Service parts for the D415FJJ4
Grouped by system, with how many of each the parts manual calls for.
Fuel system
1 requiredOil system
1 requiredPrices captured from merchant listings; some links are affiliate links. Confirm against your serial number before ordering.
Specifications
| Frequency | 60.0 Hz |
|---|---|
| Standby power | 415 kW |
| Standby kVA | 518 |
| Prime power | 345 kW |
| Controller | KASSEC-24 VDC |
| Oil capacity | 42.0 L |
| Alternator | Marathon 433PSL6200 (4-pole, Class Class H (suitable for continuous duty at Class F rise) insulation) |
| Voltage options | 277/480 V, 120/208 V, 120/240 V, 347/600 V |
| Phase | 3 |
| Rated current | 1248 A |
| Power factor | 0.8 |
| Coolant capacity | 104.5 L |
| Sound level | 128.0 dBA @ 7 m |
Engine
| Oil capacity | 42.0 L |
|---|---|
| Coolant capacity | 16.2 L |
| Displacement | 7.66 L |
| Aspiration | Turbocharged ~ Air to Air Intercooled |
| Rated speed | 1800 rpm |
Maintenance & consumables
for the Katolight 6125HF070| Item | Spec | Capacity | Part # | Interval | |
|---|---|---|---|---|---|
| Air filter | — | 500 hr | |||
| Fuel filter | — | 500 hr | |||
| Fuel filter | Check the glass sediment bowl (A) of the fuel filter/water separator for water or debris. Loosen thumb screw (B) and drain water and debris from bowl into a suitable container, as needed. | RE502203 | 500 hr | Amazon eBay $30.00 FridayParts $49.99 | |
| Oil filter | RG8536 | 250 hr | Amazon eBay | ||
| Battery | — | ||||
| Belt | — | 500 hr | |||
| Coolant | — | 2000 hr | |||
| Coolant filter | — | ||||
| Oil | — | 100 hr | |||
| Spark plug | — |
Compatible filters for the Katolight 6125HF070 — cross-referenced via Donaldson. Options to verify against your serial number, not confirmed for this exact unit.
- Air filter: John Deere AT220822 John Deere AT203051 John Deere AH115833 John Deere AH148880 John Deere RE67829
Service intervals
17| Item | Action | Hours | Months | Notes |
|---|---|---|---|---|
| Fire extinguisher | Inspect | 100 hr | 1 mo | At least every 100 hours of engine operation or once a month; recharge once operated |
| Battery | Test | 250 hr | 6 mo | Check electrolyte level, clean and tighten connections, keep fully charged |
| Coolant pump weep hole foam filter | Check | 250 hr | 6 mo | |
| Engine mounts (generator sets) | Check | 250 hr | 6 mo | Use only Grade SAE 8 or higher hardware |
| Engine oil and oil filter | Change | 250 hr | 6 mo | Change first at 100 hours maximum (break-in), then every 250 hours; may extend 50% to 375 hours with PLUS-50 or ACEA-E4/E5 oil plus John Deere filter |
| Air intake hoses, connections & system | Check | 500 hr | 12 mo | Inspect hoses for cracks; tighten clamps |
| Automatic belt tensioners and belt wear | Inspect | 500 hr | 12 mo | Upper spring tension 18-23 Nm (13-17 lb-ft); lower spring tension 81-99 Nm (60-73 lb-ft) |
| Coolant solution analysis; add SCAs as required | Test | 500 hr | 12 mo | Test at 500 hours or 12 months; test at 12 months or less in general |
| Cooling system | Check | 500 hr | 12 mo | Check for leaks; inspect hoses for hard, flimsy or cracked condition |
| Cooling system and radiator cap | Test | 500 hr | 12 mo | Pressure test to 48 kPa (0.48 bar) (7 psi) |
| Crankcase ventilation assembly | Clean | 500 hr | 12 mo | Inspect and clean; replace O-rings as necessary |
| Engine ground connection | Check | 500 hr | 12 mo | Must be tight and clean to prevent electrical arc |
