Generator Set Warranty Flat Rates and Failure Codes

Warranty Flat Rates/ Failure Codes
Industrial 20--2000 kW Generator Sets including Industrial Rental, Transfer Switches, and Switchgear
TP-5178 9/03c
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Failure Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine/Alternator Cross-Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 1 Generator Set Accessory Flat Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 Battery Chargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Fuel Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 2 Transfer Switch Flat Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 Circuit Breaker/Contactor Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 M340 Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 R340/S340 Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 30--4000 Amp Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 Model KCT/KCP/KBT/KBP Transfer Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3 Engine Flat Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 Detroit Diesel 125--200 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 Detroit Diesel 135--400 kW (Series 50/60 Gas, Series 60 Diesel) . . . . . . . . . . . . 3.3 Detroit Diesel 200--2000 kW (Single Bearing, Series 71, 92, and 149) . . . . . . . . 3.4 Detroit Diesel 1250--2000 kW (Series 4000 Diesel) . . . . . . . . . . . . . . . . . . . . . . . . 3.5 Deutz 20--170 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6 Ford 20--100 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7 General Motors 30--100 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8 John Deere 20--200 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9 Perkins 20--100 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i iii iv 1 1 2 3 3 4 4 5 5 6 6 7 9 10 13 16 18 20 25
Section 4 Generator Flat Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 4.1 20--300 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 4.2 301--2000 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Section 5 Switchgear Flat Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 5.1 Low-Voltage Switchgear, 600 Volts or Less . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 5.2 Medium-Voltage Switchgear, 601--5000 Volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Section 6 Industrial Rental Trailer Flat Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
TP-5178 9/03
Table of Contents
Introduction
This manual provides flat rates and failure codes for 20--2000 kW generator sets including engines, accessories, transfer switches, and switchgear. A flat rate is the maximum time allowed for making warranty repairs. The manufacturer assigns a flat rate number to each flat rate. The manufacturer sets flat rates using facilities and equipment which any service shop should have available. You must write the flat rate number on the warranty claim form (K-1500) in the space marked Flat Rate No. See Figure 1-1. If you make a repair which is not listed in the flat rates, please do the following:
D Enter a description of work completed in Description
back of the form or on a separate sheet. These claims will be reviewed individually and are subject to approval by the Warranty Department. Note: Refer to TP-5180, Warranty Policies and Procedures, Industrial 20--2000 kW Generator Sets including Industrial Rental, Transfer Switches, and Switchgear, for applicable warranty policies and procedures. In addition to the flat rate number, use a failure code. Find the appropriate code in the Failure Codes section. Enter this code on the warranty claim form (K-1500) in the space marked Failure Code. This failure code applies to the primary failed part and assists us in determining the mode of failure. Note: Each flat rate time includes troubleshooting, test, and cleanup time. Note: For 5--22 kW residential/commercial generator sets and transfer switches, refer to the following: TP-6045 Warranty Flat Rates/Failure Codes TP-6046 Warranty Policies and Procedures Note: For 200--500REOZV engine flat rates, refer to TP-6220, Warranty Flat Rates/Failure Codes.
of Work Performed area on the warranty claim form.

D Give the appropriate failure code. D Enter the actual time in space marked Miscellaneous
Labor Hours on the claim form. If you exceed an allowable flat rate time because of unforeseen circumstances, enter the actual time and the flat rate number with an explanation of the causes in the Description of Work Performed area. Do not put extra time under Miscellaneous Labor Hours. If you need additional space for explanation, continue on the
TP-5178 9/03
Introduction
Figure 1-1
ii
K-1500
TP-5178 9/03
Introduction
Failure Codes
Electrical EA EC EH EL EO ES EU HO LO NV OU PN WI Mechanical BD BT CD CK LP MA MB ML MN MO MV NS PL ST SZ TW Binding Bent Casting Defect Cracked Loose Parts Assembled Improperly Mechanically Broken Leaking Noisy Out of Adjustment Vibration Not Sealing Plugged Sticking Seized Twisted Electrically Out of Adjustment Connection Defect High Voltage Low Voltage Open Shorted Unstable Voltage High Output Low Output No Voltage No Output Pinched/Crimped Wired Incorrectly from Factory Paint PA PC PE PO PR Packaging CN PM Concealed Damage Material Adhesion Corrosion (Oxidation, Rust) Peeling Paint Overspray Runs, Sags
Miscellaneous FC FF FM IN IP IS MP RE SB Field Compaign * Fast Fax * Foreign Material Intermittent Incorrect Parts Supplied Incorrect Shipment Missing Parts Product Recall * Service/Parts Bulletin *
* When utilizing this failure code, the warranty claim must contain the corresponding number of the service bulletin, field compaign, fast fax, or product recall.
TP-5178 9/03
Introduction
iii
Engine/Alternator Cross-Reference
Use the following chart to determine the engine manufacturer for specific kW models. Use the following chart to determine the alternator manufacturer for specific kW models.
Alternator Cross-Reference Chart Model Industrial 20--300 kW 300--2000 kW Kohler Marathon Alternator
Engine Cross-Reference Chart Model Diesel engines* 20--200 kW John Deere, Detroit Diesel Series 40, Deutz, Perkins Detroit Diesel Ford, General Motors Detroit Diesel, Cummins Engine
200--2000 kW Gas engines 20--100 kW 125--275 kW
* Include an O in the model number (Example: 20ROZJ).
iv
Introduction
TP-5178 9/03
Section 1 Generator Set Accessory Flat Rates

1.1 Battery Chargers
Flat Rate Description AC or output cables Ammeter or voltmeter Charger R & R Circuit board Circuit board connector Fuse holder Lamps/bulbs Power resistor Replace wiring SCR module Terminal strip Transformer Trickle-Type Battery Charger AC or DC cord Ammeter Charger R & R Circuit breaker Diodes/resistors Fuse holder Lamp/holder Replace wiring Rheostat Switch Terminal strip Transformer 2265 2256 2381 2259 2261 2258 2257 2266 2262 2263 2264 2260 1.00 1.25 1.25 1.00 1.50 1.00 1.00 1.00 1.50 1.25 1.00 1.75 Flat Rate Number 2553 2243 2255 2247 2251 2245 2244 2249 2254 2246 2252 2250 Flat Rate Hours 1.00 1.25 1.50 1.50 1.00 1.00 1.00 1.50 1.25 1.50 1.25 1.75 Each Each, AC or DC For replacement of wall-mounted units Main or alarm, includes calibration Comments
Float/Equalize Battery Charger, 12/24 Volts DC, 10 Amp*
* The float/equalize battery charger 12 volts DC, 6 amp/24 volts DC, 3 amp is not serviceable. Note: R & R means remove and replace.
TP-5178 9/03
1.2 Fuel Tanks

Flat Rate Description Day Tanks* Control board Control relay or wiring Float switch Motor or pump Subbase Fuel and Day Tanks* Control relay or wiring Float switch Gauge sender Motor or pump
* Supply the day tank serial number when filing the warranty. Note: See Engine Fuel System for subbase tank R & R.
Flat Rate Number 1929 1931 1930 1928 1926 1925 1927 1924
Flat Rate Hours 1.50 1.25 1.25 1.50 1.25 1.25 1.25 1.50
Comments
TP-5178 9/03
Section 2 Transfer Switch Flat Rates

2.1 Circuit Breaker/Contactor Models
Flat Rate Hours Flat Rate Description Circuit Breaker/Contactor Auxiliary switch Brake assembly Cam Circuit breaker, 2-pole Circuit breaker, 3-pole Circuit breaker, 4-pole Gear motor Load bus bar Mechanical interlocks Motor arm Neutral bar Nonautomatic 2- and 3-pole Normal limit switch Nylon freewheel, gear, or roller (center, spur, or idler gear) Nylon wheel Operating arm Transfer mechanism Controller Battery charger Circuit card Cranking limiter Current transformer Meters (volt, amp, or hour) Pilot lamps Plant exerciser Relays Selector switch Transformer Wiring harness plug socket Logic package, 6- and 9-card 1819 1814 1818 1822 1821 1817 1820 1815 1816 1811 1812 1813 1.80 1.50 2.25 1.30 1.50 0.75 1.80 1.50 2.00 1.75 1.50 1.75 1.80 1.50 2.25 1.30 1.50 0.75 1.80 1.50 2.00 1.75 1.50 1.75 1.80 1.50 2.25 1.30 1.50 0.75 1.80 1.75 2.00 1.75 1.50 1.75 1.80 1.50 2.25 1.30 1.50 0.75 1.80 1.75 2.00 1.75 1.50 1.75 1.80 1.50 2.25 1.30 1.50 0.75 1.80 1.75 2.00 1.75 1.50 1.75 1.80 1.50 2.25 1.30 1.50 0.75 1.80 1.75 2.00 1.75 1.50 1.75 Flat Rate Number 1807 1800 1801 1794 1795 1796 1799 1810 1808 1805 1809 1797 1806 1802 1804 1803 1798 30-104 Amps 1.25 2.50 2.50 2.50 1.75 1.00 1.50 1.20 1.00 2.50 1.25 1.10 1.25 1.50 105-225 Amps 1.25 1.25 2.75 3.00 3.25 1.75 1.50 1.50 1.25 1.50 1.25 226-400 Amps 1.25 1.25 3.25 3.50 3.75 1.75 1.50 1.50 1.25 1.50 1.50 401-600 Amps 1.25 1.25 3.50 3.75 4.25 1.75 1.50 1.50 1.25 1.50 1.50 601-1000 Amps 1.25 1.25 4.00 4.50 4.75 1.75 1.50 1.50 1.50 1.50 1.50 1001-2000 Amps 1.25 1.25 8.50 8.50 8.50 1.75 1.50 1.50 1.50 1.50 2.00
TP-5178 9/03
2.2 M340 Logic

