalent 14-amp fuse.
3. For VDO Instrument Panels, the fuse is located
on the electronic control card inside the panel's rear
access cover. Remove cover and check fuse (F). If
defective, replace with a 10-amp fuse. There is a spare
fuse (G) available on the card in the “SPARE” terminal.
NOTE: For main electrical system fuses, see
engine wiring diagrams later in this manual
in Troubleshooting Section.
North American ( —1998) Standard Instrument Panel Shown
A—25 Amp Fuse E—Fuse Holder
B—Ammeter F— 10 Amp Fuse
C—Key Switch G—Spare Fuse
D—14 Amp Fuse
RG11937 —UN—17OCT01
North American (1999— ) Instrument Panel Shown
RG12067 —UN—29JAN02
VDO Instrument Panel

RG,RG34710,5601 -19-07JAN02-1/1
45-8 081922
PN=98
Service as Required
Checking Air Compressor (If Equipped)

Air compressors are offered as options with John Deere
OEM engines to provide compressed air to operate
air-powered devices like vehicle air brakes.
Air compressors are engine-driven piston types. They
are either air cooled or cooled with engine coolant.
The compressors are lubricated with engine oil. The
compressor runs continuously as gear or spline driven
by the auxiliary drive of the engine but has “loaded” and
“unloaded” operating modes. This is controlled by the
vehicle's air system (refer to vehicle technical manual for
complete air system checks and services).
See your John Deere engine distributor or servicing dealer
for diagnostic and troubleshooting information. If diagnosis
leads to an internal fault in the compressor, replace the
complete compressor as a new or remanufactured unit.
RG12836 —UN—27FEB03
Air Compressor (Optional)
OURGP12,00001E0 -19-26FEB03-1/1
Bleeding the Fuel System

X9811 —UN—23AUG88
If ANY fluid is injected into the skin, it must
be surgically removed within a few hours High-Pressure Fluids
gangrene may result. Doctors unfamiliar with
this type of injury may call the Deere & Company • After engine has run out of fuel.
IMPORTANT: DO NOT pressurize fuel tank to push
fuel through system, as the pressure can
damage fuel injection pump seals
Bleed the fuel system anytime the fuel system has been
opened up. This includes:
IMPORTANT: Do not operate the engine at high speeds
• After fuel filter changes. or full loads just before bleeding the fuel system
• After injection pump or nozzle replacement. as this may cause fuel injection pump failure.
• Anytime fuel lines have been disconnected.
Continued on next page OURGP11,000000D -19-18OCT06-1/7
45-9 081922
PN=99
Service as Required
1. Loosen the air bleed vent screws (A) two full turns by
hand on fuel filter base. (One screw with single filter
option.)
A—Air Bleed Vent Screws
RG13544 —UN—29JUL04
Air Bleed Vent Screws (Final Filter at Left, Primary Filter
with Separator Bowl at Right)
OURGP11,000000D -19-18OCT06-2/7
2. Operate supply pump primer lever (B) until fuel flow

is free from air bubbles.
3. Tighten bleed plug securely, continue operating hand
primer until pumping action is not felt. Push hand
primer inward (toward engine) as far as it will go.
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.
B—Fuel Supply Pump Primer

Lever Fuel Supply Pump Primer Lever
OURGP11,000000D -19-18OCT06-3/7
At Fuel Injection Pump

On Stanadyne rotary pumps:
1. Slightly loosen fuel return line connector (A) at fuel
injection pump.
2. Operate fuel supply pump primer lever until fuel,
RG6264 —UN—03NOV97
without air bubbles, flows from fuel return line
connection.
3. Tighten return line connector to 27 N·m (20 lb-ft).
4. Primer lever is spring-loaded and will return to normal
position.
Stanadyne Rotary Fuel Injection Pump
A—Fuel Return Line Connector
45-10 081922
PN=100
Service as Required
On Lucas rotary pumps:

1. Loosen bleed screw (B) on pump cover.
NOTE: On Models DP200/201/203 Injection Pumps,
bleed screw is located on top of cover near
the fuel return line.
RG7948 —UN—13NOV97
2. Operate fuel supply pump primer lever or turn ignition
switch to “ON”.
3. Wait until fuel flow is free of air bubbles. Tighten bleed
screw.
4. Primer lever is spring loaded and will return to normal
Lucas Rotary Fuel Injection Pumps
position.
B—Bleed Screw C—Screw

CAUTION: NEVER loosen screw (C) securing
pump head, otherwise pump damage may occur.
OURGP11,000000D -19-18OCT06-5/7
On DENSO and Motorpal in-line pumps:

1. On DENSO pump shown, unscrew hand primer on
fuel supply pump until it can be pulled by hand.
2. Open fuel filter port plug.
3. Operate the hand primer until a smooth flow of fuel,
RG8069 —UN—23NOV97
free of bubbles, comes out of the filter plug hole.
4. Simultaneously stroke the hand primer down and close
the filter port plug. This prevents air from entering the
system. Tighten plug securely. DO NOT overtighten.
IMPORTANT: Be sure hand primer is all the way
down in barrel before tightening to prevent DENSO Fuel Injection Pump Shown
internal thread damage.
5. On DENSO pump shown, lock hand primer in position.

OURGP11,000000D -19-18OCT06-6/7
At Fuel Injection Nozzles

1. Move the engine speed control lever to half throttle
position. On engines equipped with electronic fuel
shut-off solenoid, energize solenoid.
2. Using two open-end wrenches, loosen fuel line
RG7725 —UN—08JAN97
connection at injection nozzle as shown.

3. Crank engine over with starter motor, (but do not
start engine), until fuel free from bubbles flows out of
loosened connection.
4. Retighten connection to 27 N·m (20 lb-ft).
5. Repeat procedure for remaining injection nozzles (if Fuel Line Connection
necessary) until all air has been removed from fuel
system. If engine still will not start, see your authorized
servicing dealer or engine distributor.
OURGP11,000000D -19-18OCT06-7/7
45-11 081922
PN=101
Troubleshooting
General Troubleshooting Information
Troubleshooting engine problems can be difficult. An A reliable program for troubleshooting engine problems
engine wiring diagram is provided in this section to help should include the following basic diagnostic thought
isolate electrical problems on power units using John process:
Deere wiring harness and instrument (gauge) panel.
Wiring diagrams are shown for the two types of instrument
• Know the engine and all related systems.
panels offered for these engines.
• Study the problem thoroughly.
• Relate the symptoms to your knowledge of engine and
Later in this section is a list of possible engine problems systems.
that may be encountered accompanied by possible • Diagnose the problem starting with the easiest things
causes and corrections. The illustrated diagrams and first.
troubleshooting information are of a general nature, final • Double-check before beginning the disassembly.
design of the overall system for your engine application • Determine cause and make a thorough repair.
may be different. See your engine distributor or servicing • After making repairs, operate the engine under normal
dealer if you are in doubt. conditions to verify that the problem and cause was
corrected.
RG,RG34710,5605 -19-07JAN02-1/1
50-1 081922
PN=102
Troubleshooting
50-2 081922
PN=103
Troubleshooting
Engine Wiring Diagram Legend (Standard Instrument Panel For North America)
A1 — Speed Control Unit P6 — Ammeter
B1 — Magnetic Speed Sensor R1 — Resistor (48 ohm)3
B2 — Coolant Temperature Sensor S1 — Key Switch
B3 — Oil Pressure Sensor S2 — Magnetic Safety Switch—North American
F1 — Starting Circuit Fuse (14 amp) Auto Override Module—European (Saran)
F3 — Fuse (Early Models)1 W1 — Ground on K1 Starter Relay Mounting Stud
G1 — Battery Y1 — Starter Solenoid
G2 — Alternator Y2 — Fuel Shut-off Solenoid
H1 — Coolant Temperature Indicator Lamp BLK — Black
H2 — Oil Pressure Indicator Lamp BLU — Blue
H3 — Alternator Indicator Lamp BRN — Brown
K1 — Starter Relay DK BLU — Dark Blue
M1 — Starter Motor GRN — Green
P1 — Coolant Temperature Gauge ORG — Orange
P2 — Oil Pressure Gauge PUR — Purple
P3 — Crankcase Oil Level Switch/Gauge RED — Red
P4 — Tachometer1 YEL — Yellow
P5 — Hourmeter (Early Models)2
1
P4 tachometer has a built-in hourmeter. On some earlier engines,
a separate hourmeter (P5) and fuse (F3) were used.
2
P4 tachometer has a built-in hourmeter. On some engines, a
separate hourmeter (P5) and fuse (F3) are used.
3
Later harnesses have two parallel 100 ohm resistors for the alternator.
DPSG,RG41165,126 -19-19JUN00-1/1
50-3 081922
PN=104
Troubleshooting
Wiring Diagram (Standard Instrument Panel For North America)
RG11329 —UN—13SEP00
DPSG,RG41165,127 -19-19JUN00-1/1
50-4 081922
PN=105
Troubleshooting
Engine Wiring Diagram—VDO Instrument Panel (Except North America)
CD623P5 —UN—13NOV98
DPSG,RG41165,131 -19-19JUN00-1/1
50-5 081922
PN=106
Troubleshooting
Engine Wiring Diagram Legend—VDO Instrument Panel (Except North America)

A — 6 mm2, Red M — 0.75 mm2, Green/Yellow
B — 1.5 mm2, Black N — 0.75 mm2, Red
C — 6 mm2, Blue O—R — Not Used
D — 4 mm2, Black S — Preheater
E — 0.75 mm2, Orange T — Battery
F — 0.75 mm2, White U — Starter Motor
G — 0.75 mm2, Blue V — Electrical Shut-Off
H — 0.75 mm2, Purple W — Alternator
I — 0.75 mm2, Grey X — Oil Pressure Sensor
J — 0.75 mm2, Brown Y — Coolant Temperature Sensor
K — 0.75 mm2, Dark Blue Z — Fuel Tank Gauge
L — 0.75 mm2, Black
DPSG,RG41165,129 -19-19JUN00-1/1
50-6 081922
PN=107
Troubleshooting
Engine Troubleshooting
Symptom Problem Solution
Engine cranks but will not start Incorrect starting procedure. Verify correct starting procedure.
No fuel. Check fuel in tank and manual

shut-off valve.
Exhaust restricted. Check and correct exhaust restriction.
Fuel filter plugged or full of water. Replace fuel filter or drain water from
filter.
Injection pump not getting fuel or air Check fuel flow at supply pump or
in fuel system. bleed fuel system.
Faulty injection pump or nozzles. Consult authorized diesel repair

station for repair or replacement.
Engine hard to start or will not start Engine starting under load. Disengage driveline.
Improper starting procedure. Review starting procedure.
No fuel. Check fuel tank.
Air in fuel line. Bleed fuel line.
Cold weather. Use cold weather starting aids.
Slow starter speed. See “Starter Cranks Slowly”.
Crankcase oil too heavy. Use oil of proper viscosity.
Improper type of fuel. Consult fuel supplier; use proper type

fuel for operating conditions.
Water, dirt, or air in fuel system. Drain, flush, fill, and bleed system.
Clogged fuel filter. Replace filter element.
Dirty or faulty injection nozzles. Have authorized servicing dealer or

engine distributor check injectors.
Injection pump shut-off not reset. Turn key switch to “OFF” then to “ON”.
Engine knocks Low engine oil level. Add oil to engine crankcase.
Continued on next page OUOD006,000004C -19-13OCT06-1/5
50-7 081922
PN=108
Troubleshooting
Injection pump out of time. See your authorized servicing dealer

or engine distributor.
Low coolant temperature. Remove and check thermostat.
Engine overheating. See “Engine Overheats”.
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.
Poor quality fuel. Change to better quality fuel.

Below normal engine temperature Defective thermostat. Remove and check thermostat.
Defective temperature gauge or Check gauge, sender, and

sender. connections.
Lack of power Engine overloaded. Reduce load.
Intake air restriction. Service air cleaner.
Clogged fuel filter. Replace filter elements.
Improper type of fuel. Use proper fuel.
Overheated engine. See “Engine Overheats”.
Below normal engine temperature. Remove and check thermostat.
Improper valve clearance. See your authorized servicing dealer


Injection pump out of time. See your authorized servicing dealer

Turbocharger not functioning. See your authorized servicing dealer

(Turbocharger engines only.) or engine distributor.
50-8 081922
PN=109
Troubleshooting
Leaking exhaust manifold gasket. See your authorized servicing dealer

Defective aneroid control line. See your authorized servicing dealer

Restricted fuel hose. Clean or replace fuel hose.
Low fast idle speed. See your authorized servicing dealer

Low oil pressure Low oil level. Add oil.
Improper type of oil. Drain, fill crankcase with oil of proper

viscosity and quality.
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

Engine emits white smoke Improper type of fuel. Use proper fuel.
Low engine temperature. Warm up engine to normal operating

temperature.
Defective thermostat. Remove and check thermostat.
Defective injection nozzles. See your authorized servicing dealer

Engine out of time. See your authorized servicing dealer

Engine emits black or gray exhaust Improper type of fuel. Use proper fuel.
smoke
Clogged or dirty air cleaner. Service air cleaner.
Engine overloaded. Reduce load.
Injection nozzles dirty. See your authorized servicing dealer

50-9 081922
PN=110
Troubleshooting

Turbocharger not functioning. See your authorized servicing dealer

Engine overheats Engine overloaded. Reduce load.
Low coolant level. Fill radiator to proper level, check

radiator and hoses for loose
connections or leaks.
Faulty radiator cap. Have serviceman check.
Stretched poly-vee belt or defective Check automatic belt tensioner and

belt tensioner. check belts for stretching. Replace
as required.
Low engine oil level. Check oil level. Add oil as required.
Cooling system needs flushing. Flush cooling system.
Defective thermostat. Remove and check thermostat.
Defective temperature gauge or Check water temperature with

sender. thermometer and replace, if
necessary.
Incorrect grade of fuel. Use correct grade of fuel.
High fuel consumption Improper type of fuel. Use proper type of fuel.
Clogged or dirty air cleaner. Service air cleaner.
Engine overloaded. Reduce load.
Improper valve clearance. See your authorized servicing dealer

Injection nozzles dirty. See your authorized servicing dealer


Defective turbocharger. See your authorized servicing dealer

50-10 081922
PN=111
Troubleshooting
Low engine temperature. Check thermostat.
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.
Defective battery. Test battery.
Defective alternator. Test charging system.
Battery uses too much water Cracked battery case. Check for moisture and replace as
necessary.
Defective battery. Test battery.
Battery charging rate too high. Test charging system.
Batteries will not charge Loose or corroded connections. Clean and tighten connections.
Sulfated or worn-out batteries. See your authorized servicing dealer

Stretched poly-vee belt or defective Adjust belt tension or replace belts.

belt tensioner.
Starter will not crank Engine driveline engaged. Disengage engine driveline.
Loose or corroded connections. Clean and tighten loose connections.
Low battery output voltage. See your authorized servicing dealer

Faulty start circuit relay. See your authorized servicing dealer

Blown main system fuse (MDL-25) Replace fuse.
Starter cranks slowly Low battery output. See your authorized servicing dealer
Crankcase oil too heavy. Use proper viscosity oil.
Loose or corroded connections. Clean and tighten loose connections.
OUOD006,000004C -19-13OCT06-5/5
50-11 081922
PN=112
Troubleshooting
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
Blown main system fuse (MDL-25). Replace fuse.
OUOD006,000004C -19-13OCT06-6/5
50-12 081922
PN=113
Storage
Engine Storage Guidelines
IMPORTANT: Special considerations should be 3. John Deere engines can be stored inside for up to six
taken prior to storage when using BioDiesel. months with no long-term preparation.
See BioDiesel Fuel in the Fuels, Lubricants,
and Coolant Section. 4. John Deere engines expected to be stored more than
six months must have long-term storage preparation.
1. John Deere engines can be stored outside for up to See Preparing Engine for Long-Term Storage in the
three months with no long-term preparation if covered Storage Section.
by a waterproof covering. No outside storage is
recommended without a waterproof covering.
2. John Deere engines can be stored in a standard
overseas shipping container for up to three months
with no long-term preparation.
OURGP12,00000DF -19-04FEB15-1/1
55-1 081922
PN=114
Storage
Preparing Engine for Long-Term Storage

IMPORTANT: Any time the engine is not used for over
six months, the following recommendations for
storing it and removing it from storage helps
to minimize corrosion and deterioration.
IMPORTANT: Long-term storage is not advised when
RG35531 —UN—22MAR22
using BioDiesel. For storage longer than one
year, use straight hydrocarbon fuel.
If BioDiesel must be used it is recommended
the blend not exceed B7 and a high-quality
fuel stabilizer be used. Storage should
not exceed one year.
For more information see BioDiesel Fuel in the
Fuels, Lubricants, and Coolants Section.
NOTE: The following storage preparations are used for

long-term engine storage up to one year. After
that, the engine should be started, warmed up, and
retreated for an extended storage period.
1. Change engine oil and replace filter. Used oil does

not give adequate protection. Add 30 mL of rust
preventive oil to the engine crankcase for every 1 L of
engine oil, or 1 oz. of rust preventative oil per 1 qt. of
engine oil. This rust preventive oil should be an SAE
10W oil with 1%-4% morpholine or equivalent vapor
corrosion inhibitor, such as NOX RUST VCI-10 OIL
from Daubert Chemical Company, Inc.
2. Replace air cleaner.
IMPORTANT: Avoid damage to the engine cooling
system components. Engine cooling system
must be drained, flushed, and refilled for
prolong storage of more than one year.
3. Draining and flushing of cooling system is not

necessary if the engine is only stored for less than one
RG35532 —UN—22MAR22
year. However, for extended storage periods of a year
or longer, it is recommended that the cooling system
be drained, flushed, and refilled. Refill with appropriate
coolant. See Diesel Engine Coolant (engine with wet
sleeve cylinder liners) in the Fuels, Lubricants, and
Coolants Section.
4. Prepare a solution of diesel fuel and rust preventive oil Effects of Prolong Storage of Coolant — More Than One Year
in a temporary container, add 78 mL of rust preventive
oil per 1 L of diesel fuel, 10 oz. of rust preventive oil 6. Crank the engine several revolutions with starter.
per 1 gal. of diesel fuel. Do not allow the engine to start. This allows rust
preventive oil solution to circulate.
5. Remove existing lines and plugs as required. Run a
temporary line from the temporary container to the See your authorized dealer for the proper procedure
engine fuel intake before the fuel filters, and another for your application.
temporary line from the fuel return to the temporary
container, so rust preventive oil solution is circulated 7. Remove temporary lines installed in Step 5 and
through the injection system during cranking. replace any lines or plugs previously removed.
IMPORTANT: Do not operate starter more than 30 8. Loosen (or remove) and store fan and alternator
seconds at a time. Wait at least 2 minutes for poly-vee belt.
starter to cool before trying again.
Continued on next page OUOD006,00000FC -19-23MAR22-1/2
55-2 081922
PN=115
Storage
9. Remove and clean batteries. Store them in a cool, dry 13. Seal all openings on engine with plastic bags and tape.
place and keep them fully charged.
14. Store the engine in a dry protected place. If engine
10. Disengage the clutch for any driveline. must be stored outside, cover it with a waterproof
canvas or other suitable protective material and use
11. Clean the exterior of the engine with salt-free water a strong waterproof tape.
and touch up any scratched or chipped painted
surfaces with a good quality paint.
12. Coat all exposed bare metal surfaces with grease or
corrosion inhibitor if not feasible to paint.
OUOD006,00000FC -19-23MAR22-2/2
Removing Engine from Long Term Storage

