John Deere Powertech 6068 Users Manual 100525UNIT

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2015-02-03

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P
OWER
T
ECH
4.5 and 6.8 L
4045 and 6068
Tier 2 / Stage II
OEM Diesel Engines
OPERATOR’S MANUAL
P
OWER
T
ECH
4.5 and 6.8 L Tier 2 /
Stage II OEM Diesel Engines
OMRG33324 Issue 7Aug06 (ENGLISH)
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
If this product contains a gasoline engine:
WARNING
The engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth
defects or other reproductive harm.
The State of California requires the above two warnings.
John Deere Power Systems
LITHO IN U.S.A.
Introduction
OURGP11,000006E –19–04AUG06–1/2
Foreword
THIS MANUAL CONTAINS INFORMATION to operate
and service the following Tier 2 / Stage II
emission-certified
1
engines:
Saran-built (France) Tier 2 Mechanically Controlled
Engines:
•CD4045DF270
•CD4045TF270
Saran-built (France) Tier 2 Electronically Controlled
Engines:
•CD4045TF275 (DE10 Fuel System)
•CD4045HF275 (DE10 Fuel System)
•CD4045HF475 (HPCR System; 4-Valve Head)
•CD6068TF275 (DE10 Fuel System)
•CD6068HF275 (DE10/VP44 Fuel System)
•CD6068HF475 (HPCR System; 4-Valve Head)
Torreon-built (Mexico) Tier 2 Mechanically Controlled
Engines:
•PE4045DF270
•PE4045TF270
Torreon-built (Mexico) Tier 2 Electronically Controlled
Engines:
•PE4045TF275 (DE10 Fuel System)
•PE4045HF275 (DE10 Fuel System)
•PE4045HF475 (HPCR System; 4-Valve Head)
•PE6068TF275 (DE10 Fuel System)
•PE6068HF275 (DE10/VP44 Fuel System)
•PE6068HF475 (HPCR System; 4-Valve Head)
READ THIS MANUAL carefully to learn how to operate
and service your engine correctly. Failure to do so
could result in personal injury or equipment damage.
THIS MANUAL SHOULD BE CONSIDERED a
permanent part of your engine and should remain with
the engine when you sell it.
MEASUREMENTS IN THIS MANUAL are given in both
metric and customary U.S. unit equivalents. Use only
correct replacement parts and fasteners. Metric and
inch fasteners may require a specific metric or inch
wrench.
WRITE ENGINE SERIAL NUMBERS and option codes
in the spaces indicated in the Record Keeping Section.
Accurately record all the numbers. Your dealer also
needs these numbers when you order parts. File the
identification numbers in a secure place off the engine.
SETTING FUEL DELIVERY beyond published factory
specifications or otherwise overpowering will result in
loss of warranty protection for this engine.
CERTAIN ENGINE ACCESSORIES such as radiator,
air cleaner, and instruments are optional equipment on
John Deere OEM Engines. These accessories may be
provided by the equipment manufacturer instead of
John Deere. This operator’s manual applies only to the
engine and those options available through the John
Deere distribution network.
1
Emission certified for United States as EPA Tier 2 and for European
Union as Stage II.
080706
PN=2
Introduction
OURGP11,000006E –19–04AUG06–2/2
IMPORTANT: This manual covers only
P
OWER
T
ECH
Tier 2 / Stage II
emission certified 4.5 and 6.8 L OEM
engines listed. These engines meet
Tier 2 emission certification
standards.
2
(This is for both the U.S.
EPA and European Union Council
(EU) standards.) Engines with
mechanical controls which are
non-emission certified or Tier 1 /
Stage I emission certified (U.S. and
EU) are covered in a separate
operators manual, OMRG25204.
NOTE: This manual covers engines provided to OEM
(Original Equipment Manufacturers). For
engines in Deere machines, refer to the
machine operator’s manual.
P
OWER
T
ECH
is a trademark of Deere & Company.
2
Two exceptions: The 4045HF475 and 6068HF475 for generator
applications at 1500 rpm are still emission non-certified.
080706
PN=3
Introduction
080706
PN=4
Introduction
OURGP11,0000251 –19–27JUL06–1/1
Engine Owner
John Deere Engine Owner:
Don’t wait until you need warranty or other service to
meet your local John Deere Engine Distributor or
Service Dealer. To register your engine for warranty
via the Internet, use the following URL:
http://www.johndeere.com/enginewarranty
Learn who your dealer is and where he is. At your first
convenience, go meet him. He’ll want to get to know
you and to learn what your needs might be.
Aux Utilisateurs De Moteurs John Deere:
N’attendez pas d’e
ˆtre oblige
´d’avoir recours a
`votre
concessionnaire John Deere ou au point de service le
plus proche pour vous adresser a
`lui. Pour enregistrer
votre moteur pour la garantie via Internet, utilisez
l’adresse suivante:
http://www.johndeere.com/enginewarranty
Renseignez-vous de
`s que possible pour l’identifier et
le localiser. A la premie
`re occasion, prenez contact
avec lui et faites-vous connaı
ˆtre. Il sera lui aussi
heureux de faire votre connaissance et de vous
proposer ses services le moment venu.
An Den Besitzer Des John Deere Motors:
Warten Sie nicht auf einen evt. Reparaturfall, um den
na
¨chstgelegenen John Deere Ha
¨ndler kennen zu
lernen. Zur Registrierung Ihres Motors fu
¨r die Garantie
dient folgende Internet-Adresse:
http://www.johndeere.com/enginewarranty
Machen Sie sich bei ihm bekannt und nutzen Sie sein
“Service Angebot”.
Proprietario del motore John Deere:
Non aspetti fino al momento di far valere la garanzia o
di chiedere assistenza per fare la conoscenza del
distributore dei motori John Deere o del
concessionario che fornisce l’assistenza tecnica. Per
registrare via Internet la garanzia del suo motore, si
collegi al seguente sito URL:
http://www.johndeere.com/enginewarranty
Lo identifichi e si informi sulla sua ubicazione. Alla
prima occasione utile lo contatti. Egli desidera fare la
sua conoscenza e capire quali potrebbero essere le
sue necessita
`.
Propietario De Equipo John Deere:
No espere hasta necesitar servicio de garantı
´aode
otro tipo para conocer a su Distribuidor de Motores
John Deere o al Concesionario de Servicio. Registre
su motor para la garantı
´a en la siguiente direccio
´nde
internet: http://www.johndeere.com/enginewarranty
Ente
´rese de quie
´nes,ydo
´nde esta
´situado. Cuando
tenga un momento, vaya a visitarlo. A e
´l le gustara
´
conocerlo, y saber cua
´les podrı
´an ser sus
necesidades.
Till a
¨gare av John Deere motorer:
Ta reda pa
˚vem din a
˚terfo
¨rsa
¨ljare a
¨r och beso
¨k honom
sa
˚snart tillfa
¨lle ges. Va
¨nta inte tills det a
¨r dags fo
¨r
service eller eventuellt garantiarbete. Din motor
garantiregistrerar Du via Internet pa
˚
http://www.johndeere.com/enginewarranty
Din a
˚terfo
¨rsa
¨ljare vill mycket ga
¨rna tra
¨ffa dig fo
¨r att la
¨ra
ka
¨nna dina behov och hur ba
¨st han kan hja
¨lpa dig.
080706
PN=5
Introduction
OUOD002,0000162 –19–04AUG06–1/1
POWERTECH4.5 L Engines With Electronic Fuel Systems (Tier 2 Emission Certified)
(Two-Valve Cylinder Head Models)
RG11931 –UN–06NOV01
4045 Engine (Stanadyne DE10 Injection Pump Shown)
RG11932 –UN–06NOV01
4045 Engine
P
OWER
T
ECH
is a trademark of Deere & Company.
080706
PN=6
Introduction
OUOD002,0000163 –19–04AUG06–1/1
POWERTECH6.8 L Engines With Electronic Fuel Systems (Tier 2 Emission Certified)
(Two-Valve Cylinder Head Models)
RG11933 –UN–24OCT01
6068 Engine (Bosch VP44 Injection Pump Shown)
RG11934 –UN–24OCT01
6068 Engine
P
OWER
T
ECH
is a trademark of Deere & Company.
080706
PN=7
Introduction
OURGP11,000018B –19–04AUG06–1/1
POWERTECH4.5/6.8 L Engines With Electronic Fuel Systems (Tier 2 Emission Certified)
(Four-Valve Cylinder Head “475” Models)
RG12199 –UN–24MAY02
6068HF475 Engine Shown (Level 11 Electronic Fuel System With
Denso High Pressure Common Rail)
RG12200 –UN–24MAY02
6068HF475 Shown
P
OWER
T
ECH
is a trademark of Deere & Company.
080706
PN=8
Contents
Page
Page
Record Keeping Using Touch Switches to Display
Information ..........................16-10PowerTech Medallion .....................01-1 Changing Units of Measure (English or
Engine Serial Number Plate ................01-1 Metric)..............................16-12
Record Engine Serial Number ..............01-2 Viewing Engine Configuration Data .........16-14
Engine Option Codes .....................01-3 Viewing Active Engine Service
Record Engine Control Unit (ECU) Serial Codes/Diagnostic Trouble Codes (DTCs) . . . 16-16
Number..............................01-5 Viewing Stored Service
Record Fuel Injection Pump Model Number ....01-5 Codes/Diagnostic Trouble Codes
(DTCs) in the Engine ECU ..............16-17
Safety ................................05-1
Instrument Panel - Elect. Cont. Later Engines
Fuels, Lubricants, and Coolant Instrument Panels........................17-1
Diesel Fuel .............................10-1 Using Diagnostic Gauge to Access Engine
Lubricity of Diesel Fuel....................10-1 Information ...........................17-4
Handling and Storing Diesel Fuel ............10-2 Main Menu Navigation ....................17-5
Testing Diesel Fuel.......................10-2 Engine Configuration Data .................17-6
Bio-Diesel Fuel..........................10-3 Accessing Stored Trouble Codes ............17-8
Minimizing the Effect of Cold Weather on Accessing Active Trouble Codes ...........17-10
Diesel Engines ........................10-4 Engine Shutdown Codes .................17-12
Diesel Engine Break-In Oil .................10-5 Adjusting Backlighting....................17-13
Diesel Engine Oil ........................10-6 Adjusting Contrast ......................17-15
Diesel Engine Oil and Filter Service Intervals. . . 10-7 Selecting Units Of Measurement ...........17-17
Mixing of Lubricants ......................10-9 Setup 1-Up Display .....................17-20
Oil Filters .............................10-10 Setup 4-Up Display .....................17-26
OILSCANand COOLSCAN.............10-10
Alternative and Synthetic Lubricants.........10-11 Instrument Panel - Mech. Cont. “270” Engines
Lubricant Storage .......................10-11 Instrument Panel (Earlier 4.5 L “270”
Grease ...............................10-12 Engines) .............................18-1
Diesel Engine Coolant ...................10-13 Instrument Panel (Later 4.5 L “270” Engines) . . . 18-3
Drain Intervals for Diesel Engine Coolant ....10-14
Supplemental Coolant Additives ............10-15 Engine Operation - Except 4.5L “270” Engines
Testing Diesel Engine Coolant .............10-15 Engine Break-In Service...................19-1
Operating in Warm Temperature Climates ....10-16 Starting the Engine.......................19-4
Disposing of Coolant ....................10-16 Normal Engine Operation ..................19-7
Warming Engine.........................19-8
Instrument Panel Identification Cold Weather Operation...................19-9
Instrument Panels - Identification ............15-1 Using a Booster Battery or Charger .........19-11
Avoid Excessive Engine Idling .............19-12
Instrument Panel - Elect. Cont. Earlier Engines Changing Engine Speed..................19-13
Instrument Panel ........................16-1 Stopping The Engine ....................19-16
Using Diagnostic Gauge to Access Engine
Continued on next page
Information ...........................16-8
All information, illustrations and specifications in this manual are based on
the latest information available at the time of publication. The right is
reserved to make changes at any time without notice.