Flat Rate Hours Flat Rate Description Accessories All hardware options Bypass Isolation Bypass isolation handle Bypass switch Transfer switch fingers Controller Microprocessor assembly R & R Power supply circuit board R & R
Note: R & R means remove and replace.
Flat Rate Number 1898 1921 1919 1920 1897 1910
30-150 Amps 2.00 1.00 3.00 1.25 6.00 2.00
151-800 Amps 2.00 1.00 4.00 1.25 6.00 2.00
801-4000 Amps 2.00 1.00 5.00 1.50 6.00 2.00
Comments
Includes setup/adjustments
2.3 R340/S340 Logic

Flat Rate Hours Flat Rate Description Accessories Accessory card Accessory card cage Accessory relay or socket Battery charger In-phase monitor/sync check relay/load shed Meter Optional circuit board Pilot lamp(s) Plant exerciser Selector switch Bypass Isolation Bypass isolation handle Bypass switch Transfer switch fingers Controller Control relays Daughter logic board Main logic board Main wire harness Transformer or assembly 1914 1912 1911 1913 1915 1.50 1.75 3.00 5.00 1.50 1.50 1.75 3.00 5.00 1.50 1.50 1.75 3.00 5.00 1.50 1918 1916 1917 1.00 3.00 1.25 1.00 4.00 1.25 1.00 5.00 1.50 Flat Rate Number 1783 1784 1789 1785 1788 1790 1792 1791 1786 1787 30-150 Amps 1.50 1.75 1.25 1.80 2.00 1.50 1.50 0.75 1.80 2.00 151-800 Amps 1.50 1.75 1.25 1.80 2.00 1.50 1.50 0.75 1.80 2.00 801-4000 Amps 1.50 1.75 1.25 1.80 2.00 1.50 1.50 0.75 1.80 2.00 Voltmeter or ammeter, each Comments
TP-5178 9/03
2.4 30-4000 Amp Contactors

Flat Rate Hours Flat Rate Description ATS Contactor Auxiliary, miniature contacts R & R Coil clearing contact, adjust Contactor assembly Contactor coil Contactor wire harness Moveable main/arcing contacts Rectifier Resistor Stationary main/arcing contact Terminal bracket and lug Terminal lug
Flat Rate Number 1780 1779 1772 1774 1773 1781 1777 1778 1782 1775 1776
30-150 Amps 1.00 1.00 2.00 1.50 2.00 1.00
151-800 Amps 1.50 1.50 3.50 1.50 4.00 1.50 1.00 1.00 1.75 1.50 1.40
801-4000 Amps 1.50 1.50 6.00 2.00 2.00 2.00 1.00 1.00 2.00 1.50 1.40
Comments Adjustment
Lug only, each
2.5 Model KCT/KCP/KBT/KBP Transfer Switches

Flat Rate Hours Flat Rate Description Accessories All hardware options Bypass Isolation Bypass isolation handle Bypass switch Transfer switch fingers MPAC 1000tController Microprocessor assembly R & R
Flat Rate Number 5307 5310 5311 5314 5292
30-150 Amps 2.00 1.00 3.00 1.25 2.00
151-800 Amps 2.00 1.00 4.00 1.25 2.00
801-4000 Amps 2.00 1.00 5.00 1.50 2.00
Comments
Includes setup/adjustments
TP-5178 9/03
Section 3 Engine Flat Rates

3.1 Detroit Diesel* 125-200 kW
Flat Rate Description Air Intake and Exhaust Air cleaner assembly, replace Air cleaner assembly, replace Air cleaner element Exhaust silencer R & R Flexible exhaust connector Cooling Block heater assembly R & R Block heater cord or thermostat Block heater R & R Coolant hose Fan blade, replace Radiator assembly, replace Radiator, repair Engine Electrical Engine wiring harness Magnetic pickup Shutdown/gauge sender/switch Engine Mounting Skid base R & R Vibration isolators Fuel Auxiliary fuel pump Flexible fuel lines Subbase fuel tank[ Starter Starter relay 1738 0.80
* The Warranty Department requires that repairs made on Detroit Diesel engines be performed by an authorized Detroit Diesel service center. [ Contact factory prior to performing any warranty work. Note: R & R means remove and replace.
Flat Rate Number 3367 3369 1564 1566 1565 1576 1578 1575 1573 1574 1572 3456 1562 1561 1559 1570 1571 1583 1582 1584
Flat Rate Hours 0.80 1.00 0.30 4.00 1.50 1.25 1.25 2.00 0.80 1.25 3.25 2.00 2.00 2.00 1.50 4.50 1.75 1.50 1.00 6.00
Comments Standard Heavy duty
Tank assembly or element only Complete kit
Each pair
TP-5178 9/03
3.2 Detroit Diesel* 135-400 kW (Series 50/60 Gas, Series 60 Diesel)

Flat Rate Hours Flat Rate Description Air Intake and Exhaust Air inlet manifold R & R Air inlet piping R & R Air-to-air piping R & R Charge air cooler R & R Turbocharger Exhaust manifold R & R Exhaust manifold outlet connection R & R Cooling System Belt tensioner and bracket R & R Pressure check cooling system Radiator assembly, replace Radiator, repair Thermostat R & R Thermostat housing seals R & R Water pump R & R Crankshaft, Mains, and Flywheel Bull gear R & R Belt set R & R Crankshaft oil seal front R & R Crankshaft oil seal rear R & R Crankshaft pulley R & R Flywheel R & R Flywheel housing R & R Gear case cover R & R Vibration damper R & R Cylinder Head and Valves Breather pad R & R Rocker cover R & R Valve and injector arm assembly R & R Valve and injector mechanism R & R Valve springs and/or seals R & R Engine Electrical Alternator bracket R & R Starter motor and drive assembly R & R Starter solenoid R & R 4913 4914 4915 0.40 0.20 0.20 0.40 0.20 0.20 Starter removed 4908 4909 4910 4911 4912 0.10 0.10 0.10 0.10 0.30 0.80 Head installed Each 4900 4901 4902 4903 4904 4905 4906 4907 5239 0.40 0.30 0.20 0.30 0.20 0.70 0.20 0.90 0.10 0.40 0.30 0.20 0.30 0.20 0.70 0.20 0.90 0.10 4895 4896 5162 5163 4897 4898 4899 0.50 0.50 3.25 2.00 0.10 0.50 0.10 0.50 0.50 3.25 2.00 0.10 0.50 0.10 Front mounted Flat Rate Number 4888 4889 4890 4891 4892 4893 4894 135-275 kW Gas 0.20 0.30 0.20 230-400 kW Diesel Comments 0.20 0.20 0.30 0.20 Each
* The Warranty Department requires that repairs made on Detroit Diesel engines be performed by an authorized Detroit Diesel service center. Note: R & R means remove and replace.
TP-5178 9/03
Detroit Diesel* 135-400 kW (Series 50/60 Gas, Series 60 Diesel), continued

Flat Rate Hours Flat Rate Description Fuel System Compression test DDEC connector R & R Flat Rate Number 4916 4917 135-275 kW Gas 0.10 230-400 kW Diesel Comments 0.70 0.10 Three cylinders Each, includes R & R turbocharger boost, oil pressure, oil temperature, coolant level, air temperature, or water temperature (DDEC III) sensors. Per module Primary Secondary
DDEC II or DDEC III, reprogram Electronic control module R & R Fuel filter assembly R & R Fuel filter assembly R & R Fuel lines R & R Fuel pump and/or coupling R & R Fuel pump drive assembly R & R Injector R & R Injector (overhead removed) SRS or TRS assembly R & R Subbase fuel tank R & R Lubricating System Dipstick tube and adapter Oil cooler elements R & R Oil cooler pressure test Oil filter adapter R & R Oil filter elements R & R Oil pan and gasket R & R
4918 4919 4920 4921 4922 4923 4924 4925 4926 4927 5255 5241 5242 5243 5244 5245 5246
0.50 1.00 0.20 0.10 6.00 0.10 0.20 0.60 0.20 0.20 0.20
0.50 1.00 0.30 0.30 0.20 0.10 0.10 2.50 0.10 0.10 6.00 0.10 0.20 0.60 0.20 0.20 0.20
One Each additional
3.3 Kohler-Branded 200-500 kW