Refer to the appropriate section for detailed services IMPORTANT: DO NOT operate starter more than 30
listed below or have your authorized servicing dealer or seconds at a time. Wait at least 2 minutes for
engine distributor perform services that you may not be starter to cool before trying again.
familiar with.
1. Remove all protective coverings from engine. Unseal 6. Crank engine for 20 seconds with starter (do not allow
all openings in engine and remove covering from the engine to start). Wait 2 minutes and crank engine
electrical systems. an additional 20 seconds to assure bearing surfaces
are adequately lubricated.
2. Remove the batteries from storage. Install batteries
(fully charged) and connect the terminals. 7. Start engine and run at low idle and no load for several
minutes. Warm up carefully and check all gauges
3. Install fan/alternator poly-vee belt if removed. before placing engine under load.
4. Fill fuel tank. 8. On the first day of operation after storage, check
overall engine for leaks and check all gauges for
5. Perform all appropriate prestarting checks. ( See
correct operation.
DAILY PRESTARTING CHECKS in Lubrication and
Maintenance/Daily Section.) NOTE: If using BIODIESEL blends after long term storage,
frequency of fuel filter plugging may increase initially.
OUOD006,00000FD -19-02OCT07-1/1
55-3 081922
PN=116
Specifications
General OEM Engine Specifications — 4.5
L Engines
ITEM 4045 (4.5 L) 4045 (4.5 L)
(Naturally Aspirated) (Turbocharged)
Number of Cylinders 4 4
Bore 106 mm (4.19 in.) 106 mm (4.19 in.)
Stroke 127 mm (5.0 in.) 127 mm (5.0 in.)
Displacement 4.5 L 4.5 L
(276 cu in.) (276 cu in.)
Compression Ratio 17.6:1 17.0:1
Max. Crank Pressure 0.5 kPa 0.5 kPa
(2 H2O) (2 H2O)
Governor Regulation (Industrial) 7—10 % 7—10 %
Governor Regulation (Generator) 5 % 5 %
Oil Pressure, Rated Speed, Full Load (±15 psi) 345 kPa (50 psi) 345 kPa (50 psi)
Oil Pressure, Low Idle (Minimum) 105 kPa (15 psi) 105 kPa (15 psi)
Lengtha 844.0 mm (33.2 in.) 861.0 mm (33.9 in.)
Widtha 550 mm (21.7 in.) 598 mm (23.5 in.)
a
Height 871 mm (34.3 in.) 980 mm (38.6 in.)
a
Weight 429 kg (945 lb) 396 kg (872 lb)
a
Measurement may vary depending on installed options
OURGP12,0000041 -19-20AUG15-1/1
General OEM Engine Specifications — 6.8

L Engines
6068 (6.8 L) 6068 (6.8 L)
ITEM
(Naturally Aspirated) (Turbocharged)
Number of Cylinders 6 6
Bore 106 mm (4.19 in.) 106 mm (4.19 in.)
Stroke 127 mm (5.0 in.) 127 mm (5.0 in.)
Displacement 6.8 L 6.8 L
(414 cu in.) (414 cu in.)
Compression 17.6:1 17.0:1
Max. Crank Pressure 0.5 kPa 0.5 kPa
(2 H2O) (2 H2O)
Governor Regulation (Industrial) 7—10 % 7—10 %
Governor Regulation (Generator) 5 % 5%
Oil Pressure At Rated Speed, Full Load (±15 psi) 345 kPa (50 psi) 345 kPa (50 psi)
Oil Pressure At Low Idle (Minimum) 105 kPa (15 psi) 105 kPa (15 psi)
a
Length 1117 mm (44.0 in.) 1141 mm (44.9 in.)
a
Width 598 mm (23.5 in.) 623 mm (24.5 in.)
a
Height 956 mm (37.6 in.) 1009 mm (39.7 in.)
Weighta 522 kg (1149 lb) 568 kg (1250 lb)
a
Measurement may vary depending on installed options
OURGP12,0000042 -19-20AUG15-1/1
60-1 081922
PN=117
Specifications
Engine Power Ratings And Fuel Injection Pump Specifications — 4.5 L Engines
NOTE: The power specifications shown below apply to application requirements. Refer to your machine
Dubuque, Torreon and Saran-built OEM engines. technical manual for engine speeds that are
Specifications are subject to change. Refer different from those preset at the factory.
to factory DTAC for assistance.
Power ratings specify flywheel power for a bare
Engine speeds listed are as preset to factory engine without the drag effect of a cooling fan or
specification. In most cases, slow idle speed other accessories like an air compressor.
will be reset depending upon specific vehicle
POWER RATINGS ON DYNAMOMETER FOR OEM ENGINES

Original Replaced
Injection Injection By Injection Rated Speed
Pump Option Pump (Part Pump (Part Governor (rpm) At Full Slow Idle No Load Fast Power Rating
Code No.) No.) Regulation Load (rpm) Idle (rpm) kW (HP)
1601 RE61649 RE67557 STD 2500 850 2700 60 (80)
1601 RE67557 STD 2500 850 2700 60 (80)
1602 RE59809 STD 2500 850 2700 63 (85)
1603 RE63555 RE67558 3—5% 1800 1150 1870 53 (71)
1603 RE67558 RE505070 3—5% 1800 1150 1870 53 (71)
1603 RE505070 RE506132 3—5% 1800 1150 1870 53 (71)
1603 RE506132 3—5% 1800 1150 1870 53 (71)
1605 RE61668 RE69781 STD 2500 850 2700 86 (115)
1605 RE69781 STD 2500 850 2700 86 (115)
1606 RE64133 RE505927 STD 2400 850 2600 93 (125)
1606 RE505927 STD 2400 850 2600 93 (125)
1608 RE67564 3—5% 1800 1400 1870 84 (113)
1610 RE68826 RE505928 STD 2400 850 2600 104 (140)
1611 RE60237 3—5% 1800 1400 1870 95 (127)
1656 RE63610 RE67562 3—5% 1800 1150 1870 75 (100)
1656 RE67562 3—5% 1800 1150 1870 75 (100)
1663 RE71089 RE500949 STD 2500 1600 2700 60 (80)
1663 RE500949 STD 2500 1600 2700 60 (80)
1667 RE59968 STD 2400 850 2600 93 (125)
1675 RE60091 RE69782 STD 2500 850 2700 86 (115)
1675 RE69782 STD 2500 850 2700 86 (115)
1676 RE60093 RE61668 STD 2500 850 2700 86 (115)
1676 RE61668 STD 2500 850 2700 86 (115)
1677 RE60096 RE67563 3—5% 1800 1150 1870 75 (100)
1677 RE67563 3—5% 1800 1150 1870 75 (100)
1671 RE67559 RE502714 STD 2500 850 2700 60 (80)
1671 RE502714 STD 2500 850 2700 60 (80)
1673 RE60085 RE67560 3—5% 1800 1400 1870 53 (71)
1673 RE67560 RE506130 3—5% 1800 1400 1870 53 (71)
1673 RE506130 3—5% 1800 1400 1870 53 (71)
1674 RE60089 RE67561 3—5% 1800 1400 1870 53 (71)
Continued on next page BL90236,0000001 -19-26MAR21-1/4
60-2 081922
PN=118
Specifications

Original Replaced
1674 RE67561 RE506131 3—5% 1800 1400 1870 53 (71)
1674 RE506131 3—5% 1800 1400 1870 53 (71)
1677 RE60096 RE67563 3—5% 1800 850 1870 75 (100
1677 RE67563 3—5% 1800 850 1870 75 (100
1682 RE67566 3—5% 1800 1400 1870 84 (113)
1683 RE60124 RE505926 STD 2400 850 2600 93 (125)
1683 RE505926 STD 2400 850 2600 93 (125)
1691 RE61649 RE500831 STD 2500 850 2700 60 (80)
1691 RE500831 RE500948 STD 2500 850 2700 60 (80)
1691 RE500948 STD 2500 850 2700 60 (80)
1692 RE61668 RE500881 STD 2500 1400 2700 86 (115)
1692 RE500881 RE502416 STD 2500 1400 2700 86 (115)
1692 RE502416 STD 2500 1400 2700 86 (115)
1694 RE67863 RE69779 STD 2500 850 2700 75 (100)
1694 RE69779 STD 2500 850 2700 75 (100)
1695 RE69739 RE69780 STD 2500 850 2700 75 (100)
1695 RE69780 STD 2500 850 2700 75 (100)
160B RE68827 3—5% 1800 1400 1870 95 (127)
160C RE69588 RE505959 STD 2400 850 2600 104 (140)
160R RE70941 3—5% 1800 1400 1870 84 (113)
161A RE509525 STD 2100 850 2200 107 (143)
161B RE509526 STD 2100 850 2200 107 (143)
161C RE507525 RE506881 3—5% 1800 1400 1870 100 (134)
161D RE507526 RE506882 3—5% 1800 1400 1870 100 (134)
163Z RE505927 STD 2400 850 2600 93 (125)
165D RE506989 3—5% 1500 — 1560 70 (94)
165E RE506990 3—5% 1500 — 1560 70 (94)
165F RE503729 3—5% 1500 — 1560 44 (59)
165G RE504693 3—5% 1500 — 1560 44 (59)
165W RE500949 STD 2500 1600 2700 60 (80)
168Q RE521143 3—5% 1500 — 1560 83 (111)
168R RE522388 3—5% 1500 — 1560 83 (111)
169E RE522414 3—5% 3000 850 3120 152 (204)
169F RE522698 3—5% 3000 850 3120 152 (204)
169P RE522714 3—5% 3000 850 3120 119 (160)
169Q RE522697 3—5% 3000 850 3120 119 (160)
16AB RE69779 STD 2500 850 2700 75 (100)
16AX RE500551 STD 2400 850 2600 76 (102)
16AY RE500505 STD 2400 850 2600 62 (83)
60-3 081922
PN=119
Specifications

Original Replaced
16BF RE500848 STD 2200 950 2400 73 (98)
16BG RE69778 RE502712 STD 2500 850 2700 63 (85)
16BG RE502712 STD 2500 850 2700 63 (85)
16BH RE500873 RE502715 STD 2500 850 2700 63 (85)
16BH RE502715 STD 2500 850 2700 63 (85)
16BJ RE500589 STD 2250 850 2450 36 (48)
16CE RE501180 STD 2500 850 2700 75 (100)
16CL RE501364 RE502713 STD 2200 950 2400 58 (78)
16CL RE502713 STD 2200 950 2400 58 (78)
16CM RE501365 STD 2200 950 2400 66.6 (89)
16CU RE501192 STD 2200 850 2400 79.5 (107)
16CV RE501346 STD 2200 950 2400 85 (114)
16DL RE70452 STD 2400 850 2600 61 (82)
16EN RE502019 STD 2500 850 2700 60 (80)
16GB RE502711 STD 2500 850 2700 60 (80)
16GB RE502711 STD 2500 850 2700 60 (80)
16GC RE502716 STD 2500 850 2700 60 (80)
16GL RE502706 STD 2300 850 2500 78 (105)
16GQ RE503048 RE506544 3—5% 1500 — 1560 83 (111)
16GQ RE506544 3—5% 1500 — 1560 83 (111)
16GR RE503050 RE506965 3—5% 1500 — 1560 102 (137)
16GR RE503050 RE506965 3—5% 1500 — 1560 102 (137)
16HJ RE500948 STD 2500 1400 2700 60 (80)
16HK RE500949 STD 2500 1600 2700 60 (80)
16HV RE503258 STD 2250 850 2450 36 (48)
16JS RE500505 STD 2400 850 2600 62 (83)
16JT RE500551 STD 2400 850 2600 76 (102)
16KE RE503560 STD 2500 850 2700 52 (70)
16LM RE502711 STD 2500 850 2700 53 (71)
16LN RE67558 RE505070 3—5% 1800 1150 1870 53 (71)
16LN RE505070 RE506132 3—5% 1800 1150 1870 53 (71)
16LN RE506132 3—5% 1800 1150 1870 53 (71)
16LP RE67562 3—5% 1800 1150 1870 75 (100)
16LQ RE67564 3—5% 1800 1400 1870 84 (113)
16LV RE503830 RE506545 3—5% 1500 — 1560 83 (111)
16LV RE506545 3—5% 1500 — 1560 83 (111)
16LZ RE503735 3—5% 1800 — 1870 82 (110)
16LW RE503832 RE506966 3—5% 1500 — 1560 102 (137)
16LW RE506966 3—5% 1500 — 1560 102 (137)
60-4 081922
PN=120
Specifications

Original Replaced
16LZ RE503735 3—5% 1800 1400 1870` 70 (94)
16MA RE504696 RE504931 3—5% 1800 1400 1870 82 (110)
16MA RE504931 3—5% 1800 1400 1870 82 (110)
16MB RE503737 3—5% 1800 1400 1870 91(122)
16MC RE504932 3—5% 1800 1400 1870 91 (122)
16ME RE503739 3—5% 1800 1400 1870 123 (165)
16MF RE504698 RE504966 3—5% 1800 1400 1870 123 (170)
16MF RE504966 3—5% 1800 1400 1870 123 (170)
16MR RE504463 STD 2500 850 2700 63 (85)
16MS RE504464 STD 2500 850 2700 63 (85)
16MT RE503733 RE505050 3—5% 1500 1400 1560 70 (94)
16MT RE505050 3—5% 1500 1400 1560 70 (94)
16MT RE503733 RE506989 3—5% 1500 — 1560 70 (94)
16MT RE506989 3—5% 1500 — 1560 70 (94)
16MU RE504695 RE505050 3—5% 1500 — 1560 70 (94)
16MU RE505050 RE506990 3—5% 1500 — 1560 70 (94)
16MU RE506990 3—5% 1500 — 1560 70 (94)
16MV RE503736 3—5% 1800 1400 1870 100 (134)
16MW RE504682 3—5% 1800 1400 1870 100 (134)
16NH RE505411 3—5% 1800 1150 2240 75 (100)
16NT RE504465 STD 2500 850 2700 86 (115)
16NU RE504466 STD 2500 850 2700 86 (115)
16PZ RE500848 STD 2200 850 2400 73 (98)
16QZ RE503050 3—5% 1800 1400 1870 111 (149)
16RA RE503832 3—5% 1800 1400 1870 111 (149)
16RB RE503729 3—5% 1500 — 1560 44 (59)
16RC RE504693 3—5% 1500 — 1560 44 (59)
16RM RE505959 STD 2400 850 2600 104 (140)
16TE RE507257 STD 2400 850 2600 85 (114)
16TG RE507941 STD 2000 850 2185 77 (103)
16VC ETN183028 3—5% 1500 — 1560 103 (134)
16VD ETN183029 3—5% 1800 — 1860 115 (154)
16VE ETN183030 3—5% 1500 — 1560 103 (134)
16VF ETN183031 3—5% 1800 — 1860 115 (154)
16YJ RE508834 STD 2000 850 2185 77 (103)
16YU RE508754 3—5% 1800 — 1870 75 (101)
16ZC RE518780 STD 2200 950 2400 66 (89)
16ZW
(Naturally
aspirated) RE509527 3—5% 2500 850 2700 63 (85)
BL90236,0000001 -19-26MAR21-4/4
60-5 081922
PN=121
Specifications

Original Replaced
16ZW RE509527 3—5% 1500 1400 1560 70 (94)
16ZX (Naturally
aspirated) RE509528 3—5% 2500 850 2700 63 (85)
16ZX RE509528 3—5% 1500 1400 1560 70 (94)
16ZY (Naturally
aspirated) RE509529 3—5% 2500 850 2700 63 (85)
16ZY RE509529 3—5% 1500 1400 1560 70 (94)
16ZZ RE508613 STD 2100 850 2200 107 (143)
BL90236,0000001 -19-26MAR21-5/4
60-6 081922
PN=122
Specifications
Engine Power Ratings And Fuel Injection Pump Specifications — 6.8 L Engines

Original Replaced
1611 ETN246579 3—5% 1800 — 1860 164 (220)
1613 RE59861 STD 2500 850 2700 93 (125)
1614 RE61669 RE69789 STD 2500 850 2700 127 (170)
1614 RE69789 STD 2500 850 2700 127 (170)
1615 RE62366 RE69791 STD 2400 850 2600 138 (185)
1615 RE69791 STD 2400 850 2600 138 (185)
1619 ETN246580 3—5% 1800 — 1860 164 (220)
1619 RE67573 3—5% 1800 1150 1870 124 (166)
1621 RE66575 RE505930 STD 2400 850 2600 157 (210)
1621 RE505930 STD 2400 850 2600 157 (210)
a
1622 RE59521 STD 2400 850 2600 168 (225)
1623 RE66761 a
3—5% 1800 — 1870 148 (198)
1626 ETN246581 3—5% 1800 — 1860 195 (261)
1629 ETN246582 3—5% 1800 — 1860 195 (261)
a
1668 RE59969 STD 2400 850 2600 138 (185)
1678 RE60101 STD 2500 850 2700 93 (125)
1680 RE60105 RE69790 STD 2500 850 2700 127 (170)
1680 RE69790 STD 2500 850 2700 127 (170)
1681 RE60107 RE67571 3—5% 1800 1150 1870 112 (150)
1681 RE67571 3—5% 1800 1150 1870 112 (150)
1685 RE67574 3—5% 1800 1150 1870 124 (166)
1686 RE60131 RE69792 STD 2400 850 2600 138 (185)
1686 RE69792 STD 2400 850 2600 138 (185)
1688 RE67572 3—5% 1800 1150 1870 112 (150)
1696 RE67864 RE69787 STD 2500 850 2700 116 (155)
1696 RE69787 STD 2500 850 2700 116 (155)
1697 RE68740 RE69788 STD 2500 850 2700 116 (155)
1697 RE69788 STD 2500 850 2700 116 (155)
160D RE69589 RE505962 STD 2400 850 2600 157 (210)
160D RE505962 STD 2400 850 2600 157 (210)
163D RE516159 STD 2200 850 2400 125 (168)
60-7 081922
PN=123
Specifications

Original Replaced
165H RE503740 3—5% 1500 — 1560 105 (141)
165J RE505052 3—5% 1500 — 1560 105 (141)
165K RE503049 3—5% 1500 — 1560 120 (161)
165L RE503834 3—5% 1500 — 1560 120 (161)
168Z RE522415 3—5% 3000 850 3120 225 (302)
169A RE522694 3—5% 3000 850 3120 225 (302)
169A RE522809 3—5% 2200 850 2400 129 (173)
16AZ RE522808 3—5% 2800 850 3000 226 (303)
16BE RE63559 RE501302 STD 2200 950 2400 117 (157)
16BE RE501302 STD 2200 950 2400 117 (157)
16BU RE547841 3—5% 1500 — 1555 183 (245)
16CN RE501522 RE509681 STD 2100 950 2300 110.5 (148)
16CN RE509681 STD 2100 950 2300 110.5 (148)
16CP RE501523 STD 2200 950 2400 94 (126)
16CY RE501345 STD 2200 1350 2400 143 (192)
16CW RE501344 STD 2200 950 2400 106 (142)
16CX RE70390 STD 2300 900 2500 128 (172)
16DK RE70938 STD 2100 900 2300 96 (129)
16DY RE501758 STD 2500 850 2700 116 (155)
16GM RE502693 STD 2300 850 2500 110 (148)
16GN RE502704 STD 2400 850 2600 116 (155)
16GS RE503049 3—5% 1500 — 1560 121 (162)
16GT RE503051 3—5% 1500 — 1560 155 (208)
16JU RE69787 STD 2500 850 2700 116 (155)
16KK RE502694 STD 2500 850 2700 127 (170)
16LR RE59861 STD 2500 850 2700 93 (125)
16LS RE67572 3—5% 1800 1150 1870 112 (150)
16LT RE69791 STD 2400 850 2600 138 (185)
16LU RE67573 3—5% 1800 1150 1870 124 (166)
16LX RE503834 3—5% 1500 — 1560 121 (162)
16LX RE503836 3—5% 1500 1400 1560 121 (162)
16LX RE503834 3—5% 1500 — 1560 155 (208)
16LY RE503834 3—5% 1500 1400 1560 155 (208)
16LY RE503836 3—5% 1500 — 1560 153 (205)
16MG RE503742 3—5% 1800 — 1870 123 (165)
16MH RE504966 RE504967 3—5% 1800 — 1870 123 (165)
16MH RE504967 3—5% 1800 — 1870 123 (165)
16MJ RE503744 3—5% 1800 — 1870 142 (190)
16MK RE504701 RE504968 3—5% 1800 — 1870 142 (190)
60-8 081922
PN=124
Specifications