COPYRIGHT
2006
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION
Manual
Previous Editions
Copyright
2001, 2002, 2003, 2004, 2006
i
080706
PN=1
Contents
Page Page
Auxiliary Gear Drive Limitations ............19-17 Checking Crankshaft Vibration Damper
Generator Set (Standby) Applications........19-17 (6-Cylinder Engine Only).................35-2
Flushing and Refilling Cooling System ........35-3
Engine Operation- 4.5 L “270” Engines Testing Thermostats Opening Temperature ....35-6
Normal Engine Operation ..................20-1 Check and Adjust Valve Clearance (All
Break-In Service.........................20-2 Engines Except 4045HF475 And
Auxiliary Gear Drive Limitations .............20-3 6068HF475) ..........................35-9
Generator Set (Standby) Power Units.........20-4 Check and Adjust Valve Clearance
Starting The Engine ......................20-4 (4045HF475 And 6068HF475 Engines).....35-12
Cold Weather Starting ....................20-6 Test Glow Plugs for Continuity
Warming Engine.........................20-8 (4045HF475 And 6068HF475 Engines).....35-15
Avoid Excessive Engine Idling ..............20-9
Stopping the Engine.....................20-10 Service as Required
Using a Booster Battery or Charger .........20-11 Additional Service Information ..............40-1
Do Not Modify Fuel System ................40-2Lubrication and Maintenance
Observe Service Intervals..................21-1 Adding Coolant..........................40-3
Use Correct Fuels, Lubricants, and Coolant ....21-1 Replacing Single Stage Air Cleaner ..........40-5
Lubrication and Maintenance Service Replacing Axial Seal Air Cleaner Filter
Interval Chart—Standard Industrial Engines . . 21-2 Element .............................40-6
Lubrication and Maintenance Service Replacing Radial Seal Air Cleaner Filter
Interval Chart—Generator (Standby) Element .............................40-8
Applications ..........................21-4 Replacing Fan and Alternator Belts .........40-10
Checking Fuses ........................40-11
Lubrication & Maintenance/Daily Checking Air Compressors ................40-11
Daily Prestarting Checks ..................25-1 Bleeding the Fuel System (Engines With
Electronic Fuel Systems And Bosch VP44
Lubrication & Maintenance/500 Hour/12 Month Pump)..............................40-12
Servicing Fire Extinguisher .................30-1 Bleed the Fuel System (Engines with
Checking Engine Mounts ..................30-1 Electronic Fuel Systems and Stanadyne DE10
Servicing Battery ........................30-2 Pump)..............................40-14
Manual Belt Tensioner Adjustment ...........30-4 Bleed the Fuel System (Engines with
Manual Belt Tensioner Adjustment Using Electronic Fuel Systems and Denso High
Belt Tension Tool (Alternate Method Pressure Common Rail) (4045HF475,
For Engines Without Auxiliary Drive)........30-5 6068HF475) .........................40-17
Changing Engine Oil and Replacing Filter .....30-7
Checking Crankcase Vent System ...........30-9 Bleed the Fuel System (4045DF270,
Checking Air Intake System ...............30-11 4045TF270) .........................40-19
Replacing Fuel Filter Elements.............30-12
Checking Belt Tensioner Spring Tension Troubleshooting
and Belt Wear (Automatic Tensioner) ......30-14 General Troubleshooting Information .........45-1
Checking Engine Electrical Ground Precautions For Welding On Engines
Connections .........................30-16 Equipped With Electronic Engine Control Unit
Checking Cooling System.................30-16 (ECU) ...............................45-2
Replenishing Supplemental Coolant Precautions for Electrical System When
Additives (SCAs) Between Coolant Steam Cleaning Engine .................45-2
Changes ............................30-17 Engine Wiring Layout (Electronic Fuel
Testing Diesel Engine Coolant .............30-19 System With Stanadyne DE10 Injection
Pressure Testing Cooling System...........30-20 Pump)...............................45-3
Checking and Adjusting Engine Speeds ......30-21 Engine Wiring Layout (Electronic Fuel
System With Bosch VP44 Injection Pump) . . . 45-4Lubrication & Maint./2000 Hour/24 Month
Adjusting Variable Speed (Droop) — 4.5
Continued on next page
L “270” Generator Set Engines Only........35-1
ii
080706
PN=2
Contents
Page Page
Engine Wiring Layout (Electronic Fuel Lubrication and Maintenance Records
Using Lubrication and Maintenance Records . . . 60-1
System With Denso High Pressure Common Daily (Prestarting) Service .................60-1
Rail)(4045HF475,6068HF475).............45-5 500 Hour/12 Month Service ................60-2
Engine Wiring Diagram (With Earlier 2000 Hour/24 Month Service ...............60-3
Electronic Instrument Panel) ..............45-6 Service as Required ......................60-4
Engine Wiring Diagram (Engines With
Electronic Instrument Panel) ..............45-7 Emission System Warranty
Engine Wiring Diagram (With Later U.S. EPA Emmission Control Warranty
Full-Featured Electronic Instrument Panel) . . . 45-8 Statement ............................65-1
Engine Wiring Diagram (With Later Emission Control System Certification Label....65-2
Full-Featured Electronic Instrument Panel)—
Continued ............................45-9
Engine Troubleshooting ..................45-10
Blink Code Method for Retrieving
Diagnostic Trouble Codes (All Except
Early VP44 Pump Engines)..............45-17
Blink Code Method for Retrieving
Diagnostic Trouble Codes (Early VP44
Pump Engines Only) ...................45-18
Instrument Panel Method for Retrieving
Diagnostic Trouble Codes...............45-20
Displaying Of Diagnostic Trouble Codes
(DTCs) .............................45-21
Listing of Diagnostic Trouble Codes (DTCs)
(Engines With Electronic Fuel
Systems And Stanadyne DE10 Pump) .....45-22
Listing of Diagnostic Trouble Codes (DTCs)
(Engines With Electronic Fuel
Systems And Bosch VP44 Pump).........45-24
Listing of Diagnostic Trouble Codes (DTCs)
(Engines With Electronic Fuel Systems
And Denso High Pressure Common Rail) (“475”
Engines) ............................45-26
Error Codes Displayed (With Early
Electronic Panels) .....................45-28
Intermittent Fault Diagnostics (With
Electronic Controls)....................45-29
Displaying Diagnostic Gauge Software
(Later Engines) .......................45-29
Storage
Engine Storage Guidelines .................50-1
Preparing Engine for Long Term Storage ......50-2
Removing Engine from Long Term Storage ....50-3
Specifications
General OEM Engine Specifications..........55-1
Engine Power Ratings And Fuel System
Specifications .........................55-3
Engine Crankcase Oil Fill Quantities .........55-6
Unified Inch Bolt and Screw Torque Values ....55-7
Metric Bolt and Screw Torque Values.........55-8
iii
080706
PN=3
Contents
iv
080706
PN=4
Record Keeping
OURGP11,0000274 –19–04AUG06–1/1
POWERTECHMedallion
RG11608 –UN–17OCT01RG11609 –UN–17OCT01
A medallion is located on the rocker arm cover which
identifies each engine as a John Deere P
OWER
T
ECH
engine.
NOTE: Four-valve head engines also have “16V” or “24V”
printed on their medallions. The 4045HF475 has
“16V” to denote 16 valves total while 6068HF475
has “24V” to denote 24 valves total.
P
OWER
T
ECH
is a trademark of Deere & Company.
RG,RG34710,5506 –19–27JUL06–1/1
Engine Serial Number Plate
RG8007 –UN–15JAN99
13-Digit Engine Serial Number Plate
A—Serial Number Plate
Each engine has a 13-digit John Deere engine serial
number. The first two digits identify the factory that
produced the engine:
•“CD” = Saran, France
•“PE” = Torreon, Mexico
•“T0” = Dubuque, Iowa
•“J0” = Rosario, Argentina
The engine’s serial number plate (A) is located on the
right-hand side of cylinder block behind the fuel filter.
01-1
080706
PN=11
Record Keeping
OURGP11,0000070 –19–27JUL06–1/1
Record Engine Serial Number
RG11949 –UN–07NOV01
Saran Engine Serial Number Plate
RG11948 –UN–06NOV01
Torreon Engine Serial Number Plate
Record all of the numbers and letters found on your
engine serial number plate in the spaces provided below.
This information is very important for repair parts or
warranty information.
Engine Serial Number (B)
Engine Model Number (C)
Coefficient of Absorption Value (D)
(Saran Engines Only)
NOTE: Effective in April 2005, engine serial numbers
were changed at the 7th digit to show the
Emission Level. Previously this digit identified the
type of aspiration.
On earlier engines the 7th digit showed the
aspiration code as follows:
•
“A” for turbocharged with air-to-water aftercooler
•
“D” for naturally aspirated
•
“H” for turbocharged with air-to-air aftercooler
•
“T” for turbocharged only
On later engines after April 2005, the seventh digit
will be as follows:
•
“B” for non-certified engines
•
“C” for Tier 1 / Stage I engines
•
“G” for Tier 2 / Stage II engines
•
“L” for Tier 3 / Stage IIIA engines
01-2
080706
PN=12
Record Keeping
RG,RG34710,5508 –19–27JUL06–1/2
Engine Option Codes
RG11946 –UN–06NOV01
A—Engine Base Code
In addition to the serial number plate, OEM engines
have an engine option code label affixed to the rocker
arm cover. These codes indicate which of the engine
options were installed on your engine at the factory.
When in need of parts or service, furnish your
authorized servicing dealer or engine distributor with
these numbers.
The engine option code label includes an engine base
code (A). This base code must also be recorded along
with the option codes.
The first two digits of each code identify a specific
group, such as alternators. The last two digits of each
code identify one specific option provided on your
engine, such as a 12-volt, 55-amp alternator.
NOTE: These option codes are based on the latest
information available at the time of publication.
The right is reserved to make changes at any
time without notice.
If an engine is ordered without a particular component,
the last two digits of that functional group option code
will be 99, 00, or XX. The list on the next page shows
only the first two digits of the code numbers. For future
reference such as ordering repair parts, it is important
to have these code numbers available. To ensure this
availability, enter the third and fourth digits shown on
your engine option code label in the spaces provided
on the following page.
01-3
080706
PN=13
Continued on next page
Record Keeping
RG,RG34710,5508 –19–27JUL06–2/2
NOTE: Your engine option code label may not contain
all option codes if an option has been added
after the engine left the producing factory.
If option code label is lost or destroyed,
consult your servicing dealer or engine
distributor selling the engine for a replacement.
An additional option code label may also be
delivered with the engine. Place this sticker or
tag, for reference, either on this page or in the
engine owner’s warranty booklet under
OPTION CODES title.
Option Codes Description Option Codes Description
11 Rocker Arm Cover 50 Oil Pump
12 Oil Fill Inlet 51 Cylinder Head With Valves
13 Crankshaft Pulley/Damper 52 Auxiliary Gear Drive
14 Flywheel Housing 53 Fuel Heater
15 Flywheel 55 Shipping Stand
16 Fuel Injection Pump 56 Paint Option
17 Air Inlet 57 Coolant Pump Inlet
18 Air Cleaner 59 Oil Cooler
19 Oil Pan 60 Add-on Auxiliary Drive Pulley
20 Coolant Pump 62 Alternator Mounting Bracket
21 Thermostat Cover 63 Low Pressure Fuel Line
22 Thermostat 64 Exhaust Elbow
23 Fan Drive 65 Turbocharger
24 Fan Belt 66 Coolant Temperature Switch
25 Fan 67 Electronic Sensors (Base Engine)
26 Engine Coolant Heater 68 Crankshaft Rear Damper
27 Radiator 69 Engine Serial Number Plate
28 Exhaust Manifold 71 Engine Oil Bypass Filter
29 Crankcase Ventilator System 72 ECU Electronic Software Option
30 Starter Motor 74 Air Conditioning (Freon) Compressor
31 Alternator 75 Air Restriction Indicator
32 Instrument Panel 76 Pressure Switches and Sensors
33 Tachometer 77 Timing Gear Cover
35 Fuel Filters 78 Air Compressor
36 Front Plate 79 Engine Certification
37 Fuel Transfer Pump 81 Primary Fuel Filter And Water Separator
39 Thermostat Housing 83 Electronic Software (Vehicle Option)
40 Oil Dipstick 84 Electrical Wiring Harness
41 Belt-Driven Front Auxiliary Drive 86 Fan Pulley
43 Starting Aid 87 Belt Tensioner
44 Timing Gear Cover With Gears 88 Oil Filter
46 Cylinder Block With Liners and Camshaft 95 Special Equipment (Factory Installed)
47 Crankshaft and Bearings 96 Engine Installation Kit
48 Connecting Rods and Pistons 97 Special Equipment (Field Installed)
49 Valve Actuating Mechanism 98 Shipping (Engine Hanger Straps)
99 Service Only Items
Engine Base Code (See “A” on previous page.)