Refer to TP-6220, Warranty Flat Rates/ Failure Codes, Industrial 200--500REOZV Generator Sets, for codes pertaining to these models.
TP-5178 9/03
3.4 Detroit Diesel* 200-2000 kW (Single Bearing, Series 71, 92, and 149)
kW Flat Rate Number 1564 1566 1565 1575 1577 3363 1576 1579 1578 1573 1574 1581 1580 1572 2354 1562 1559 1561 1570 1571 1583 1582 1586 1585 1584 3382 3594 3595 3593 1738 200-400 450-800 801-2000 Comments 0.75 Each 2.50 Each 1.50 Each 3.00 Complete block heater kit 1.50 2.00 Complete box or circuit board 4.00 Tank assembly or element only 1.50 2.50 2.50 Includes drain and refill of radiator 6.00 Includes fan guard(s) R & R 2.50 Includes guards R & R, tension adjustment 3.50 10.00 Unit-mounted radiator 1.50 3.50 1.50 2.00 Controller crank disconnect Call factory 2.50 Skid to pad spring isolators (each) 1.50 2.00 0.20 1.50 For base tank 12.00 1.50 4.80 0.70 14.50 Includes radiator 1.50
Flat Rate Description Air Intake and Exhaust Air cleaner element Exhaust silencer Flexible exhaust connector Cooling Block heater Block heater circulating pump Block heater control box Block heater element or tank Block heater relay/cord Block heater thermostat Coolant hoses Cooling fan Fan belt Fan guard Radiator R & R[ Engine Electrical Air damper microswitch Engine wiring harness Senders/shutdown switches Speed pickup Engine Mounting Skid base Vibration isolators Fuel Auxiliary fuel pump Flexible fuel lines Fuel filter Fuel gauge sender Skid base tank[ Governor Governor controller Lubrication Flush lube oil system Oil filter element R & R Oil pump R & R Starter Starter relay (solenoid)
Flat Rate Hours 0.75 1.50 1.50 2.00 1.50 2.00 1.50 1.50 1.50 3.50 1.50 1.50 6.50 1.50 2.50 1.50 2.00 1.00 1.50 1.50 0.20 1.50 6.00 1.50 1.50 0.75 2.00 1.50 2.50 1.50 3.00 1.50 2.00 2.00 4.50 2.00 2.50 8.00 1.50 3.00 1.50 2.00 2.00 1.50 2.00 0.20 1.50 9.00 1.50 4.80 0.70 14.50 1.50
* The Warranty Department requires that repairs made on Detroit Diesel engines be performed by an authorized Detroit Diesel service center. [ Contact factory prior to performing any warranty work. Note: R & R means remove and replace.
TP-5178 9/03
3.5 Detroit Diesel* 1250-2000 kW (Series 4000 Diesel)

kW Flat Rate Number 4928 4929 4930 4931 4932 4933 4934 4935 4936 4937 4938 4939 4940 4941 4942 4943 4944 4945 4946 4947 4966 4967 4968 4969 4970 5164 4971 4972 4973 4974 4975 4976 1250 1500 1750 2000 Comments 0.30 Each section 1.40 One side complete 2.30 All 1.90 Each 2.50 1.00 All, each bank 0.90 1.30 Each bank 1.10 Supply and return 1.30 One 2.60 Set of two 0.50 One 0.90 All One 0.50 All 0.30 One 1.80 All 0.60 One 3.80 All 0.10 All, between turbochargers 1.00 6.20 Upper 0.10 One section 0.30 One side 1.00 1.50 0.80 1.50 0.60 1.00 0.80 Flat Rate Hours 0.30 1.90 2.50 1.00 0.90 1.30 2.60 0.50 0.40 0.60 0.10 1.00 6.20 0.30 1.00 1.50 0.80 1.50 0.60 1.00 0.80 0.30 1.90 2.50 1.00 0.90 1.30 2.60 0.50 0.40 0.60 0.10 1.00 6.20 0.30 1.00 1.50 0.80 1.50 0.60 1.00 0.80 0.30 1.40 2.30 1.90 2.50 1.00 0.90 1.30 1.10 1.30 2.60 0.50 0.90 0.50 0.30 1.80 0.60 3.80 0.10 1.00 6.20 0.10 0.30 1.00 1.50 0.80 1.50 0.60 1.00 0.80
Flat Rate Description Air Intake and Exhaust Air inlet manifold R & R Air inlet manifold R & R Air inlet manifolds R & R Charge air cooler assembly R & R Charge air cooler mounting R & R Charge air cooler piping seals R & R Charge air cooler top cover and seal R & R Charge air piping to turbocharger R & R Coolant piping, charge air cooler R & R Turbocharger R & R Turbocharger R & R Turbocharger oil drain line R & R Turbocharger oil drain line R & R Turbocharger oil supply line R & R Turbocharger oil supply line R & R Exhaust crossover tube R & R Exhaust crossover tube R & R Exhaust manifold R & R Exhaust manifold R & R Exhaust manifold outlet connection R & R Cooling System Belt tensioner and bracket, adjust R & R Distribution housing R & R Manifold, water outlet R & R Manifold, water outlet R & R Pressure check cooling system Radiator, replace Thermostat, high temperature R & R Thermostat, low temperature R & R Thermostat housing, high temperature R & R Thermostat housing, low temperature R & R Water pump, high temperature R & R Water pump, low temperature R & R
10.00 10.00 10.00 10.00
10
TP-5178 9/03
Detroit Diesel* 1250-2000 kW (Series 4000 Diesel), continued

kW Flat Rate Number 4948 4949 4950 4951 4952 4953 4954 4955 4956 4957 4964 4965 4958 4959 4960 4961 4962 4963 4977 4978 5165 4979 4980 4981 4982 4983 4984 4985 4986 4987 4988 4989 4990 4991 4992 4993 1250 1500 1750 2000 Comments 2.50 0.60 1.40 0.90 0.90 0.90 3.80 0.10 1.30 0.40 0.30 2.60 0.10 0.30 2.00 0.30 0.60 5.30 1.30 1.00 1.00 1.00 0.60 1.40 0.50 1.30 0.60 0.10 0.30 0.80 0.80 0.80 0.30 2.10 0.30 One All One, cylinder head to return rail One Two One, front Both Primary Secondary One B bank Each One All Intake and exhaust One cylinder All Each All Generator removed Generator removed Two Flat Rate Hours 2.50 0.60 1.40 0.90 0.90 0.90 3.80 0.10 1.30 0.40 0.30 1.50 0.10 0.30 1.90 0.30 0.40 5.30 1.30 1.00 1.00 1.00 0.60 1.10 1.40 0.50 1.30 0.60 0.10 0.30 0.80 0.80 0.80 0.30 1.60 0.30 2.50 0.60 1.40 0.90 0.90 0.90 3.80 0.10 1.30 0.40 0.30 1.50 0.10 0.30 1.90 0.30 0.40 5.30 1.30 1.00 1.00 1.00 0.60 1.10 1.40 0.50 1.30 0.60 0.10 0.30 0.80 0.80 0.80 0.30 1.60 0.30 2.50 0.60 1.40 0.90 0.90 0.90 3.80 0.10 1.30 0.40 0.30 2.60 0.10 0.30 2.00 0.30 0.60 5.30 1.30 1.00 1.00 1.00 0.60 1.40 0.50 1.30 0.60 0.10 0.30 0.80 0.80 0.80 0.30 2.10 0.30
Flat Rate Description Crankshaft, Mains, and Flywheel Belt set R & R Dust shields, install Crankshaft oil seal front R & R Crankshaft oil seal rear R & R Crankshaft pulley R & R Flywheel R & R Flywheel housing R & R Flywheel housing inspection covers R & R Vibration damper Vibration damper guard Cylinder Block, Liners, Pistons, and Rods Swing arm assembly R & R Swing arm assembly R & R Cylinder Head and Valves Push rods R & R Rocker arm and bridge R & R Rocker arm and bridge R & R Rocker cover R & R Rocker cover R & R SRS pulse wheel R & R Engine Electrical Alternator R & R Alternator/accessory drive R & R Starter R & R Fuel System Control solenoid, high pressure pump R & R Coupling R & R DDEC sensor harness R & R Electronic control module Electronic control module cold plate R & R Electronic control module cold plate R & R Fuel filter assembly R & R Fuel filter elements R & R Fuel flow limiter valve R & R Fuel junction block assembly R & R Fuel lines, high pressure pump R & R Fuel lines, low pressure transfer pump R & R Fuel line to injector, high pressure R & R Fuel line to injector, high pressure R & R Fuel line, return R & R
TP-5178 9/03
11
Detroit Diesel* 1250-2000 kW (Series 4000 Diesel), continued