| Cooling system | Drain | 2000 hr | 24 mo | Flush and refill; with John Deere COOL-GARD extend to 3000 hours/36 months, or 5000 hours/60 months if tested annually and additives replenished |
| Crankshaft vibration damper | Check | 2000 hr | 24 mo | Replace at 4500 hours or 60 months, whichever occurs first |
| Thermostats | Test | 2000 hr | 24 mo | Opening temperature 80-84 C (175-182 F); full open 94 C (202 F) |
| Engine valve clearance and EUI preload | Adjust | 2500 hr | First service — One-time adjustment after first 2500 hours on all new and overhauled engines; by John Deere dealer | |
| Fuel filter element / clean water separator | Replace | 12 mo | As required when alarm/trouble code indicates plugged filter; otherwise every 12 months or 500 hours |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Service specifications
30| Type | Item | Value | Unit | Condition |
|---|---|---|---|---|
| Clearance | Crankshaft vibration damper maximum radial runout | 0.76 | mm | 0.030 in; engine at operating temperature |
| Pressure | Cooling system test pressure | 48 | kPa | 0.48 bar (7 psi); engine warmed up |
| Pressure | Engine oil pressure, full load rated speed | 310 +/- 103 | kPa | 45 +/- 15 psi at 1500-2100 rpm, oil at 115 C (240 F) |
| Pressure | Engine oil pressure, low idle (minimum) | 138 | kPa | 1.38 bar (20 psi) minimum |
| Pressure | Maximum air intake restriction | 25 | in. H2O | 625 mm H2O (6.25 kPa) (0.06 bar) (1.0 psi) |
| Pressure | Maximum crankcase pressure | 0.5 | kPa | 2 in. H2O |
| Pressure | Radiator cap test pressure | 48 | kPa | 0.48 bar (7 psi); gauge should hold 10 seconds |
| Speed | Engine overspeed shutdown | 66 | Hz | Diesel units (71 Hz for gas units) |
| Speed | Generator speed / frequency relationship | 1800 | RPM | 60 Hz at 1800 rpm, 1500 rpm for 50 Hz; Hz x 30 = RPM |
| Speed | Starter crank disconnect speed | 500-750 | RPM | Starter disconnects when engine reaches this speed |
| Temperature | Engine coolant temperature range | 82-94 | C | 180-202 F; derate at approximately 100 C (212 F) |
| Temperature | Thermostat start-to-open temperature | 80-84 | C | 175-182 F; full open 94 C (202 F) |
| Torque | Air filter restriction indicator/retaining nut | 14 | Nm | 10 lb-ft |
| Torque | Cable connector (wiring lug), 1/4 in. socket | 200 | in-lb | across flats 1/4 in.; TQD, TQDL |
| Torque | Cable connector (wiring lug), 3/8 in. socket | 375 | in-lb | across flats 3/8 in. |
| Torque | Cable connector (wiring lug), 5/16 in. socket | 275 | in-lb | across flats 5/16 in. |
| Torque | Crankcase vent baffle-to-rocker arm cover cap screws | 15 | Nm | 11 lb-ft (133 lb-in) |
| Torque | E150 line lug mounting | 30 | in-lb | minimum |
| Torque | F225 line lug mounting | 90 | in-lb | minimum |
| Torque | J600 line lug mounting | 60 | in-lb | minimum |
| Torque | K1200 line lug mounting | 200 | in-lb | minimum |
| Torque | Lower belt tensioner spring tension | 81-99 | Nm | 60-73 lb-ft; align marks 25 mm (1.0 in.) apart |
| Torque | Oil drain plug (1-1/2 in.) | 64 | Nm | 47 lb-ft |
| Torque | Oil drain plug (1-1/4 in.) | 46 | Nm | 34 lb-ft |
| Torque | Shunt trip locknut (GE shunt trip accessory) | 6 | in-lb | tighten against plunger to prevent loss of adjustment |
| Torque | Thermostat cover long cap screws | 50 | Nm | 37 lb-ft |
| Torque | Thermostat cover short cap screws | 35 | Nm | 26 lb-ft |