Original Replaced
16MK RE504968 3—5% 1800 — 1870 142 (190)
16ML RE503746 3—5% 1800 1400 1870 187 (251)
16ML RE503746 3—5% 1800 1400 1870 187 (251)
16MM RE504702 RE505049 3—5% 1800 1400 1870 187 (251)
16MM RE505049 3—5% 1800 1400 1870 187 (251)
16MX RE503740 3—5% 1500 — 1560 105 (141)
16MY RE504699 RE505052 3—5% 1500 — 1560 105 (141)
16MY RE505052 3—5% 1500 — 1560 105 (141)
16NJ RE505358 3—5% 1800 1150 1870 112 (150)
16PD RE70938 STD 2100 850 2250 96 (129)
16QV RE503051 3—5% 1800 1400 1870 166 (223)
16QW RE503836 3—5% 1800 1400 1870 166 (223)
16RJ RE506084 3—5% 2100 950 2200 172 (231)
16RK RE506083 3—5% 2600 850 2700 138 (185)
16RL RE506085 3—5% 2100 950 2200 197 (264)
16SG RE506625 3—5% 2100 950 2200 172 (231)
16SH RE506626 3—5% 2600 850 2700 138 (185)
16SJ RE506627 3—5% 2100 950 2200 197 (264)
16TM RE506885 3—5% 1800 — 1870 210 (282)
16TN RE506886 3—5% 1800 — 1870 210 (282)
16TP RE506883 3—5% 1500 1150 1560 183 (245)
16TQ RE506884 3—5% 1500 1150 1560 183 (245)
16TV RE506398 STD 2400 800 2550 168 (225)
16UG RE506956 RE504321 STD 2400 925 2600 149(200)
16UG RE504321 STD 2400 925 2600 149 (200)
16VM ETN142172 3—5% 1500 — 1560 200 (268)
16VN ETN142173 3—5% 1800 — 1860 200 (268)
16VP ETN142174 3—5% 1500 — 1560 200 (268)
16VU ETN142175 3—5% 1800 — 1860 200 (268)
16YH RE59969 STD 2400 850 2600 138 (185)
16ZH RE62366 STD 2400 850 2600 138 (185)
16ZL RE509424 3—5% 2100 950 2200 172 (231)
16ZM RE509425 3—5% 2100 950 2200 172 (231)
16ZN RE509426 STD 2600 850 2800 138 (185)
16ZP RE509427 STD 2600 850 2800 138 (185)
16ZQ RE509428 3—5% 2100 950 2200 197 (264)
16ZR RE509429 3—5% 2100 950 2200 197 (264)
a
In-line fuel injection pump.
BL90236,0000002 -19-26MAR21-3/3
60-9 081922
PN=125
Specifications
Engine Power Ratings And Fuel Injection Pump Specifications


Injection Original Replaced
Pump Injection By Injection Rated No Load Power
Option Pump (Part Pump (Part Governor Speed (rpm) Slow Idle Fast Idle Rating
Engine Model Code No.) No.) Regulation At Full Load (rpm) (rpm) kW (HP)
4045DF120 16MR RE504463 STD 2500 850 2700 63 (85)
16MS RE504464 STD 2500 850 2700 63 (85)
165F RE503729 3—5% 1500 — 1560 44 (59)
165G RE504693 3—5% 1500 — 1560 44 (59)
16RB RE503729 3—5% 1500 — 1560 44 (59)
16RC RE504693 3—5% 1500 — 1560 44 (59)
16ZW RE509527 3—5% 2500 850 2700 63 (85)
16ZX RE509528 3—5% 2500 850 2700 63 (85)
16ZY RE509529 3—5% 2500 850 2700 63 (85)
4045DF150 1601 RE61649 RE67557 STD 2500 850 2700 60 (80)
1601 RE67557 STD 2500 850 2700 60 (80)
1602 RE59809 STD 2500 850 2700 63 (85)
1603 RE63555 RE67558 3—5% 1800 1150 1870 53 (71)
1603 RE67558 RE505070 3—5% 1800 1150 1870 53 (71)
1603 RE505070 RE506132 3—5% 1800 1150 1870 53 (71)
1603 RE506132 3—5% 1800 1150 1870 53 (71)
1663 RE71089 RE500949 STD 2500 1600 2700 60 (80)
1663 RE500949 STD 2500 1600 2700 60 (80)
1671 RE67559 RE502714 STD 2500 850 2700 60 (80)
1671 RE502714 STD 2500 850 2700 60 (80)
1673 RE60085 RE67560 3—5% 1800 1400 1870 53 (71)
1673 RE67560 RE506130 3—5% 1800 1400 1870 53 (71)
1673 RE506130 3—5% 1800 1400 1870 53 (71)
1674 RE60089 RE67561 3—5% 1800 1400 1870 53 (71)
1674 RE67561 RE506131 3—5% 1800 1400 1870 53 (71)
1674 RE506131 3—5% 1800 1400 1870 53 (71)
1691 RE61649 RE500831 STD 2500 850 2700 60 (80)
1691 RE500831 RE500948 STD 2500 850 2700 60 (80)
1691 RE500948 STD 2500 850 2700 60 (80)
16BG RE69778 RE502712 STD 2500 850 2700 63 (85)
16BG RE502712 STD 2500 850 2700 63 (85)
60-10 081922
PN=126
Specifications

16BH RE500873 RE502715 STD 2500 850 2700 63 (85)
16BH RE502715 STD 2500 850 2700 63 (85)
16BJ RE500589 STD 2250 850 2450 36 (48)
16CL RE501364 RE502713 STD 2200 950 2400 58 (78)
16CL RE502713 STD 2200 950 2400 58 (78)
16DL RE70452 STD 2400 850 2600 61 (82)
16EN RE502019 STD 2500 850 2700 60 (80)
16GB RE502711 STD 2500 850 2700 60 (80)
16GC RE502716 STD 2500 850 2700 60 (80)
16HJ RE500948 STD 2500 1400 2700 60 (80)
16HK RE500949 STD 2500 1600 2700 60 (80)
16HV RE503258 STD 2250 850 2450 36 (48)
16KE RE503560 STD 2500 850 2700 52 (70)
16LM RE502711 STD 2500 850 2700 53 (71)
16LN RE67558 RE505070 3—5% 1800 1150 1870 53 (71)
16LN RE505070 RE506132 3—5% 1800 1150 1870 53 (71)
16LN RE506132 3—5% 1800 1150 1870 53 (71)
16RB RE503729 3—5% 1500 1400 1560 44 (59)
16RC RE504693 3—5% 1500 1400 1560 44 (59)
165W RE500949 STD 2500 1600 2700 60 (80)
4045DF151 1663 RE71089 RE500949 STD 2500 1600 2700 60 (80)
1663 RE500949 STD 2500 1600 2700 60 (80)
4045DF152 1601 RE67557 STD 2500 850 2700 60 (80)
16GB RE502711 STD 2500 850 2700 60 (80)
4045DF154 16AY RE500505 STD 2400 850 2600 62 (83)
16JS RE500505 STD 2400 850 2600 62 (83)
4045HF120 16GR RE503050 RE506965 3—5% 1500 1400 1560 102 (137)
16LW RE503832 RE506966 3—5% 1500 1400 1560 102 (137)
4045HF150 1610 RE68826 RE505928 STD 2400 850 2600 104 (140)
1611 RE60237 3—5% 1800 1400 1870 95 (127)
160B RE68827 3—5% 1800 1400 1870 95 (127)
160C RE69588 RE505959 STD 2400 850 2600 104 (140)
16GR RE503050 3—5% 1500 1150 1560 100 (134)
16LW RE503832 3—5% 1500 1150 1560 100 (134)
16ME RE503739 3—5% 1800 — 1870 120 (161)
16MF RE504966 3—5% 1800 — 1870 123 (164)
16QZ RE503050 3—5% 1800 1400 1870 111 (149)
16RA RE503832 3—5% 1800 1400 1870 111 (149)
4045HF152 16RM RE505959 STD 2400 850 2600 104 (140)
60-11 081922
PN=127
Specifications

4045HF157 16GR RE503050 1500 — 1560 102 (137)
16LW RE503832 1500 __ 1560 102 (137)
4045HF158 16GR RE503050 3—5% 1500 1150 1560 100 (134)
16LW RE503832 3—5% 1500 1150 1560 100 (134)
16ME RE503739 3—5% 1800 1400 1870 123 (165)
16MF RE504698 RE504966 3—5% 1800 1400 1870 123 (170)
16MF RE504966 3—5% 1800 1400 1870 123 (170)
4045HF252 RE522414 3—5% 3000 850 3120 125 (168)
RE522698 3—5% 3000 850 3120 125 (168)
169E RE522414 3—5% 3000 850 3120 152 (204)
169F RE522698 3—5% 3000 850 3120 152 (204)
4045TF120 16MT RE503733 RE505989 3—5% 1500 1400 1560 70 (94)
16MT RE506989 3—5% 1500 1400 1560 70 (94)
16MU RE505050 RE506990 3—5% 1500 1400 1560 70 (94)
16MU RE506990 3—5% 1500 1400 1560 70 (94)
16ZW RE509527 3—5% 1500 1400 1560 70 (94)
16ZX RE509528 3—5% 1500 1400 1560 70 (94)
16ZY RE509529 3—5% 1500 1400 1560 70 (94)
165D RE506989 3—5% 1500 — 1560 70 (94)
165E RE506990 3—5% 1500 — 1560 70 (94)
4045TF150 1605 RE61668 RE69781 STD 2500 850 2700 86 (115)
1605 RE69781 STD 2500 850 2700 86 (115)
1606 RE64133 RE505927 STD 2400 850 2600 93 (125)
1606 RE505927 STD 2400 850 2600 93 (125)
1656 RE63610 RE67562 3—5% 1800 1150 1870 75 (100)
1656 RE67562 3—5% 1800 1150 1870 75 (100)
1675 RE60091 RE69782 STD 2500 850 2700 86 (115)
1675 RE69782 STD 2500 850 2700 86 (115)
1676 RE60093 RE61668 STD 2500 850 2700 86 (115)
1676 RE61668 STD 2500 850 2700 86 (115)
1677 RE60096 RE67563 3—5% 1800 1150 1870 75 (100)
1677 RE67563 3—5% 1800 1150 1870 75 (100)
1692 RE61668 RE500881 STD 2500 1400 2700 86 (115)
1692 RE500881 RE502416 STD 2500 1400 2700 86 (115)
1692 RE502416 STD 2500 1400 2700 86 (115)
1694 RE67863 RE69779 STD 2500 850 2700 75 (100)
1694 RE69779 STD 2500 850 2700 75 (100)
1695 RE69739 RE69780 STD 2500 850 2700 75 (100)
1695 RE69780 STD 2500 850 2700 75 (100)
60-12 081922
PN=128
Specifications

16AB RE69779 STD 2500 850 2700 75 (100)
16BF RE500848 STD 2200 950 2400 73 (98)
16CE RE501180 STD 2500 850 2700 75 (100)
16CM RE501365 STD 2200 950 2400 66.6 (89)
16GL RE502706 STD 2300 850 2500 78 (105)
16LP RE67562 3—5% 1800 1150 1870 75 (100)
16LZ RE503735 3—5% 1800 1400 1870` 70 (94)
16MA RE504696 RE504931 3—5% 1800 1400 1870 82 (110)
16MA RE504931 3—5% 1800 1400 1870 82 (110)
16MT RE503733 RE505050 3—5% 1500 1400 1560 70 (94)
16MT RE505050 3—5% 1500 1400 1560 70 (94)
16MU RE504695 RE505050 3—5% 1500 1400 1560 70 (94)
16MU RE505050 RE506990 3—5% 1500 1400 1560 70 (94)
16MU RE506990 3—5% 1500 1400 1560 70 (94)
16TG RE507941 STD 2000 850 2185 77 (103)
16YJ RE508834 STD 2000 850 2185 77 (103)
16YU RE508754 3—5% 1800 — 1870 75 (101)
16ZC RE518780 STD 2200 950 2400 66 (89)
4045TF151 1677 RE60096 RE67563 3—5% 1800 850 1870 75 (100
1677 RE67563 3—5% 1800 850 1870 75 (100
16CU RE501192 STD 2200 850 2400 79.5 (107)
16NH RE505411 3—5% 1800 1150 2240 75 (100)
4045TF152 16AX RE500551 STD 2400 850 2600 76 (102)
4045TF154 1605 RE69781 STD 2500 850 2700 86 (115)
4045TF155 16AX RE500551 STD 2400 850 2600 76 (102)
16JT RE500551 STD 2400 850 2600 76 (102)
4045TF157 16GQ RE503048 3—5% 1500 — 1560 83 (111)
16LV RE503830 3—5% 1500 — 1560 83 (111)
4045TF158 16GQ RE503048 3—5% 1500 — 1560 83 (111)
16LZ RE503735 3—5% 1800 — 1870 82 (110)
16MA RE504696 3—5% 1800 — 1870 82 (110)
16MT RE503733 RE506989 3—5% 1500 — 1560 70 (94)
16MT RE506989 3—5% 1500 — 1560 70 (94)
16MU RE504695 RE505050 3—5% 1500 — 1560 70 (94)
16MU RE505050 RE506990 3—5% 1500 — 1560 70 (94)
16MU RE506990 3—5% 1500 — 1560 70 (94)
4045TF161 16PZ RE500848 STD 2200 850 2400 73 (98)
4045TF162 16GL RE502706 STD 2300 850 2500 78 (104)
4045TF220 16GQ RE503048 RE506544 3—5% 1500 1400 1560 83 (111)
60-13 081922
PN=129
Specifications

16GQ RE506544 3—5% 1500 1400 1560 83 (111)
16LV RE503830 RE506545 3—5% 1500 1400 1560 83 (111)
16LV RE506545 3—5% 1500 1400 1560 83 (111)
16MT RE503733 3—5% 1500 1400 1560 70 (94)
16MV RE503736 3—5% 1800 1400 1870 100 (134)
16MW RE504682 3—5% 1800 1400 1870 100 (134)
16NT RE504465 STD 2500 850 2700 86 (115)
16NU RE504466 STD 2500 850 2700 86 (115)
16ZZ RE508613 STD 2100 850 2200 107 (143)
161A RE509525 STD 2100 850 2200 107 (143)
161B RE509526 STD 2100 850 2200 107 (143)
168Q RE521143 3—5% 1500 — 1560 83 (111)
168R RE522388 3—5% 1500 — 1560 83 (111)
4045TF250 1606 RE64133 RE505927 STD 2400 850 2600 93 (125)
1606 RE505927 STD 2400 850 2600 93 (125)
1608 RE67564 3—5% 1800 1400 1870 84 (113)
1667 RE59968 STD 2400 850 2600 93 (125)
1682 RE67566 3—5% 1800 1400 1870 84 (113)
1683 RE60124 RE505926 STD 2400 850 2600 93 (125)
1683 RE505926 STD 2400 850 2600 93 (125)
160R RE70941 3—5% 1800 1400 1870 84 (113)
16CV RE501346 STD 2200 950 2400 85 (114)
16GQ RE503048 3—5% 1500 1150 1560 83 (111)
16LQ RE67564 3—5% 1800 1400 1870 84 (113)
16LV RE503830 3—5% 1500 1150 1560 83 (111)
16MB RE503737 3—5% 1800 1400 1870 91(122)
16MC RE504932 3—5% 1800 1400 1870 91 (122)
161C RE507525 RE506881 3—5% 1800 1400 1870 100 (134)
161D RE507526 RE506882 3—5% 1800 1400 1870 100 (134)
163Z RE505927 STD 2400 850 2600 93 (125)
4045TF251 1606 RE64133 RE505927 STD 2400 850 2600 93 (125)
1606 RE505927 STD 2400 850 2600 93 (125)
4045TF252 169P RE522714 3—5% 3000 850 3120 119 (160)
169Q RE522697 3—5% 3000 850 3120 119 (160)
4045TF253 16TE RE507257 STD 2400 850 2600 85 (114)
4045TF257 16GQ RE503048 3—5% 1500 — 1560 83 (111)
16LV RE503830 3—5% 1500 — 1560 83 (111)
4045TF258 16GQ RE503048 3—5% 1500 — 1560 83 (111)
16LV RE503830 3—5% 1500 — 1560 83 (111)
60-14 081922
PN=130
Specifications

16MB RE503737 3—5% 1800 1400 1870 91 (122)
16MC RE504932 3—5% 1800 1400 1870 91 (122)
16MV RE503736 3—5% 1800 1400 1870 100 (134)
16MW RE504682 3—5% 1800 1400 1870 100 (134)
6068DF150 1613 RE59861 STD 2500 850 2700 93 (125)
1678 RE60101 STD 2500 850 2700 93 (125)
16LR RE59861 STD 2500 850 2700 93 (125)
6068HF120 16GT RE503051 3—5% 1500 1400 1560 155 (208)
16LY RE503834 3—5% 1500 1400 1560 155 (208)
16RL RE506085 3—5% 2100 950 2200 197 (264)
16SJ RE506627 3—5% 2100 950 2200 197 (264)
16TP RE506883 3—5% 1500 1150 1560 183 (245)
16TQ RE506884 3—5% 1500 1150 1560 183 (245)
16ZQ RE509428 3—5% 2100 950 2200 197 (264)
16ZR RE509429 3—5% 2100 950 2200 197 (264)
6068HF150 1621 RE66575 RE505930 STD 2400 850 2600 157 (210)
1621 RE505930 STD 2400 850 2600 157 (210)
160D RE69589 RE505962 STD 2400 850 2600 157 (210)
160D RE505962 STD 2400 850 2600 157 (210)
16CY RE501345 STD 2200 1350 2400 143 (192)
16GT RE503051 3—5% 1500 1400 1560 153 (205)
16LY RE503836 3—5% 1500 1400 1560 153 (205)
16ML RE503746 3—5% 1800 1400 1870 187 (251)
16MM RE504702 RE505049 3—5% 1800 1400 1870 187 (251)
16MM RE505049 3—5% 1800 1400 1870 187 (251)
16QV RE503051 3—5% 1800 1400 1870 166 (223)
16QW RE503836 3—5% 1800 1400 1870 166 (223)
16TM RE506885 3—5% 1800 — 1870 210 (282)
16TN RE506886 3—5% 1800 — 1870 210 (282)
6068HF157 16GT RE503051 3—5% 1500 — 1560 155 (208)
16LY RE503836 3—5% 1500 — 1560 155 (208)
6068HF158 16GT RE503051 3—5% 1500 — 1560 155 (208)
16LY RE503836 3—5% 1500 — 1560 155 (208)
16ML RE503746 3—5% 1800 1400 1870 187 (251)
16MM RE504702 RE505049 3—5% 1800 1400 1870 187 (251)
16MM RERE50504 3—5% 1800 1400 1870 187 (251)
9
6068HF250 1622 RE59521a STD 2400 850 2600 168 (225)
1623 RE66761a
3—5% 1800 — 1870 148 (198)
60-15 081922
PN=131
Specifications

16TV RE506398 STD 2400 800 2550 168 (225)
16YH RE59969 STD 2400 850 2600 138 (185)
6068HF252 169A RE522694 3—5% 3000 850 3120 225 (302)
168Z RE522415 3—5% 3000 850 3120 225 (302)
6068HF254 3—5% 2800 850 3000 226 (303)
3—5% 2800 850 3000 184 (247)
6068HF258 16TM (12V) RE506885 3—5% 1800 — 1870 210 (282)
16TN (24V) RE506886 3—5% 1800 — 1870 210 (282)
16TP (12V) RE506883 3—5% 1500 — 1560 183 (245)
16TQ (24V) RE506884 3—5% 1500 — 1560 183 (245)
6068TF120 16MX RE503740 3—5% 1500 1400 1560 105 (141)
16MY RE505052 3—5% 1500 1400 1560 105 (141)
6068TF150 1614 RE61669 RE69789 STD 2500 850 2700 127 (170)
1614 RE69789 STD 2500 850 2700 127 (170)
1680 RE60105 RE69790 STD 2500 850 2700 127 (170)
1680 RE69790 STD 2500 850 2700 127 (170)
1681 RE60107 RE67571 3—5% 1800 1150 1870 112 (150)
1681 RE67571 3—5% 1800 1150 1870 112 (150)
1688 RE67572 3—5% 1800 1150 1870 112 (150)
1696 RE67864 RE69787 STD 2500 850 2700 116 (155)
1696 RE69787 STD 2500 850 2700 116 (155)
1697 RE68740 RE69788 STD 2500 850 2700 116 (155)
1697 RE69788 STD 2500 850 2700 116 (155)
16BE RE63559 RE501302 STD 2200 950 2400 117 (157)
16BE RE501302 STD 2200 950 2400 117 (157)
16CN RE501522 RE509681 STD 2100 950 2300 110.5 (148)
16CN RE509681 STD 2100 950 2300 110.5 (148)
16CP RE501523 STD 2200 950 2400 94 (126)
16DK RE70938 STD 2100 900 2300 96 (129)
16DY RE501758 STD 2500 850 2700 116 (155)
16GM RE502693 STD 2300 850 2500 110 (148)
16GN RE502704 STD 2400 850 2600 116 (155)
16LS RE67572 3—5% 1800 1150 1870 112 (150)
16MG RE503742 3—5% 1800 1400 1870 123 (165)
16MH RE504967 3—5% 1800 1400 1870 123 (165)
6068TF151 1681 RE60107 RE67651 3—5% 1800 1150 1870 112 (150)
1681 RE67651 3—5% 1800 1150 1870 112 (150)
16NJ RE505358 3—5% 1800 1150 1870 112 (150)
1696 RE69787 STD 2500 850 2700 116 (155)
60-16 081922
PN=132
Specifications