01-4
080706
PN=14
Record Keeping
OURGP12,00000AD –19–27JUL06–1/1
Record Engine Control Unit (ECU) Serial
Number
RG13799 –UN–18NOV04
Record Engine Control Unit (ECU) Serial Number
A—Serial Number Label
Record the part number and serial number information
found on the serial number label (A) on the Engine
Control Unit (ECU) mounted on or near the engine.
Part No.
Serial No.
RG,RG34710,5511 –19–27JUL06–1/1
Record Fuel Injection Pump Model Number
RG11943 –UN–06NOV01
Record Injection Pump Serial Number
A—Serial Number Plate
Record the fuel injection pump model and serial
information found on the serial number plate (A).
Model No. RPM
Manufacturer’s No.
Serial No.
01-5
080706
PN=15
Safety
DX,ALERT –19–29SEP98–1/1
Recognize Safety Information
T81389 –UN–07DEC88
This is a safety-alert symbol. When you see this symbol
on your machine or in this manual, be alert to the
potential for personal injury.
Follow recommended precautions and safe operating
practices.
DX,SIGNAL –19–03MAR93–1/1
Understand Signal Words
TS187 –19–30SEP88
A signal word—DANGER, WARNING, or CAUTION—is
used with the safety-alert symbol. DANGER identifies the
most serious hazards.
DANGER or WARNING safety signs are located near
specific hazards. General precautions are listed on
CAUTION safety signs. CAUTION also calls attention to
safety messages in this manual.
DX,READ –19–03MAR93–1/1
Follow Safety Instructions
TS201 –UN–23AUG88
Carefully read all safety messages in this manual and on
your machine safety signs. Keep safety signs in good
condition. Replace missing or damaged safety signs. Be
sure new equipment components and repair parts include
the current safety signs. Replacement safety signs are
available from your John Deere dealer.
Learn how to operate the machine and how to use
controls properly. Do not let anyone operate without
instruction.
Keep your machine in proper working condition.
Unauthorized modifications to the machine may impair the
function and/or safety and affect machine life.
If you do not understand any part of this manual and need
assistance, contact your John Deere dealer.
05-1
080706
PN=16
Safety
DX,SIGNS1 –19–04JUN90–1/1
Replace Safety Signs
TS201 –UN–23AUG88
Replace missing or damaged safety signs. See the
machine operator’s manual for correct safety sign
placement.
RG,RG34710,7508 –19–27JUL06–1/1
Prevent Bypass Starting
RG5419 –UN–28FEB89
Prevent Bypass Starting
Avoid possible injury or death from engine runaway.
Do not start engine by shorting across starter terminal.
Engine will start with PTO engaged if normal circuitry is
bypassed.
Start engine only from operator’s station with PTO
disengaged or in neutral.
DX,FIRE1 –19–03MAR93–1/1
Handle Fuel Safely—Avoid Fires
TS202 –UN–23AUG88
Handle fuel with care: it is highly flammable. Do not refuel
the machine while smoking or when near open flame or
sparks.
Always stop engine before refueling machine. Fill fuel tank
outdoors.
Prevent fires by keeping machine clean of accumulated
trash, grease, and debris. Always clean up spilled fuel.
05-2
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Safety
DX,FIRE2 –19–03MAR93–1/1
Prepare for Emergencies
TS291 –UN–23AUG88
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service,
hospital, and fire department near your telephone.
DX,FIRE3 –19–16APR92–1/1
Handle Starting Fluid Safely
TS1356 –UN–18MAR92
Starting fluid is highly flammable.
Keep all sparks and flame away when using it. Keep
starting fluid away from batteries and cables.
To prevent accidental discharge when storing the
pressurized can, keep the cap on the container, and store
in a cool, protected location.
Do not incinerate or puncture a starting fluid container.
DX,FLAME –19–29SEP98–1/1
Handle Fluids Safely—Avoid Fires
TS227 –UN–23AUG88
When you work around fuel, do not smoke or work near
heaters or other fire hazards.
Store flammable fluids away from fire hazards. Do not
incinerate or puncture pressurized containers.
Make sure machine is clean of trash, grease, and debris.
Do not store oily rags; they can ignite and burn
spontaneously.
05-3
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Safety
OURGP12,00001DA –19–27JUL06–1/1
Service Engines Safely
TS228 –UN–23AUG88
Moving Parts
Tie long hair behind your head. Do not wear a necktie,
scarf, loose clothing, or necklace when you work near
machine tools or moving parts. If these items were to get
caught, severe injury could result.
Remove rings and other jewelry to prevent electrical
shorts and entanglement in moving parts.
DX,WEAR –19–10SEP90–1/1
Wear Protective Clothing
TS206 –UN–23AUG88
Wear close fitting clothing and safety equipment
appropriate to the job.
Prolonged exposure to loud noise can cause impairment
or loss of hearing.
Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.
Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones
while operating machine.
DX,NOISE –19–03MAR93–1/1
Protect Against Noise
TS207 –UN–23AUG88
Prolonged exposure to loud noise can cause impairment
or loss of hearing.
Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.
05-4
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Safety
DX,MSDS,NA –19–03MAR93–1/1
Handle Chemical Products Safely
TS1132 –UN–26NOV90
Direct exposure to hazardous chemicals can cause
serious injury. Potentially hazardous chemicals used with
John Deere equipment include such items as lubricants,
coolants, paints, and adhesives.
A Material Safety Data Sheet (MSDS) provides specific
details on chemical products: physical and health hazards,
safety procedures, and emergency response techniques.
Check the MSDS before you start any job using a
hazardous chemical. That way you will know exactly what
the risks are and how to do the job safely. Then follow
procedures and recommended equipment.
(See your John Deere dealer for MSDS’s on chemical
products used with John Deere equipment.)
OUO1004,0000BD8 –19–27JUL06–1/1
Stay Clear of Rotating Drivelines
TS1644 –UN–22AUG95
Rotating Drivelines
Entanglement in rotating driveline can cause serious injury
or death.
Keep master shield and driveline shields in place at all
times. Make sure rotating shields turn freely.
Wear close-fitting clothing. Stop the engine and be sure
PTO driveline is stopped before making adjustments,
connections, or performing any type of service on the
engine or PTO-driven equipment.
05-5
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Safety
DX,SERV –19–17FEB99–1/1
Practice Safe Maintenance
TS218 –UN–23AUG88
Understand service procedure before doing work. Keep
area clean and dry.
Never lubricate, service, or adjust machine while it is
moving. Keep hands, feet , and clothing from
power-driven parts. Disengage all power and operate
controls to relieve pressure. Lower equipment to the
ground. Stop the engine. Remove the key. Allow machine
to cool.
Securely support any machine elements that must be
raised for service work.
Keep all parts in good condition and properly installed. Fix
damage immediately. Replace worn or broken parts.
Remove any buildup of grease, oil, or debris.
On self-propelled equipment, disconnect battery ground
cable (-) before making adjustments on electrical systems
or welding on machine.
On towed implements, disconnect wiring harnesses from
tractor before servicing electrical system components or
welding on machine.
DX,AIR –19–17FEB99–1/1
Work In Ventilated Area
TS220 –UN–23AUG88
Engine exhaust fumes can cause sickness or death. If it is
necessary to run an engine in an enclosed area, remove
the exhaust fumes from the area with an exhaust pipe
extension.
If you do not have an exhaust pipe extension, open the
doors and get outside air into the area
05-6
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Safety
DX,FLUID –19–03MAR93–1/1
Avoid High-Pressure Fluids
X9811 –UN–23AUG88
Escaping fluid under pressure can penetrate the skin
causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.
Search for leaks with a piece of cardboard. Protect hands
and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid
injected into the skin must be surgically removed within a
few hours or gangrene may result. Doctors unfamiliar with
this type of injury should reference a knowledgeable
medical source. Such information is available from Deere
& Company Medical Department in Moline, Illinois, U.S.A.
DX,TORCH –19–10DEC04–1/1
Avoid Heating Near Pressurized Fluid Lines
TS953 –UN–15MAY90
Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to
yourself and bystanders. Do not heat by welding,
soldering, or using a torch near pressurized fluid lines or
other flammable materials. Pressurized lines can
accidentally burst when heat goes beyond the immediate
flame area.
DX,WW,HPCR1 –19–07JAN03–1/1
Do Not Open High-Pressure Fuel System
TS1343 –UN–18MAR92
High-pressure fluid remaining in fuel lines can cause
serious injury. Do not disconnect or attempt repair of fuel
lines, sensors, or any other components between the
high-pressure fuel pump and nozzles on engines with
High Pressure Common Rail (HPCR) fuel system.
Only technicians familiar with this type of system can
perform repairs. (See your John Deere dealer.)
05-7
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PN=22
Safety
DX,PAINT –19–24JUL02–1/1
Remove Paint Before Welding or Heating
TS220 –UN–23AUG88
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated
by welding, soldering, or using a torch.
Remove paint before heating:
•Remove paint a minimum of 100 mm (4 in.) from area
to be affected by heating. If paint cannot be removed,
wear an approved respirator before heating or welding.
•If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
•If you use solvent or paint stripper, remove stripper with
soap and water before welding. Remove solvent or
paint stripper containers and other flammable material
from area. Allow fumes to disperse at least 15 minutes
before welding or heating.
Do not use a chlorinated solvent in areas where welding
will take place.
Do all work in an area that is well ventilated to carry toxic
fumes and dust away.
Dispose of paint and solvent properly.
DX,RCAP –19–04JUN90–1/1
Service Cooling System Safely
TS281 –UN–23AUG88
Explosive release of fluids from pressurized cooling
system can cause serious burns.
Shut off engine. Only remove filler cap when cool enough
to touch with bare hands. Slowly loosen cap to first stop
to relieve pressure before removing completely.
05-8
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Safety
OUOD006,000009D –19–27JUL06–1/1
Install Fan Guards
TS677 –UN–21SEP89
Rotating Fan
Rotating cooling system fans can cause serious injury.
Keep fan guards in place at all times during engine
operation. Wear close fitting clothes. Stop the engine and
be sure fan is stopped before making adjustments or
connections, or cleaning near the front of the engine.
OURGP12,0000135 –19–27JUL06–1/1
Avoid Hot Parts
TS271 –UN–23AUG88
Hot Surface
Avoid skin contact with exhaust manifolds, turbochargers
and mufflers. Keep flammable materials clear of the
turbocharger.
External dry exhaust parts become very hot during
operation. Turbochargers and exhaust manifolds may
reach temperatures as high as 600°C (1112°F) under full
load. This may ignite paper, cloth or wooden materials.
Parts on engines that have been at full load and reduced
to no load idle will maintain approximately 150°C (302°F).
05-9
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PN=24
Safety
DX,DUST –19–15MAR91–1/1
Avoid Harmful Asbestos Dust
TS220 –UN–23AUG88
Avoid breathing dust that may be generated when
handling components containing asbestos fibers. Inhaled
asbestos fibers may cause lung cancer.
Components in products that may contain asbestos fibers
are brake pads, brake band and lining assemblies, clutch
plates, and some gaskets. The asbestos used in these
components is usually found in a resin or sealed in some
way. Normal handling is not hazardous as long as
airborne dust containing asbestos is not generated.
Avoid creating dust. Never use compressed air for
cleaning. Avoid brushing or grinding material containing
asbestos. When servicing, wear an approved respirator. A
special vacuum cleaner is recommended to clean
asbestos. If not available, apply a mist of oil or water on
the material containing asbestos.
Keep bystanders away from the area.
DX,SPARKS –19–03MAR93–1/1
Prevent Battery Explosions
TS204 –UN–23AUG88
Keep sparks, lighted matches, and open flame away from
the top of battery. Battery gas can explode.
Never check battery charge by placing a metal object
across the posts. Use a volt-meter or hydrometer.
Do not charge a frozen battery; it may explode. Warm
battery to 16°C (60°F).