kW Flat Rate Number 1250 1500 1750 2000 Comments Flat Rate Hours
Flat Rate Description Fuel System, continued Fuel pump and/or coupling, low pressure transfer R & R Fuel pump assembly, high pressure R & R Fuel pump injection pressure sensor, high pressure R & R Fuel rail, high pressure R & R Fuel rail, return R & R Injector assembly R & R Injector assembly R & R Injector harness R & R Prime fuel system Relief valve, high pressure fuel rail R & R SRS sensor R & R TRS sensor R & R Temperature or pressure sensor R & R Subbase fuel tank R & R Lubricating System Dipstick tube and adapter R & R Breather assembly R & R Centrifugal filter assembly R & R Crankcase to breather tube R & R Element, oil cooler pressure test Oil cooler housing and/or cores R & R Oil distribution manifold and seal R & R Oil filter adapter housing R & R Oil filter bypass valve and spring R & R Oil filter elements R & R Oil pan and seal R & R
4994 4995 4996 4997 4998 4999 5000 5001 5002 5003 5004 5005 5006 5257 5007 5008 5009 5010 5011 5012 5013 5014 5015 5016 5017
0.60 1.40 0.10 0.10 0.80 3.30 0.90 0.10 0.80 0.10 0.10 0.50
0.60 1.40 0.10 0.10 0.80 3.30 0.90 0.10 0.80 0.10 0.10 0.50
0.60 1.40 0.10 0.10 1.00 0.80 4.30 0.10 0.80 0.10 0.10 0.50
0.60 1.40 0.10 0.10 Set of two 1.00 0.80 One 4.30 All One 0.10 Complete 0.80 0.10 0.10 Flywheel removed 0.50 Any one
12.00 12.00 12.00 12.00 0.10 0.80 0.30 0.10 0.50 1.90 1.30 0.10 0.60 3.10 0.10 0.80 0.30 0.10 0.50 1.90 1.30 0.10 0.60 3.10 0.10 0.80 0.30 0.10 0.50 1.90 0.90 1.30 0.10 0.60 4.10 0.10 0.80 Two 0.30 0.10 One 0.50 One 1.90 Set of three 0.90 1.30 0.10 0.60 Set of four 4.10
12
TP-5178 9/03
3.6 Deutz 20-170 kW

kW Flat Rate Number 4696 4698 4699 4702 4697 4703 4700 4701 4650 4709 4658 4722 4720 4718 4721 4719 4651 4649 4648 4655 4654 4717 4656 4662 4663 4664 4665 4666 4667 4657 4661 4710 4711 20 30 40 50-60 70-100 115-170 Comments 0.60 0.80 0.30 0.20 0.30 1.50 1.50 1.45 1.50 0.30 0.10 0.90 0.20 0.25 0.65 0.70 0.35 0.40 0.40 3.75 0.45 0.15 1.20 0.10 0.05 0.35 0.30 0.35 0.05 0.60 One cylinder Each additional All cylinders One Each additional All One Each additional All Each
Flat Rate Description Air Intake and Exhaust Charge air line R & R Exhaust manifold R & R Exhaust manifold, check flange side Fuel return line seals R & R Intake manifold R & R Oil supply line seals R & R Turbocharger R & R Turbocharger, repair Camshaft and Timing Gear Front cover gasket R & R Time gear case cover R & R Toothed belt R & R Cooling Coolant compensating R & R Coolant line to thermostat R & R Coolant pump R & R Line to exchanger crankcase R & R Thermostat housing R & R Crankshaft, Mains, and Flywheel Cover gasket, rear, R & R Crankshaft flywheel seal R & R Crankshaft front seal R & R Flywheel R & R V-belt pulley R & R Vibration damper R & R Cylinder Head and Valves Cylinder head or gasket R & R Rocker arm bracket, push rods R & R Rocker arm bracket, push rods R & R Rocker arm bracket, push rods, R&R Rocker arm bracket w/rocker arms, repair Rocker arm bracket w/rocker arms, repair Rocker arm bracket w/rocker arms, repair Rocker cover gasket R & R Valve clearance, adjust Valve clearance, adjust Valve clearance, adjust
Flat Rate Hours 0.60 0.15 0.15 1.00 1.35 0.65 0.30 0.25 0.95 0.15 0.15 0.90 0.20 0.10 0.40 0.10 0.05 0.25 0.15 0.15 0.05 0.25 0.60 0.20 0.20 1.00 1.35 0.65 0.30 0.25 0.95 0.15 0.15 1.10 0.25 0.10 0.55 0.10 0.05 0.25 0.20 0.20 0.05 0.35 0.60 0.50 0.20 0.05 1.00 0.10 1.50 1.50 1.35 0.65 0.30 0.25 0.95 0.15 0.15 1.40 0.25 0.10 0.55 0.10 0.05 0.25 0.20 0.20 0.05 0.35 0.80 0.50 0.20 0.20 0.10 1.50 1.50 1.35 1.50 0.30 0.10 0.90 0.20 0.25 0.65 0.70 0.35 0.40 0.40 2.90 0.35 0.15 0.80 0.10 0.05 0.25 0.20 0.25 0.05 0.40 0.40 0.75 0.20 0.20 0.10 1.50 1.50 1.35 1.50 0.30 0.10 0.90 0.20 0.25 0.65 0.70 0.35 0.40 0.40 2.90 0.35 0.15 0.80 0.10 0.05 0.25 0.20 0.25 0.05 0.40
TP-5178 9/03
13
Deutz 20-170 kW, continued

kW Flat Rate Number 4704 4706 4707 4708 4725 4726 4727 4728 4690 4691 4692 4678 4679 4680 4672 4673 4674 4681 4713 4695 4682 4693 4669 4670 4671 4694 4675 4676 4677 4687 4688 4689 4683 4684 4685 4686 4714 4715 4716 20 30 40 50-60 70-100 115-170 Comments 0.10 0.25 0.10 0.10 0.05 0.45 0.25 1.20 0.25 0.05 0.40 0.15 0.10 0.45 0.10 0.05 0.25 0.10 0.55 0.10 0.25 0.10 0.50 0.20 1.10 0.25 0.35 0.10 0.65 0.10 0.05 0.25 0.30 0.25 0.05 0.40 0.55 0.10 0.55 0.10 0.25 0.10 0.10 0.05 0.55 0.25 1.80 0.35 0.05 0.60 0.15 0.10 0.65 0.10 0.05 0.35 0.10 0.60 0.10 0.25 0.10 0.55 0.20 1.55 0.35 0.45 0.10 0.95 0.10 0.05 0.35 0.40 0.35 0.05 0.60 0.60 0.10 0.60 One Each additional All One, includes R & R Each additional All One Each additional All One Each additional All One Each additional All One Each additional All One Each additional All One Each additional All One Each additional All
Flat Rate Description Engine Electrical Alternator V-belt R & R Alternator w/reg cutout R & R Oil pressure sensor R & R Shutdown solenoid R & R Coolant temp. sensor R & R Heater plug, 1-pin type R & R Heater plug, 1-pin type R & R Heater plug, 1-pin type R & R Fuel Back leakage pipe R & R Back leakage pipe R & R Back leakage pipe R & R Ejection pressure, set Ejection pressure, set Ejection pressure, set Eject and spray pattern, test Eject and spray pattern, test Eject and spray pattern, test Exchangeable fuel filter R & R Fuel delivery, single injector R & R Fuel hose line from fuel pump to fuel filter Fuel pump R & R Fuel pump fuel line R & R Injection pump R & R Injection pump R & R Injection pump R & R Injection pump fuel line R & R Injector R & R Injector R & R Injector R & R Injection line, clean Injection line, clean Injection line, clean Injection lines, test Injection line R & R Injection line R & R Injection line R & R TDC cylinder TDC cylinder TDC cylinder
Flat Rate Hours 0.10 0.25 0.05 0.10 0.05 0.05 0.15 0.15 0.10 0.35 0.10 0.05 0.20 0.05 0.05 0.20 0.05 0.25 0.20 0.65 0.20 0.15 0.15 0.45 0.10 0.20 0.20 0.15 0.10 0.10 0.30 0.10 0.25 0.05 0.10 0.05 0.05 0.20 0.15 0.10 0.45 0.10 0.05 0.25 0.05 0.05 0.20 0.05 0.30 0.20 0.85 0.25 0.20 0.15 0.60 0.10 0.25 0.25 0.20 0.10 0.10 0.40 0.10 0.25 0.05 0.10 0.05 0.05 0.20 0.15 0.10 0.45 0.10 0.05 0.25 0.05 0.05 0.20 0.05 0.30 0.20 0.85 0.25 0.20 0.15 0.60 0.10 0.25 0.25 0.20 0.10 0.10 0.40 0.10 0.25 0.10 0.10 0.05 0.45 0.25 1.20 0.25 0.05 0.40 0.15 0.10 0.45 0.10 0.05 0.25 0.10 0.55 0.10 0.25 0.10 0.50 0.20 1.10 0.25 0.35 0.10 0.65 0.10 0.05 0.25 0.30 0.25 0.05 0.40 0.55 0.10 0.55
14
TP-5178 9/03
Deutz 20-170 kW, continued