6068TF152 1696 RE69787 STD 2500 850 2700 116 (155)
16JU RE69787 STD 2500 850 2700 116 (155)
6068TF157 16GS RE503049 3—5% 1500 — 1560 121 (162)
16LX RE503834 3—5% 1500 — 1560 121 (162)
6068TF158 16GS RE503049 3—5% 1500 — 1560 121 (162)
165H RE503740 3—5% 1500 — 1560 105 (141)
165J RE505052 3—5% 1500 — 1560 105 (141)
16MG RE503742 3—5% 1800 — 1870 123 (165)
16MH RE504966 RE504967 3—5% 1800 — 1870 123 (165)
16MH RE504967 3—5% 1800 — 1870 123 (165)
16MX RE503740 3—5% 1500 — 1560 105 (141)
16MY RE504699 RE505052 3—5% 1500 — 1560 105 (141)
16MY RE505052 3—5% 1500 — 1560 105 (141)
6068TF159 16PD RE70938 STD 2100 850 2250 96 (129)
6068TF220 16GS RE503049 3—5% 1500 1400 1560 121 (162)
16KK RE502694 STD 2500 850 2700 127 (170)
16LX RE503836 3—5% 1500 1400 1560 121 (162)
16RK RE506083 3—5% 2600 850 2700 138 (185)
16RJ RE506084 3—5% 2100 950 2200 172 (231)
16SG RE506625 3—5% 2100 950 2200 172 (231)
16SH RE506626 3—5% 2600 850 2700 138 (185)
16ZL RE509424 3—5% 2100 950 2200 172 (231)
16ZM RE509425 3—5% 2100 950 2200 172 (231)
16ZN RE509426 STD 2600 850 2800 138 (185)
16ZP RE509427 STD 2600 850 2800 138 (185)
165K RE503049 3—5% 1500 — 1560 120 (161)
165L RE503834 3—5% 1500 — 1560 120 (161)
6068TF250 1615 RE62366 RE69791 STD 2400 850 2600 138 (185)
1615 RE69791 STD 2400 850 2600 138 (185)
1619 RE67573 3—5% 1800 1150 1870 124 (166)
a
1668 RE59969 STD 2400 850 2600 138 (185)
1685 RE67574 3—5% 1800 1150 1870 124 (166)
1686 RE60131 RE69792 STD 2400 850 2600 138 (185)
1686 RE69792 STD 2400 850 2600 138 (185)
16CW RE501344 STD 2200 950 2400 106 (142)
16CX RE70390 STD 2300 900 2500 128 (172)
16GS RE503049 3—5% 1500 1400 1560 120 (161)
16LT RE69791 STD 2400 850 2600 138 (185)
16LU RE67573 3—5% 1800 1150 1870 124 (166)
OURGP11,000001D -19-13OCT06-8/8
60-17 081922
PN=133
Specifications

16LX RE503834 3—5% 1500 1400 1560 120 (161)
16MJ RE503744 3—5% 1800 1400 1870 142 (190)
16MK RE504701 RE504968 3—5% 1800 1400 1870 142 (190)
16MK RE504968 3—5% 1800 1400 1870 142 (190)
163D RE516159 STD 2200 850 2400 125 (168)
16UG RE506956 RE504321 STD 2400 925 2600 149(200)
16UG RE504321 STD 2400 925 2600 149 (200)
16YH RE59969 STD 2400 850 2600 138 (185)
6068TF251 1615 RE62366 STD 2400 850 2600 138 (185)
16ZH RE62366 STD 2400 850 2600 138 (185)
6068TF257 16GS RE503049 3—5% 1500 — 1560 121 (162)
16LX RE503834 3—5% 1500 — 1560 155 (208)
6068TF258 16GS RE503049 3—5% 1500 — 1560 121 (162)
16LX RE503834 3—5% 1500 — 1560 155 (208)
16MJ RE503744 3—5% 1800 — 1870 142 (190)
16MK RE504701 RE504968 3—5% 1800 — 1870 142 (190)
16MK RE504968 3—5% 1800 — 1870 142 (190)
a
In-line fuel injection pump.
OURGP11,000001D -19-13OCT06-9/8
60-18 081922
PN=134
Specifications
Engine Crankcase Oil Fill Quantities the rocker arm cover. The first two digits of the code (19)
identify the oil pan option group. The last two digits of
NOTE: Crankcase oil capacity may vary slightly from each code identify the specific oil pan on your engine.
amount shown. ALWAYS fill crankcase to within
crosshatch on dipstick. DO NOT overfill. The following table lists engine crankcase oil fill quantities
for each “19__” option code for these engines.
To determine the option code for the oil fill quantity of your
engine, refer to the engine option code label affixed to
Engine Model Oil Pan Option Code(s) Crankcase Oil Capacity L (qt)
4045 1901 7.5 (8.0)
1902 8.0 (8.5)
1903 12.0 (12.7)
1904 13.5 (14.3)
1914 13 (13.7)
1921 16.5 (17.4)
1922 16.5 (17.4)
1923 15.0 (15.8)
1934 12.5 (13.2)
1936 12.5 (13.2)
1937 12.5 (13.2)
1949 12.0 (12.7)
1962 14.0 (14.8)
19AE 15.2 (16.1)
6068 1907 19.5 (20.6)
1908 19.0 (20.1)
1909 19.0 (20.1)
1924 24.2 (25.6)
1944 20.0 (21.1)
1948 20.0 (21.1)
1950 20.0 (21.1)
1956 19.0 (20.1)
1961 33.0 (34.9)
1963 21.5 (22.7)
1968 32.0 (33.8)
19AC 28.0 (29.6)
OURGP11,000001E -19-24JUN22-1/1
60-19 081922
PN=135
Specifications
Unified Inch Bolt and Screw Torque Values

TS1671 —UN—01MAY03
SAE Grade 1a SAE Grade 2b SAE Grade 5, 5.1 or 5.2 SAE Grade 8 or 8.2
c c c
Bolt or Screw Hex Head Flange Hex Head Flange Hex Head Flange Hex Headc Flange
Size Headd Headd Headd Headd
N·m lb·in N·m lb·in N·m lb·in N·m lb·in N·m lb·in N·m lb·in N·m lb·in N·m lb·in
1/4 3.1 27.3 3.2 28.4 5.1 45.5 5.3 47.3 7.9 70.2 8.3 73.1 11.2 99.2 11.6 103
N·m lb·ft N·m lb·ft
5/16 6.1 54.1 6.5 57.7 10.2 90.2 10.9 96.2 15.7 139 16.8 149 22.2 16.4 23.7 17.5
3/8 10.5 93.6 11.5 102 17.6 156 19.2 170 27.3 20.1 29.7 21.9 38.5 28.4 41.9 30.9
7/16 16.7 148 18.4 163 27.8 20.5 30.6 22.6 43 31.7 47.3 34.9 60.6 44.7 66.8 49.3
1/2 25.9 19.1 28.2 20.8 43.1 31.8 47 34.7 66.6 49.1 72.8 53.7 94 69.3 103 75.8
9/16 36.7 27.1 40.5 29.9 61.1 45.1 67.5 49.8 94.6 69.8 104 77 134 98.5 148 109
5/8 51 37.6 55.9 41.2 85 62.7 93.1 68.7 131 96.9 144 106 186 137 203 150
3/4 89.5 66 98 72.3 149 110 164 121 230 170 252 186 325 240 357 263
7/8 144 106 157 116 144 106 157 116 370 273 405 299 522 385 572 422
1 216 159 236 174 216 159 236 174 556 410 609 449 785 579 860 634
1-1/8 305 225 335 247 305 225 335 247 685 505 751 554 1110 819 1218 898
1-1/4 427 315 469 346 427 315 469 346 957 706 1051 775 1552 1145 1703 1256
1-3/8 564 416 618 456 564 416 618 456 1264 932 1386 1022 2050 1512 2248 1658
1-1/2 743 548 815 601 743 548 815 601 1665 1228 1826 1347 2699 1991 2962 2185
The nominal torque values listed are for general use only with the assumed Replace fasteners with the same or higher property class. If
wrenching accuracy of 20%, such as a manual torque wrench. higher property class fasteners are used, tighten these to the
DO NOT use these values if a different torque value or tightening procedure is strength of the original.
given for a specific application.
For lock nuts, for stainless steel fasteners, or for nuts on U-bolts, see the
tightening instructions for the specific application.
• Make sure that fastener threads are clean.

• Apply a thin coat of Hy-Gard™ or equivalent oil under the head and on the threads of the fastener, as shown in the following image.
• Be conservative with the amount of oil to reduce the potential for hydraulic lockup in blind holes due to excessive oil.
• Properly start thread engagement.
TS1741 —UN—22MAY18
a
Grade 1 applies for hex cap screws over 6 in (152 mm) long, and for all other types of bolts and screws of any length.
b
Grade 2 applies for hex cap screws (not hex bolts) up to 6 in (152 mm) long.
c
Hex head column values are valid for ISO 4014 and ISO 4017 hex head, ISO 4162 hex socket head, and ISO 4032 hex nuts.
d
Hex flange column values are valid for ASME B18.2.3.9M, ISO 4161, or EN 1665 hex flange products.
DX,TORQ1 -19-09MAY22-1/1
60-20 PN=136
081922
Specifications
Metric Bolt and Screw Torque Values

TS1742 —UN—31MAY18
4.8 8.8 9.8 10.9 12.9
4.8 8.8 9.8 10.9 12.9
Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9

a a a
Bolt or Screw Hex Head Flange Hex Head Flange Hex Head Flange Hex Heada Flange
Size Headb Headb Headb Headb
N·m lb·in N·m lb·in N·m lb·in N·m lb·in N·m lb·in N·m lb·in N·m lb·in N·m lb·in
M6 3.6 31.9 3.9 34.5 6.7 59.3 7.3 64.6 9.8 86.7 10.8 95.6 11.5 102 12.6 112
N·m lb·ft N·m lb·ft N·m lb·ft N·m lb·ft
M8 8.6 76.1 9.4 83.2 16.2 143 17.6 156 23.8 17.6 25.9 19.1 27.8 20.5 30.3 22.3
N·m lb·ft N·m lb·ft N·m lb·ft
M10 16.9 150 18.4 13.6 31.9 23.5 34.7 25.6 46.8 34.5 51 37.6 55 40.6 60 44.3
N·m lb·ft
M12 — — — — 55 40.6 61 45 81 59.7 89 65.6 95 70.1 105 77.4
M14 — — — — 87 64.2 96 70.8 128 94.4 141 104 150 111 165 122
M16 — — — — 135 99.6 149 110 198 146 219 162 232 171 257 190
M18 — — — — 193 142 214 158 275 203 304 224 322 245 356 263
M20 — — — — 272 201 301 222 387 285 428 316 453 334 501 370
M22 — — — — 365 263 405 299 520 384 576 425 608 448 674 497
M24 — — — — 468 345 518 382 666 491 738 544 780 575 864 637
M27 — — — — 683 504 758 559 973 718 1080 797 1139 840 1263 932
M30 — — — — 932 687 1029 759 1327 979 1466 1081 1553 1145 1715 1265
M33 — — — — 1258 928 1398 1031 1788 1319 1986 1465 2092 1543 2324 1714
M36 — — — — 1617 1193 1789 1319 2303 1699 2548 1879 2695 1988 2982 2199
The nominal torque values listed are for general use only with the assumed Replace fasteners with the same or higher property class. If
wrenching accuracy of 20%, such as a manual torque wrench. higher property class fasteners are used, tighten these to the
DO NOT use these values if a different torque value or tightening procedure is strength of the original.
given for a specific application.
For lock nuts, for stainless steel fasteners, or for nuts on U-bolts, see the
tightening instructions for the specific application.
• Make sure that fastener threads are clean.

• Apply a thin coat of Hy-Gard™ or equivalent oil under the head and on the threads of the fastener, as shown in the following image.
• Be conservative with the amount of oil to reduce the potential for hydraulic lockup in blind holes due to excessive oil.
• Properly start thread engagement.
TS1741 —UN—22MAY18
a
Hex head column values are valid for ISO 4014 and ISO 4017 hex head, ISO 4162 hex socket head, and ISO 4032 hex nuts.
b
Hex flange column values are valid for ASME B18.2.3.9M, ISO 4161, or EN 1665 hex flange products.
DX,TORQ2 -19-09MAY22-1/1
60-21 PN=137
081922
Lubrication and Maintenance Records
Using Lubrication and Maintenance Records
Refer to specific Lubrication and Maintenance Section for the date in the spaces provided. For a complete listing
detailed service procedures. of all items to be performed and the service intervals
required, refer to the quick-reference chart near the
1. Keep a record of the number of hours you operate front of the Lubrication and Maintenance Section.
your engine by regular observation of hour meter.
IMPORTANT: The service recommendations covered
2. Check your record regularly to learn when your engine in this manual are for the accessories that are
needs service. provided by John Deere. Follow manufacturer's
3. DO ALL the services within an interval section. Write service recommendations for servicing engine
the number of hours (from your service records) and driven equipment not supplied by Deere.
RG,RG34710,5620 -19-24AUG10-1/1
Daily (Prestarting) Service • Check fuel filter/water separator bowl.

• Check engine oil level. • Check air cleaner dust unloader valve and air restriction
indicator, if equipped.
• Check coolant level. • Visual walkaround inspection.
IMPORTANT: Drain water by rotating drain valve on
fuel/water separator bowl counterclockwise.
Premature injection pump failure may occur
if water is not drained daily.
RG,RG34710,5621 -19-07JAN02-1/1
250 Hour/6 Month Service
• Change engine oil and filter.1 • Service battery.

• Service fire extinguisher. • Check automatic belt tensioner and belt wear.
• Check engine mounts.
Hours
Date
Hours
Date
Hours
Date
Hours
Date
Hours
Date
Hours
Date
Hours
Date
Hours
Date
1
If John Deere PLUS-50 or ACEA-E4/E5 oil is used along
with a John Deere oil filter, the oil and filter change interval
may be extended by 50 percent.
OURGP12,0000043 -19-31OCT06-1/1
65-1 081922
PN=138
• Clean crankcase vent tube. • Check engine electrical ground connection.

• Check air intake hoses, connections, and system. • Check cooling system.
• Replace single or dual fuel filter elements. • Coolant solution analysis – add SCAs as needed.
• Check automatic belt tensioner and belt wear. • Pressure test cooling system.
• Check engine speeds.
Hours
Date
Hours
Date
Hours
Date
Hours
Date
Hours
Date
Hours
Date
Hours
Date
Hours
Date
OURGP12,0000044 -19-07JUL04-1/1
65-2 081922
PN=139
• Check crankshaft vibration damper (6-cylinder only). • Test thermostats.

• Flush cooling system.1 • Check and adjust valve clearance.
Hours
Date
Hours
Date
Hours
Date
Hours
Date
Hours
Date
Hours
Date
Hours
Date
Hours
Date
1
If John Deere COOL-GARD is used, the flushing interval may be
extended to 3000 hours, or 36 months. If John Deere COOL-GARD is
used and the coolant is tested annually AND additives are replenished as
needed by adding a supplemental coolant additive, the flushing interval
may be extended to 5000 hours or 60 months, whichever occurs first.
RG,RG34710,5625 -19-20MAY96-1/1
65-3 081922
PN=140
Service as Required • Check fuses

• Check air compressor (if equipped).
• Add coolant • Bleed fuel system
• Service air cleaner.
• Replace poly-vee belts.
Hours
Date
Hours
Date
Hours
Date
Hours
Date
Hours
Date
Hours
Date
Hours
Date
Hours
Date
OURGP12,0000045 -19-07JUL04-1/1
65-4 081922
PN=141
Warranty
John Deere Warranty in OEM Applications
Warranty Duration
Overview
Unless otherwise provided in writing by John Deere, John
This section focuses on John Deere engines marketed Deere makes the following warranty to the first retail
in products manufactured by companies other than purchaser and each subsequent purchaser (if purchase
John Deere or its affiliates, and on John Deere repower is made prior to the expiration of applicable warranty)
engines in all applications. Herein appears the original of each John Deere new off-highway engine marketed
warranty applicable to the engine as delivered to the as part of a product manufactured by a company other
retail purchaser on or after 1 May 2010. The following is than John Deere or its affiliates and on each John Deere
information about the warranty and warranty service. engine used in an off-highway repower application:
NOTE: “John Deere” means John Deere Power Systems • 12 months, unlimited hours of use, or
with respect to users in the United States, John • 24 months and before the accumulation of 2000 hours
Deere Canada ULC with respect to users in of use
Canada, and Deere & Company or its subsidiary
NOTE: In the absence of a functional hourmeter,
responsible for making John Deere equipment in
hours of use are determined on the basis of 12
other countries where the user is located.
hours of use per calendar day.
Promptly register the engine online at https://warrantyregi-
Warranty Coverage
stration.deere.com/WarrantyReg/web/WarrantyReg.
This warranty applies to the engine and to integral
When Warranty Service Is Needed
components and accessories sold by John Deere, and
The nearest dealer stands ready with genuine parts and delivered to the first retail purchaser on or after 1 May
trained and equipped personnel should the need arise. 2010.
If following the Operator’s Manual delivered with the All John Deere-warranted parts and components of John
engine/machine are not adequate to correct an engine Deere engines which, as delivered to the purchaser, are
problem, contact the nearest John Deere service dealer defective in materials and/or workmanship will be repaired
for assistance. Authorized engine service dealers can be or replaced, as John Deere elects. Warrantable repairs
found at: https://www.deere.com/or https://www.deere.ca/ will be made without charge for parts or engine repair
(click on “Find a Dealer”). labor, including reasonable labor costs to remove and
NOTE: When requesting warranty service, the purchaser reinstall non-engine parts or components of the equipment
must be prepared to provide proof that the engine in which the engine is installed. If necessary, reasonable
is within the warranty period. labor costs for engine removal and reinstallation will
also be included. All coverage is based on the defect
The following information is always required: Engine appearing within the warranty period as measured from
serial number, date of delivery, engine owner, name and the date of delivery to the first retail purchaser.
location of dealer and specific person contacted, date of
Obtaining Warranty Service
contact, nature of engine problem, and outcome of the
service dealer contact. Warranty service must be requested of the nearest
authorized John Deere engine service outlet before the
Given that normally it is the dealer contacted who in
expiration of the warranty. An authorized service outlet is
the end provides the service required, maintaining a
a John Deere engine distributor, a John Deere engine
purchaser-dealer relationship of mutual respect from the
service dealer, or a John Deere equipment dealer selling
beginning is always helpful.
and servicing equipment with an engine of the type
Privacy Notice covered by this warranty. (See When Warranty Service
is Needed.)
At John Deere privacy is important. We collect, use,
and disclose personal information in accordance with Authorized service outlets will use only new or
the John Deere privacy statement. For instance, we remanufactured parts or components furnished or
collect, use, and disclose personal information to provide approved by John Deere.
the products and services requested; to communicate NOTE: Authorized engine service locations are listed
with the customer (examples include warranty and on the Internet at https://www.deere.com/or
product improvement programs) and to meet safety and https://www.deere.ca/ (click on “Find a Dealer”).
legal requirements; and for marketing and promotional
purposes. Sometimes, we may ask our John Deere At the time of requesting warranty service, the purchaser
affiliates, dealers, or business partners to do work for must be prepared to present evidence of the date of
us, which involves personal information. For complete delivery of the engine.
details on privacy rights and to obtain a copy of the
John Deere Privacy Statement, visit our website at
https://www.deere.com/or https://www.deere.ca/.
Continued on next page CM22194,00011A1 -19-10MAY22-1/3
70-1 081922
PN=142
Warranty
John Deere reimburses authorized service outlets for Charges by dealers for initial start-up and inspection
limited travel expenses incurred in making warranty deemed unnecessary by John Deere when an Operator’s
service repairs in non-John Deere applications when Manual is supplied with the product are followed.
travel is performed. The limit, as of the date of publication
of this booklet, is US$400.00 (US$500.00 if engine is Costs related to interpretation or translation services.
marine) or equivalent. If distances and travel times are
No Representations or Implied Warranty
greater than reimbursed by John Deere, the service
outlet will charge the purchaser for the difference. Where permitted by law, neither John Deere nor
any company affiliated with it makes any guaranties,
Warranty Exclusions
warranties, conditions, representations or promises,
John Deere’s obligations will not apply to components and express or implied, oral or written, as to the nonoccurrence
accessories that are not furnished or installed by John of any defect or the quality of performance of its engines
Deere, nor to failures caused by such items, except as other than those set forth in this booklet, and DOES NOT
required by law. MAKE ANY IMPLIED WARRANTY OR CONDITIONS OF
MERCHANTABILITY OR FITNESS otherwise provided
Purchaser’s Responsibilities for in the Uniform Commercial Code or required by any
Sale of Goods Act or any other statute. This exclusion
The cost of normal maintenance and depreciation. includes fundamental terms. In no event will a John Deere
Consequences of negligence, misuse, or accident engine distributor or engine service dealer, John Deere
involving the product, or improper application, installation, equipment dealer, or John Deere or any company affiliated
or storage. with John Deere be liable for incidental or consequential
damages or injuries including, but not limited to, loss
Consequences of service performed by someone other of profits, loss of crops, rental of substitute equipment
than an authorized John Deere engine service outlet. or other commercial loss, damage to the equipment in
which the engine is installed or for damage suffered by
Consequences of any product modification or alteration purchaser as a result of fundamental breaches of contract
not approved by John Deere, including, but not limited to, or breach of fundamental terms, unless such damages or
tampering with engine fuel and air delivery systems. injuries are caused by the gross negligence or intentional
Consequences of failure of non-product components. acts of the foregoing parties.
Consequences of fuels, lubricants, or coolants that fail Remedy Limitation