DX,LIFT –19–04JUN90–1/1
Use Proper Lifting Equipment
TS226 –UN–23AUG88
Lifting heavy components incorrectly can cause severe
injury or machine damage.
Follow recommended procedure for removal and
installation of components in the manual.
05-10
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Safety
DX,REPAIR –19–17FEB99–1/1
Use Proper Tools
TS779 –UN–08NOV89
Use tools appropriate to the work. Makeshift tools and
procedures can create safety hazards.
Use power tools only to loosen threaded parts and
fasteners.
For loosening and tightening hardware, use the correct
size tools. DO NOT use U.S. measurement tools on
metric fasteners. Avoid bodily injury caused by slipping
wrenches.
Use only service parts meeting John Deere specifications.
05-11
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PN=26
Safety
DPSG,OUO1004,2758 –19–27JUL06–1/1
Handling Batteries Safely
TS204 –UN–23AUG88
Explosion
TS203 –UN–23AUG88
Acid
CAUTION: Battery gas can explode. Keep
sparks and flames away from batteries. Use a
flashlight to check battery electrolyte level.
Never check battery charge by placing a metal
object across the posts. Use a voltmeter or
hydrometer.
Always remove grounded (—) battery clamp
first and replace it last.
CAUTION: Sulfuric acid in battery electrolyte is
poisonous. It is strong enough to burn skin, eat
holes in clothing, and cause blindness if
splashed into eyes.
Avoid the hazard by:
1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is
added.
4. Avoiding spilling or dripping electrolyte.
5. Using proper jump start procedure.
If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize
the acid.
3. Flush your eyes with water for 15—30
minutes. Get medical attention immediately.
If acid is swallowed:
1. Do not induce vomiting.
2. Drink large amounts of water or milk, but do
not exceed2L(2qt.).
3. Get medical attention immediately.
WARNING: Battery posts, terminals, and related
accessories contain lead and lead compounds, chemicals
known to the State of California to cause cancer and
reproductive harm. Wash hands after handling.
05-12
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Safety
DX,SPRAY –19–16APR92–1/1
Protect Against High Pressure Spray
TS1343 –UN–18MAR92
Spray from high pressure nozzles can penetrate the skin
and cause serious injury. Keep spray from contacting
hands or body.
If an accident occurs, see a doctor immediately. Any high
pressure spray injected into the skin must be surgically
removed within a few hours or gangrene may result.
Doctors unfamiliar with this type of injury should reference
a knowledgeable medical source. Such information is
available from Deere & Company Medical Department in
Moline, Illinois, U.S.A.
DX,DRAIN –19–03MAR93–1/1
Dispose of Waste Properly
TS1133 –UN–26NOV90
Improperly disposing of waste can threaten the
environment and ecology. Potentially harmful waste used
with John Deere equipment include such items as oil, fuel,
coolant, brake fluid, filters, and batteries.
Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.
Do not pour waste onto the ground, down a drain, or into
any water source.
Air conditioning refrigerants escaping into the air can
damage the Earth’s atmosphere. Government regulations
may require a certified air conditioning service center to
recover and recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of waste
from your local environmental or recycling center, or from
your John Deere dealer.
05-13
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PN=28
Fuels, Lubricants, and Coolant
DX,FUEL1 –19–17NOV05–1/1
Diesel Fuel
Consult your local fuel distributor for properties of the
diesel fuel available in your area.
In general, diesel fuels are blended to satisfy the low
temperature requirements of the geographical area in
which they are marketed.
Diesel fuels specified to EN 590 or ASTM D975 are
recommended.
Required fuel properties
In all cases, the fuel shall meet the following
properties:
Cetane number of 45 minimum. Cetane number
greater than 50 is preferred, especially for
temperatures below -20°C (-4°F) or elevations above
1500 m (5000 ft).
Cold Filter Plugging Point (CFPP) below the
expected low temperature OR Cloud Point at least
5°C(9°F) below the expected low temperature.
Fuel lubricity should pass a minimum level of 3100
grams as measured by ASTM D6078 or maximum
scar diameter of 0.45 mm as measured by ASTM
D6079 or ISO 12156-1.
Sulfur content:
•Diesel fuel quality and fuel sulfur content must
comply with all existing emissions regulations for the
area in which the engine operates.
•Use of diesel fuel with sulfur content less than
0.10% (1000 ppm) is STRONGLY recommended.
•Use of diesel fuel with sulfur content 0.10% (1000
ppm to 0.50% (5000 ppm) may result in REDUCED
oil and filter change intervals.
•BEFORE using diesel fuel with sulfur content greater
than 0.50% (5000 ppm), contact your John Deere
dealer.
•DO NOT use diesel fuel with sulfur content greater
than 1.0%.
IMPORTANT: Do not mix used diesel engine oil or
any other type of lubricating oil with
diesel fuel.
IMPORTANT: Improper fuel additive usage may
cause damage on fuel injection
equipment of diesel engines.
DX,FUEL5 –19–27OCT05–1/1
Lubricity of Diesel Fuel
Most diesel fuels manufactured in the United States,
Canada, and the European Union have adequate
lubricity to ensure proper operation and durability of
fuel injection system components. However, diesel
fuels manufactured in some areas of the world may
lack the necessary lubricity.
IMPORTANT: Make sure the diesel fuel used in
your machine demonstrates good
lubricity characteristics.
Fuel lubricity should pass a minimum load level of
3100 grams as measured by ASTM D6078 or a
maximum scar diameter of 0.45 mm as measured by
ASTM D6079 or ISO 12156-1.
If fuel of low or unknown lubricity is used, add John
Deere PREMIUM DIESEL FUEL CONDITIONER (or
equivalent) at the specified concentration.
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Fuels, Lubricants, and Coolant
DX,FUEL4 –19–19DEC03–1/1
Handling and Storing Diesel Fuel
CAUTION: Handle fuel carefully. Do not fill
the fuel tank when engine is running.
DO NOT smoke while you fill the fuel tank or
service the fuel system.
Fill the fuel tank at the end of each day’s operation to
prevent water condensation and freezing during cold
weather.
Keep all storage tanks as full as practicable to
minimize condensation.
Ensure that all fuel tank caps and covers are installed
properly to prevent moisture from entering.
Monitor water content of the fuel regularly.
When using bio-diesel fuel, the fuel filter may require
more frequent replacement due to premature plugging.
Check engine oil level daily prior to starting engine. A
rising oil level may indicate fuel dilution of the engine
oil.
IMPORTANT: The fuel tank is vented through the
filler cap. If a new filler cap is
required, always replace it with an
original vented cap.
When fuel is stored for an extended period or if there
is a slow turnover of fuel, add a fuel conditioner to
stabilize the fuel and prevent water condensation.
Contact your fuel supplier for recommendations.
DX,FUEL6 –19–14NOV05–1/1
Testing Diesel Fuel
DIESELSCANis a John Deere fuel analysis program
that can be used to monitor the quality of your fuel. The
DIESELSCAN analysis verifies fuel type, cleanliness,
water content, suitability for cold weather operation, and
whether the fuel meets specifications.
Check with your John Deere dealer for availability of
DIESELSCAN kits.
DIESELSCAN is a trademark of Deere & Company
10-2
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Fuels, Lubricants, and Coolant
DX,FUEL7 –19–14NOV05–1/1
Bio-Diesel Fuel
Consult your local fuel distributor for properties of the
bio-diesel fuel available in your area.
Bio-diesel fuels may be used ONLY if the bio-diesel
fuel properties meet the latest edition of ASTM D6751,
EN 14214, or equivalent specification.
It is recommended to purchase bio-diesel fuel blended
with B100 from a BQ-9000 Accredited Producer or a
BQ-9000 Certified Marketer as recommended by the
National Bio-diesel Board.
The maximum allowable bio-diesel concentration is a
5% blend (also known as B5) in petroleum diesel fuel.
It has been found that bio-diesel fuels may improve
lubricity in concentrations up to this 5% blend.
When using a blend of bio-diesel fuel, the engine oil
level must be checked daily when the air temperature
is –10°C (14°F) or lower. If oil becomes diluted with
fuel, shorten oil change intervals accordingly.
IMPORTANT: Raw pressed vegetable oils are NOT
acceptable for use as fuel in any
concentration in John Deere
engines.
These oils do not burn completely,
and will cause engine failure by
leaving deposits on injectors and in
the combustion chamber.
A major environmental benefit of bio-diesel fuel is its
ability to biodegrade. This makes proper storage and
handling of bio-diesel fuel especially important. Areas
of concern include:
•Quality of new fuel
•Water content of the fuel
•Problems due to aging of the fuel
Potential problems resulting from deficiencies in the
above areas when using bio-diesel fuel in
concentrations above 5% may lead to the following
symptoms:
•Power loss and deterioration of performance
•Fuel leakage
•Corrosion of fuel injection equipment
•Coked and/or blocked injector nozzles, resulting in
engine misfire
•Filter plugging
•Lacquering and/or seizure of internal components
•Sludge and sediments
•Reduced service life of engine components
Consult your fuel supplier for additives to improve
storage and performance of bio-diesel fuels.
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Fuels, Lubricants, and Coolant
DX,FUEL10 –19–16DEC05–1/2
Minimizing the Effect of Cold Weather on Diesel Engines
John Deere diesel engines are designed to operate
effectively in cold weather.
However, for effective starting and cold weather
operation, a little extra care is necessary. The
information below outlines steps that can minimize the
effect that cold weather may have on starting and
operation of your engine. See your John Deere dealer
for additional information and local availability of cold
weather aids
Use Winter Grade Fuel
When temperatures fall below 5°C (40°F), winter grade
fuel (Grade No. 1-D fuel in North America) is best
suited for cold weather operation. Winter grade fuel
has a lower cloud point and a lower pour point.
Cloud point is the temperature at which wax will begin
to form in the fuel and this wax causes fuel filters to
plug. Pour point is the temperature at which fuel
begins to thicken and becomes more resistant to flow
through fuel pumps and lines.
NOTE: On an average, winter grade fuel has a lower
BTU (heat content) rating. Using winter grade
fuel may reduce power and fuel efficiency, but
should not cause any other engine
performance effects. Check the grade of fuel
being used before troubleshooting for low
power complaints in cold weather operation.
Air Intake Heater
An air intake heater is an available option to aid cold
weather starting.
CAUTION: Do not use any starting fluid with
an air intake heater.
Starting Fluid
A starting fluid port on the intake is available to aid
cold weather starting.
CAUTION: Do not use any starting fluid with
an engine equipped with glow plugs
Coolant Heater
An engine block heater (coolant heater) is an available
option to aid cold weather starting.
Seasonal Viscosity Oil and Proper Coolant
Concentration
Use seasonal grade viscosity engine oil based ion the
expected air temperature range between oil changes
and proper concentration of low silicate antifreeze as
recommended. (See DIESEL ENGINE OIL and
ENGINE COOLANT requirements this section.)
Diesel Fuel Flow Additive
Use John Deere Premium Diesel Fuel Conditioner
(Winter) or equivalent to treat fuel during the cold
weather season. This winter formulation is a
combination diesel fuel conditioner and anti-gel
additive.
IMPORTANT: Treat fuel when outside temperature
drops below 0°C (32°F). For best
results, use with untreated fuel.
Follow all recommended instructions
on label.
Winterfronts
Use of fabric, cardboard , or solid winterfronts is not
recommended with any John Deere engine. Their use
can result in excessive engine coolant, oil, and charge
air temperatures. This can lead to reduced engine life,
loss of power and poor fuel economy. Winterfronts
may also put abnormal stress on fan and fan drive
components potentially causing premature failures.
10-4
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Continued on next page
Fuels, Lubricants, and Coolant
DX,FUEL10 –19–16DEC05–2/2
If winterfronts are used, they should never totally close
off the grill frontal area. Approximately 25% area in the
center of the grill should remain open at all times. At
no time should the air blockage device be applied
directly to the radiator core.
Radiator Shutters
If equipped with a thermostatically controlled radiator
shutter system, this system should be regulated in
such a way that the shutters are completely open by
the time the coolant reaches 93°C (200°F) to prevent
excessive intake manifold temperatures. Manually
controlled systems are not recommended.
If air-to-air aftercooling is used, the shutters must be
completely open by the time the intake manifold air
temperature reaches the maximum allowable
temperature out of the charge air cooler.