| Torque | Upper belt tensioner spring tension | 18-23 | Nm | 13-17 lb-ft; align marks 21 mm (0.83 in.) apart |
| Torque | Water separator bowl-to-filter housing | 5 | Nm | 44 lb-in; hand tighten until seal contacts |
| Voltage | High engine temperature / low oil pressure fault switch thresholds (controller displays) | 225 F / 15 psi | High engine temp shutdown above 225 F (107 C); pre-alarm 215 F (102 C); low oil pressure shutdown 15 psi (103 kPa); pre-alarm 20 psi (138 kPa) |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Recommended fluids
| Fluid | Grade | Standard | Ambient | Capacity | Notes |
|---|---|---|---|---|---|
| Coolant | John Deere COOL-GARD Prediluted Coolant | ASTM D6210; low silicate ethylene/propylene glycol, 40 to 60% concentrate with quality water | above -37°C | 104.5 L | 50% ethylene glycol gives freeze protection to -37 C (-34 F); 50% propylene glycol -33 C (-27 F). System filled to -37 C (-34 F). Do not use automotive-type coolants (ASTM D3306/D4656) |
| Engine oil | John Deere Engine Break-In Oil | Factory fill; order TY22041. Do not exceed 100 hours of operation with break-in oil. Do not use PLUS-50 or CI-4/CH-4/E4/E5 oils during first 100 hours | |||
| Engine oil | SAE 0W-40 | API CI-4 / CH-4; ACEA E4/E5 | Listed in engine oil viscosity chart | ||
| Engine oil | SAE 10W-40 | API CI-4 / CH-4; ACEA E4/E5 | Listed in engine oil viscosity chart | ||
| Engine oil | SAE 15W-40 | John Deere PLUS-50 (preferred); TORQ-GARD SUPREME; API CI-4 / CH-4; ACEA E4/E5 or E3 | 40.0 L | Select viscosity from the printed viscosity/temperature chart. Multi-viscosity oils preferred. Reduce oil/filter interval by 100 hours with fuel sulfur above 0.05% (500 ppm) | |
| Engine oil | SAE 5W-30 | API CI-4 / CH-4; ACEA E4/E5 | Listed in engine oil viscosity chart | ||
| Fuel | Diesel, Grade No. 1-D for cold weather below 5 C (40 F) | EN 590 or ASTM D975 | Cetane number 45 minimum, 50 preferred below -20 C or above 1500 m. Sulfur less than 0.05% (500 ppm) preferred; do not use above 1.0%. Do not mix used engine oil with diesel fuel. Bio-diesel only per ASTM PS121 / DIN 51606, up to 5% blend | ||
| Grease | John Deere SD POLYUREA GREASE R220 (preferred) | NLGI Performance Classification GC-LB | Also HD MOLY, HD LITHIUM COMPLEX, HD WATER RESISTANT, GREASE-GARD. Generator bearings: Cheveron SRI or equivalent, range -30 to +175 C (-22 to +350 F) | ||
| Other | John Deere LIQUID COOLANT CONDITIONER (supplemental coolant additive) | Replenish every 12 months or as determined by coolant testing; 3% by total system capacity for pre-charge; do not mix brands |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Fault codes
29| Code | Name | Meaning | Severity | Action |
|---|---|---|---|---|
| 627/01 | Injector Supply Voltage Problem | Injector supply voltage problem | Warning | Contact your John Deere distributor or servicing dealer |
| 629/13 | ECU Error | Engine control unit error | Warning | Contact dealer |
| 636/02 | Cam Position Input Noise | Camshaft position sensor input noise | Warning | Inspect sensor and wiring; contact dealer |
| 636/08 | Cam Position Input Missing | Camshaft position input missing | Shutdown | Inspect sensor and wiring; contact dealer |
| 636/10 | Cam Position Input Pattern Error | Camshaft position input pattern error | Warning | Contact dealer |
| 637/02 | Crank Position Input Noise | Crankshaft position sensor input noise | Warning | Inspect sensor and wiring; contact dealer |