to meet the specifications and requirements listed in the
Operator’s Manual. The remedies set forth in this warranty are the purchaser’s
exclusive remedies in connection with the performance
The effects of cooling system neglect as manifested of, or any breach of guaranty, condition, or warranty
in cylinder liner or cylinder block cavitation (“pitting, in respect of new John Deere engines. In the event
“erosion”, “electrolysis”). the warranty fails to correct purchaser’s performance
problems caused by defects in workmanship and/or
Any premium for overtime labor requested by the materials, purchaser’s exclusive remedy shall be limited to
purchaser. payment by John Deere of actual damages in an amount
Costs of transporting the product or the equipment in not to exceed the cost of the engine.
which it is installed to and from the location at which the No Seller’s Warranty
warranty service is performed, if such costs are in excess
of the travel reimbursement payable to the dealer had the No person or entity, other than John Deere, who sells
warranty service been performed at the product’s location. the engine or product in which the engine has been
installed makes any guaranty or warranty of its own on
Costs incurred in gaining access; for example, overcoming
any engine warranted by John Deere unless it delivers
physical barriers such as walls, fences, floors, decks, or
to the purchaser a separate written guaranty certificate
similar structures impeding access to the product, rental
specifically guaranteeing the engine, in which case
of cranes or similar, or construction of ramps or lifts or
John Deere shall have no obligation to the purchaser.
protective structures for product removal and reinstallation.
Neither original equipment manufacturers, engine or
Incidental travel costs including meals, lodging, and equipment distributors, engine or equipment dealers, nor
similar, and any travel time or mileage costs in excess any other person or entity, has any authority to make any
of the maximum allowance. representation or promise on behalf of John Deere or to
modify the terms or limitations of this warranty in any way.
Service outlet costs incurred in solving or attempting to
solve non-warrantable problems.
Services performed by a party other than an authorized
John Deere service dealer.
Continued on next page CM22194,00011A1 -19-10MAY22-2/3
70-2 081922
PN=143
Warranty
Replacement Parts Warranty Local Warranty Requirements

John Deere and John Deere Reman parts and Warranties required by local statutes will be furnished by
components (excluding replacement engines) installed the seller.
during engine warranty service are warranted for the
remaining warranty period of the engine or the applicable Option Codes (Engine Manufacturing Configuration)
warranty term for the installed service part, whichever is
greater. A new or remanufactured engine replacing a When in need of engine replacement parts, your
failed engine under warranty is warranted for 90 days authorized John Deere service dealer will must know the
or the remaining warranty period of the original engine, corresponding “Option Codes” for your engine. The option
whichever is greater. code label on the engine rocker arm cover may become
damaged over time. By recording the four-digit codes
Warranty Transfer when the engine is new, and storing this manual where it
can be found when parts are needed, fast, accurate parts
The remainder of the original engine warranty and the ordering and service will be assured. See Engine Option
emissions control-related warranty may be transferred to Codes in Section 01.
a subsequent owner of the engine. The Engine Warranty
Transfer card should be used to report the transfer to John Should there be a question about an engine
Deere. If a card is not available, contact your Dealer or option code, note the engine serial number and
simply send the following Information to JDPS Warranty call 1-800-JDENGINE from the U.S.A. or Canada,
Administration at Diesel-US@JohnDeere.com. or fax U.S.A. number 1-309-749-0816; or E-mail
at diesel-us@johndeere.com, Attention: Warranty
1. The complete 13-character engine serial number. Administration; or in Europe fax number 33.2.38.84.62.66,
2. The name and mailing address of the original or E-mail at saranservice@johndeere.com.
purchaser.
3. Delivery date to the original purchaser. Registering the Engine for Warranty
4. Hours at the time of transfer.
5. Date of transfer to the new owner. Completion and submission of the John Deere Engine
6. Name and mailing address of the new owner. Warranty Registration form (cut out sheet found in this
7. How the engine/drivetrain being used, that is, what manual) is important. John Deere will not deny warranty
equipment it powers, by manufacturer and model. service on an engine within its warranty period if the
8. Equipment it powers, by manufacturer and model. engine has not been registered. However, registering your
engine will assure your servicing dealer that the engine is
Purchased Extended Warranty within the warranty period.
Extended warranty may be purchased on most engines in The easiest way to register your engine is via the Internet.
many areas of the world. John Deere engine distributors Go to website https://www.johndeere.com/enginewarranty
and equipment dealers, and dealers of manufacturers You can use the sheet in this manual to gather the
using John Deere engines in their products, have information needed to register the warranty.
details. John Deere may also be contacted at U.S.A. NOTE: Information provided on the form must be legible!
fax number 1-309-749-0816, or in Europe fax number
33.2.38.84.62.66. Typing is preferred, but legible handwritten reports are
Emissions Warranties acceptable. “Block” numbers and Roman alphabet letters
should be used. For example: 1,2,3,4 and A, B, C, D.
Emissions warranties appear in the Operator’s Manual
furnished with the engine/machine. (Warning: Statutes All requested information should be given. Much of
providing severe penalties for tampering with it contributes to reports, including those required by
emissions controls may apply at the user’s location.) governments.
John Deere may also be contacted at U.S.A. fax The purchaser’s telephone number or E-mail address
number 1-309-749-0816; or in Europe fax number allows John Deere to make contact should there be
33.2.38.84.62.66. questions concerning the registration. The purchaser
should sign and date the form.
CM22194,00011A1 -19-10MAY22-3/3
70-3 081922
PN=144
Warranty
Emissions Control System Certification Label
RG33429 —UN—04FEB21
Engine Emissions Label
CAUTION: Statutes providing severe penalties The emissions label has applicable US EPA and/or
for tampering with emissions controls may CARB regulatory year. The regulatory year determines
apply to the user or dealer. which warranty statement is applicable to engine.
See “EPA Non-road Emissions Control Warranty
The emissions warranty applies to those engines Statement—Compression Ignition” and “CARB Non-road
marketed by John Deere that have been certified by the Emissions Control Warranty Statement—Compression
United States Environmental Protection Agency (EPA) Ignition”. For additional regulatory year warranty
and/or California Air Resources Board (CARB); and used statements, see www.JohnDeere.com or contact the
in the United States and Canada in Non-road equipment. nearest John Deere service dealer for assistance.
The presence of an emissions label like the one shown
Emission Control System(s) Laws
signifies that the engine has been certified with the EPA
and/or CARB. The EPA and CARB warranties only apply The U.S. EPA and California ARB prohibit the removal or
to new engines having the certification label affixed to the rendering inoperative of any device or element of design
engine and sold as stated above in the geographic areas. installed on or in engines/equipment in compliance with
The presence of an EU number signifies that the engine applicable emission regulations prior to or after the sale
has been certified with the European Union countries and delivery of the engines/equipment to the ultimate
per Regulation (EU) 2016/1628 and supplementing purchaser.
legislation. The EPA and/or CARB emissions warranties
do not apply to the EU countries.
DX,EMISSIONS,LABEL -19-05FEB21-1/1
70-4 081922
PN=145
Warranty
EPA Non-road Emissions Control Warranty Statement—Compression Ignition

DXLOGOV1 —UN—28APR09
U.S. AND CANADA EMISSION CONTROL WARRANTY STATEMENT

YOUR WARRANTY RIGHTS AND OBLIGATIONS
To determine if the John Deere engine qualifies for the additional warranties set forth below, look for the "Emissions Control Information" label
located on the engine. If the engine is operated in the United States or Canada and the Emissions Control information label states: "This engine
complies with US EPA regulations for nonroad and stationary diesel engines”, or “This engine conforms to US EPA nonroad compression-ignition
regulations”, refer to the "U.S. and Canada Emission Control Warranty Statement." If the engine is operated in California, and the label states:
"This engine complies with US EPA and CARB regulations for nonroad diesel engines”, or “This engine conforms to US EPA and California
nonroad compression-ignition emission regulations”, also refer to the "California Emission Control Warranty Statement.”
Warranties stated on this certificate refer only to emissions-related parts and components of your engine. The complete engine warranty, less
emissions-related parts and components, is provided separately. If you have any questions about your warranty rights and responsibilities,
you should contact John Deere at 1-319-292-5400.
JOHN DEERE'S WARRANTY RESPONSIBILITY
John Deere warrants to the ultimate purchaser and each subsequent purchaser that this off-road diesel engine including all parts of its
emission-control system was designed, built and equipped so as to conform at the time of the sale with Section 213 of the Clean Air Act and is
free from defects in materials and workmanship which would cause the engine to fail to conform with applicable US EPA regulations for a period of
five years from the date the engine is placed into service or 3,000 hours of operation, whichever first occurs.
Where a warrantable condition exists, John Deere will repair or replace, as it elects, any part or component with a defect in materials or
workmanship that would increase the engine’s emissions of any regulated pollutant within the stated warranty period at no cost to you, including
expenses related to diagnosing and repairing or replacing emission-related parts. Warranty coverage is subject to the limitations and exclusions
set forth herein. Emission- related components include engine parts developed to control emissions related to the following:
Air-Induction System Aftertreatment Devices
Fuel System Crankcase Ventilation Valves
Ignition System Sensors
Exhaust Gas Recirculation Systems Engine Electronic Control Units
EMISSION WARRANTY EXCLUSIONS
John Deere may deny warranty claims for malfunctions or failures caused by:
• Non-performance of maintenance requirements listed in the Operator’s Manual

• The use of the engine/equipment in a manner for which it was not designed
• Abuse, neglect, improper maintenance or unapproved modifications or alterations
• Accidents for which it does not have responsibility or by acts of God
The off-road diesel engine is designed to operate on diesel fuel as specified in the Fuels, Lubricants and Coolants section in the Operators
Manual. Use of any other fuel can harm the emissions control system of the engine/equipment and is not approved for use.
To the extent permitted by law John Deere is not liable for damage to other engine components caused by a failure of an emission-related
part, unless otherwise covered by standard warranty.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING ANY WARRANTY OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. REMEDIES UNDER THIS WARRANTY ARE LIMITED TO THE
PROVISIONS OF MATERIAL AND SERVICES AS SPECIFIED HEREIN. WHERE PERMITTED BY LAW, NEITHER JOHN DEERE NOR ANY
AUTHORIZED JOHN DEERE ENGINE DISTRIBUTOR, DEALER, OR REPAIR FACILITY OR ANY COMPANY AFFILIATED WITH JOHN
DEERE WILL BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.
Emission_CI_EPA (18Dec09)
Continued on next page DX,EMISSIONS,EPA -19-12DEC12-1/2
70-5 081922
PN=146
Warranty
TS1721 —UN—15JUL13
DX,EMISSIONS,EPA -19-12DEC12-2/2
70-6 081922
PN=147
Warranty
CARB Non-road Emissions Control Warranty Statement—Compression Ignition

Emissions Control Warranty Statement 2019 through 2021
CALIFORNIA EMISSIONS CONTROL WARRANTY STATEMENT

To determine if the John Deere engine qualifies for the additional warranties set forth below, look for the “Emission Control Information” label located
on the engine. If the engine is operated in the United States or Canada and the engine label states: “This engine complies with US EPA regulations
for nonroad and stationary diesel engines”, or “This engine complies with US EPA regulations for stationary emergency diesel engines”, refer to
the “U.S. and Canada Emission Control Warranty Statement.” If the engine is operated in California, and the engine label states: “This engine
complies with US EPA and CARB regulations for nonroad diesel engines” also refer to the “California Emissions Control Warranty Statement.”
emission-related parts and components, is provided separately. If you have any questions about your warranty rights and responsibilities,
CALIFORNIA EMISSIONS CONTROL WARRANTY STATEMENT:
The California Air Resources Board (CARB) is pleased to explain the emission-control system warranty on 2019 through 2021 off-road diesel
engines. In California, new off-road engines must be designed, built and equipped to meet the State’s stringent anti-smog standards. John Deere
must warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse, neglect or
improper maintenance of your engine.
Your emission control system may include parts such as the fuel injection system and the air induction system. Also included may be hoses, belts,
connectors and other emission-related assemblies.
John Deere warrants to the ultimate purchaser and each subsequent purchaser that this off-road diesel engine was designed, built, and equipped
so as to conform at the time of sale with all applicable regulations adopted by CARB and is free from defects in materials and workmanship which
would cause the failure of a warranted part to be identical in all material respects to the part as described in John Deere's application for certification
for a period of five years from the date the engine is delivered to an ultimate purchaser or 3,000 hours of operation, whichever occurs first for all
engines rated at 19 kW and greater. In the absence of a device to measure hours of use, the engine shall be warranted for a period of five years.
EMISSIONS WARRANTY EXCLUSIONS:
John Deere may deny warranty claims for failures caused by the use of an add-on or modified part which has not been exempted by the CARB. A
modified part is an aftermarket part intended to replace an original emission-related part which is not functionally identical in all respects and
which in any way affects emissions. An add-on part is any aftermarket part which is not a modified part or a replacement part.
In no event will John Deere, any authorized engine distributor, dealer, or repair facility, or any company affiliated with John Deere be liable
for incidental or consequential damage.
Continued on next page DX,EMISSIONS,CARB -19-26AUG20-1/8
70-7 PN=148
081922
Warranty
JOHN DEERE'S WARRANTY RESPONSIBILITY:
Where a warrantable condition exists, John Deere will repair or replace, as it elects, your off-road diesel engine at no cost to you, including
diagnosis, parts or labor. Warranty coverage is subject to the limitations and exclusions set forth herein. The off-road diesel engine is warranted
for a period of five years from the date the engine is delivered to an ultimate purchaser or 3,000 hours of operation, whichever occurs first. The
following are emissions-related parts:
Air Induction System Emission control labels Advanced Oxides of Nitrogen (NOx) Controls
• Intake manifold Particulate Controls • NOx absorbers and catalysts

• Turbocharger
• Charge air cooler • Any device used to capture particulate SCR systems and urea containers/dispensing
emissions systems
Fuel Metering system • Any device used in the regeneration of the
capturing system Miscellaneous Items used in Above Systems
• Fuel injection system • Enclosures and manifolding
• Smoke Puff Limiters • Electronic control units, sensors, actuators,
Exhaust Gas Recirculation wiring harnesses, hoses, connectors, clamps,
Positive Crankcase Ventilation (PCV) System fittings, gasket, mounting hardware
• EGR valve
• PCV valve
Catalyst or Thermal Reactor Systems • Oil filler cap
• Catalytic converter
• Exhaust manifold
Any warranted emissions-related part scheduled for replacement as required maintenance is warranted by John Deere for the period of time
prior to the first scheduled replacement point for the part. Any warranted emissions-related part not scheduled for replacement as required
maintenance or scheduled only for regular inspection is warranted by John Deere for the stated warranty period.
OWNER'S WARRANTY RESPONSIBILITIES:
As the off-road diesel engine owner you are responsible for the performance of the required maintenance listed in your Operator’s Manual. John
Deere recommends that the owner retain all receipts covering maintenance on the off-road diesel engine, but John Deere cannot deny warranty
solely for the lack of receipts or for the owner’s failure to ensure the performance of all scheduled maintenance. However, as the off-road diesel
engine owner, you should be aware that John Deere may deny you warranty coverage if your off-road diesel engine or a part has failed due to
abuse, neglect, improper maintenance or unapproved modifications.
Manual. Use of any other fuel may result in the engine no longer operating in compliance with applicable emissions requirements.
The owner is responsible for initiating the warranty process, and should present the machine to the nearest authorized John Deere dealer as soon
as a problem is suspected. The warranty repairs should be completed by the authorized John Deere dealer as quickly as possible.
Emissions regulations require the customer to bring the unit to an authorized servicing dealer when warranty service is required. As a result, John
Deere is NOT liable for travel or mileage on emissions warranty service calls.
Emission_CI_CARB (01Feb17)
70-8 PN=149
081922
Warranty
Emissions Cont ro l Wa rra n ty S ta te m e n t 2019 th ro u g h 2021

DXLOGO V1 —UN—28AP R09
CALIFORNIA EMISSIO NS CONT ROL WARRANTY S TATEMENT

YOUR WARR ANTY RIGHTS AND OBL IGATIONS
To deter mine if the John Deer e engine qualifie s for the additional war ranties set forth below , look for the “Emis s ion Cont rol Informa tion” label loca te d
on the engine. If the engine is oper ated in the United States or Cana da and the engine label state s : “This engine complie s with US EPA re gula tions
for nonr oad and stati ona ry dies e l engines”, or “This engine compl ies with US EPA re gula tions for s ta tiona ry e me rge ncy dies e l engines ”, re fe r to the
“U.S . and Cana da Emis s ion Contr ol Warr anty Statement.” If the engine is oper ated in California, and the engine label s ta te s : “This engine complie s
with US EPA and CARB re gula tions for nonr oad dies e l engines” als o re fe r to the “Ca lifornia Emiss ions Cont rol Wa rra nty S ta te me nt.”
Warr anties stated on this certificate refe r only to emis sions -re la te d par ts and components of your engine. The comple te engine war ra nty, les s
emis sion -re la te d par ts and components, is pro vide d separate ly. If you have any questions about your war ra nty rights and re s pons ibilitie s ,
you should contact John Deer e a t 1-319 -292 -5400.
CALIFORNIA EMISSIO NS CONT ROL WARR ANTY S TATEMENT:
The California Air Resour ce s Board (CARB) is pleased to expl a in the emis sion -contr ol s ys te m war ra nty on 2019 through 2021 off-roa d dies e l
engines. In California, new off-roa d engines must be desi gne d, built and equipped to meet the S ta te ’s s tringe nt ant i-s mog s ta nda rds . J ohn Deer e
must war rant the emis sion control s ys te m on your engine for the per iods of time lis te d below provide d the re has been no abus e , neglec t or
Your emis sion control s ys te m may include par ts suc h a s the fuel injection s ys te m and the air induc tion s ys te m. Als o included ma y be hos e s , belt s ,
connectors and other emis sion -re la te d ass emb lie s .
John Deer e war rants to the ultimat e pur cha s e r and each subs e que nt pur cha s e r that this off-roa d dies e l engine was des igned, built, and equipped
s o a s to conform a t the time of sal e with all applic able re gula tions adopted by CARB and is fre e from def e cts in ma te ria ls and workma ns hip which
would caus e the failure of a war ranted par t to be identic a l in all mater ia l re s pe cts to the par t a s de s cribe d in J ohn Deer e's applic a tion for ce rtifica tion
for a per iod of five years from the date the engine is deliver e d to a n ultima te pur cha s e r or 3,000 hour s of oper a tion, whichev e r occurs firs t for all
engines ra te d a t 19 kW and gre a te r. In the absence of a devi ce to measur e hour s of use, the eng ine s ha ll be war ra nte d for a per iod of five ye a rs .
RG29280 —UN—02FEB17
EMISSIO NS WARRANTY EXCLUS IONS :
John Deer e may deny war ranty cla ims for failure s caus e d by the use of a n add -on or modified par t which has not been e xe mpte d by the CARB. A
modified par t is a n after market par t intended to re pla ce a n origina l emis sion -re la te d par t which is not functiona lly ident ica l in all re s pe cts and which
in any way a ffects emis sions . An add -on par t is any after market par t which is not a modified par t or a re pla ce me nt par t.
In no event will John Deer e , any author ize d engine dis tributor, dealer , or re pa ir facility, or any compa ny a ffilia te d with J ohn Deer e be liable
for incidental or cons e que ntia l damage .
70-9 081922
PN=150
Warranty
RG29281 —UN—27FEB17
70-10 081922
PN=151
Warranty
Emissions Control Warranty Statement 2022 through 2024