For more information, see your John Deere dealer.
DX,ENOIL4 –19–19DEC05–1/1
Diesel Engine Break-In Oil
New engines are filled at the factory with John Deere
ENGINE BREAK-IN OIL. During the break-in period,
add John Deere ENGINE BREAK-IN OIL as needed to
maintain the specified oil level.
Change the oil and filter after the first 100 hours of
operation of a new or rebuilt engine.
After engine overhaul, fill the engine with John Deere
ENGINE BREAK-IN OIL.
If John Deere ENGINE BREAK-IN OIL is not available,
use a diesel engine oil meeting one of the following
during the first 100 hours of operation:
•API Service Classification CE
•API Service Classification CD
•API Service Classification CC
•ACEA Oil Sequence E2
•ACEA Oil Sequence E1
After the break-in period, use John Deere PLUS-50
or other diesel engine oil as recommended in this
manual.
IMPORTANT: Do not use PLUS-50 oil or engine
oils meeting any of the following
during the first 100 hours of
operation of a new or rebuilt engine:
API CI-4 PLUS API CF
API CI-4 ACEA E7
API CH-4 ACEA E6
API CG-4 ACEA E5
API CF-4 ACEA E4
API CF-2 ACEA E3
These oils will not allow the engine
to break-in properly.
PLUS-50 is a trademark of Deere & Company.
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Fuels, Lubricants, and Coolant
DX,ENOIL7 –19–23NOV05–1/1
Diesel Engine Oil
TS1675 –UN–31OCT03
Use oil viscosity base on the expected air temperature
range during the period between oil changes.
John Deere PLUS-50oil is preferred.
Oil meeting one of the following specifications are also
recommended:
•ACEA Oil Sequence E7
•ACEA Oil Sequence E6
•ACEA Oil Sequence E5
•ACEA Oil Sequence E4
Extended service intervals may apply when John Deere
PLUS-50, ACEA E7, ACEA E6, ACEA E5, or ACEA E4
engine oils are used. Consult your John Deere dealer for
more information.
Other oils may be used if they meet one or more of the
following:
•John Deere TORQ-GARD SUPREME
•API Service Category CI-4 PLUS
•API Service Category CI-4
•API Service Category CH-4
•ACEA Oil Sequence E3
Multi-viscosity diesel engine oils are preferred.
Diesel fuel quality and fuel sulfur content must comply
with all existing emissions regulations for the area in
which the engine operates.
DO NOT use diesel fuel with sulfur content greater than
1.0% (10 000 ppm).
PLUS-50 is a trademark of Deere & Company
TORQ-GARD SUPREME is a trademark of Deere & Company
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Fuels, Lubricants, and Coolant
OURGP11,0000012 –19–27JUL06–1/3
Diesel Engine Oil and Filter Service Intervals
The oil and filter service intervals in the following
charts should be used as guidelines. Actual service
intervals depend on operation and maintenance
practices. Use oil analysis to determine the actual
useful life of the oil and to aid in selection of the
proper oil and filter service interval.
Oil and filter service intervals are based on a
combination of oil pan capacity, type of engine oil and
filter used, and sulfur content of the diesel fuel.
Diesel fuel sulfur level will affect engine oil and filter
service intervals. Higher fuel sulfur levels reduce oil
and filter service intervals as shown in the table:
•Use of diesel fuel with sulfur content less than
0.05% (500 ppm ) is strongly recommended.
•Use of diesel fuel with sulfur content 0.05% (500
ppm) to 0.50% (5000 ppm) may result in REDUCED
oil and filter change intervals as shown in the table.
•BEFORE using diesel fuel with sulfur content greater
than 0.50% (5000 ppm), contact your John Deere
dealer.
Oil types (premium or standard) in the tables include:
•“Premium Oils” include John Deere PLUS-50,
ACEA E7, ACEA E6, ACEA E5 or ACEA E4 oils.
•“Standard Oils” include John Deere TORQ-GARD
SUPREME, API CI-4 PLUS, API CI-4, , API CH4
or ACEA E3 oils.
NOTE: The 500 hour extended oil and filter change
interval is allowed only if
ALL
the following
conditions are met:
•Engine equipped with an oil pan that allows capacity
for this extended drain interval.
•Use of premium oil John Deere PLUS-50, ACEA E7,
ACEA E6, ACEA E5 or ACEA E4
•Use of an approved John Deere oil filter
•Use of diesel fuel with sulfur content less than
0.05% (500 ppm)
Refer to the charts on the following pages to find the
proper oil and filter service interval for your engine.
Using Charts to Find Oil and Filter Service Interval
1. Determine your engine model and power rating and
find it in the left column of 4.5 L or 6.8 L chart.
2. Locate your engine oil pan option code (19__) on
engine label.
3. In the chart column under your oil pan code, select
whether you use premium oil (PLUS-50or
equivalent) or standard grade oil.
4. Determine the sulfur content of your diesel fuel.
5. Now you can find the proper oil and filter change
interval by lining up your power level and fuel sulfur
content with oil pan/oil type column. The number
indicates how frequent your oil and filter should be
changed (example: every 500 hours of operation).
PLUS-50 is a trademark of Deere & Company
TORQ-GARD SUPREME is a trademark of Deere & Company
10-7
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Continued on next page
Fuels, Lubricants, and Coolant
OURGP11,0000012 –19–27JUL06–2/3
4.5 L Engine Oil and Filter Service Intervals in Hours of Operation
Oil Pan Option Codes
Power Fuel Sulfur Content
a
1901, 1902 1903 1904 1923 1976
Rating
Interval Interval Interval Interval Interval
kW (hp) Std Prem Std Oil Prem Std Prem Std Oil Prem Std Oil Prem
Oil Oil Oil Oil Oil Oil Oil
36-50 Less Than 0.05% (500 ppm) 250 500 250 500 250 500 250 500 250 500
(48-67)
0.05% - 0.50% (500 - 5000 ppm) 150 400 150 400 150 400 150 400 150 400
0.50% - 1.0% (5000 - 10,000 ppm) 125 250 125 250 125 250 125 250 125 250
63-86 Less Than 0.05% (500 ppm) 250 375 250 500 250 500 250 500 250 500
(84-115)
0.05% - 0.50% (500 - 5000 ppm) 150 275 150 400 150 400 150 400 150 400
0.50% - 1.0% (5000 - 10,000 ppm) 125 175 125 250 125 250 125 250 125 250
93 (125) Less Than 0.05% (500 ppm) 250 375 250 375 250 500 250 500 250 500
0.05% - 0.50% (500 - 5000 ppm) 150 275 150 275 150 400 150 400 150 400
0.50% - 1.0% (5000 - 10,000 ppm) 125 175 125 175 125 250 125 250 125 250
99-108 Less Than 0.05% (500 ppm) 250 375 250 375 250 375 250 500 250 500
(133-145)
0.05% - 0.50% (500 - 5000 ppm) 150 275 150 275 150 275 150 400 150 400
0.50% - 1.0% (5000 - 10,000 ppm) 125 175 125 175 125 175 125 250 125 250
117-143 Less Than 0.05% (500 ppm) 250 375 250 375 250 375 250 375 250 500
(157-192)
0.05% - 0.50% (500 - 5000 ppm) 150 275 150 275 150 275 150 275 150 400
0.50% - 1.0% (5000 - 10,000 ppm) 125 175 125 175 125 175 125 175 125 250
Use of premium oil also requires use of an approved John Deere oil filter.
a
If considering fuel with sulfur content over 0.50% (5000 ppm), contact your John Deere Dealer (dealer to reference DTAC solution).
Continued on next page
10-8
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PN=36
Fuels, Lubricants, and Coolant
OURGP11,0000012 –19–27JUL06–3/3
6.8 L Engine Oil and Filter Service Intervals in Hours of Operation
Oil Pan Option Codes
Power Fuel Sulfur Content
a
1956 1907, 1908, 1924 19AC 1961
Rating 1909, 1944
Interval Interval Interval Interval Interval
kW (hp) Std Prem Std Prem Std Prem Std Prem Std Prem
Oil Oil Oil Oil Oil Oil Oil Oil Oil Oil
101-129 Less Than 0.05% (500 ppm) 250 500 250 500 250 500 250 500 250 500
(135-173)
0.05% - 0.50% (500 - 5000 ppm) 150 400 150 400 150 400 150 400 150 400
0.50% - 1.0% (5000 - 10,000 ppm) 125 250 125 250 125 250 125 250 125 250
138 (185) Less Than 0.05% (500 ppm) 250 375 250 500 250 500 250 500 250 500
0.05% - 0.50% (500 - 5000 ppm) 150 275 150 400 150 400 150 400 150 400
0.50% - 1.0% (5000 - 10,000 ppm) 125 175 125 250 125 250 125 250 125 250
149-175 Less Than 0.05% (500 ppm) 250 375 250 375 250 500 250 500 250 500
(200-235)
0.05% - 0.50% (500 - 5000 ppm) 150 275 150 275 150 400 150 400 150 400
0.50% - 1.0% (5000 - 10,000 ppm) 125 175 125 175 125 250 125 250 125 250
187 (250) Less Than 0.05% (500 ppm) 250 375 250 375 250 375 250 500 250 500
0.05% - 0.50% (500 - 5000 ppm) 150 275 150 275 150 275 150 400 150 400
0.50% - 1.0% (5000 - 10,000 ppm) 125 175 125 175 125 175 125 250 125 250
205-210 Less Than 0.05% (500 ppm) 250 375 250 375 250 375 250 375 250 500
(275-272)
0.05% - 0.50% (500 - 5000 ppm) 150 275 150 275 150 275 150 275 150 400
0.50% - 1.0% (5000 - 10,000 ppm) 125 175 125 175 125 175 125 175 125 250
234 (314) Less Than 0.05% (500 ppm) 250 375 250 375 250 375 250 375 250 375
0.05% - 0.50% (500 - 5000 ppm) 150 275 150 275 150 275 150 275 150 275
0.50% - 1.0% (5000 - 10,000 ppm) 125 175 125 175 125 175 125 175 125 175
Use of premium oil also requires use of an approved John Deere oil filter.
a
If considering fuel with sulfur content over 0.50% (5000 ppm), contact your John Deere Dealer (dealer to reference DTAC solution).
DX,LUBMIX –19–18MAR96–1/1
Mixing of Lubricants
In general, avoid mixing different brands or types of oil.
Oil manufacturers blend additives in their oils to meet
certain specifications and performance requirements.
Mixing different oils can interfere with the proper
functioning of these additives and degrade lubricant
performance.
Consult your John Deere dealer to obtain specific
information and recommendations.
10-9
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PN=37
Fuels, Lubricants, and Coolant
DX,FILT –19–18MAR96–1/1
Oil Filters
Filtration of oils is critical to proper operation and
lubrication.
Always change filters regularly as specified in this manual.
Use filters meeting John Deere performance
specifications.
DX,OILSCAN –19–02DEC02–1/1
OILSCANand COOLSCAN
T6828AB –UN–15JUN89T6829AB –UN–18OCT88
OILSCANand COOLSCANare John Deere sampling
programs to help you monitor machine performance and
identify potential problems before they cause serious
damage.
Oil and coolant samples should be taken from each
system prior to its recommended change interval.
Check with your John Deere dealer for the availability of
OILSCANand COOLSCANkits.
OILSCAN is a registered trademark of Deere & Company.
COOLSCAN is a trademark of Deere & Company.
10-10
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PN=38
Fuels, Lubricants, and Coolant
DX,ALTER –19–15JUN00–1/1
Alternative and Synthetic Lubricants
Conditions in certain geographical areas may require
lubricant recommendations different from those printed in
this manual.
Some John Deere brand coolants and lubricants may not
be available in your location.
Consult your John Deere dealer to obtain information and
recommendations.
Synthetic lubricants may be used if they meet the
performance requirements as shown in this manual.
The temperature limits and service intervals shown in this
manual apply to both conventional and synthetic oils.
Re-refined base stock products may be used if the
finished lubricant meets the performance requirements.
DX,LUBST –19–18MAR96–1/1
Lubricant Storage
Your equipment can operate at top efficiency only
when clean lubricants are used.
Use clean containers to handle all lubricants.
Whenever possible, store lubricants and containers in
an area protected from dust, moisture, and other
contamination. Store containers on their side to avoid
water and dirt accumulation.