| 637/07 | Crank Position/Cam Position Out of Sync | Crankshaft and camshaft position out of synchronization | Shutdown | Contact dealer |
| 637/08 | Crank Position Input Missing | Crankshaft position input missing | Shutdown | Contact dealer |
| 637/10 | Crank Position Input Pattern Error | Crankshaft position input pattern error | Warning | Contact dealer |
| 639/13 | CAN (Network) Error | Control Area Network communication error | Warning | Inspect CAN wiring and connectors; contact dealer |
| 651/05 | Cylinder #1 EUI Circuit Open | Cylinder 1 electronic unit injector circuit open | Shutdown | Contact dealer |
| 651/06 | Cylinder #1 EUI Circuit Shorted | Cylinder 1 electronic unit injector circuit shorted | Shutdown | Contact dealer |
| 652/05 | Cylinder #2 EUI Circuit Open | Cylinder 2 electronic unit injector circuit open | Shutdown | Contact dealer |
| 652/06 | Cylinder #2 EUI Circuit Shorted | Cylinder 2 electronic unit injector circuit shorted | Shutdown | Contact dealer |
| 653/05 | Cylinder #3 EUI Circuit Open | Cylinder 3 electronic unit injector circuit open | Shutdown | Contact dealer |
| 653/06 | Cylinder #3 EUI Circuit Shorted | Cylinder 3 electronic unit injector circuit shorted | Shutdown | Contact dealer |
| 654/05 | Cylinder #4 EUI Circuit Open | Cylinder 4 electronic unit injector circuit open | Shutdown | Contact dealer |
| 654/06 | Cylinder #4 EUI Circuit Shorted | Cylinder 4 electronic unit injector circuit shorted | Shutdown | Contact dealer |
| 655/05 | Cylinder #5 EUI Circuit Open | Cylinder 5 electronic unit injector circuit open | Shutdown | Contact dealer |
| 655/06 | Cylinder #5 EUI Circuit Shorted | Cylinder 5 electronic unit injector circuit shorted | Shutdown | Contact dealer |
| 656/05 | Cylinder #6 EUI Circuit Open | Cylinder 6 electronic unit injector circuit open | Shutdown | Contact dealer |
| 656/06 | Cylinder #6 EUI Circuit Shorted | Cylinder 6 electronic unit injector circuit shorted | Shutdown | Contact dealer |
| 970/02 | Auxiliary Engine Shutdown Switch Signal Invalid | Auxiliary engine shutdown switch signal invalid | Warning | Inspect auxiliary shutdown switch wiring; contact dealer |
| 970/31 | Auxiliary Engine Shutdown Switch Active | Auxiliary engine shutdown switch active | Shutdown | Determine why shutdown switch activated; contact dealer |
| 971/31 | External Fuel Derate Switch Active | External fuel derate switch active | Warning | Investigate derate switch activation; contact dealer |
| 1109/31 | Engine Shutdown Warning | Engine shutdown warning condition present | Warning | Contact dealer |
| 1110/31 | Engine Shutdown | Engine shutdown condition present | Shutdown | Contact dealer |
| 1569/31 | Fuel Derate | Fuel derate condition present | Warning | Contact dealer |
| 2000/13 | Security Violation | Security violation | Warning | Contact dealer |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Procedures
12Testing Thermostats Opening Temperature diagnostic
⚠ Do not allow thermostat or thermometer to rest against side or bottom of container
Tools: Thermometer, Container
- Remove radiator cap and partially drain cooling system.
- Remove four cap screws and thermostat cover.
- Remove gasket and both thermostats.
- Inspect thermostats for corrosion or damage.
- Suspend thermostat and thermometer in water and heat.
- Stir water, observe opening action against specification.
- Observe closing action as it cools; replace as matched set.