CALIFORNIA EMISSIONS CONTROL WARRANTY STATEMENT

To determine if the John Deere engine qualifies for the additional warranties set forth below, look for the “Emission Control Information” label located
on the engine. If the engine is operated in the United States or Canada and the engine label states: “This engine complies with US EPA regulations
for nonroad and stationary diesel engines”, or “This engine complies with US EPA regulations for stationary emergency diesel engines”, refer to the
“U.S. and Canada Emission Control Warranty Statement.” If the engine is operated in California, and the engine label states: “This engine complies
with US EPA and California regulations for nonroad/off-road diesel engines” also refer to the “California Emissions Control Warranty Statement.”
emission-related parts and components, is provided separately. If you have any questions about your warranty rights and responsibilities,
CALIFORNIA EMISSIONS CONTROL WARRANTY STATEMENT:
The California Air Resources Board (CARB) is pleased to explain the emission-control system warranty on 2022 through 2024 off-road diesel
engines. In California, new off-road engines must be designed, built and equipped to meet the State’s stringent anti-smog standards. John Deere
must warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse, neglect or
Your emission control system may include parts such as the fuel injection system and the air induction system. Also included may be hoses, belts,
connectors and other emission-related assemblies.
John Deere warrants to the ultimate purchaser and each subsequent purchaser that this off-road diesel engine was designed, built, and equipped
so as to conform at the time of sale with all applicable regulations adopted by CARB. John Deere warrants that this engine is free from defects in
materials and workmanship which would cause the failure of emissions warrantied parts to be identical in all material respects to the part as
described in John Deere's application for certification for a period of five years from the date the engine is delivered to an ultimate purchaser or
3,000 hours of operation, whichever occurs first. This applies to all engines rated at 19 kW and greater. In the absence of a device to measure
hours of use, the engine shall be warranted for a period of five years.
EMISSIONS WARRANTY EXCLUSIONS:
John Deere may deny warranty claims for failures caused by the use of an add-on or modified part which has not been exempted by the CARB. A
modified part is an aftermarket part intended to replace an original emission-related part which is not functionally identical in all respects and
which in any way affects emissions. An add-on part is any aftermarket part which is not a modified part or a replacement part.
In no event will John Deere, any authorized engine distributor, dealer, or repair facility, or any company affiliated with John Deere be liable
for incidental or consequential damage.
70-11 PN=152
081922
Warranty
JOHN DEERE'S WARRANTY RESPONSIBILITY:
Where a warrantable condition exists, John Deere will repair or replace, as it elects, your off-road diesel engine at no cost to you, including
diagnosis, parts or labor. Warranty coverage is subject to the limitations and exclusions set forth herein. The off-road diesel engine is warranted
for a period of five years from the date the engine is delivered to an ultimate purchaser or 3,000 hours of operation, whichever occurs first. The
following are emissions-related parts:
Air Induction System Emission control labels Advanced Oxides of Nitrogen (NOx) Controls
• Intake manifold Particulate Controls • NOx absorbers and catalysts

• Turbocharger
• Charge air cooler • Any device used to capture particulate SCR systems and urea containers/dispensing
emissions systems
Fuel Metering system • Any device used in the regeneration of the
capturing system Miscellaneous Items used in Above Systems
• Fuel injection system • Enclosures and manifolding
• Smoke Puff Limiters • Electronic control units, sensors, actuators,
Exhaust Gas Recirculation wiring harnesses, hoses, connectors, clamps,
Positive Crankcase Ventilation (PCV) System fittings, gasket, mounting hardware
• EGR valve
• PCV valve
Catalyst or Thermal Reactor Systems • Oil filler cap
• Catalytic converter
• Exhaust manifold
Any warranted emissions-related part scheduled for replacement as required maintenance is warranted by John Deere for the period of time
prior to the first scheduled replacement point for the part. Any warranted emissions-related part not scheduled for replacement as required
maintenance or scheduled only for regular inspection is warranted by John Deere for the stated warranty period.
OWNER'S WARRANTY RESPONSIBILITIES:
As the off-road diesel engine owner you are responsible for the performance of the required maintenance listed in your Operator’s Manual. John
Deere recommends that the owner retain all receipts covering maintenance on the off-road diesel engine, but John Deere cannot deny warranty
solely for the lack of receipts or for the owner’s failure to ensure the performance of all scheduled maintenance. However, as the off-road diesel
engine owner, you should be aware that John Deere may deny you warranty coverage if your off-road diesel engine or a part has failed due to
abuse, neglect, improper maintenance or unapproved modifications.
Manual. Use of any other fuel may result in the engine no longer operating in compliance with applicable emissions requirements.
The owner is responsible for initiating the warranty process, and should present the machine to the nearest authorized John Deere dealer as soon
as a problem is suspected. The warranty repairs should be completed by the authorized John Deere dealer as quickly as possible.
Emissions regulations require the customer to bring the unit to an authorized servicing dealer when warranty service is required. As a result, John
Deere is NOT liable for travel or mileage on emissions warranty service calls.
Emission_CI_CARB (14Apr20)
70-12 PN=153
081922
Warranty
RG32758 —UN—19AUG20
70-13 081922
PN=154
Warranty
RG32759 —UN—19AUG20
DX,EMISSIONS,CARB -19-26AUG20-8/8
70-14 081922
PN=155
Technical Information
Technical information can be purchased from John Deere.
Publications are available in print or CD-ROM format.
Orders can be made using one of the following:
• John Deere Technical Information Store:
www.JohnDeere.com/TechInfoStore
• Call 1-800-522-7448
• Contact your John Deere dealer
Available information includes:
PARTS CATALOGS list service parts available for your
machine with exploded view illustrations to help you
identify the correct parts. It is also useful in assembling
and disassembling.
DX,SERVLIT -19-07DEC16-1/4
OPERATOR’S MANUALS providing safety, operating,

maintenance, and service information.
TS191 —UN—02DEC88
TECHNICAL MANUALS outlining service information for

your machine. Included are specifications, illustrated
assembly and disassembly procedures, hydraulic oil flow
diagrams, and wiring diagrams. Some products have
separate manuals for repair and diagnostic information.
Some components, such as engines, are available in a
separate component technical manual.
Continued on next page DX,SERVLIT -19-07DEC16-3/4
75-1 081922
PN=156
EDUCATIONAL CURRICULUM including five

comprehensive series of books detailing basic information
regardless of manufacturer:
• Agricultural Primer series covers technology in farming
and ranching.
• Farm Business Management series examines
TS1663 —UN—10OCT97
“real-world” problems and offers practical solutions in
the areas of marketing, financing, equipment selection,
and compliance.
• Fundamentals of Services manuals show you how to
repair and maintain off-road equipment.
• Fundamentals of Machine Operation manuals
explain machine capacities and adjustments, how to
improve machine performance, and how to eliminate
unnecessary field operations.
• Fundamentals of Compact Equipment manuals provide
instruction in servicing and maintaining equipment up to
40 PTO horsepower.
75-2 081922
PN=157
75-3 081922
PN=158
Index
Page
Page
A
Cooling system
Acid burns................................................................... 30-3 Adding coolant ........................................................ 45-2
Air cleaner Check...................................................................... 35-6
Air intake restriction indicator.................................. 25-1 Flush ....................................................................... 40-4
Dust unloader valve ................................................ 25-1 Pressure test........................................................... 35-9
Replace single stage element................................. 45-4 Pressure test radiator cap....................................... 35-9
Air compressor ........................................................... 45-9 Refill ........................................................................ 40-4
Air Filter, Radial, Replacement ................................... 45-6 Crankcase vent tube, clean ........................................ 35-1
Air intake system, check............................................. 35-1 Crankshaft vibration damper ...................................... 40-3
Alternator belts ........................................................... 45-7
Ammeter ............................................................ 15-2, 15-3 D
Auxiliary gear drive, limitations ................................... 15-6
Aviation fuels .............................................................. 10-4 Damper, checking....................................................... 40-3
Avoid static electricity risk when fueling ..................... 05-6 Diesel engine oil
Non-Emissions certified and certified tier
B 1 and stage I ......................................................... 10-8
Extended service intervals .................................. 10-9
Batteries Diesel engines, cold weather effect............................ 10-6
Charge/Boost ........................................................ 15-12 Diesel fuel................................................................... 10-1
Service .................................................................... 30-3 Supplemental additives........................................... 10-2
Battery acid burns....................................................... 30-3 Diesel fuel, testing ...................................................... 10-4
Battery explosion ........................................................ 30-3
Battery Handling, Safety E
Safety, Battery Handling ......................................... 05-7
Belt tensioner Effect of cold weather on diesel engines .................... 10-6
Manual tensioner, adjust ......................................... 30-5 Emission system
Manual tensioner, adjust with tool........................... 30-6 Certification label .................................................... 70-4
Belt tensioner, automatic ............................................ 35-4 Emissions
Belts, fan and alternator Required language
Replacing ................................................................ 45-7 EPA ..................................................................... 20-1
Biodiesel fuel .............................................................. 10-3 Engine
Bleeding fuel system .................................................. 45-9 Break-in................................................................... 15-4
Bolt and screw torque values Check electrical ground .......................................... 35-6
Metric .................................................................... 60-21 Idling ..................................................................... 15-10
Unified inch ........................................................... 60-20 Operation ................................................................ 15-8
Break-in engine oil Power ratings ........................................................ 60-10
Non-Emissions certified and certified tier 4.5 L .................................................................... 60-2
1, tier 2, tier 3, stage I, stage II, and stage III........ 10-7 6.8 L .................................................................... 60-7
Break-in, engine ......................................................... 15-4 Serial number.......................................................... 01-1
Burner fuels ................................................................ 10-4 Starting.................................................................... 15-6
Stopping.................................................................15-11
C Troubleshooting ...................................................... 50-7
Warming.................................................................. 15-8
Check engine electrical ground .................................. 35-6 Engine coolant
Cold weather aids....................................................... 15-9 Disposing of .......................................................... 10-13
Compressor, air .......................................................... 45-9 Engine mounts
Coolant Checking ................................................................. 30-3
Adding..................................................................... 45-2 Engine oil
Diesel engine Break-In
Engine with wet sleeve cylinder liners................10-11 Non-Emissions certified and certified
Disposing .............................................................. 10-13 tier 1, tier 2, tier 3, stage I, stage II,
Mixing with concentrate, water quality .................. 10-12 and stage III....................................................... 10-7
Replenishing supplemental additives...................... 35-7 Change ................................................................... 30-1
Testing..................................................................... 35-8 Diesel
Testing freeze point............................................... 10-13 Non-Emissions certified and certified
Warm temperature climates .................................. 10-12 tier 1 and stage I................................................ 10-8
Index-1 081922
PN=1
Index
Page Page
Extended service intervals............................... 10-9

Engine speed, changing ........................................... 15-10 L
F Long-term storage
Preparing engine..................................................... 55-2
Fan belts..................................................................... 45-7 Lubricant
Filter, Air, Replacement .............................................. 45-6 Mixing...................................................................... 10-9
Filter, replace Lubricant Storage
Fuel ......................................................................... 35-2 Storage, Lubricant................................................. 10-10
Oil............................................................................ 30-1 Lubricants, safety ....................................................... 10-9
Fire extinguisher, service............................................ 30-1 Lubrication and maintenance
Fuel As required
Aviation ................................................................... 10-4 Pre-start cleaning guide ...................................... 45-3
Biodiesel ................................................................. 10-3 Lubrication and Maintenance
Burner ..................................................................... 10-4 Service Interval Chart ............................................. 20-2
Diesel ...................................................................... 10-1 Lubrication and Maintenance Records ....................... 65-1
Handling and storing ............................................... 10-2 Lubricity of diesel fuel ................................................. 10-2
Jet ........................................................................... 10-4
Kerosene................................................................. 10-4 M
Lubricity................................................................... 10-2
Fuel filter Maintenance Records................................................. 65-1
Checking ................................................................. 25-1 Manual belt tensioner ................................................. 30-5
Draining water......................................................... 25-1 Manual belt tensioner - using belt tension tool ........... 30-6
Replace................................................................... 35-2 Metric bolt and screw torque values ......................... 60-21
Fuel Filters Mixing lubricants......................................................... 10-9
Filters, Fuel ............................................................. 10-5 Mounts, engine
Fuel injection pump model number ............................ 01-5 Checking ................................................................. 30-3
Fuel system
Bleeding .................................................................. 45-9 O
Fuses, checking.......................................................... 45-8
Oil
G Dipstick ................................................................... 25-1
Engine
Gauge panel ...................................................... 15-2, 15-3 Non-Emissions certified and certified
Gauges ..................................................... 15-2, 15-3, 15-8 tier 1 and stage I................................................ 10-8
Fill quantity............................................................ 60-19
H Filler locations ......................................................... 25-1
Oil filter, change.......................................................... 30-1
Hand throttle ...................................................... 15-2, 15-3 Oil filters.................................................................... 10-10
Hardware torque values Oil pressure gauge ............................................ 15-2, 15-3
Metric .................................................................... 60-21 Operating engine
Unified inch ........................................................... 60-20 Break-in................................................................... 15-4
Cold weather........................................................... 15-9
Normal operation .................................................... 15-8
I
Idling engine ............................................................. 15-10 P
Instrument panels .............................................. 15-2, 15-3
Poly-vee belts
Replace................................................................... 45-7
J Power ratings............................................................ 60-10
4.5 L ........................................................................ 60-2
Jet fuels ...................................................................... 10-4
6.8 L ........................................................................ 60-7
Pre start cleaning
K Guide ...................................................................... 45-3
Key switch ......................................................... 15-2, 15-3
Index-2 081922
PN=2
Index
Page Page
Removing from........................................................ 55-3

R Storing fuel ................................................................. 10-2
Supplemental coolant additives
Radiator cap testing.................................................... 35-9 Replenishing ........................................................... 35-7
Recordkeeping
Engine serial number .............................................. 01-1 T
Injection pump model number................................. 01-5
Refueling, avoid static electricity risk.......................... 05-6 Temperature gauge (coolant) ............................ 15-2, 15-3
Tensioner, belt
S Automatic ................................................................ 35-4
Manual .................................................................... 30-5
Safety Testing diesel fuel ....................................................... 10-4
Protect against noise .............................................. 05-7 Thermostat
Safe maintenance, practice .................................... 05-9 Install....................................................................... 40-6
Safety, Avoid High-Pressure Fluids Remove................................................................... 40-6
Avoid High-Pressure Fluids .................................. 05-10 Test opening temperature ....................................... 40-6
Safety, Handle Fuel Safely, Avoid Fires Torque charts
Avoid Fires, Handle Fuel Safely.............................. 05-4 Metric .................................................................... 60-21
Safety, lubricants ........................................................ 10-9 Unified inch ........................................................... 60-20
Serial number Trademarks .................................................................... -7
Engine..................................................................... 01-1 Troubleshooting
Fuel injection pump................................................. 01-5 General, engine ...................................................... 50-7
Service
As required U
Pre-start cleaning guide ...................................... 45-3
Battery..................................................................... 30-3 Unified inch bolt and screw torque values ................ 60-20
Fire extinguisher ..................................................... 30-1
Service intervals V
Extended diesel engine oil
Non-Emissions certified and certified Valves
tier 1 and stage I................................................ 10-9 Clearance, check and adjust................................... 40-9
Signal words, understand ........................................... 05-1 Vibration damper ........................................................ 40-3
Specifications
4.5 L ........................................................................ 60-1
6.8 L ........................................................................ 60-1
W
Battery capabilities.................................................. 30-3
Warming engine ......................................................... 15-8
Belt tensioner .......................................................... 35-4
Warranty
Damper ................................................................... 40-3
Information and registration ........................................ -3
Engine crankcase oil fill ........................................ 60-19
Non-road emissions control warranty
Fuel injection pump............................................... 60-10
statement--compression ignition
4.5 L .................................................................... 60-2
CARB .................................................................. 70-7
6.8 L .................................................................... 60-7
EPA ..................................................................... 70-5
Standby power units ................................................... 15-6
OEM applications.................................................... 70-1
Starting engine ........................................................... 15-6
Wiring diagram
Stopping engine.........................................................15-11
Except North America ............................................. 50-5
Storage
North America ......................................................... 50-3
Guidelines ............................................................... 55-1
Index-3 081922
PN=3
Index
Index-4 081922
PN=4
Operation and maintenance manual
Alternator
KH00351T KH00371T KH00440T KH00442T KH00461T KH00462T

KH070T KH07830T KH08560T KH08890T KH09720T
Supplied by
33521034901_1_1
2//2022
Preface
Contents
CONTENTS 1
SECTION 1. PREFACE ............................................................................................................................................................. 3
1.1 General guidelines............................................................................................................................................................ 3
1.2 Instructions and safety regulations (personal protection).................................................................................................. 4
SECTION 2. APPLICABLE DIRECTIVES AND STANDARDS ................................................................................................. 4
SECTION 3. SPECIFICATIONS ................................................................................................................................................ 5
3.1 Mass ................................................................................................................................................................................. 5
SECTION 4. MAINTENANCE .................................................................................................................................................... 5
4.1 General checking of the installation .................................................................................................................................. 5
4.2 Maintenance schedule...................................................................................................................................................... 6
4.2.1 Stator..................................................................................................................................................................... 6
4.2.2 Rotor...................................................................................................................................................................... 6
4.2.3 Terminal box.......................................................................................................................................................... 7
4.2.4 Anti friction bearing................................................................................................................................................ 7
4.2.5 Rubber dampers.................................................................................................................................................... 7
4.2.6 Protection devices ................................................................................................................................................. 7
4.3 Cleaning the alternator ..................................................................................................................................................... 7
4.4 Checking the ventilation circuit ......................................................................................................................................... 8
4.5 Checking bearings ............................................................................................................................................................ 8
4.5.1 Bearings lubricated for life ..................................................................................................................................... 8
4.5.2 Regreasable bearings ........................................................................................................................................... 8
4.6 Checking the winding........................................................................................................................................................ 9
4.7 Checking the windings and rotating diodes using separate excitation .............................................................................. 9
4.8 Maintenance of the regulator ............................................................................................................................................ 9
4.8.1 Recommendations................................................................................................................................................. 9
4.8.2 Access to connections and the regulation system ................................................................................................. 9
4.8.3 Regulator R180 (Scenario 1) ............................................................................................................................... 10
4.8.3.1 Presentation of the regulator ................................................................................................................. 10
4.8.3.2 Setting the regulator .............................................................................................................................. 10
4.8.4 Regulator R250 (Scenario 0) ............................................................................................................................... 11
4.8.5 Regulator R449 ................................................................................................................................................... 12
4.8.6 Regulator R450 or R450M/R450T (scenario 1) ................................................................................................... 13
4.8.7 Regulator D510C................................................................................................................................................. 15
4.8.8 D350 Regulator ................................................................................................................................................... 18
4.8.9 D550 Regulator ................................................................................................................................................... 19
4.8.9.3 Replacing the regulator ......................................................................................................................... 20
SECTION 5. STORAGE........................................................................................................................................................... 20
5.1 Storage instructions ........................................................................................................................................................ 20
5.2 Storage in Warehouse .................................................................................................................................................... 20
5.3 Storage in Maritime packing ........................................................................................................................................... 21
5.4 Storage of antifriction bearings ....................................................................................................................................... 21
5.5 Storage of open drip proof machines.............................................................................................................................. 21
SECTION 6. REPAIRING FAULTS ......................................................................................................................................... 21
6.1 Mechanical faults ............................................................................................................................................................ 21
6.2 Electrical faults................................................................................................................................................................ 21
6.2.1 R180.................................................................................................................................................................... 22
6.2.2 R220/R250/R438/R450/R450M/R450T ............................................................................................................... 22
6.2.3 R449.................................................................................................................................................................... 23
6.2.3.1 In case of 1F, parallel operation between alternators ............................................................................ 23
6.2.3.2 Example of 2F and 3F ........................................................................................................................... 24
6.2.4 D510C ................................................................................................................................................................. 25
624_EN 2022-12-01 1
Preface
6.2.5 D350 .................................................................................................................................................................... 27

