PowerTech 6068HF475 Generator Set

⚠ Valve clearance must be checked and adjusted with engine COLD.

Tools: Feeler gauge, JDE83 or JDG281A Flywheel Turning Tool, JDG1571 Timing Pin

1. Disconnect NEGATIVE battery terminal.
2. Remove rocker arm cover and crankcase ventilator tube.
3. Rotate flywheel to No. 1 cylinder TDC compression; insert timing pin.
4. Check intake and exhaust valve clearance cold.
5. Loosen jam nut; turn adjusting screw until feeler gauge slips with slight drag.
6. Hold adjusting screw; tighten jam nut to specification.
7. Recheck clearance after tightening jam nut.
8. Replace rocker arm cover and ventilator tube.

⚠ Do not pry against alternator rear frame.

Tools: JDG1341 Belt Tension Gauge

1. Install JDG1341 Belt Tension Gauge on belt halfway between pulleys.
2. Loosen cap screws.
3. Slide alternator or tensioner bracket to remove excess slack.
4. Stretch belt by prying outward until specified tension achieved.
5. Tighten cap screws.
6. Run engine 10 minutes and re-check belt tension per used belt spec.
7. Reset tension as necessary.

⚠ Always use a backup wrench when loosening or tightening fuel lines.

Tools: Open-end wrenches

1. Loosen air bleed vent screw two full turns on fuel filter base.
2. Operate fuel supply pump primer lever or primer button.
3. Tighten bleed plug securely; continue operating primer until pumping action not felt.
4. Start engine and check for leaks.
5. If needed, loosen fuel return line at injection pump and bleed until free of bubbles.
6. Tighten return line to 27 N.m (20 lb-ft).
7. If needed, loosen two nozzle fuel line connections and crank 15 seconds.
8. Retighten nozzle delivery lines to 27 N.m (20 lb-ft).

⚠ Do not apply extra 3/4 to 1-1/4 turn after gasket contact.

Tools: Filter wrench

1. Run engine about 5 minutes to warm oil; shut engine off.
2. Remove oil pan drain plug and drain crankcase oil while warm.
3. Remove oil filter element with a filter wrench; discard.
4. Apply clean engine oil to new filter inner and outer seals.
5. Wipe header sealing surfaces; check dust seal notches.
6. Install and hand-tighten new filter until firmly against dust seal.
7. Tighten drain plug to specification.
8. Fill crankcase with correct oil; crank 30 seconds without starting; check level after 10 minutes.

⚠ Do not run engine longer than 10 minutes with water.

1. Pressure test cooling system and cap if not done.
2. Open filler/radiator cap slowly to relieve pressure.
3. Open engine block drain valve/plug and radiator drain valve.
4. Fill system with clean water; run engine about 10 minutes.
5. Drain water; refill with water and heavy-duty cooling system cleaner.
6. Drain cleaner; flush with water; close all drain valves.
7. Install thermostats with new gasket; add coolant to bottom of filler neck.
8. Run engine to operating temperature; check level and leaks.

1. Change engine oil and replace filter; add rust preventive oil.
2. Service air cleaner.
3. Drain, flush, and refill cooling system for extended storage.
4. Pour three ounces of rust preventive oil into turbocharger intake.
5. Circulate diesel fuel/rust preventive oil solution through injection system while cranking.
6. Loosen or remove fan/alternator poly-vee belt.
7. Remove, clean, and store batteries fully charged.
8. Clean exterior; seal all openings; store in dry protected place.

⚠ Only remove filler cap when cool enough to touch with bare hands.

Tools: D05104ST Tester

1. Remove radiator cap and attach to D05104ST Tester.
2. Pressurize cap; gauge should hold 70 kPa (10 psi) for 10 seconds.
3. Remove cap, turn 180 degrees, and retest.
4. Allow engine to cool; remove radiator cap; fill to normal level.
5. Connect gauge and adapter to radiator filler neck; pressurize.
6. Check hose connections, radiator, and engine for leaks.

Tools: Breaker bar

1. Inspect belts for cracks, fraying, or stretched-out areas.
2. Release tension using breaker bar and socket on tension arm (automatic) or tensioner (manual).
3. Remove poly-vee belt from pulleys and discard.
4. Inspect pulleys and bearings while belt removed.
5. Install new belt correctly seated in all pulley grooves.
6. Apply tension; remove socket.
7. Install fan guard if removed.
8. Start engine and check belt alignment.

⚠ Escaping fluid under pressure can penetrate the skin causing serious injury.

1. Close fuel shut-off valve; thoroughly clean filter assemblies.
2. Disconnect water sensor wiring if equipped.
3. Loosen drain plugs and drain fuel into a suitable container.
4. Rotate retaining ring clockwise 1/4 turn; remove ring with element.
5. Clean mounting base; install new elements firmly seated.
6. Reconnect water sensor wiring; open fuel valve and bleed system.

⚠ Do not allow thermostat or thermometer to rest against container side or bottom.

Tools: Thermometer

1. Remove radiator pressure cap and partially drain cooling system.
2. Remove thermostat cover and thermostat(s).
3. Suspend thermostat and thermometer in a container of water.
4. Stir water as it heats; observe opening action and temperatures.
5. Compare with thermostat test specifications.
6. Remove thermostat and observe closing action as it cools.
7. Replace defective thermostats; on dual thermostat engines replace both.

⚠ Do not use starting fluid on engines equipped with air intake heaters or glow plugs.

1. Perform prestarting checks; disengage driveline.
2. Open fuel supply shut-off valve.
3. 275 engines without air intake heaters: manually activate ether injectors.
4. 275 engines with air intake heaters and 475 engines with glow plugs: turn key ON.
5. Do not crank engine until Engine Preheater Indicator light turns off.
6. Crank engine to start.

⚠ Do not operate the starter for more than 30 seconds at a time.

1. Perform all prestarting checks.
2. Open fuel supply shut-off valve if equipped.
3. Disengage clutch controlling any engine drivelines.
4. Set slow idle.
5. Turn key start switch clockwise to crank; release when engine starts.
6. Idle engine at not more than 1200 rpm until warm.
7. Check all gauges for normal operation.