Bleeding Fuel System maintenance
- Drain water from clear separator sediment bowl via drain valve.
- Attach open line to diagnostic port, place end in container.
- Pump hand primer until steady flow without bubbles.
- Disconnect line from diagnostic port.
- Start engine and run for five minutes.
Changing Engine Oil and Replacing Oil Filter maintenance
⚠ Metal surfaces may be hot after shutdown
⚠ Do not overfill; fill within crosshatch on dipstick
Tools: Filter wrench, Torque wrench
- Run engine about 5 minutes to warm oil, then shut off.
- Remove oil pan drain plug and drain oil while warm.
- Remove and discard oil filter element using filter wrench.
- Remove packing, clean filter mounting pad.
- Oil new packing, install new element, tighten 1/2-3/4 turn by hand.
- Install drain plug with new O-ring; torque 46 Nm (34 lb-ft).
- Fill crankcase with correct John Deere engine oil.
- Crank engine 30 seconds without starting; run and check leaks.
Replacing Air Cleaner Filter Elements maintenance
⚠ Do not clean, wash or reuse the secondary element
- Remove wing nut, canister cover and primary filter assembly.
- Thoroughly clean all dirt from inside canister.
- Squeeze dust unloader valve to remove dust.
- Replace secondary element only if green dot disappeared.
- Install new primary element and tighten wing nut securely.
- Depress air restriction indicator reset button if equipped.
Replacing Fan/Alternator V-Belts maintenance
Tools: 3/4-in. breaker bar (lower), 1/2-in. breaker bar (upper)
- Release tension on lower belt with breaker bar in tensioner.
- Remove V-belt from pulleys and discard.
- Install new belt correctly seated in all pulley grooves.
- Release tensioner to apply tension; remove ratchet.
- Lower V-belt must be removed before upper V-belt.
- Check belt alignment; start engine and visually recheck.
Replacing Fuel Filter / Cleaning Water Separator maintenance
⚠ Engine and fuel filter housing may be hot
Tools: Strap wrench
- Close fuel shut-off valve, clean area around filter.
- Remove cap from fuel filter housing.
- Operate hand primer until filter pops up to relieve vacuum.
- Remove and drain filter element into suitable container.
- Remove and clean water separator bowl with strap wrench.
- Install new dry fuel filter into housing.
- Reinstall cap hand-tight; open fuel shut-off valve.
- Restart engine and run five minutes minimum.
Automatic Operation Sequence operation
- Leave engine control in AUTO position.
- Leave generator circuit breaker in ON position.
- On power failure remote start contact closes, engine starts.
- Set reaches speed and voltage, then transfers load.
- On power return load retransfers after time delay.
- Remote start contact opens; unit shuts down.
Emergency Stop (optional equipment) operation
⚠ This stops and locks out the generator set
- Push red mushroom head emergency stop button.
- Pull button out to reset and extinguish red light.
- Place engine control in OFF to reset.
- Reset main line circuit breaker before AUTOMATIC operation.
Manual Shutdown operation
- Open generator circuit breaker, move handle DOWN.
- Place engine control in OFF position.
- For automatic operation reset breaker handle to UP.
Manual Start operation
⚠ Check operator's manual if engine does not start
- Ventilate the space or open doors and windows.
- Open the generator circuit breaker.
- Place engine control in MANUAL/RUN position.
- Check frequency; 60 Hz rated speed within 3-5%.
- Check AC voltage and engine parameters on gauges.
- Close the generator circuit breaker.
Starting the Engine operation
⚠ Install proper exhaust ventilation before starting in a confined building
- Perform all daily prestarting checks.
- Open the fuel supply shut-off valve, if equipped.
- Disengage power to any engine drivelines.
- Set slow idle using speed select switch.
- Turn key start switch clockwise to crank engine.
- After start, idle at not more than 1200 rpm until warm.
- Check all gauges for normal operation.
Stopping the Engine operation
⚠ Ensure exhaust stack rain cap is installed when engine is not running
- Disengage PTO clutch lever, if equipped.