6.2.6 D550 .................................................................................................................................................................... 28
2 624_EN 2022-12-01
Preface
Section 1. Preface
2 possibilities for the type of excitation:

- Case 0: KH00404TN4N - short-circuit not maintained at 3 In for 10 seconds("N" for "No")
- Case 1: KH00404TO4N - short-circuit maintained at 3 In for 10 seconds ("Y" for "Yes")
Regulator:
Case 0 (N) R250/R450 (_/M/T)/D510C
Case 1 (Y) R180 / R449 / R450 (_/M/T) / D350 / D510C / D550
Standard configuration:
Alternator
KH00351T KH00371T KH00440T KH00442T KH00461T KH00462T KH00590T KH00601T
reference
Case 1 1 1 1 1 1 1 1
Regulator D350 R180 D350 D350 D350 R180 R180 D350
Alternator
reference
Case 1 1 1 1 1 1 1 1
Regulator R180 R180 R450 R450 R180 R180 D350 R180
Alternator
reference
Case 1 1 1 1 1 0 1 1
Regulator R180 R450 R450 R180 R180 R250 R180 R450M
Alternator
reference
Case 1 1 0 1 0 0 0 0
Regulator R180 R180 R250 R180 R250 R250 R250 R250
Alternator
reference
Case 1 1 1 0 1 1 1 1
Regulator R450M R180 R180 R250 R450 R450M R450M R450M
Alternator
reference
Case 1 1 0 1 0 1 1 1
Regulator R450 R450M R250 R450M R250 D350 R450M R450M
Alternator
reference
Case 1 1 1 1 1 1 1 1
Regulator D350 R450M R450 D350 D510C D510C D510C D510C
Alternator
reference
Case 1 1 1 1 1 1 1 1
Regulator D350 D510C D510C D510C D350 D510C D510C D510C
Alternator
KH06932T KH06550T KH07760T KH07830T KH08560T KH08890T KH09720T
reference
Case 1 1 1 1 1 1 1
Regulator D510C D510C D550 D510C D510C D510C D510C
1.1 General guidelines

Before using your machine, it is important to read the whole of this maintenance manual. All necessary operations and
interventions on this machine must be performed by a qualified technician. Our technical support service will be pleased to
provide any additional information you may require. The various operations described in this manual are accompanied by
recommendations or symbols to alert the user to the potential risk of accidents. It is vital that you understand and take notice of
the different warning symbols used.
In this manual, the warning messages are used as follows:
Immediate danger.
Indicates an imminent danger which may result in death or serious injury. Failure to follow the instruction
shown may pose serious risks to the health and life of those concerned.
DANGER
624_EN 2022-12-01 3
Applicable directives and standards
Potential danger.
Indicates a dangerous situation if the warning is not heeded. Failure to follow the instruction indicated may
cause minor injuries to those concerned or damage to equipment.
IMPORTANT
Note : The manufacturer reserves the right to modify the characteristics of its products at any time to incorporate the latest
technological developments. The information contained in this document are subject to change without previous notice.
1.2 Instructions and safety regulations (personal protection)
RISK OF INJURY.
During operation, do not allow anyone to stand in front of the air outlet guards, in case anything is ejected
from them.
Do not allow children younger than 14 to go near the air outlet guards.
IMPORTANT
RISK OF BURN.
Never touch the alternator during operation or immediately after the stopping of the unit because some
surface parts might still be very hot.
IMPORTANT
It is forbidden to spray or put any liquid containers on electrical parts.

Electric rotating machines have dangerous parts : when operating they have live and rotating components.
Therefore:
- improper use,
- the removal of protective covers and the disconnection of protection devices,
IMPORTANT - inadequate inspection and maintenance can cause personal injury or property damage.
Section 2. Applicable directives and standards
DIRECTIVES:
- Low Voltage Directive no. 2014/35/EU of 26th February 2014
- Machinery Directive no. 2006/42/EC of 17 May 2006
- EMC Directive no. 2014/30/EU of 26th February 2014
STANDARDS:
- EN 55011, Group 1, Class B : “Industrial, scientific and medical equipment – Radio-frequency disturbance characteristics
– Limits and methods of measuring”
- EN and IEC 60034 – 1 "Rotating electrical machines - Part 1: Rating and Performance"
- IEC 60034 – 5 – “Rotating electrical machines, Part 5: Degrees of protection provided by the integral design of rotating
electrical machines”
- ISO 8528 – 3 – “Reciprocating internal combustion engine driven alternating current generating sets – Part 3: Alternating
current generators for generating sets”
4 624_EN 2022-12-01
Specifications
Section 3. Specifications
3.1 Mass
Masses (kg)
Units : kg :
Values given for information only
Alternator KH00351T KH00371T KH00440T KH00442T KH00461T KH00462T KH00590T KH00601T

Single bearing 87 117 102 102 133 133 247 165
Dual bearings 96 / 109 109 145 / / 170
Single bearing 165 186 295 295 280 280 187 187
Dual bearings / / 301 301 / / 207 /
Single bearing 187 332 368 353 353 569 383 599
Dual bearings / 338 374 / / 569 / 599
Single bearing 599 607 433 418 674 682 976 754
Dual bearings / / 439 / 674 682 996 754
Single bearing 754 539 539 1113 1113 888 888 1245
Dual bearings 754 / / 1126 1126 888 888 1245
Single bearing 1420 1431 450 1578 1372 2290 1639 1792
Dual bearings 1445 1480 544 1622 1392 2330 1683 1835
Single bearing 2490 1841 1820 2760 3705 3705 3737 3737
Dual bearings 2530 1884 1845 2800 3724 3748 / /
Single bearing 2980 3950 3950 3989 3260 4433 4435 4924
Dual bearings 3010 3991 3991 / 3300 4476 / 4967
Alternator KH06932T KH06550T KH07760T KH07830T KH08560T KH8890T KH09720T
Single bearing 4738 5700 / 6300 5935 8545 8995
Dual bearings / / / / 6092 / /
Section 4. Maintenance
4.1 General checking of the installation
ELECTRICAL EQUIPEMENT – RISK OF ELECTRICAL SHOCK

All work on the alternator terminals during reconnection or checks must be made
with absolute certainty of no tension in them.
DANGER
RISK OF INJURY
Before any work on the generator, make sure that the start-up cannot be activated
by any manual or automatic signal. Check that all locks are engaged and follow
the site safety procedures.
DANGER
RISK OF INJURY
Before working on the machine, make sure that you have understood the
operating principles of the system. If necessary, refer to the appropriate chapters
in this manual.
DANGER
624_EN 2022-12-01 5
Maintenance
To obtain additional information on the maintenance of sub-assemblies, refer to the chapters dealing with the subassemblies
concerned.
- When a defective part is replaced with a spare part, make sure that it is in good condition.
- For any electrical work use electrical schematics for assistance
- The whole machine must be kept clean.
- Check the operation at regular intervals (no abnormal noise or vibration).
- Check the tightness of all nuts and bolts in particular of the electric connections.
All the cleaning period indicated in this manual may be changed (increased or decreased)
according to site conditions
IMPORTANT
- The air inlet and air outlet surfaces must be maintained clean (Louvers can be cleaned as per the filters).
Dirt entering the machine may pollute and thus reduce the electrical connection.
IMPORTANT
Any product (sealing compound, cleaning product) used during maintenance or servicing
must be in accordance with local regulation and environmental standard.
IMPORTANT
4.2 Maintenance schedule

The purpose of the general maintenance schedule below is to help establish the maintenance schedule particular to the
installation. The suggestions and recommendations are to be followed as closely as possible in order to maintain the machine
efficiency and in order not to reduce the service life of the machine.
The maintenance operations are detailed in the chapters relative to the concerned subjects.
Task duration are for information only.
Name Hours Comments Task Duration

Major overhaul 40 000 Or 5 to 7 years following site conditions 4 weeks
4.2.1 Stator

Winding temperature 24 Daily operation, (without gen stop).
Insulation
4hrs
Polarisation index
Bolts tightening 8000 2hrs
Or once a year whichever come first
Winding visual inspection 1hr
Stator RTD function
Cleaning air inlet and outlet 1000
4.2.2 Rotor
Insulation
0.5 hr
Polarisation index
Winding visual inspection
8000 Or once a year whichever come first
Cleaning diodes
Diodes and varistor check 0.5 hr
Diodes tightening
6 624_EN 2022-12-01
Maintenance
4.2.3 Terminal box

Cleaning Or once a year whichever come first 0.5 hr
Or once a year whichever come first (applicable if
Regulator assembly & supports 8000
mounted in the terminal box)
Bolts tightening Or once a year whichever come first 1.5 hrs
4.2.4 Anti friction bearing

Re greasing See lub plate; Or every 6 months whichever come first
Bearing temperature 24 Daily operation, (without gen stop)
4.2.5 Rubber dampers

Rubber dampers 8000 Or once a year whichever come first
4.2.6 Protection devices

Protection devices 8000 Or once a year whichever come first
4.3 Cleaning the alternator

Electrical part
Do not use: trichlorethylene, perchlorethylene, trichloroethane or any alkaline products.
IMPORTANT
- Use commercially-available volatile degreasing agents.
Nota : The insulating components and the impregnation system are not at risk of damage from solvents.
- Avoid letting the cleaning product run into the slots.

- Apply the product with a brush, sponging frequently to avoid accumulation in the housing.
- Dry the winding with a dry cloth and let any traces evaporate before reassembling the machine.
- Check the winding insulation.
Mechanical part
These operations must be performed at a cleaning station, equipped with a vacuum system that collects
and flushes out the products used.
IMPORTANT
Cleaning the machine using water or a highpressure washer is strictly prohibited.

Any problems arising from such treatment are not covered by our warranty.
Use compressed air only in low pressure for the alternator external cleaning.
IMPORTANT
- Degrease the alternator using a brush and detergent(suitable for paintwork).

- Dust using an air gun.
- If the machine is fitted with air inlet and outlet filters, clean them routinely at regular intervals.
- In the case of dry dust, clean the filter using compressed air and/or replace it if it is clogged.
- After cleaning the alternator, it is essential to check the winding insulation
624_EN 2022-12-01 7
Maintenance
4.4 Checking the ventilation circuit
ELECTRICAL EQUIPMENT - RISK OF ELECTRIC SHOCK

Removing the filters should be done when the installation is stopped, this operation
gives access to parts that could be under voltage.
DANGER
- Ensure that air flow is not reduced by partial blocking of the suction and discharge grids: mud, fiber, grease, etc ...
- Check for corrosion or abrasion grids air outlet.
If your system is equipped with filters:
- Remove the grid and remove the filter.
- Clean the filter with low pressure compressed air or replace if it is clogged.
.
Air inlet
Filter
Support
4.5 Checking bearings

4.5.1 Bearings lubricated for life
The approximate lifetime of the grease (depending on use) is 20 000 hours or 3 years.
- Control the temperature rising of the bearings which must not exceed 90 ° C.
- In the case of exceeding this value, stop the alternator and proceed to a checking.
- Contact an authorized agent for bearings change.
4.5.2 Regreasable bearings
It is imperative to lubricate the alternator during operation.

Before using another grease, check for compatibility with the original one.
IMPORTANT
If your equipement is doted of regreasable bearings, it is recommended to :

- lubricate the alternator during operation.
- Check for the temperature rising of the bearings.
KH01100T - KH01220T KH01630T - KH01741T KH02400T - KH02401T

KH02971T - KH03541T
Alternator KH01420T - KH01421T KH02070T - KH02450T KH02850T - KH03003T
KH03890T - KH04450T
reference KH01640T - KH01641T KH02880T KH03390T - KH03542T
KH05090T
KH02100T - KH02101T KH03603T
Quantity of grease (g) : LITHIUM - standard - NLGI 3
Front bearing 33 41 60 60
Rear bearing 30 30 50 50
Lubrication frequency (h)
4000 3500 4500 3600
KH04402T - KH04404T
KH04406T - KH04972T
Alternator
- KH04973T - KH04974T KH04403T - KH06931T KH07760T
reference
KH05793T - KH05794T
KH06932T - KH08560T
Quantity of grease (g) : Mobil polyrex EM – NLGI 2
Front bearing 70 70 70 See nameplate
Rear bearing 35 40 40 See nameplate
Lubrication frequency (h)
1700 2100 1500 6 months
8 624_EN 2022-12-01
Maintenance
4.6 Checking the winding
The insulation must be higher than 1 MΩ for the stator and 100 000 Ω for the other windings.
Damage caused to the AVR in such conditions is not covered by our warranty.
IMPORTANT
- Disconnect all AVR wires.

- Check the winding insulation by performing a high voltage test.
To restore the minimum values of 1 M Ω and 100 000Ω, two methods are possible :
- Dry out the machine for 24 hours in a drying oven at a temperature of 110 °C (without the regulator).
- Blow hot air into the air intake, having made sure that the machine is rotating with the exciter field disconnected.
4.7 Checking the windings and rotating diodes using separate excitation

During this procedure, make sure that the alternator is disconnected from any
external load and inspect the terminal box to check that the connections are fully
tightened.
DANGER
1. Stop the unit, disconnect and isolate the AVR wires.

2. Connect a 12 V battery in series with a rheostat of approximately 50 ohms - 300 W and a diode on both exciter field
wires (5+) and (6-).
This system should have characteristics which are compatible with the field excitation power of the machine(see the
nameplate).
3. Run the unit at its rated speed.
4. Gradually increase the exciter field current by adjusting the rheostat or the variac and measure the output voltages on
L1 - L2 - L3, checking the excitation voltage and current at no load (see the machine nameplate or ask for the factory
test report).
When the output voltage is at its rated value and balanced within 1% for the rated excitation level, the machine is in good
working order. The fault therefore comes from the AVR or its associated wiring (ie. sensing, auxiliary windings).
4.8 Maintenance of the regulator

4.8.1 Recommendations
During the warranty period, this operation should only be carried out in an approved workshop or in our
factory, otherwise the warranty may be invalidated.
Whilst being handled, the machine should remain horizontal (rotor not locked in position). Check how
much the machine weighs before choosing the lifting method.
IMPORTANT
4.8.2 Access to connections and the regulation system

Access directly by removing the box lid or the AVR access door.
624_EN 2022-12-01 9
Maintenance
4.8.3 Regulator R180 (Scenario 1)

4.8.3.1 Presentation of the regulator
UFRO selection line:
Open 60 Hz operation mode.
Closed 50 Hz operation mode.
UFRO Pot.
45 Hz to 55 Hz in 50 Hz mode.
55 Hz to 65 Hz in 60 Hz mode.
Voltage
The operating voltage is set by the potentiometer marked "V".
Droop
The droop is set by the potentiometer marked "Droop".
Entry-level accessory and external pot.
The entry-level accessory is set by the potentiometer marked "Acc". This potentiometer sets the maximum voltage
range of the external potentiometer or the entry-level accessory range.
Stability
The potentiometer is used to set the stability of the alternator output voltage; move it clockwise to increase the speed.
The desired setting is obtained by moving the stability potentiometer clockwise into the position at which the voltage
becomes unstable, then reducing the setting by 1 turn.
Display
- Overexcitation limit
- Loss of voltage detection
- UFRO
4.8.3.2 Setting the regulator
Immediate danger.
To prevent electric shock and personal injury care be taken not to touch live parts.
DANGER
Potential danger.
Adjustments be done carefully and gradually while alternator is running otherwise the system may
experience fluctuations.
IMPORTANT
- VOLT : Full CCW

- STAB : Centre of Travel
- UFRO : Select 50Hz or 60Hz mode
10 624_EN 2022-12-01
Maintenance
Start - Up
- Check that all connections, the position of the encoder, the straps and add-ons are repositioned identically than the initial
regulator.
- Start the prime-mover and bring the alternator to rated speed (rpm).
- The terminal voltage will show voltage build-up.
- Adjust the terminal voltage using voltage adjust pot.
- If oscillations are seen on the voltmeter (A.C.) indicating the alternator terminal voltage, gradually turn the
«STABILITY» trimmer on R180 clock-wise and stop turning it at the position where oscillations disappear.
- If oscillations are not seen at build-up, turn the «STABILITY» trimmer CCW till oscillations appear and then slightly turn
it CW to remove oscillations. This will help tune the controller and alternator time constants.
- Set Ufro knee point at 47.5Hz for 50Hz or 57Hz for 60Hz.
- If external voltage adjust potentiometer is required, stop the alternator and connect 1Kohms potentiometer in place of
Link at terminal A1 and A2.
- If droop is required connect droop current transformer at Q1 and Q2.
4.8.4 Regulator R250 (Scenario 0)

R250

- Check that all connections, the position of the encoder, the straps and add-ons are repositioned identically than the initial
regulator.
- Make the adjustement of the regulator as follows :
1. Set the P1 potentiometer (voltage adjustment) fully anti-clockwise.
2. Set the voltage adjustment potentiometer in centre position.
3. Run the alternator at its rated speed. If the voltage does not increase, the magnetic circuit should be
remagnetized.
4. Turn the AVR voltage adjustment potentiometer P1 slowly until the output voltage rated value is obtained.
5. Adjust the stability setting using P2.
624_EN 2022-12-01 11
Maintenance
4.8.5 Regulator R449

R449

Check that all connections, the position of the encoder, the straps and add-ons are repositioned identically than the initial
regulator.
Contact an authorized agent.
12 624_EN 2022-12-01
Maintenance
4.8.6 Regulator R450 or R450M/R450T (scenario 1)

R450
R450M/R450T
624_EN 2022-12-01 13
Maintenance

Check that all connections, the position of the encoder, the straps and add-ons are repositioned identically than the initial
regulator.
Adjusting the voltage and the stability

Make the adjustment of the regulator as follows :
1. Adjust the potentiometers in their Initial settings (see table below).
Action Factory setting Pot.
Voltage minimum fully anti-clockwise 400V -50Hz
Not set
Stability
(centre position)
10A
Excitation ceiling - Factory-sealed
maximum
Voltage quadrature droop (// operation

with C.T.) - 0 quadrature droop fully Not set (fully anti-clockwise)
anti-clockwise
2. Install a D.C. analogue voltmeter (needle dial) cal. 100 V on terminals E+, E- and an A.C. voltmeter cal. 300 - 500 or
1000 V on the alternator output terminals and check the rotating switch selection.
3. Adjust the voltage potentiometer P1 at minimum, fully anti-clockwise then adjust the stability potentiometer P2 around
1/3 in from the anti-clockwise stop..
4. Start the engine and set its speed to a frequency of 48 Hz for 50 Hz, or 58 for 60 Hz.
5. Set the output voltage to the desired value using P1, rated voltage UN for solo operation (eg. 400 V) or UN + 2 to 4% for
parallel operation with C.T. (eg. 410 V -). If the voltage oscillates, use P2 to make adjustments (try both directions),
observing the voltage between F+ and F- (approx. 10 V D.C.). The best response time is obtained at the limit of the
instability. If no stable position can be obtained, try selecting the fast position.
6. Check LAM operation: depending on the rotating switch selection.
7. Vary the frequency (speed) around 48 or 58 Hz according to the operating frequency, and check the change in voltage
from that observed previously (~ 15%).
8. Readjust the speed of the genset to its rated no-load value.
14 624_EN 2022-12-01
Maintenance
4.8.7 Regulator D510C

D510C
Supply
Terminals Signals Scheme

X1 Power supply
X2 - Auxiliary winding input
Z1 - PMG input
Z2 - SHUNT input
Up to
180 V
L1 Mains voltage measurement

L2 Main
Up to
530 V
624_EN 2022-12-01 15
Maintenance
Terminals Signals Scheme

U Alternator voltage
V measurement
W For single-phase: use V and W
Up to
530 V
IU = (s1, s2) Alternator current

IV = (s1, s2) measurement
IW = (s1, s2)
AI1 Analog inputs:
AI2 External setting
DI1 Digital inputs:

DI2 U=U and PF/kVAR regulation
B+ DC power supply
B
11V to
30V
F+ Field excitation: 6 A
F up to 15 A/10 s
CTP Temperature sensors

PT100_1
PT100_2
PT1003
CAN_H CAN BUS

CAN_L
USB_D+ USB 2.0 communication port

USB_D
16 624_EN 2022-12-01
Maintenance
The LEDs serve to inform the user whether the AVR is working correctly or not.
LEDs
Name Colour Meaning