kW Flat Rate Number 4653 4668 4712 4652 4723 4724 20 30 40 50-60 70-100 115-170 Comments 0.10 0.05 0.15 0.70 0.30 0.25 0.10 0.05 0.15 0.70 0.30 0.25
Flat Rate Description Lubrication Drain plug R & R Lube oil filter R & R Oil heat exchanger, leak check Oil pan R & R Starter Starter motor R & R Starter pinion R & R
Flat Rate Hours 0.10 0.05 0.20 0.15 0.25 0.10 0.05 0.25 0.15 0.25 0.10 0.05 0.25 0.15 0.25 0.10 0.05 0.15 0.60 0.30 0.25
TP-5178 9/03
15
3.7 Ford 20-100 kW

kW Flat Rate Number 1547 1546 1542 1544 1545 1549 1550 1548 1543 2423 1515 1514 1737 1524 1519 1521 1525 1522 3385 1518 1523 1520 1512 1508 1511 1510 1509 1513 1538 1536 1537 1535 1532 1533 1534 1531 20-30 31-45 50-100 Comments Standard Heavy duty Each Each Flat Rate Hours 0.40 1.00 0.10 0.75 1.25 1.25 0.25 1.25 0.75 2.25 3.00 1.25 1.75 0.80 1.50 1.25 2.50 1.50 1.00 0.50 1.75 3.80 0.90 2.70 3.00 0.30 7.00 3.70 1.00 0.20 1.80 1.80 0.50 0.60 1.00 0.10 0.75 1.25 1.25 0.25 1.25 0.75 2.25 3.40 4.80 1.25 1.75 0.80 1.50 1.25 2.50 1.50 1.00 0.50 2.00 4.60 0.60 0.50 2.00 0.30 7.50 3.10 1.30 0.20 2.70 0.50 2.00 1.20 1.00 1.20 0.10 0.75 1.00 1.50 0.50 1.50 0.75 2.25 4.50 5.60 1.25 1.75 0.80 1.50 1.25 2.75 1.50 1.00 0.50 2.00 4.40 0.80 2.50 2.30 0.30 11.50 6.10 1.00 0.20 1.80 0.40 2.50 Each head All All Each head All Complete kit or block heater assembly Each
Flat Rate Description Air Intake and Exhaust Air cleaner assembly Air cleaner assembly Air cleaner element Exhaust manifold, dry Exhaust manifold, wet Exhaust silencer Exhaust stack pipe Flexible exhaust connector Intake manifold Turbocharger R & R Camshaft and Timing Gear Camshaft gear and chain Camshaft R & R Cooling Block heater element or tank Block heater R & R Coolant hoses Cooling fan Heater cord or thermostat Radiator Radiator, repair Thermostat/housing V-belt Water pump, coolant Crankshaft, Mains, and Flywheel Balancer R & R Crankshaft and main bearings Crankshaft damper Crankshaft flywheel seal Crankshaft front cover seal Flywheel R & R Pistons and/or rings Cylinder Head and Valves Cylinder head or gasket R & R Cylinder head retorque Valve cover gasket or breather Valve, grind or replace Valve push rod Valve spring or stem seal R & R Valve tappet, adjust
Cylinder Block, Liners, and Pistons, Rods
16
TP-5178 9/03
Ford 20-100 kW, continued

kW Flat Rate Number 1551 1958 1957 1558 1557 1556 1499 1502 1500 1002 1501 1506 1507 1503 1504 1505 1528 1526 1529 1527 1530 1498 1495 1496 1497 1494 1493 3362 1517 1516 1540 1541 1539 1553 1552 1554 1555 20-30 31-45 50-100 Comments Flat Rate Hours 1.30 1.50 1.50 3.00 3.00 1.50 0.30 0.90 1.10 1.75 0.90 0.50 0.50 1.25 1.50 1.00 1.25 0.50 1.50 1.50 1.50 1.40 1.50 0.40 0.25 0.25 0.25 1.60 1.90 8.00 7.00 4.00 0.90 1.40 1.90 1.25 1.50 1.50 1.50 3.50 3.50 1.50 0.30 0.90 1.10 1.75 0.90 0.50 0.50 1.25 1.50 1.00 1.25 0.50 1.50 1.50 1.50 1.40 1.50 0.40 0.40 0.30 0.25 1.90 2.00 8.00 7.00 5.00 0.90 1.40 1.90 1.25 1.50 1.50 1.50 4.00 4.00 1.75 0.30 0.90 1.10 2.00 0.90 0.50 0.50 1.25 1.50 1.00 1.50 0.50 1.50 1.50 1.50 1.40 1.50 0.40 0.50 0.40 0.25 1.70 0.30 10.00 8.00 6.00 0.90 1.40 1.90 1.25 Testing Includes R & R, testing Includes valve service Excludes valve service Distributorless ignition system DIS or distributor type Electronic ignition Distributor type ignition Replace Mechanical governor Includes adjustment Mechanical governor; includes adjustment Test and adjustment Includes choke adjustment Gas or gasoline Gasoline Includes adjustment Per pair
Flat Rate Description Engine Electrical Battery charging alternator Engine wiring harness Gauge senders/shutdown switch Engine Mounting Engine R & R Skid Base Vibration isolators Fuel System Carburetor, adjust Carburetor fuel shutdown solenoid Carburetor R & R Carburetor, rebuild Electric choke R & R Flexible fuel line R & R Fuel filter, gasoline Fuel pump R & R Gas fuel regulator/vaporizer R & R Gas solenoid valve Governor Governor actuator Governor, adjust Governor controller Governor R & R Magnetic pickup Ignition Crankshaft position sensor Ignition coil R & R Ignition module Ignition timing Spark plug wires Spark plugs, replace and cap Lubrication Oil filter R & R Oil pan or gasket Oil pump, replace Rebuild Major overhaul Minor overhaul Short block R & R Starter Starter drive R & R Starter motor R & R Starter, rebuild Starter relay
Note: R & R means remove and replace. TP-5178 9/03
17
3.8 General Motors 30-100 kW

Flat Rate Description Air Intake and Exhaust Manifold/intake gasket R & R Camshaft and Timing Gear Camshaft timing gear R & R Crankshaft gear Camshaft Crankshaft, Mains, and Flywheel Bearing, crankshaft main Bearing, main Bearings, main Chain, timing, replace Cover/gasket timing Crankshaft Crankshaft gear Expansion plug Flywheel Flywheel housing Seal, main rear Seal, timing cover oil Cooling Block heater Block heater element Coolant hoses Heater cord or thermostat Radiator Water pump/gasket Cylinder Block, Liner, Pistons, and Rods Bearing, connecting rod Bearing, connecting rod Bearing, connecting rod Connecting rod or rings Connecting rod or rings Connecting rings Connecting rings Connecting rod Connecting rod Piston rod Piston rod
Flat Rate Number 4789 4813 4814 4815 4819 4820 4821 4811 4810 4825 4812 4835 4834 4841 4818 4809 5150 5152 5149 5151 5148 4840 4822 4823 4824 4826 4827 4828 4829 4830 4831 4832 4833
Flat Rate Hours 1.80 3.00 0.20 6.00 3.40 0.70 2.80 3.00 1.80 5.00 0.20 0.30 0.70 0.30 3.00 0.70 1.75 1.25 0.80 1.25 1.50 0.70 3.00 0.40 2.80 8.00 10.00 0.40 2.60 0.30 2.00 0.40 3.00
Comments
Excludes camshaft
Includes oil pan One All Includes balancer R & R Excludes timing
Includes oil pan Includes balancer R & R
One, includes oil pan Each additional All One Both Each piston All pistons Each All One All
18
TP-5178 9/03
General Motors 30-100 kW, continued