- Run engine at 1000-1200 rpm for at least 2 minutes.
- Set slow idle speed.
- Turn key start switch to OFF and remove key.
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Voltage reconnection
| Voltage | Phase | Connection | Leads | Notes |
|---|---|---|---|---|
| 120 (240 L-L) | 3 | 12 lead low delta | 12 | Delta connection with 12 lead generators only |
| 120/240 | 1 | 12 lead zig-zag | 12 | Zig-zag connection with 12 lead machine only; used for the single-phase D415FGJ4 model |
| 208/120 (also 190/110) | 3 | 10 lead low wye | 10 or 20 cables | One end of three inner coils connected together |
| 208/120 (also 220/127, 230/133, 240/139) | 3 | 12 lead low wye | 12 or 24 cables | Dual voltage, six coils |
| 240 (also 480) | 3 | 6 lead delta | 6 or 12 cables | Six lead generators have 3 coil groups |
| 240/120 (also 190/110, 208/120, 220/127, 230/133) | 3 | 6 lead wye | 6 or 12 cables or bus bars | Six lead generators have 3 coil groups |
| 240/120 (also 200/100, 220/110) | 3 | 12 lead hi delta | 12 | Delta connection with 12 lead generators only |
| 480 (also 240) | 3 | 3 lead delta | 3, 6 or 12 cables or 3 bus bars | One end of each coil group connected into a delta internally |
| 480/277 (also 380/219, 400/231, 416/240, 440/254, 460/266) | 3 | 10 lead hi wye | 10 or 20 cables | One end of three inner coils connected together |
| 480/277 (also 380/219, 400/231, 416/240, 440/254, 460/266) | 3 | 12 lead hi wye | 12 or 24 cables | Dual voltage, six coils; two reconnect voltage ranges (high/low) |
| 480/277 (also 380/219, 400/231, 416/240, 440/254, 460/266, 600/346) | 3 | 4 lead wye | 4, 8 or 16 cables or 4 bus bars | One end of each of the 3 coil groups connected together |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Common questions
What is the power rating of the Katolight D415FJJ4?
The Katolight D415FJJ4 is rated 415 kW standby (518.75 kVA).
Which engine powers the Katolight D415FJJ4?
The Katolight D415FJJ4 is powered by the Katolight 6125HF070 engine.
What's the oil capacity on a Katolight D415FJJ4?
The Katolight 6125HF070 engine in the Katolight D415FJJ4 has an oil capacity of 42.0 liters.
What is the coolant capacity of the Katolight D415FJJ4?
The Katolight D415FJJ4 cooling system holds 104.5 liters (27.6 US gallons) for the radiator system including the engine, per the manufacturer specification sheet.
What is the prime power rating of the Katolight D415FJJ4?
The Katolight D415FJJ4 is rated 345 kW prime (431 kVA), against 415 kW standby.
What is the sound level of the Katolight D415FJJ4?
The Katolight D415FJJ4 is rated at 128.0 dBA at 7 m, per the manufacturer specification sheet.
What voltages is the Katolight D415FJJ4 available in?
The Katolight D415FJJ4 is offered in 277/480 V, 120/208 V, 120/240 V, 347/600 V, 3-phase.
What alternator does the Katolight D415FJJ4 use?
The Katolight D415FJJ4 uses a Marathon 433PSL6200 alternator. It has 4 poles. Insulation class Class H (suitable for continuous duty at Class F rise).
What oil filter does the Katolight D415FJJ4 use?
The Katolight D415FJJ4 uses oil filter part number RG8536.
What fuel filter does the Katolight D415FJJ4 use?
The Katolight D415FJJ4 uses fuel filter part number RE502203.
What air filter fits the Katolight D415FJJ4?
The Katolight D415FJJ4 uses air filter part numbers JOHN DEERE AT220822, JOHN DEERE AT203051.