Power ON Green The board is supplied with power
Hz Red Speed drop

Red Problem of overvoltage or undervoltage
Volt
Red Problem of overexcitation or underexcitation
Exc.
Red Problem on the exciter field diode bridge
Fault
Manu Yellow Manual mode enabled
PF / KVAR Yellow Regulation of the power factor or reactive power enabled
U=U Yellow Alternator voltage = Mains voltage
USB Blue AVR connected to a PC

EasyReg is a Software which allows to :
- Easily configure the digital regulator D510C or D350.
- Monitor several important parameters such as alternator output voltage, excitation current, active and reactive power,
etc…
- Optimize the regulation loop.
- Set the AVR parameters.
- Configure the inputs and outputs.
- Display faults and parameter measurements.
It is the interface between the user and the digital AVR.
624_EN 2022-12-01 17
Maintenance
4.8.8 D350 Regulator

Excitation
Analogue input
input
Excitation
PT100 or output
CTP input
Alternator
Digital voltage
input detection
2x digital LEDs
outputs
NFlink Current measurement

programming Alternator
Voltage and droop (Parallel operation CT)
module TM
potentiometers
LEDs serve to inform the userof the operation or malfunctioning of the regulator.
The statuses of the two LEds are given in the table below according to the events.
Description GREEN LED RED LED

Normal operation ON OFF
Loss of voltage reference (1 s) OFF Flashing
Stator short circuit (10 s)
loss of reference voltage fault OFF ON
Stator short circuit fault
Overload and overheating ON Flashing
NFC communication + machine off Flashing OFF
Firmware programming Flashing Flashing

EasyReg is a Software which allows to :
- Easily configure the digital regulator D510C or D350.
- Monitor several important parameters such as alternator output voltage, excitation current, active and reactive power,
etc…
18 624_EN 2022-12-01
Maintenance
4.8.9 D550 Regulator

AC power Exciter Auxilliary power supply Grid voltage Voltage sensing
supply field in DC voltage sensing connection connection
Alternator
current
measurement
Temperature
sensor
connections
Communication
Earth terminal
LEDs Communication Input/Output

connections
LEDs serve to inform the userof the operation or malfunctioning of the regulator.
The statuses of the two LEds are given in the table below according to the events.
Name Colour Meaning

(Under) Hz Red Frequency Fault ON = Underspeed operation
(Under/Over) Volt Red Voltage Fault ON = Under or Over Voltage
Red Excitation Fault ON = Rotor overheating
(Under/Over)
BLINK = Rotor Overload or Under Excitation or Minimum
Exc.
excitation
Fault (diode) Red Diode Fault ON = Diode Open or in short circuit
I Exc. Yellow Iex regulation ON = Manual excitation mode
PF or kVAR
PF / kVAR Yellow ON = PV or kVAR regulation mode
Regulation
U=U Yellow Voltage equalization ON = Voltage equalization mode
Green Power ON ON = Regulation in operation
Power ON
BLINK = Product Energized
USB Blue USB OK ON = USB connected

EasyReg Advanced® is a Software which allows to :
- Easily configure the digital regulator D550..
- Monitor several important parameters such as alternator output voltage, excitation current, active and reactive power, etc.
624_EN 2022-12-01 19
Storage
4.8.9.3 Replacing the regulator

These operations must be performed by qualified staff.To replace a faulty D550 AVR, proceed as follows:
1. Stop the alternator if not already done.
2. Switch off and electrically isolate the auxiliary supply and power supply and check
3. that no voltage is present.
4. Carefully remove all the AVR connectors, noting their position.
5. Undo all the AVR mounting brackets so it can be removed from its position.
6. If you do not have the AVR configuration file and the D550 status allows it, import the configuration from the faulty D550
using EasyReg Advanced and a USB cable.
7. Still using the PC software, export the retrieved configuration to the new D550 AVR.
8. Disconnect the D550 USB stick.
9. Fix the new D550 in place of the faulty AVR.
10. Reconnect all the connectors on the new AVR.
11. Power up the auxiliary supply and check that the AVR is energized
12. Start up the alternator drive system.
13. Before exciting the alternator, check the alternator voltage measurement and power supply voltage (VBus).
14. Switch on the alternator excitation.
15. Check all the AVR measurements and regulation modes, and any controlled outputs.
Section 5. Storage
5.1 Storage instructions

If the alternator will not be used for a period of 6 to 18 months, the equipment must be protected.
The alternator must be stored flat, in a room protected from humidity (<90%) and extreme or frequent variations in temperature,
and free from dust, gas, major vibrations and all corrosive products.
During storage, the following is recommended:
- Measure the coil insulation resistance every three months
- Check the coil insulation every three months.
- For versions equipped with bearings requiring lubrication, turn the shaft once or twice a month to prevent corrosion
and stop the grease hardening.
Before removal from storage:

- Check the rotor and stator insulation, resistance and continuity.
- If equipped with bearings requiring lubrication, grease the bearings.
IMPORTANT
Material damage - INSULATION
After an extended period of storage or if there are clear signs of humidity/condensation,
check the condition of the insulation.
All operations must be performed by qualified personnel. In case of doubt, contact one of our agents.
5.2 Storage in Warehouse

This chapter applies to generators not protected by a waterproof.
The machine must be stored in clean and dry premises which are not subject to abrupt changes in temperature or to high
humidity (75% maximum) Storage at an ambient temperature of +5 to +45° C is recommended.
The machine must not be subject to vibrations higher than 1mm/s rms.
IMPORTANT
The heating resistor must be continuously switched ON.
20 624_EN 2022-12-01
Repairing faults
5.3 Storage in Maritime packing

The synchronous machine has been hermetically sealed at the factory then packed in a wooden crate (SEI standard class 4c).
Storage under hermetically sealed packing and wooden crate done by Kohler is guaranteed two years.
In such case, there is no request for specific preservation procedure against weather constraint.
The machine must not be subject to vibrations higher than 1mm/s rms
IMPORTANT
Breaking the hermatic protective film discharges Kohler of its long storage
guarantee.
5.4 Storage of antifriction bearings

This chapter must be taken in consideration if a machine is stopped more than 6 months.
After 6 months of stop; grease by injecting two time the grease volume used for a standard maintenance.
Then, each 3 months turn the machine shaft line of few turns while injecting a standard grease volume.
5.5 Storage of open drip proof machines

For an open machine, it is recommended that the air inlet and outlet be closed.
Section 6. Repairing faults
When working on the rotating diodes, the excitation (induced, inductors) or the main field, contact an
authorized dealer.
IMPORTANT
6.1 Mechanical faults

Fault Action
Excessive overheating of one or both - If the bearing has turned blue or if the grease has turned black,
bearings (bearing temperature 80°C change the bearing.
Bearing
above the ambient temperature) (With - Bearing not fully locked (abnormal play in the bearing cage)
or without abnormal bearing noise) - End shields incorrectly aligned
- Air flow (inlet-outlet) partially clogged or hot air is being recycled
Excessive overheating of alternator
Abdnormal from the alternator or engine
frame (more than 40° C above the
temperature - Alternator operating at too high a voltage (>105% of Un on load)
ambient temperature)
- Alternator overloaded
- Misalignment (coupling)
Too much vibration - Defective mounting or play in coupling
Vibrations - Rotor balancing fault (Engine - Alternator)
Excessive vibration and humming - Phase imbalance
noise coming from the machine - Stator short-circuit
- System short-circuit
- Misparalleling
Possible consequences
Alternator damaged by a significant
Abnormal - Broken or damaged coupling
impact, followed by humming and
noise - Broken or bent shaft end
vibration
- Shifting and short-circuit of main field
- Fan fractured or coming loose on shaft
- Irreparable damage to rotating diodes/AVR, surge suppressor
6.2 Electrical faults

After operational testing, replace all access panels or covers.
DANGER
624_EN 2022-12-01 21
Repairing faults
6.2.1 R180
Symptom Cause Action
No voltage build-up Fuse links blown Change the fuse links.
Low residual voltage Run alternator at correct RPM. If problem persist, disconnect AVR
across X1 and X2 and connect 24dc battery between F1 and F2. This process will
increase residual voltage.
Incorrect wiring Verify and repair wiring as per interconnection drawing.
Voltmeter defective Replace voltmeter
Faulty regulator Replace regulator
Voltage too high Incorrect voltage setting Set according to requirement
Low voltage External pot link open Connect link or pot according to requirement
Sensing voltage absent Connect according to diagram
Prime mover rpm falls Set RPM
Poor regulation Prime mover rpm falls Set RPM
High distortion Non- Reduce non-linear load
linear load
Alternator running on P.F. correction required
very low P.F.
Unbalanced load Redistribute the load equally to three phases.
Rotating diodes failed Replace diodes
Droop connected Remove droop connection if not needed
Voltage unstable Incorrect wiring Verify and repair wiring. Make sure that the contacts are firm.
Stability setting incorrect Set stability pot
Voltage builds-up but Incorrect wiring Verify and repair wiring. Make sure that the contacts are firm.
collapses/ erratic behavior Electronic card settings Set as per instructions in the manual
not correct
6.2.2 R220/R250/R438/R450/R450M/R450T
Fault Action Effect Check/Cause
The alternator builds up
and its voltage is still correct
- Lack of residual magnetism
when the battery is
Connect a new
removed.
battery of 4 to 12
The alternator builds up but its - Check the connection of the voltage reference
No voltage at volts to terminals
voltage does not reach the to the AVR
no load on E-(F-) and E+(F+),
rated value when the battery is - Faulty diode
start-up respecting the
removed. - Armature short-circuit
polarity, for 2 to 3
- Faulty AVR
seconds The alternator builds up but its
- Field windings open circuit (check winding)
voltage disappears when the
- Main field winding open circuit (check the
battery is removed.
resistance)
Check the AVR connections (possible AVR
failure)
- Field windings short-circuited
Correct speed
- Rotating diodes burnt out
Check the drive
Voltage too low - Main field winding short-circuited
speed
- Check the resistance
Increase the drive speed (do not touch the AVR
Speed too low voltage pot. (P2) before running at the correct
speed)
Voltage too Adjust AVR voltage
Adjustment ineffective Faulty AVR
high potentiometer
- Check the speed : possibility of cyclic
irregularity
Voltage Adjust AVR stability If no effect : try normal / fast - Loose connections
oscillations potentiometer recovery modes (ST2) - Faulty AVR
- Speed too low when on load (or AVR LAM set
too high)
22 624_EN 2022-12-01
Repairing faults
Fault Action Effect Check/Cause

R438
Scenario 1 : U<10V
Voltage correct Scenario 2 : U<20V Check the speed (or AVR LAM set too high)
Run at no load
at no load and R450
and check the
too Scenario 1 : U<10V
voltage between
low when on R438
E-(F-) and E+(F+) - Faulty rotating diodes
load Scenario 1 : U>15V
on the AVR - Short-circuit in the main field. Check the
(*) Scenario 2 : U>30V
resistance.
R450
- Faulty exciter armature. Check the resistance.
Scenario 1 : U>15V
(*) Warning : During single-phase operation, check that the sensing wires from the AVR are connected to the correct output
terminals.
Check the AVR, the
Voltage surge suppressor, - Exciter winding open circuit
disappears the rotating diodes, The voltage does not return - Faulty exciter armature
during and replace any to the rated value. - Faulty AVR
operation (**) defective - Main field open circuit or short-circuited
components
(**) (R438/R450/R450M/R450T) Warning : The AVR internal protection may cut in (overload lost connection, short circuit).
(1) R250/R438/R450/R450M/R450T
6.2.3 R449
6.2.3.1 In case of 1F, parallel operation between alternators
Symptom Probable causes Solutions
- No residual magnetism or polarity - Voltage built-up is required.
inversion between the excitation output
and the exciter input.
- De-energising contacts open. - Close this contact.
- The speed is less than the rated speed. - Adjust the speed.
- Connection lost between the regulator - Check the wiring.
Absence of voltage on start-
and the exciter.
up, at no load.
- Alternator loaded or short-circuited. - Remove the load from the alternator.
- External potentiometer connected - Check the wiring.
incorrectly.
- Faulty regulator. - Test it or change it.
- Faulty exciter or rotating diode bridge. - Check the exciter and the diodes.
- Fuses blown. - Replace the fuses.
- Incorrect voltage at the sensing - Check the wiring of the 0, 110V, 220V, 380V
terminals. terminals on terminal block J1.
Voltage too high and - Check the wiring.
adjustment potentiometer not - Loss of sensing. - Set a potentiometer with the correct value.
operating. - The external potentiometer has an
incorrect value. - Test it or change it.
- Faulty regulator.
- Voltage potentiometer set too high. - Adjust voltage potentiometer P2 or the
Voltage too high, but external potentiometer..
adjustable by the adjustment - Regulator sensing incorrect. - Check the wiring and the sensing value, at
potentiometer. 0V and 110V, 220V, 380V terminals.
- Regulator faulty. - Test it or change it.
- ST3 and ST4 jumpers - Check the presence of the ST3 and ST4
Voltage too low, but adjustable
jumpers.
by the adjustment
- The speed is too low. - Set to the correct speed.
potentiometer.
- Exciter and rotating diodes. - Check the exciter and the rotating diodes.
- Distortion of the waveform, non-linear - Contact manufacturer.
load. - Balance the load or change the sensing
- Unbalanced load. points.
Incorrect regulation.
- The speed is not at the correct value. - Adjust the speed.
- Exciter or rotating diodes faulty. - Check the exciter and the rotating diodes.
- Frequency unstable. - Check the stability of the drive system
- Secondary sensing of a transformer speed.
supplying other devices. - Provide separate sensing for the alternator.
Voltage unstable.
- Stability potentiometer P3 is incorrectly
set. - Adjust stability potentiometer P3.
- Stability adjustment. - Adjust stability potentiometer P3 and the
Response time too long. ST2 jumper.
- Speed regulator response too long. - Adjust the stability of the speed.
624_EN 2022-12-01 23
Repairing faults

- Vectorial composition fault between the - Check the wiring of the sensing and parallel
Considerable drop in voltage, voltage and the current. operation CT.
on-load. - The parallel operation CT ratio is - Correct the CT ratio.
incorrect.
- Quadrature droop potentiometer needs - Adjust the quadrature droop potentiometer.
adjusting.
- The no-load voltages are not identical. - Check that all the alternators have the same
kVAR not stable between
no-load voltage value.
alternators (reactive current
- Phases not connected to the sensing - Check the sensing wiring.
circulation).
correctly.
- The CT is not on the correct phase. - Check the position of the parallel operation
CT.
6.2.3.2 Example of 2F and 3F

- - Vectorial composition fault between the - - Check the sensing wiring and the parallel
sensing voltage and the stator current. operation CT.
- - R 726 faulty. - - Change the module.
Incorrect regulation of PF, PF
- - R 726 ST2 jumper missing.
potentiometer not operating.
- - Wiring fault between the R 449 and the - - Check the wiring, in particular the wires
R 726. between 1 and 2 of terminal block J1 on the
R 726.
PF range incorrect. - - Settings on potentiometers P2 incorrect. - Reset the range as shown above.
The LEDs will not light up. - - Contacts 2F and 3F missing. - Check the wiring.
Cannot adjust the voltage - The sensing voltage is incorrect or - Check the wiring and the value of the
matching circuit. incorrectly connected. voltage.
24 624_EN 2022-12-01
Repairing faults
6.2.4 D510C
624_EN 2022-12-01 25
Repairing faults
26 624_EN 2022-12-01
Repairing faults
6.2.5 D350
624_EN 2022-12-01 27
Repairing faults
6.2.6 D550
- Alternator sensing VT broken. - Replace faulty VT and restart the alternator.
Voltage sensing fault.
- Internal measurement broken. - Replace the AVR.
- Faulty component or opening of the field - Replace the AVR.
Excitation fault. excitation circuit which caused a voltage
surge on the transistor.
- External supply fault. - Replace the 24 VDC power supply and
24 VDC auxiliary supply fault. - Voltage converter fault. restart the alternator.
- Replace the AVR.
The AVR is not responding - Microcontroller fault. - Replace the AVR.
(display frozen, no
communication, etc.).
- Faulty input. - Switch control of the regulation mode to
The regulation mode - The wiring is faulty. another input and restart the alternator.
controlled by an input is not - Replace the AVR.
active. - Check that the input has been enabled by
shunting the 0 V and the local input.
- Faulty starting input. - Switch control of starting to another input.
- The AVR power is not switched on. - Check the VBus voltage on the HMI.
The field excitation does not
- The 24 VDC power supply is faulty. - Check that the AVR is powered up by
start.
looking at power LED.
- Restart the alternator.
- The active power is too low to have a - Use kVAr mode for low load regulation (less
correct power factor measurement. than 10% of rated load).
Regulation of the power factor - The stator current measurement is - Check the CT wiring on the current
is unstable. incorrect. measurement input and the CT.
- Replace the AVR if the wiring is correct.
- Restart the alternator.
28 624_EN 2022-12-01
Repairing faults
Field excitation
switched on? yes
Is field current
Field current
regulation yes
regulation
active?
no
Is the mains
yes
contactor closed?
Is grid PF
Grid PF
regulation yes
regulation
active?
no
Is kVAr
regulation yes kVAR regulation
no
active?
no
Machine PF
no
regulation
Is the voltage
match circuit yes Voltage match circuit
active?
no
Is voltage
regulation yes Voltage regulation
active?
no
Field current regulation
End
624_EN 2022-12-01 29
Repairing faults
30 624_EN 2022-12-01

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User and maintenance manual

for generating sets

Benefits & features GENERAL SPECIFICATIONS

KOHLER premium quality Engine brand JOHN DEERE

General Lubrication System

Number of cylinders 4 Max. intake restriction (mm H2O) 625

Displacement (l) 4.48 Combustion air flow (l/s) 91

Bore (mm) * Stroke (mm) 106 * 127 Exhaust system

Compression ratio 17 : 1 PRP ESP

Governor type Mechanical Cooling system

Fuel system Fan power 50Hz (kW) 2.50

* Engine reference may be partially modified depending on genset

Dimensions compact version

Length (mm) * Width (mm) * Height (mm) 1950 * 1084 * 1455

M138 - Dimensions soundproofed version

Length (mm) * Width (mm) * Height (mm) 2572 * 1126 * 1571

Dimensions DW compact version

Length (mm) * Width (mm) * Height (mm) 2600 * 1150 * 1676

M138 - Dimensions DW soundproofed version

Length (mm) * Width (mm) * Height (mm) 2600 * 1150 * 1792

M138 - Dimensions DW 48h soundproofed version

Length (mm) * Width (mm) * Height (mm) 2600 * 1150 * 1858

* dimensions and weight without options

The APM303 is a versatile unit which can be operated in manual or automatic

BASIC GENERATING SET AND POWER PLANT CONTROL

STANDARD SCOPE OF SUPPLY

- Industrial water cooled DIESEL engine

CODES AND STANDARDS

- Machinery Directive 2006/42/EC of May 17th 2006

POWER RATINGS DEFINITION according to ISO8528-1 (2018-02 edition) and ISO-3046-1

- for Products in "back-up" service

7.1.3 High voltage installations ..................................................................................................................................... 30

9.3.6 Starter batteries ................................................................................................................................................... 55

1.1 Organization of the documentation

DANGER RISK TO THE HEALTH OF THOSE CONCERNED

IMPORTANT Material damage

1.2 Warnings regarding all operations on the generating set

DANGER RISK TO THE HEALTH OF THOSE CONCERNED

1.3 Contact your authorized Kohler distributor/dealer for service

Section 2. Meaning of the pictograms on the generating set

Section 3. Equipment description

3.1 Identification plates

3.1.2 Location of plates on containerized generating sets

Figure 2: Position of the nameplate for generator sets in a container

3.1.3 Identifying sets

Generator sets and their components are identified by means of Nameplates.

Figure 3: Example of a generator set Nameplate

3.1.4 Identifying generating set components

3.2 Generating sets with and without an enclosure

3.2.1 Enclosed generating set

Figure 4: General description of a generator set with enclosure

1 Lifting eye 6 Engine 11 Skid

3.2.2 Generating set without enclosure

Figure 5: General description of a generator set without enclosure

1 Air filter 5 Engine 9 Frame

3.3 Containerised generating sets

3.3.1 ISO 20 and ISO 40 containers

Figure 6: Example of an ISO 20 container

soundproof air inlet AIPR ⃰