Page 136

PowerTech 4045TF280 - Page 136

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Table of Contents

Introduction2
Contents5
Record Keeping7
Engine Serial Number Plate7
Record Engine Serial Number7
Engine Option Codes8
Record Fuel Injection Pump Information10
Safety11
Signal Words11
Replace Safety Signs12
Practice Safe Maintenance14
Fuels, Lubricants and Coolant27
Diesel Fuel27
Required Fuel Properties27
Sulfur Content27
Lubricity of Diesel Fuel28
Handling and Storing Diesel Fuel28
Testing Diesel Fuel29
Bio-Diesel Fuel30
Air Intake Heater32
Coolant Heater32
Diesel Fuel Flow Additive32
Diesel Engine Break-In Oil33
Winterfronts33
Radiator Shutters33
Diesel Engine Oil34
Diesel Engine Oil and Filter Service Intervals35
Mixing of Lubricants36
Oil Filters36
Oilscan and Coolscan36
Alternative and Synthetic Lubricants37
Lubricant Storage37
Grease38
Diesel Engine Coolant39
Additional Recommended Coolants39
Other Coolants39
Drain Intervals for Diesel Engine Coolant40
Supplemental Coolant Additives41
Testing Diesel Engine Coolant41
Coolant Test Strips41
Operating in Warm Temperature Climates42
Disposing of Coolant42
Engine Operation43
Instrument Panel43
Normal Engine Operation45
Break-In Service46
Auxiliary Gear Drive Limitations47
Generator Set Power Units48
Starting the Engine48
Cold Weather Starting50
Warming Engine51
Stopping the Engine53
Using a Booster Battery or Charger54
Lubrication and Maintenance56
Lubrication and Maintenance Service Interval Chart57
Lubrication & Maintenance/Daily61
Daily Prestarting Checks61
Servicing Fire Extinguisher65
Checking Engine Mounts65
Servicing Battery66
Manual Belt Tensioner Adjustment68
Changing Engine Oil and Replacing Filter71
To Change Engine Oil and Oil Filter72
Checking Crankcase Vent System74
Closed Crankcase Ventilation System75
Checking Air Intake System76
Replacing Fuel Filter Elements77
Checking Belt Tensioner Spring Tension and Belt Wear79
Checking Belt Wear79
Checking Tensioner Spring Tension80
Checking Engine Electrical Ground Connections81
Checking Cooling System81
Replenishing Supplemental Coolant Additives between Coolant Changes82
Pressure Testing Cooling System85
Test Radiator Cap85
Test Cooling System85
Checking and Adjusting Engine Speeds86
Adjusting Variable Speed87
Flushing and Refilling Cooling System88
Testing Thermostats Opening Temperature91
To Remove Thermostat91
To Install Thermostats93
Check and Adjust Valve Clearance94
Adjustment Procedure95
Additional Service Information96
Adding Coolant97
Replacing Single Stage Air Cleaner99
Replacing Axial Seal Air Cleaner Filter Element100
Replacing Radial Seal Air Cleaner Filter Element102
Replacing Fan and Alternator Belts104
Checking Fuses105
Checking Air Compressors105
Bleeding the Fuel System106
At Fuel Injection Pump107
Troubleshooting109
Engine Troubleshooting110
Storage116
Engine Storage Guidelines116
Preparing Engine for Long Term Storage117
Removing Engine from Long Term Storage118
Specifications119
Engine Crankcase Oil Fill Quantities121
Unified Inch Bolt and Screw Torque Values122
Metric Bolt and Screw Torque Values123
Lubrication and Maintenance Records124
Using Lubrication and Maintenance Records124
Daily Service124
Index133

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