Flat Rate Description Cylinder Head and Valves Balancer, harmonic Cylinder head gasket Cylinder head gasket Cylinder head Cylinder head Lifter valve Push rod Push rod Rocker arm Rocker arms Rocker arm cover/gasket Rocker arm balance stud valve Rocker arm balance stud valve Valve, recondition Valve, recondition Ream/fit guides oversize Valve, replace Valve, replace Valve seals Engine Electrical Battery charging alternator Engine wiring harness Gauge senders/shutdown switch Engine Mounting Engine, complete Engine, partial Engine; additional to recondition all valves/guides Skid base Vibromounts Lubrication Engine oil pump Oil pan and gasket Oil plug Starter Starter drive R & R Starter motor Starter rebuild Starter relay
Flat Rate Number 4808 4795 4796 4797 4798 4807 4805 4806 4790 4791 4792 4793 4794 4801 4802 4803 4799 4800 4804 5157 5159 5158 4839 4837 4838 5161 5160 4817 4816 4836 5154 5153 5155 5156
Flat Rate Hours 0.50 5.00 8.00 6.00 9.50 2.50 0.50 0.90 0.40 1.30 0.50 0.50 0.30 2.00 3.50 0.20 5.00 8.20 1.80 1.50 1.50 1.50 4.00 8.20 3.50 3.00 1.50 2.20 2.00 0.30 0.90 1.40 1.80 1.25
Comments
One Both One Both Includes R & R rocker One, includes R & R rocker Both, includes R & R rocker Each All One Each additional One side Both One Both Includes R & R rocker
Complete Partial Additional
Includes oil Includes filter
TP-5178 9/03
19
3.9 John Deere* 20-200 kW

kW Flat Rate Number 1059 1060 1058 1024 1659 1055 1054 1051 1052 1053 1658 1061 1057 1056 1048 1049 1050 1078 20-60 70-100 101-200 Comments Standard Heavy duty Flat Rate Hours 0.30 0.50 0.20 1.00 0.50 0.60 0.60 0.60 0.80 1.80 1.25 1.25 0.60 1.00 0.80 1.80 1.00 6.50 0.70 0.90 0.30 1.00 0.50 0.60 0.60 0.80 1.00 2.00 1.50 1.50 0.60 1.00 0.80 1.80 1.00 7.00 0.80 1.00 0.30 1.00 0.50 0.60 0.60 1.40 1.40 2.20 2.00 1.50 0.60 1.00 0.40 1.80 0.80 3.60 Includes R & R When already removed R & R fuel pump, crankshaft pulley, and timing gear cover; R & R cylinder head; retorque head bolts and adjust valves R & R front crankshaft pulley, front cover, fuel pump, bracket, valve cover, and rocker arm assembly, replace camshaft and/or gear Includes R & R Transfer exhaust Elbow and turbocharger
Flat Rate Description Air Intake and Exhaust Air cleaner assembly, replace Air cleaner assembly, replace Air cleaner element, replace Air cleaner R & R Exhaust elbow Exhaust elbow coupling, replace Exhaust elbow, replace Exhaust manifold gasket, replace Exhaust manifold, replace Exhaust manifold w/turbo, replace Exhaust silencer R & R Flexible exhaust connector Intake elbow and gasket, replace Intake manifold/gasket, replace Turbocharger/gasket, replace Turbocharger, recondition Turbocharger, recondition Camshaft and Timing Gear Camshaft and cam followers
Camshaft, replace
1077
4.40
5.00
3.30
Rocker arm assembly, recondition Rocker arm cover and/or gasket Timing gear cover and/or gasket Cooling Block heater assembly R & R Block heater cord or thermostat Block heater R & R Coolant hose Fan belts, replace Fan blade, replace Fan pulley, replace Idler pulley, recondition Radiator assembly, replace Radiator, repair Thermostats, covers, gaskets Thermostat housing, replace Water pump/gasket, replace Water pump, recondition Water pump, recondition
1080 1079 1081 1657 1656 1655 1105 1095 1096 1097 1098 1104 3383 1102 1103 1099 1100 1101
1.20 0.60 2.20 1.25 1.25 1.75 0.80 0.60 0.60 0.60 0.60 2.50 2.00 0.60 0.60 1.00 2.00 1.00
1.40 0.60 2.40 1.25 1.25 1.75 0.80 0.60 0.60 0.60 0.60 2.75 2.00 0.60 0.60 1.00 2.00 1.00
0.60 0.40 2.20 1.25 1.25 2.00 0.80 0.60 0.60 0.60 3.25 2.00 0.60 0.60 1.50 2.50 1.00
Includes R & R; replace ball bearings, sleeve, and/or pulley
Adjust fan belt Includes R & R When already removed
* John Deere requires that the distributor/dealer have a factory-trained technician. Note: R & R means remove and replace.
20
TP-5178 9/03
John Deere* 20-200 kW, continued

kW Flat Rate Number 1069 1071 1073 1068 1067 20-60 70-100 101-200 Comments Flat Rate Hours 2.20 2.60 0.60 0.80 6.50 2.40 2.60 0.60 0.80 7.00 2.90 0.60 1.20 7.50 R & R flywheel and flywheel housing Replace rod and main bearings, check and/or recondition oil pump, and make all adjustments R & R flywheel, replace rear crankshaft seal R & R flywheel Each additional R & R oil pan and oil pump Deglaze cylinder liners and replace piston rings, all seals, main bearings, and rod bearings; transfer and/or replace all parts and assemblies and make all adjustments R & R head and oil pump, replace piston rings, check and/or replace rod bearings, retorque head bolts, adjust valves Each additional R & R head and oil pump, replace piston rings, check and/or replace rod bearings, retorque head bolts, adjust valves Each additional R & R head and oil pump, replace rod bearings, retorque head bolts, adjust valves Replace rod and main bearings, retorque head bolts, adjust valves R & R head and oil pump, check and/or replace main bearings and rod bearings, reset valves, retorque head bolts, adjust valves R & R head and oil pump, replace piston rings, replace cylinder packings, R & R and deglaze liners, check and/or replace piston pin, bushings, and rod bearings Each additional R & R head and oil pump, check and/or replace piston pin, rod bushings, and bearings; R & R and deglaze liners, replace cylinder liner packings Each additional R & R head and oil pump, remove liner ridges and deglaze, check and/or replace rod bearings and main bearings, reset valves, retorque head bolts, and adjust valves R & R timing gear cover and oil pan
Flat Rate Description Crankshaft, Mains, and Flywheel Crankshaft front oil seal Crankshaft idler gear/bushings Crankshaft pulley R & R Crankshaft rear oil seal Crankshaft, replace
Flywheel housing, replace Flywheel, replace Flywheel ring gear, replace Idler gear/bushings Main bearings, replace Cylinder block, replace
1076 1074 1075 1072 1070 1117
0.80 0.60 1.00 0.40 2.80 17.00
0.80 0.60 1.00 0.60 3.60 19.00
0.70 0.70 1.00 4.00 20.00
Cylinder Block, Liners, Pistons, and Rods
Cylinder liner package
1118
6.5
7.00
8.00
Cylinder liner packings Cylinder liner, replace
1119 1120
1.00 6.50
1.00 7.00
1.00 8.00
Cylinder liner, replace Pistons, liners, rods, replace Pistons, liners, valves, crankshaft, camshaft, valves, recondition Pistons, liners, valves, recondition
1121 1132 1136 1134
1.00 7.50 18.00 11.50
1.00 9.50 21.50 13.50
1.00 11.90 23.50 14.60
Piston, replace
1122
6.00
7.00
8.80
Piston, replace Piston rings, replace
1123 1124
1.00 6.50
1.00 7.00
1.00 8.00
Piston rings, replace Piston, rings, valves, recondition
1125 1133
1.00 13.50
1.00 17.50
1.00 14.60
TP-5178 9/03
21

kW Flat Rate Number 1135 20-60 70-100 101-200 Comments R & R head and oil pump, replace rod bearings, check and/or replace main bearings, retorque head bolts, reset and adjust valves R & R head, oil pump and liners, remove liner ridges and deglaze, replace piston rings, connect rod bearings, retorque head bolts, adjust valves R & R oil pump Each additional R & R head and oil pump, R & R piston and rings, remove liner ridges, deglaze liners, check and/or replace rod bearings Each additional Transfer all parts and assemblies and make all adjustments R & R air cleaner and bracket as one assembly, exhaust manifold with turbocharger and valve cover, adjust valves and retorque head bolts, transfer parts R & R air cleaner and bracket as one assembly, exhaust manifold with turbocharger and valve cover, adjust valves, retorque head bolts All; includes R & R, cylinder head R & R, reset valves, knurl guides R & R cylinder head, reset all valves All; R & R cylinder head, reseat valves, inserts Flat Rate Hours 13.50 15.50
Flat Rate Description Cylinder Block, Liners, Pistons, and Rods, continued Piston, rods, liners, valves, recondition 11.00
Piston, rods, replace
1131
8.00
10.00
11.90
Rod bearings, replace Rod bearings, replace Rod, main bearings, replace Rod/piston pin, replace
1126 1127 1130 1128
1.40 0.20 3.40 6.50
1.60 0.20 4.80 8.50
1.60 0.20 5.30 9.00
Rod/piston pin, replace Short block assembly, install Cylinder Head and Valves Cylinder head, component exchange
1129 1116
1.00 8.00
1.00 9.00
1.00 10.00
1112
3.20
3.80
6.20
Cylinder head gasket, replace
1111
2.80
3.80
4.80
Valves, guides, recondition Valves, recondition Valves, replace Engine Electrical Battery charging alternator Engine wiring harness Fuel rack shutdown solenoid Shutdown/gauge sender/switch Engine Mounting Skid base Vibration isolators
1114 1113 1115
6.50 6.00 6.50
8.00 7.00 8.00
8.80 7.60 9.90
1739 1740 1742 1741 1066 1065
1.20 1.50 1.50 3.50 1.50
1.20 1.50 1.50 4.00 1.75
1.20 2.00 1.50 1.50 4.50 1.75 Each pair External mounted
22
TP-5178 9/03