Make certain that all containers are properly marked to
identify their contents.
Properly dispose of all old containers and any residual
lubricant they may contain.
10-11
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Fuels, Lubricants, and Coolant
DX,GREA1 –19–07NOV03–1/1
Grease
TS1673 –UN–31OCT03
Use grease based on NLGI consistency numbers and the
expected air temperature range during the service interval.
John Deere SD POLYUREA GREASE is preferred.
The following greases are also recommended
•John Deere HD LITHIUM COMPLEX GREASE
•John Deere HD WATER RESISTANT GREASE
•John Deere GREASE-GARD
Other greases may be used if they meet the following:
NLGI Performance Classification GC-LB
IMPORTANT: Some types of grease thickeners are
not compatible with others. Consult
your grease supplier before mixing
different types of grease
GREASE-GARD is a trademark of Deere & Company
10-12
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PN=40
Fuels, Lubricants, and Coolant
DX,COOL3 –19–27OCT05–1/2
Diesel Engine Coolant
The engine cooling system is filled to provide
year-round protection against corrosion and cylinder
liner pitting, and winter freeze protection to -37°C
(-34°F). If protection at lower temperatures is required,
consult your John Deere dealer for recommendations.
John Deere COOL-GARDPrediluted Coolant is
preferred for service.
John Deere COOL-GARD Prediluted Coolant is
available in a concentration of either 50% ethylene
glycol or 55% propylene glycol.
Additional recommended coolants
The following engine coolant is also recommended:
•John Deere COOL-GARD Coolant Concentrate in a
40% to 60% mixture of concentrate with quality
water.
John Deere COOL-GARD coolants do not require use
of supplemental coolant additives, except for periodic
replenishment of additives during the drain interval.
Other fully formulated coolants
Other fully formulated low silicate ethylene or
propylene glycol base coolants for heavy-duty engines
may be used if they meet one of the following
specifications:
•ASTM D6210 prediluted (50%) coolant
•ASTM D6210 coolant concentrate in a 40% to 60%
mixture of concentrate with quality water
Coolants meeting ASTM D6210 do not require use of
supplemental coolant additives, except for periodic
replenishment of additives during the drain interval.
Coolants requiring supplemental coolant additives
Other low silicate ethylene glycol base coolants for
heavy-duty engines may also be used if they meet one
of the following specifications:
•ASTM D4985 ethylene glycol base prediluted (50%)
coolant
•ASTM D4985 ethylene glycol base coolant
concentrate in a 40% to 60% mixture of concentrate
with quality water
Coolants meeting ASTM D4985 require an initial
charge of supplemental coolant additives, formulated
for protection of heavy duty diesel engines against
corrosion and cylinder liner erosion and pitting. They
also require periodic replenishment of additives during
the drain interval.
Other coolants
It is possible that neither John Deere COOL-GARD nor
coolants meeting one of the coolant standards listed
above is available in the geographical area where
service is performed. If these coolants are unavailable,
use a coolant concentrate or prediluted coolant with a
quality additive package that provides cylinder liner
cavitation protection and protects the cooling system
metals (cast iron, aluminum alloys, and copper alloys
such as brass) from corrosion.
The additive package must be part of one of the
following coolant mixtures:
•ethylene glycol or propylene glycol base prediluted
(40% to 60%) coolant
•ethylene glycol or propylene glycol base coolant
concentrate in a 40% to 60% mixture of concentrate
with quality water
Water quality
COOL-GARD is a trademark of Deere & Company
10-13
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Continued on next page
Fuels, Lubricants, and Coolant
DX,COOL3 –19–27OCT05–2/2
Water quality is important to the performance of the
cooling system. Distilled, deionized, or demineralized
water is recommended for mixing with ethylene glycol
and propylene glycol base engine coolant concentrate.
IMPORTANT: Do not use cooling system sealing
additives or antifreeze that contains
sealing additives.
IMPORTANT: Do not mix ethylene glycol and
propylene glycol base coolants.
DX,COOL11 –19–19DEC03–1/1
Drain Intervals for Diesel Engine Coolant
Drain the factory fill engine coolant, flush the cooling
system, and refill with new coolant after the first 3 years
or 3000 hours of operation.
Subsequent drain intervals are determined by the coolant
used for service. At each interval, drain the coolant, flush
the cooling system, and refill with new coolant.
When John Deere COOL-GARDis used, the drain
interval may be extended to 5 years or 5000 hours of
operation, provided that the coolant is tested annually
AND additives are replenished, as needed, by adding a
supplemental coolant additive.
If John Deere COOL-GARD is used but the coolant is not
tested OR additives are not replenished by adding a
supplemental coolant additive, the drain interval is 3 years
or 3000 hours of operation
If COOL-GARD is not used, the drain interval is reduced
to 2 years or 2000 hours of operation.
COOL-GARD is a trademark of Deere & Company
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Fuels, Lubricants, and Coolant
DX,COOL4 –19–07NOV03–1/1
Supplemental Coolant Additives
The concentration of coolant additives is gradually
depleted during engine operation. For all
recommended coolants, replenish additives between
drain intervals by adding a supplemental coolant
additive every 12 months or as determined necessary
by coolant testing.
John Deere COOLANT CONDITIONER is
recommended as a supplemental coolant additive in
John Deere engines.
IMPORTANT: Do not add a supplemental coolant
additive when the cooling system is
drained and refilled with John
DeereCOOL-GARD.
If other coolants are used, consult the coolant supplier
and follow the manufacturer’s recommendation for use
of supplemental coolant additives.
The use of non-recommended supplemental coolant
additives may result in additive drop-out and gelation
of the coolant.
Add the manufacturer’s recommended concentration of
supplemental coolant additive. DO NOT add more than
the recommended amount.
COOL-GARD is a trademark of Deere & Company
DX,COOL9 –19–19DEC03–1/1
Testing Diesel Engine Coolant
Testing Diesel Engine Coolant
Maintaining adequate concentrations of glycol and
inhibiting additives in the coolant is critical to protect
the engine and cooling system against freezing,
corrosion, and cylinder liner erosion and pitting.
Test the coolant solution at intervals of 12 months or
less and whenever excessive coolant is lost through
leaks or overheating.
Coolant test strips
Coolant test strips are available from your John Deere
dealer. These test strips provide a simple, effective
method to check the freeze point and additive levels of
your engine coolant.
Compare the results to the supplemental coolant
additive (SCA) chart to determine the amount of
inhibiting additives in your coolant and whether more
John Deere COOLANT CONDITIONER should be
added.
COOLSCANand COOLSCAN PLUS
For a more thorough evaluation of your coolant,
perform a COOLSCAN or COOLSCAN PLUS analysis,
where available. See your John Deere dealer for
information.
COOLSCAN is a trademark of Deere & Company
COOLSCAN PLUS is a trademark of Deere & Company
10-15
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PN=43
Fuels, Lubricants, and Coolant
DX,COOL6 –19–18MAR96–1/1
Operating in Warm Temperature Climates
John Deere engines are designed to operate using glycol
base engine coolants.
Always use a recommended glycol base engine coolant,
even when operating in geographical areas where freeze
protection is not required.
IMPORTANT: Water may be used as coolant
in
emergency situations only.
Foaming, hot surface aluminum and
iron corrosion, scaling, and cavitation
will occur when water is used as the
coolant, even when coolant
conditioners are added.
Drain cooling system and refill with
recommended glycol base engine
coolant as soon as possible.
RG,RG34710,7543 –19–27JUL06–1/1
Disposing of Coolant
TS1133 –UN–26NOV90
Improperly disposing of engine coolant can threaten the
environment and ecology.
Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.
Do not pour waste onto the ground, down a drain, or into
any water source.
Inquire on the proper way to recycle or dispose of waste
from your local environmental or recycling center, or from
your John Deere engine distributor or servicing dealer.
10-16
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Instrument Panel Identification
OURGP11,0000071 –19–27JUL06–1/2
Instrument Panels - Identification
RG13343 –UN–24NOV03
Instrument Panel For Earlier Mechanically Controlled “270” Engines
(See Section 18)
RG13359 –UN–06FEB04
Deluxe Instrument Panel For Later Mechanically Controlled “270”
Engines (See Section 18)
The instrument panels shown compare the panel offered
for mechanically controlled “270” series engines (shown at
right) and electronically controlled earlier engines and
electronically controlled later engines (shown on next
page). The electronically controlled earlier instrument
panel operation is covered in Section 16. The
electronically controlled later instrument panels
(Full-Featured and Basic versions) are covered in Section
17. The mechanically controlled “270” series engines are
covered in Section 18.
Continued on next page
15-1
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PN=45
Instrument Panel Identification
OURGP11,0000071 –19–27JUL06–2/2
RG13273 –UN–20NOV03
Instrument Panel For Earlier Electronically Controlled Engines (See
Section 16)
RG13274 –UN–28OCT03
Full-Featured Instrument Panel For Later Electronically Controlled
Engines (See Section 17)
RG13275 –UN–21OCT03
Basic Instrument Panel For Later Electronically Controlled Engines
(See Section 17)
15-2
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PN=46
Instrument Panel - Elect. Cont. Earlier Engines
OURGP11,000027A –19–07AUG06–1/7
Instrument Panel
RG11169 –UN–01NOV00
Instrument Panel (Earlier Electronically Controlled Engines)
A—Engine Oil Pressure Gauge
B—Amber “WARNING” Indicator
C—Red “STOP ENGINE” Indicator
D—Diagnostic Gauge/Hour Meter
E—Touch Switch
F—Touch Switch
G—Audible Alarm (Optional)
H—Audible Alarm Override Switch (Optional)
I—Analog Throttle Control (Optional)
J—Dimmer Control (Optional)
K—Engine Preheater Indicator (Optional)
L—Key Start Switch
M—Override Shutdown Rocker Switch
N—High-Low Speed Select Rocker Switch
O—Bump Speed Enable Rocker Switch
P—Speed Select Rocker Switch
Q—Fuse Holder (5-Amp Fuse)
R—Tachometer
S—Power Meter (Percent Load) (Optional)
T—Voltmeter (Optional)
U—Engine Coolant Temperature Gauge
This instrument panel for earlier P
OWER
T
ECH
4.5 L and
6.8 L electronically controlled engines is electronically
linked to the John Deere engine control unit (ECU). This
allows the operator to monitor engine performance as well
as to diagnose any troubles during engine operation.
All electronic engine controls are optional equipment for
John Deere P
OWER
T
ECH
OEM Engines. These electronic
controls may be provided by the equipment manufacturer
instead of purchased from John Deere. Refer to your
engine application manual for specific guidelines if John
Deere sourced controls and instrumentation are not used.
P
OWER
T
ECH
is a trademark of Deere & Company.
Continued on next page
16-1
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Instrument Panel - Elect. Cont. Earlier Engines
OURGP11,000027A –19–07AUG06–2/7
RG11169 –UN–01NOV00
Instrument Panel
IMPORTANT: Any time an electric gauge or meter
does not register correctly, replace with
a new one. Do not attempt to repair it.
All gauges are plug-in type.
Following is a brief description of the electronic controls
found on John Deere-provided instrument panels. Refer to
manufacturer’s literature for information on controls not
provided by Deere.
Engine Oil Pressure Gauge
The engine oil pressure gauge (A) indicates engine oil
pressure in pounds per square inch (psi) or kPa. An
optional audible alarm (G) warns the operator if engine oil
pressure falls below a safe operating pressure.
Amber “Warning” Indicator
The amber “WARNING” indicator (B) signals an abnormal
condition such as low oil pressure, high coolant
temperature, water in fuel, low battery voltage, etc.
Observe displayed code in window of diagnostic
gauge/hour meter (D) for diagnostic trouble code (DTC).
(Use the service code menu. See USING DIAGNOSTIC
GAUGE TO ACCESS ENGINE INFORMATION later in
this section.)
Red “Stop Engine” Indicator
The Red “STOP ENGINE” indicator (C) signals operator to
stop engine immediately or as soon as safely possible. A
condition exists that could cause damage to engine.
Diagnostic Gauge/Hour Meter
The diagnostic gauge/hour meter (D) displays diagnostic
trouble codes (DTCs) as they are accessed. Other
information on the engine can be accessed using the
touch switches (E and F). The hour meter shows the
operating hours of the engine. If engine trouble occurs,
the gauge will alternately flash from displayed parameter
to the message “SvrcCode”. Then the touch switches (E
and F) can be used to access the trouble code (see
following).