Troubleshooting
6Fault codes
| Code | Meaning | Cause | Remedy |
|---|---|---|---|
| 1 | PRE HI ENGINE TEMP. Engine continues to operate. | Engine has begun to overheat and engine temperature has risen to approximately 215°F (102°C). | Reduce load if possible by turning off non-critical loads; Check air inlets and outlets and remove any obstructions to airflow; Open doors or windows in generator area to increase ventilation; If engine can be stopped, follow procedure in Step 2. |
| 2 | HI ENGINE TEMP LED. Engine shuts down. | Engine has overheated (engine temperature has risen above 225°F/107°C) or coolant level is low (sets with coolant level sensor). | Allow engine to cool down completely before proceeding; Check coolant level and replenish if low. Look for possible coolant leakage points and repair if necessary; Check for obstructions to cooling airflow and correct as necessary; Check for a slipping fan belt and tighten if loose; Reset control and restart after locating and correcting problem. Contact your Dealer or Distributor if none of the above. |
| 3 | PRE LOW OIL PRESSURE. Engine continues to operate. | Engine oil pressure has dropped to 20 psi (138kPa). | If generator is powering critical loads and cannot be shut down, wait until next shutdown period and then follow Step 4 procedure. If engine can be stopped, follow procedures in Step 4. |
| 4 | LOW OIL PRESSURE. Engine shuts down. | Engine oil pressure has dropped to 15 psi (103kPa). | Check oil level, lines and filters. If oil system is okay, but oil level is low, replenish. Reset control and restart. Contact your Dealer or Distributor if oil pressure is not in the range of 35 to 55 psi (241 to 379 kPa). |
| 5 | OVERCRANK. Engine stops cranking. Or Engine runs, shuts down, and LOW OIL PRESSURE. | Possible fuel system problem. | Check for empty fuel tank, fuel leaks, or plugged fuel lines and correct as required; Check for dirty fuel filter and replace if necessary (See Maintenance section of Engine Manual); Check for dirty or plugged air filter and replace if necessary (See Maintenance section of Engine Manual); Refer to Step 4; Reset the control and restart after correcting the problem. Contact your Dealer or Distributor for service if none of the above. |
| 6 | OVERSPEED. Engine runs and then shuts down. | Engine has exceeded normal operating speed. | Refer to governor adjust procedure. Contact your Dealer or Distributor for service. |
Fault codes and symptom→remedy steps extracted from this model’s service/owner documentation; verify against the official manual before servicing. Full Katolight D415FJJ4 troubleshooting guide (241 entries) →
Parts
40| Part # | Description | Qty | System | |
|---|---|---|---|---|
| RG34710 | Safety Alert Symbol | 1 | Oil filter | Amazon eBay |
| RG8718A | Coolant Pump Weep Hole | Pump | Amazon eBay | |
| RG8742 | Belt Tensioner Spring Tension and Belt Wear | Belt | Amazon eBay | |
| RG9918 | A—High-Low Speed Select Rocker Switch | 1 | Speed select rocker switch | Amazon eBay |
| 100302 | RG,RG34710,7600 -19-30JUN97-3/4 | Service part / kit | Amazon eBay | |
| 1400302 | RG,RG34710,7606 -19-30JUN97-1/1 | Service part / kit | Amazon eBay | |
| 160302 | RG,RG34710,7601 -19-06SEP02-1/2 | Service part / kit | Amazon eBay | |
| 4100302 | RG,RG34710,7600 -19-30JUN97-2/4 | Service part / kit | Amazon eBay | |
| 55-13 | RG,RG34710,7600 -19-30JUN97-2/4 | Service part / kit | Amazon eBay | |