kW Flat Rate Number 1922 1000 1004 1001 1005 1013 1003 1006 1020 1021 3997 1011 1008 1009 1007 1016 1017 1012 1014 1015 1923 1010 1107 1108 1109 1106 1110 20-60 70-100 101-200 Comments Flat Rate Hours 1.00 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.20 1.00 1.20 6.00 4.60 1.40 1.00 1.00 0.60 0.60 0.20 4.00 2.60 0.60 1.50 1.50 0.60 1.50 1.00 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.20 1.00 1.20 6.00 4.60 1.40 1.00 1.00 0.60 0.60 0.20 5.00 2.80 0.60 1.50 1.50 0.60 1.50 1.00 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.20 1.00 1.60 6.00 4.60 1.00 0.70 0.70 0.20 0.30 0.30 6.00 3.80 0.50 1.50 1.50 0.60 1.50 Electronic governor Electronic governor With shutoff Electronic governor One Each additional R & R injector pump, adjust engine timing and speed R & R, adjust engine timing and speed When already removed Adjust engine timing and speed One, includes R & R Each additional Fuel filter to fuel injection pump One Each additional Transfer pump to fuel filter Includes R & R
Flat Rate Description Fuel Flexible fuel lines Fuel filter body, recondition Fuel filter bracket, replace Fuel filter element(s), replace Fuel hose or tube, replace Fuel shutoff solenoid Fuel transfer pump, replace Hose or tube, replace Injector line, replace Injector line, replace Injector pump, adjust Injection pump drive shaft Injection pump, recondition Injection pump, recondition Injection pump, replace Nozzles, recondition Nozzles, recondition Leak off line, replace Nozzle, replace Nozzle, replace Subbase fuel tank Timing gear cover, drive gear R&R Governor Engine speed, adjust Governor actuator, replace Governor controller, replace Governor housing cover, replace Governor magnetic pickup, replace
TP-5178 9/03
23

kW Flat Rate Number 1091 1092 1093 1082 1084 1085 1083 1086 1087 1088 1089 1094 1090 1022 1023 1046 1041 1047 1037 1038 20-60 70-100 101-200 Comments 0.60 1.20 0.60 0.60 0.60 0.50 0.60 1.20 1.60 2.40 1.40 0.80 0.60 7.50 9.60 1.60 2.40 1.25 0.60 0.60 Includes R & R Includes armature, brushes, clutch, and R&R When already removed Includes R & R and includes R & R oil cooler Drain and refill engine coolant Check and/or replace bypass valve and/or spring, includes R & R When already removed Flat Rate Hours 0.60 1.20 0.60 0.60 0.60 0.80 0.60 1.00 1.40 1.80 0.60 0.80 0.60 3.80 5.20 1.60 2.40 1.25 0.60 0.60 0.60 1.20 0.60 0.60 0.60 0.80 0.60 1.20 1.60 2.00 0.60 0.80 0.60 6.50 8.60 1.60 2.40 1.25 0.60 0.60
Flat Rate Description Lubrication Engine oil cooler, replace Oil cooler, recondition Oil cooler, recondition Oil dipstick and/or tube, replace Oil filter elements, replace Oil filter housing, replace Oil filter inlet and/or gasket, replace Oil pan and/or gasket, replace Oil pump, replace Oil pump, R & R and recondition Oil pump, recondition Oil regulator valve, recondition Vent hose or tube Rebuild Engine, replace Short engine, install Starting Starter drive assembly, replace Starter, recondition Starter relay Starter, replace Starter solenoid, replace
24
TP-5178 9/03
3.10 Perkins* 20-100 kW

kW Flat Rate Description Air Intake and Exhaust Air cleaner assembly, replace Air cleaner assembly, replace Air cleaner element Exhaust elbow or rain cap Exhaust silencer R & R Flexible exhaust connector Cooling Block heater assembly R & R Block heater cord or thermostat Block heater R & R Coolant hose Fan blade, replace Radiator assembly, replace Radiator, repair Engine Electrical Engine wiring harness Shutdown/gauge sender/switch Engine Mounting Skid base R & R Vibration isolators Fuel Auxiliary fuel pump Flexible fuel lines Subbase fuel tank Governor Governor actuator, replace Governor controller, replace Governor magnetic, replace pickup Starter Starter relay 2415 0.80 0.80
* The Warranty Department requires that repairs made on Perkins engines be performed by an authorized Perkins service center. Note: R & R means remove and replace.
Flat Rate Number 2390 2391 2392 2387 2388 2389 2406 2405 2404 2403 2394 2402 3457 2407 2408 2416 2417 2410 2409 2411 2412 2413 2414
20-60
70-100 Comments Standard Heavy duty
Flat Rate Hours 0.30 0.50 0.20 0.50 1.25 1.25 1.25 1.25 1.75 0.80 1.25 2.50 2.00 1.50 1.50 3.50 1.50 1.50 1.00 4.00 1.50 1.50 1.50 0.70 0.90 0.30 0.50 1.50 1.50 1.25 1.25 1.75 0.80 1.25 2.75 2.00 1.50 1.50 4.00 1.75 1.50 1.00 5.00 1.50 1.50 1.50
Each pair
Electronic governor Electronic governor Electronic governor
TP-5178 9/03
25
Section 4 Generator Flat Rates

4.1 20-300 kW
kW Flat Rate Number 2350 2351 1895 1893 1894 1624 1610 1619 1620 1608 1609 1613 1611 1617 1616 1618 1621 1622 1606 1612 1614 1615 1607 1623 20-60 61-150 151-30 Comments 1.50 0.50 3.00 0.75 12.00 1.25 i.e., relay, switch, circuit board 3.00 Line or safeguard 1.75 One 0.30 Each additional 3.50 2.50 3.50 Permanent magnet or wound field exciter 14.50 Includes rotor/stator 14.50 Includes rotor/stator 3.00 Includes photo board 1.25 1.75 Stationary 3.00 Includes heat sink assembly 14.00 Includes stator 1.25 For crank disconnect 2.00 12.00 2.00
Flat Rate Description Accessories Generator strip heater Rodent guard Weather housing front rear/panel Weather housing latch Weather housing roof AC Generator Alarm horn components Circuit breaker Current transformer Current transformer End bearing End bracket Exciter field Generator adapter Generator fan Heat sink assembly Junction box LED board Photo transistor board Rotor and assembly Rotor rectifier module Speed sensor Speed sensor actuator cup Stator Voltage regulator
Flat Rate Hours 1.50 0.50 1.00 0.75 4.00 1.25 1.75 1.75 0.30 2.50 2.00 3.00 10.50 10.50 3.50 1.00 1.75 3.50 10.00 3.00 1.25 2.00 8.00 2.00 1.50 0.50 1.00 0.75 5.00 1.25 2.50 1.75 0.30 2.50 2.00 3.00 12.50 12.50 3.00 1.00 1.75 3.00 10.00 1.25 2.00 8.00 2.00
26
TP-5178 9/03
20-300 kW, continued