16-2
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Continued on next page
Instrument Panel - Elect. Cont. Earlier Engines
OURGP11,000027A –19–07AUG06–3/7
RG11169 –UN–01NOV00
Instrument Panel For Earlier Engines
Touch Switches
The touch switches are used to change the display on the
window of the diagnostic gauge to access engine
performance data. Pressing the DOWN switch (E) or UP
switch (F) scrolls through various engine parameters and
diagnostic trouble codes. (See Using Diagnostic Gauge
To Access Engine Information on the following pages for
instructions.)
Audible Alarm (Optional)
The audible alarm (G) sounds whenever a low oil
pressure, high coolant temperature or
water-in-fuel/plugged fuel filter condition exists. This
includes all signals that light up the amber “WARNING”
indicator (B) or the red “STOP ENGINE” indicator (C).
Audible Alarm Override Switch (Optional)
The audible alarm override switch (H) can be pressed to
silence the alarm for approximately 2-1/2 minutes.
Analog Throttle Control (Optional)
The throttle control (I) is used to control engine speed.
This control is available only on engines with analog
throttle.
Dimmer Control (Optional)
The dimmer control (J) is used to control illumination of
the instrument panel gauges.
Continued on next page
16-3
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Instrument Panel - Elect. Cont. Earlier Engines
OURGP11,000027A –19–07AUG06–4/7
RG11169 –UN–01NOV00
Instrument Panel For Earlier Engines
Engine Preheater Indicator (Optional)
The engine preheater indicator (K) lights up while the
engine is being preheated for cold weather starting. When
the engine is warmed up, the light goes off, indicating the
engine can now be started.
Key Start Switch
The three-position key start switch (L) controls the engine
electrical system. When the key switch is turned clockwise
to “START”, the engine will crank. When the engine starts,
the key is released and returns to the “ON” (RUN)
position.
Override Shutdown Rocker Switch
Switch will be present, but may not be active, depending
on engine controller (ECU) options originally selected. If
switch is active, pressing the upper half of the override
shutdown switch (M) will override an engine shutdown
signal. The switch must be pressed within 30 seconds to
prevent undesired shutdown of engine. Pressing this
switch will override the engine shutdown for 30 seconds at
a time to move vehicle to a safe location.
High-Low Speed Select Rocker Switch
This instrument panel has two versions, one with a two
position switch as shown, and one with a three position
switch. The two position switch has high/low and is used
to set the engine operating speeds at slow (turtle) or fast
(rabbit). Factory preset idle speeds can also be adjusted
using bump speed enable switch (O) with speed select
switch (P).
The three position switch has Slow (turtle), Middle (Adj)
and Fast (rabbit) settings. Slow (turtle) position is factory
preset at low engine idle, while middle (ADJ) position is
factory set at high engine idle. To adjust engine speeds,
See Changing Engine Speeds in Section 18.
Continued on next page
16-4
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Instrument Panel - Elect. Cont. Earlier Engines
OURGP11,000027A –19–07AUG06–5/7
RG11169 –UN–01NOV00
Instrument Panel For Earlier Engines
Bump Speed Enable Rocker Switch
This is a three-position switch (O) with the center position
as “OFF” (locked). With this switch in the “OFF” position,
the speed select switch (P) is also locked, to prevent
accidental changes in operating speed. Pressing upper or
lower half of switch (O) will unlock or enable the bump
speed switch to take effect using speed select switch (P).
Speed Select Rocker Switch
The speed select switch (P) is used to bump engine
speed up (+) or down (-) in small increments during
operation. This switch must be used with the bump speed
enable switch (O) in the unlocked position (top or bottom
half of button depressed).
How To Select Preset Operating Speeds (Bump
Speeds)
First select slow or fast speed option by pressing high-low
speed select switch (N) to “turtle” (slow) or “rabbit” (fast).
Then you can press either the upper or lower portion of
the bump speed enable switch (O) to unlock the high or
low setting. The bump speed enable must be held down
as the speed select switch (P) is used to change the high
or low setting by pressing (+) to increase speed or (-) to
decrease speed.
Once the slow idle speed has been set, the bump speed
enable switch must be pressed and released three
times within two seconds to commit the new
operating speed to memory. If not done, the engine’s
new speed will only be effective until the key switch is
shut off. Then the speed will revert back to the previous
setting.
The fast idle speed cannot be locked into memory. It will
always go back to the factory preset fast idle speed.
Fuse Holder
The fuse holder (Q) contains a 5-amp fuse for power to
the instrument panel.
16-5
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Continued on next page
Instrument Panel - Elect. Cont. Earlier Engines
OURGP11,000027A –19–07AUG06–6/7
RG11169 –UN–01NOV00
Instrument Panel For Earlier Engines
Tachometer
The tachometer (R) indicates engine speed in hundreds of
revolutions per minute (rpm).
Percent Load (Optional)
The power meter (S) shows percent of available power
being used by the engine.
Voltmeter
The voltmeter (T) indicates system battery voltage. The
amber “WARNING” light (B) will illuminate when battery
voltage is too low for proper operation of the fuel injection
system.
Engine Coolant Temperature Gauge
The coolant temperature gauge (U) indicates engine
coolant temperature in degrees Celsius or Fahrenheit. An
optional audible alarm (G) warns the operator if coolant
temperature rises above the preset safe operating
temperature.
Cruise Control
Engine ECUs are available with the cruise control
function. The cruise control is an off-road type that
maintains a constant engine rpm under varying load
conditions.
The cruise cancel/resume function is a one-button cancel,
then resume, function. The first time contact is made with
the cruise control active, the cruise control will disengage
and the engine speed will drop to idle. If the contact is
made again within one minute and with the engine speed
above 1300 rpm, the cruise control will “resume”. This
feature allows the placement of the cancel/resume button
in a convenient location in the vehicle cab and does not
require the use of the normal cruise controls for
momentary interruptions in cruise operation.
16-6
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Continued on next page
Instrument Panel - Elect. Cont. Earlier Engines
OURGP11,000027A –19–07AUG06–7/7
The cancel/resume function is intended for applications
like agricultural tractors and sprayers that turn around at
the end of each row in a field. This allows the operator to
use the throttle and/or brake to turn the vehicle around.
When ready to resume field operations, the operator
brings the engine speed above 1300 rpm and activates
the cancel/resume function again to resume cruise speed.
An internal timer gives the operator one minute to
complete the turnaround maneuver.
The cruise control has the normal functions of:
•Cruise control power “ON” or “OFF”.
•“Set” or “bump up” engine speed.
•“Resume” or “bump down” engine speed.
•Use vehicle brake or clutch pedal to disengage cruise
control.
The “bump up” and “bump down” speed controls allow the
operator to change the set speed. Small engine speed
changes can be made by “bumping” the control switch.
Holding the “bump up” or “bump down” switch will result in
greater engine rpm changes until the engine reaches
either full speed or idle. The cruise control cannot operate
beyond the normal min/max engine speeds.
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Using Diagnostic Gauge to Access Engine
Information
RG10031 –UN–28OCT99
Diagnostic Gauge (Earlier Engines)
A—Diagnostic Gauge
B—Touch Switches
C—Lights
The diagnostic gauge (A) allows the operator to view
many readouts of engine functions and diagnostic trouble
codes (DTCs). The gauge is linked to the electronic
control system and its sensors. This allows the operator to
monitor engine functions and to troubleshoot the engine
systems when needed.
Press the two touch switches (B) to view the various
engine functions in sequence. The displays can be
selected as either customary English or metric units.
NOTE: Engine parameters which can be accessed will
vary with the engine application.
The following menu of engine parameters can be
displayed on the diagnostic gauge window:
•Accelerator pedal position
•Percentage load @ current speed
•Actual engine percent torque
•Engine speed
•Trip distance
•Total vehicle distance
•Engine hours
•Trip fuel
•Total fuel used
•Coolant temperature
•Fuel temperature
•Engine oil temperature
•Engine intercooler temperature
•Fuel delivery pressure
•Engine oil level
•Engine oil pressure
•Coolant pressure
•Coolant level
•Wheel base vehicle speed
•Fuel rate
•Barometric pressure
•Air inlet temperature
•Boost pressure
•Intake manifold temperature
•Air filter differential pressure
•Exhaust gas temperature
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OURGP11,0000072 –19–27JUL06–2/2
•Electrical potential (voltage)
•Battery potential (voltage), switched
•Transmission oil pressure
•Transmission oil temperature
•Injector metering rail #1 pressure
•Injector metering rail #2 pressure
•Estimated percent fan speed
•Active service (diagnostic) codes
•Stored service (diagnostic) codes
The diagnostic gauge includes a two-line by
eight-character backlit Liquid Crystal Display (LCD). The
top line displays the data label, i.e. “EngHrs” and the
bottom line displays the matching unit information, i.e.
“1246 hrs.”. The diagnostic gauge uses two touch
switches (UP and DOWN) for scrolling through the engine
parameter list and viewing the menu list. Two lights (C)
(amber and red) are used to signal active trouble
messages received by the diagnostic gauge.
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Using Touch Switches to Display Information
RG9947 –19–09DEC99
Using Touch Switches
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The touch switches on the diagnostic gauge allow
quick and easy navigation through the menu to find the
information needed.
The diagram on the preceding page is a typical Main
Menu of Engine Parameters. The Main Menu has 14
entries; the first 10 are engine data parameters, and
the last four are sub-menu entry points.
Accessing the Menus
The following two rules are used for accessing the
various items on the menus:
1. To scroll through the parameter list, press
either
the UP or DOWN touch switch.
2. To select or exit a sub-menu,
simultaneously
press the UP and DOWN switches.
Selecting Engine Data Parameters
To read any of the engine parameters, press either UP
or DOWN switch (as shown on diagram) until the top
line of the display shows the desired information.
Selecting Sub-Menus
Press either the UP or DOWN switch until the top line
of the display shows the label of the desired
sub-menu. Then press BOTH the UP and DOWN
switches at the same time. This action will select the
sub-menu and the next screen on the display will list
the sub-menu items. This is also the way to access
diagnostic trouble codes (DTCs).
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Changing Units of Measure (English or Metric)
RG10018 –19–28OCT99
Changing Units Of Measure
The diagnostic gauge can display engine data in either
English or Metric units. To toggle between these, the
Units Sub-Menu
, must be selected.
To select the
Units Sub-Menu
, press the UP or DOWN
switch until the top line of the display reads “Units”.
Then press BOTH the UP and DOWN switches at the
same time to select the
Units Sub-Menu
. The above
diagram shows the steps for selecting the desired units
of measure. Two options are available:
1. Press both the switches to retain the current units
designation.
2. Press either UP or DOWN switch to toggle the units
selection, then press both switches to select the
desired unit of measure.
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Viewing Engine Configuration Data
RG10019 –19–28OCT99
Viewing Engine Configuration Data
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Instrument Panel - Elect. Cont. Earlier Engines
DPSG,OUOD007,2842 –19–27JUL06–2/2
The diagnostic gauge can display the engine
configuration data stored in the engine control unit
(ECU). To select the
Engine Configuration Sub-Menu
(see diagram on previous page), press the UP or
DOWN switch until the top line of the display reads
“E-Config”. Then press BOTH the UP and DOWN
switches at the same time to select the
Engine
Configuration Sub-Menu
. The diagnostic gauge will
display the engine configuration data as shown in the
diagram.
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Viewing Active Engine Service Codes/Diagnostic Trouble Codes (DTCs)
RG11170 –UN–02NOV00
Viewing Active Service Codes/Diagnostic Trouble Codes (DTCs)
The diagnostic gauge continuously monitors all
messages broadcast over the Control Area Network
(CAN) and displays all active service codes /diagnostic
trouble codes (DTCs) at the time the message is
broadcast. The word “SrvcCode” is displayed on the
second line. The display will cycle every 5 seconds
between the currently displayed parameter and the
“SrvcCode” message until the active service code
(DTC) clears. To view the active codes, select the
Service Code Sub-Menu
by pressing the UP or DOWN
switch until the top line of the display reads
“SrvcCode”. Then press BOTH the UP and DOWN
switches at the same time to select the Service Code
(DTC) Sub-Menu. The diagnostic gauge has the ability
to display all active service codes (DTCs) received.