| 55-14 | RG,RG34710,7600 -19-30JUN97-3/4 | Service part / kit | Amazon eBay | |
| 55-16 | RG,RG34710,7601 -19-06SEP02-1/2 | Service part / kit | Amazon eBay | |
| 55-18 | RG,RG34710,7602 -19-30JUN97-1/3 | Service part / kit | Amazon eBay | |
| 55-20 | RG,RG34710,7602 -19-30JUN97-3/3 | Service part / kit | Amazon eBay | |
| 55-22 | RG,RG34710,7606 -19-30JUN97-1/1 | Service part / kit | Amazon eBay | |
| 55-23 | Diagnostic Trouble Code Display and Touch Switches | Service part / kit | Amazon eBay | |
| JMP11TOQ2 | Yields one shot 61 6 OVERSPEED 3to2 Yields 5 cycle (el7 SWITCH tat[c7 | ca {cg fer cra cry] Te Te faa] oT dT1 d]1 [2 73 [6 19 [9 | 22] 24] | Service part / kit | Amazon eBay | |
| OUODN06 | Rear PTO Serial Number Plate | Service part / kit | Amazon eBay | |
| QUOD002 | Filling Fuel Tank | Service part / kit | Amazon eBay | |
| RG10242 | Crankcase Ventilation Assembly | Service part / kit | Amazon eBay | |
| RG5419 | Prevent Bypass Starting | 1 | Service part / kit | Amazon eBay |
| RG6241 | Radiator Coolant Check | Service part / kit | Amazon eBay | |
| RG6557 | DO5104ST Tester | Service part / kit | Amazon eBay | |
| RG8724 | Timing Gear Cover Fill Port | Service part / kit | Amazon eBay | |
| RG8727 | Upper Tensioner Spring Tension | Service part / kit | Amazon eBay | |
| RG8728 | Lower Tensioner Spring Tension | Service part / kit | Amazon eBay | |
| RG8751 | Oil Pan Adapter Fill Port | Service part / kit | Amazon eBay | |
| S203 | Handle Batteries Safely | Service part / kit | Amazon eBay FridayParts $24.89 | |
| T8953 | Avoid Flammable Spray | Service part / kit | Amazon eBay | |
| TS1356 | Store Safely | Service part / kit | Amazon eBay | |
| TS187 | Understand Signal Words | Service part / kit | Amazon eBay | |
| TS201 | Follow Safety Instructions | 1 | Service part / kit | Amazon eBay |
| TS202 | Handle Fuel Safely—Avoid Fires | Service part / kit | Amazon eBay | |
| TS204 | Battery Explosions | 0 | Service part / kit | Amazon eBay NAPA $32.48 |
| TS206 | Wear Protective Clothing | 1 | Service part / kit | Amazon eBay $1600.83 NAPA $24.94 |
| TS207 | Protect Against Noise | 1 | Service part / kit | Amazon eBay |
| TS220 | Remove Paint Before Welding or Heating | 1 | Service part / kit | Amazon eBay $13.89 NAPA $26.31 |
| TS226 | Use Proper Lifting Equipment | 1 | Service part / kit | Amazon eBay NAPA $20.32 |
| TS281 | Service Cooling System Safely | 0 | Service part / kit | Amazon eBay NAPA $24.37 |
| TS291 | Prepare for Emergencies | Service part / kit | Amazon eBay | |
| X9811 | Avoid high-pressure fluids—avoid serious injury | 1 | Service part / kit | Amazon eBay |
Service, wear & replacement parts referenced for this model and its engine — confirm the exact part for your serial number. See the full parts catalog to search and cross-reference.
Fuel consumption
| Rating | Load | L/h | gal/h |
|---|---|---|---|
| 50% | 42.5 | 11.2 | |
| 75% | 59.2 | 15.6 | |
| 100% | 77.2 | 20.3 | |
| Prime | 76.84 | 20.3 | |
| Prime | 50% | 42.4 | 11.2 |
| Prime | 75% | 21.2 | 5.6 |
| Standby | 116.97 | 30.9 |
Available documents
Spec sheet — 43462001 katolight d415frj4 415 kw operators manual (Katolight)Spec sheet — 43462001 katolight d415frj4 415 kw spec sheets (Katolight)Spec sheet — D415FRJ4 (Katolight)
This page was generated from the 3 manufacturer documents above by automated extraction; every figure shown is copied from one of them. How the data is compiled.