kW Flat Rate Number 1599 1598 3238 1587 1601 1602 2382 1595 2420 1596 1593 1597 1592 1600 1589 2383 2419 1591 1588 1590 1603 1605 1594 1604 20-60 61-150 151-30 Comments
Flat Rate Description Controller AC interlock board Control relays Controller, digital Controller R & R Controller terminal strip Cycle crank board Dry contact kit Fuse holder or DC circuit breaker Fuses Gauges/meters Hourmeter Main control board Meter scale/fault lamps Overvoltage board Panel lights Remote annunciator Ribbon cable Selector switch (volt/amp) Start/indicator panel Switches Tachometer Transformer Voltage adjust rheostat Wattmeter/transducer
Flat Rate Hours 1.00 1.25 6.00 1.00 0.50 1.25 1.50 1.25 0.50 1.25 1.25 1.50 0.50 1.00 0.50 1.50 0.80 1.75 1.50 1.25 1.00 1.75 1.00 1.50 1.00 1.25 6.00 1.00 0.50 1.25 1.50 1.25 0.50 1.25 1.25 1.50 0.50 1.00 0.50 1.50 0.80 1.75 1.50 1.25 1.00 1.75 1.00 1.50 1.00 1.25 6.00 1.00 0.50 1.25 1.50 1.25 0.50 1.25 1.25 1.50 0.50 1.00 0.50 1.50 0.80 1.75 1.50 1.25 1.00 1.75 1.00 1.50
Includes R & R, calibration
Includes troubleshooting
Assembly or circuit board Between main logic board and LED panel LED indicator board 5-16 light Emergency stop, start/stop, etc. Battery charging or control
TP-5178 9/03
27
4.2 301-2000 kW
Flat Rate Hours Flat Rate Description AC Generator Bus bar holder Current transformer End bracket Exciter armature Exciter stator Junction box Line circuit breaker Rectifier/diodes Rotor bearing Rotor/stator Safeguard breaker Surge suppressor Voltage regulator Voltage regulator accessories Controller AC interlock board Control relays Controller, digital Controller R & R Controller switches Controller terminal strip Dry contact kit Fuse holder or DC circuit breaker Fuse R & R Gauges/meters Hourmeter Main control board Meter scale/fault lamps Overvoltage board Panel lights Remote annunciator Selector switch (volt/amp) Start/indicator panel Tachometer Voltage adjust rheostat Wattmeter/transducer
Flat Rate Number 3365 1633 1629 1627 1626 1630 1632 1634 1628 1625 1631 1635 1636 1637 1650 1649 3239 1638 1641 1652 2382 1646 2420 1647 1644 1648 1643 1651 1640 2383 1642 1639 1653 1645 1654
301-600 kW 1.25 2.00 8.00 6.00 6.00 6.00 3.50 2.50 8.00 12.00 1.50 2.50 2.00 2.00 1.00 1.25 4.00 1.00 1.25 0.50 1.50 1.25 0.50 1.25 1.25 1.50 0.50 1.00 0.50 1.50 1.75 1.50 1.25 1.00 1.50
601-800 kW 2.00 9.00 6.00 6.00 7.00 3.50 2.50 9.00 18.00 1.50 2.50 2.00 2.00 1.00 1.25 4.00 1.00 1.25 0.50 1.50 1.25 0.50 1.25 1.25 1.50 0.50 1.00 0.50 1.50 1.75 1.50 1.25 1.00 1.50
801-2000 kW 2.00 10.00 6.00 6.00 Exciter field 8.00 4.00 2.50 10.00 22.00 1.50 2.50
Comments
2.00 Includes adjustments 2.00 Paralleling module, etc. 1.00 1.25 4.00 1.00 1.25 Emergency stop, start/stop, etc. 0.50 1.50 1.25 0.50 Includes troubleshooting 1.25 1.25 1.50 0.50 1.00 0.50 1.50 Assembly or circuit board 1.75 1.50 LED indicator board 1.25 Includes R & R, calibration 1.00 1.50
28
TP-5178 9/03
Section 5 Switchgear Flat Rates

5.1 Low-Voltage Switchgear, 600 Volts or Less
Flat Rate Description Control circuit breakers/fuses Control modules Current transformer Indicator lamps Meters/gauges Panel switches/pushbutton Potential transformer Power circuit breakers Relay or relay socket Selector switch Voltage adjust rheostat Voltage regulator Flat Rate Number 1943 1939 1938 1934 1933 1935 1937 1944 1940 1936 1942 1941 Flat Rate Hours 1.75 2.50 3.00 0.50 1.50 1.50 1.50 1.50 2.00 1.50 1.25 Call factory Comments
5.2 Medium-Voltage Switchgear, 601-5000 Volts

Flat Rate Description Control circuit breakers/fuses Control modules Current transformer Indicator lamps Meters/gauges Panel switches/pushbutton Potential transformer Power circuit breakers Relay or relay socket Selector switch Voltage adjust rheostat Voltage regulator Flat Rate Number 1955 1951 1950 1946 1945 1947 1949 1956 1952 1948 1954 1953 Flat Rate Hours 1.75 2.50 4.00 0.50 1.50 1.50 2.00 1.50 2.00 1.50 1.50 Call factory Comments
TP-5178 9/03
Section 5 Switchgear Flat Rates
29
Section 6 Industrial Rental Trailer Flat Rates

Flat Rate Number 3235 3230 3234 3232 3233 3236 3237 3231 3229 Flat Rate Hours 20-60 kW 3.00 1.50 0.25 0.50 0.75 7.00 6.00 0.25 1.00 61-150 kW 151-300 kW 3.00 1.50 0.25 0.50 0.75 7.00 6.00 0.25 1.00 3.00 1.50 0.25 0.50 0.75 7.00 6.00 0.25 1.00 Comments
Flat Rate Description Trailer* Axle R & R Brake actuator R & R Fuel filler cap R & R Fuel gauge R & R Fuel level switch R & R Fuel tank housing R & R Fuel tank trailer R & R Jackstand R & R Tire R & R
* Use the appropriate other sections for all other industrial rental generator set flat rates. Note:: R & R means remove and replace.
30
Section 6 Industrial Rental Trailer Flat Rates
TP-5178 9/03
KOHLER CO. Kohler, Wisconsin 53044 Phone 920-565-3381, Fax 920-459-1646 For the nearest sales and service outlet in the US and Canada, phone 1-800-544-2444 kohlergenerators.com
TP-5178 9/03c
E 1997, 1998, 1999, 2000, 2003 by Kohler Co. All rights reserved.
Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65)264-6422, Fax (65)264-6455

Generator Set Warranty Flat Rates and Failure Codes

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Generator Set Warranty Flat Rates and Failure Codes

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Warranty Flat Rates/ Failure Codes

of Work Performed area on the warranty claim form.

200--2000 kW Gas engines 20--100 kW 125--275 kW

* Include an O in the model number (Example: 20ROZJ).

Section 1 Generator Set Accessory Flat Rates

Float/Equalize Battery Charger, 12/24 Volts DC, 10 Amp*

Section 1 Generator Set Accessory Flat Rates

1.2 Fuel Tanks

Section 1 Generator Set Accessory Flat Rates

Section 2 Transfer Switch Flat Rates

Section 2 Transfer Switch Flat Rates

2.2 M340 Logic

Flat Rate Number 1898 1921 1919 1920 1897 1910

30-150 Amps 2.00 1.00 3.00 1.25 6.00 2.00

151-800 Amps 2.00 1.00 4.00 1.25 6.00 2.00

801-4000 Amps 2.00 1.00 5.00 1.50 6.00 2.00

2.3 R340/S340 Logic

Section 2 Transfer Switch Flat Rates

2.4 30-4000 Amp Contactors

30-150 Amps 1.00 1.00 2.00 1.50 2.00 1.00

Lug only, each

2.5 Model KCT/KCP/KBT/KBP Transfer Switches

Flat Rate Number 5307 5310 5311 5314 5292

30-150 Amps 2.00 1.00 3.00 1.25 2.00

151-800 Amps 2.00 1.00 4.00 1.25 2.00

801-4000 Amps 2.00 1.00 5.00 1.50 2.00

Section 2 Transfer Switch Flat Rates

Section 3 Engine Flat Rates

Comments Standard Heavy duty

Tank assembly or element only Complete kit

Section 3 Engine Flat Rates

3.2 Detroit Diesel* 135-400 kW (Series 50/60 Gas, Series 60 Diesel)

Section 3 Engine Flat Rates

Detroit Diesel* 135-400 kW (Series 50/60 Gas, Series 60 Diesel), continued

One Each additional

3.3 Kohler-Branded 200-500 kW

Section 3 Engine Flat Rates

Section 3 Engine Flat Rates

3.5 Detroit Diesel* 1250-2000 kW (Series 4000 Diesel)

10.00 10.00 10.00 10.00

Section 3 Engine Flat Rates

Detroit Diesel* 1250-2000 kW (Series 4000 Diesel), continued

Section 3 Engine Flat Rates

Detroit Diesel* 1250-2000 kW (Series 4000 Diesel), continued

Section 3 Engine Flat Rates

3.6 Deutz 20-170 kW

Section 3 Engine Flat Rates

Deutz 20-170 kW, continued

Section 3 Engine Flat Rates

Deutz 20-170 kW, continued

Section 3 Engine Flat Rates

3.7 Ford 20-100 kW

Cylinder Block, Liners, and Pistons, Rods

Note: R & R means remove and replace.

Section 3 Engine Flat Rates

Ford 20-100 kW, continued

Section 3 Engine Flat Rates

3.8 General Motors 30-100 kW

Includes oil pan Includes balancer R & R

Section 3 Engine Flat Rates

General Motors 30-100 kW, continued

Complete Partial Additional

Includes oil Includes filter