The diagram above titled
Service Code (DTC)
Sub-Menu
shows the process for selecting active
service codes (DTCs) and their values.
NOTE: For a list of Service Codes or Diagnostic
Trouble Codes (DTCs) and their causes, refer
to TROUBLESHOOTING Section 45, later in
this manual. An alternate method of accessing
trouble codes for engines for engines without
the diagnostic gauge is the blink code method.
See Section 45.
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Viewing Stored Service Codes/Diagnostic Trouble Codes (DTCs) in the Engine ECU
RG10021 –19–28OCT99
Viewing Stored Service Codes/Diagnostic Trouble Codes (DTCs)
The diagnostic gauge can request stored service
codes (DTCs) from the engine. The stored service
codes may be used for diagnostic and service needs.
To view the stored service codes, it is necessary to
select the
DM2 Codes Sub-Menu
by pressing the UP
or DOWN switch until the top line of the display reads
“DM2 Codes”. Then press BOTH the UP and DOWN
switches at the same time to select the
DM2 Codes
Sub-Menu.
The gauge will display the stored service
codes according to the menus shown in the diagram.
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Instrument Panels
RG13276 –UN–28OCT03
Full-Featured Instrument Panel
RG13277 –UN–22OCT03
Basic Instrument Panel
A—Diagnostic Gauge/Hour F—Key Switch K—Analog Throttle Control O—Arrow Keys
Meter G—Override Shutdown Rocker (Optional) P—Enter Key
B—Tachometer Switch L—Oil Pressure Gauge Q—Amber “WARNING”
C—Voltmeter (Optional) H—Bump Enable Rocker M—Coolant Temperature Indicator Light
D—Audible Alarm (Optional) Switch Gauge R—Red “STOP ENGINE”
E—Audible Alarm Override I—Speed Select Rocker Switch N—Menu Key Indicator Light
Button J—High-Low Speed Select
Rocker Switch
Later Tier 2 John Deere P
OWER
T
ECH
OEM Engines
have an electronic control system, which has the
following controls and gauges as shown. The following
information applies only to those controls and gauges
supplied by John Deere. Refer to your engine
application manual for specific guidelines if John
Deere-sourced controls and instrumentation are not
used.
Following is a brief description of the available optional
electronic controls and gauges found on John Deere
provided instrument panels. Refer to manufacturer’s
literature for information on controls not provided by
Deere.
P
OWER
T
ECH
is a trademark of Deere & Company.
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OURGP11,0000073 –19–04AUG06–2/3
Instrument Panel (Continued)
A—Diagnostic Gauge/Hour Meter
The diagnostic gauge (A) displays diagnostic trouble
codes (DTCs) as they are accessed. Other information
on the engine can be accessed using the touch keys
(N, O and P). The hour meter feature shows the
operating hours of the engine and should be used as a
guide for scheduling periodic maintenance. If the
diagnostic gauge receives a trouble code from an
engine control unit, the current display will switch to a
warning or shutdown (depending on the severity of the
code) screen that will display the trouble code number,
the description of the code and the corrective action
needed.
B—Tachometer
The tachometer (B) indicates engine speed in
hundreds of revolutions per minute (rpm).
C—Voltmeter (Optional)
The voltmeter (C) indicates system battery voltage.
The amber “Warning” light (Q) will illuminate when
battery voltage is too low for proper operation of the
fuel injection system.
D—Audible Alarm (Optional)
The audible alarm (D) will sound whenever low oil
pressure, high coolant temperature, or water-in-fuel
conditions exist. This includes all signals that light up
the amber “warning” indicator (intermittent alarm) or
the red “stop engine” indicator (steady alarm).
E—Audible Alarm Override Button
The optional audible alarm has an override button (E)
that silences the audible alarm for approximately two
minutes when pressed.
F—Key Start Switch
The three-position key start switch (F) controls the
engine electrical system. When the key switch is
turned clockwise to “START”, the engine will crank.
When the engine starts, the key is released and
returns to the “ON” (RUN) position.
G—Override Shutdown Rocker Switch
Switch will be present, but may not be active,
depending on engine controller (ECU) options
originally selected. If switch is active, pressing the
upper half of the override shutdown switch (G) will
override an engine shutdown signal. The switch must
be pressed within 30 seconds to prevent undesired
shutdown of engine. Pressing this switch will override
the engine shutdown for 30 seconds at a time to move
vehicle to a safe location.
H—Bump Speed Enable Rocker Switch
This is a three-position switch (H) with the center
position as “OFF” (locked). With this switch in the
“OFF” position, the speed select switch (I) is also
locked, to prevent accidental changes in operating
speed. Pressing upper or lower half of switch (H) will
unlock or enable the bump speed switch to take effect
using speed select switch (I).
I—Speed Select Rocker Switch
The speed select switch (I) is used to bump engine
speed up (+) or down (-) in small increments during
operation. This switch must be used with the bump
speed enable switch (H) in the unlocked position (top
or bottom half of button depressed).
J—High-Low Speed Select Rocker Switch
The high-low speed select switch (J) is used to set the
engine operating speeds at slow (turtle) or fast (rabbit).
Factory preset idle speeds can also be adjusted using
bump speed enable switch (H) with speed select
switch (I).
The basic instrument panel will have the high-low
speed select switch only. Press and hold up (+) or
down (-) to adjust engine speed as desired. The
engine speed selected will not be held in the memory.
To adjust engine speeds, See Changing Engine
Speeds in Section 18.
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OURGP11,0000073 –19–04AUG06–3/3
How To Select Preset Operating Speeds (Bump
Speeds)
First select Turtle (Slow) or Adj by pressing speed
select switch (J) to “Turtle” (slow) or “Adj”(center).
Then you can press either the upper or lower portion
of the bump speed enable switch (H) to unlock the
setting. The bump speed enable must be held down as
the speed select switch (J) is used to change the
setting by pressing (+) to increase speed or (-) to
decrease speed.
Once the slow idle speed has been set, the bump
speed enable switch must be pressed and released
three times within two seconds to commit the new
operating speed to memory. If not done, the engine’s
new speed will only be effective until the key switch is
shut off. Then the speed will revert back to the
previous setting.
The fast idle speed is not adjustable. It will always go
back to the factory preset fast idle speed.
K—Analog Throttle Control (Optional)
The throttle control (K) is used to control engine
speed. This control is available only on engines with
analog throttle.
L—Engine Oil Pressure Gauge
The oil pressure gauge (L) indicates engine oil
pressure. An audible alarm (D) warns the operator if
engine oil pressure falls below a safe operating
pressure.
M—Engine Coolant Temperature Gauge
The engine coolant temperature gauge (M) indicates
engine coolant temperature. An audible alarm (D)
warns the operator if coolant temperature rises above
the preset safe operating temperature.
N—Menu Key
The menu key is pressed to either enter or exit the
menu screens on the diagnostic gauge.
O—Arrow Keys
Use the arrow keys (O) to change the display on the
window of the diagnostic gauge and to access engine
performance data.
Pressing the left arrow to scroll to the left or upward or
the right arrow to scroll to the right or downward. This
will allow you to view various engine parameters and
any diagnostic trouble codes that occur.
Refer to the following story for accessing engine
information on the diagnostic gauge using the touch
keys.
P—Enter Key
The enter key is pressed to select the parameter that
is highlighted on the screen.
Q—Amber “WARNING” Indicator Light
When light comes on, an abnormal condition exists. It
is not necessary to shutdown engine immediately, but
problem should be corrected as soon as possible.
R—Red “STOP ENGINE” Indicator Light
When light comes on, stop engine immediately or as
soon as safely possible to prevent engine damage.
Correct problem before restarting.
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Using Diagnostic Gauge to Access Engine
Information
RG13132 –UN–09SEP03
Diagnostic Gauge (Later Engines)
A—Diagnostic Gauge
B—Menu Key
C—Arrow Keys
D—Enter Key
E—Red “STOP ENGINE” Indicator Light
F—Amber “WARNING” Indicator Light
The diagnostic gauge (A) allows the operator to view
many readouts of engine functions and trouble codes
(DTCs). The gauge is linked to the electronic control
system and its sensors. This allows the operator to
monitor engine functions and to troubleshoot the engine
systems when needed.
Press the menu key (B) to access the various engine
functions in sequence. The displays can be selected as
either customary English or metric units. The following
menu of engine parameters can be displayed on the
diagnostic gauge window:
•Engine hours
•Engine rpm
•System voltage
•Percent engine load at the current rpm
•Coolant temperature
•Oil pressure
•Throttle position
•Intake manifold temperature
•Current fuel consumption
•Active service (diagnostic) codes
•Stored service (diagnostic) codes from the engine
•Set the units for display
•View the engine configuration parameters
NOTE: Engine parameters which can be accessed will
vary with the engine application. Six languages for
readouts are available and can be selected during
setup of gauge.
The diagnostic gauge includes a graphical backlit Liquid
Crystal Display (LCD) screen. The display can show either
a single parameter or a quadrant display showing four
parameters simultaneously. The diagnostic gauge uses
two arrow keys (C) for scrolling through the engine
parameter list and viewing the menu list and an enter key
(D) for selecting highlighted items. The red (E) and amber
(F) lights are used to signal active trouble code received
by the diagnostic gauge.
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Main Menu Navigation
RG13159 –UN–26SEP03
Menu Key
NOTE: The engine does not need to be running to
navigate the diagnostic gauge screens. If engine
start up is desired, See Starting The Engine. All of
the engine values illustrated on the diagnostic
gauge indicate the engine is running.
1. Turn the key switch to the ON position. Starting at the
single or four engine parameter display, press the
"Menu" key.
OURGP11,00000A9 –19–27JUL06–2/5
RG13160 –UN–02OCT03
Menu Display
2. The first seven items of the "Main Menu" will be
displayed.
OURGP11,00000A9 –19–27JUL06–3/5
RG13161 –UN–02OCT03
Main Menu Items
3. Pressing the "Arrow" keys will scroll through the menu
selections.
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OURGP11,00000A9 –19–27JUL06–4/5
RG13162 –UN–26SEP03
Last Items On Main Menu
4. Pressing the right arrow key will scroll down to reveal
the last items of "Main Menu" screen, highlighting the
next item down.
OURGP11,00000A9 –19–27JUL06–5/5
RG13163 –UN–02OCT03
Use Arrow Buttons To Scroll / Quadrant Display
5. Use the arrow keys to scroll to the desired menu item
or press the "Menu Button" to exit the main menu and
return to the engine parameter display.
OURGP11,00000AB –19–27JUL06–1/6
Engine Configuration Data
RG13159 –UN–26SEP03
Menu Key
NOTE: The engine configuration data is a read only
function.
NOTE: The engine does not need to be running to
navigate the diagnostic gauge screens. If engine
start up is desired, See Starting The Engine. All of
the engine values illustrated on the diagnostic
gauge indicate the engine is running.
1. Turn the key switch to the ON position. Starting at the
single or four engine parameter display, press the
"Menu" key.
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OURGP11,00000AB –19–27JUL06–2/6
RG13164 –UN–07OCT03
Select Engine Configuration
2. The main menu will be displayed. Use the "Arrow" keys
to scroll through the menu until "Engine Config" is
highlighted.
OURGP11,00000AB –19–27JUL06–3/6
RG13165 –UN–02OCT03
Enter Key
3. Once "Engine Config" menu item has been highlighted,
press the "Enter" key to view the engine configuration
data.
OURGP11,00000AB –19–27JUL06–4/6
RG13166 –UN–29SEP03
Use Arrow Keys To Scroll
4. Use the "Arrow" keys to scroll through the engine
configuration data.
OURGP11,00000AB –19–27JUL06–5/6
RG13167 –UN–29SEP03
Return To Main Menu
5. Press the "Menu" key to return to the main menu.
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OURGP11,00000AB –19–27JUL06–6/6
RG13159 –UN–26SEP03
Exit Main Menu
6. Press the "Menu" key to exit the main menu and return
to the engine parameter display.
OURGP11,00000AC –19–27JUL06–1/6
Accessing Stored Trouble Codes
RG13159 –UN–26SEP03
Menu Key
NOTE: The engine does not need to be running to
navigate the diagnostic gauge screens. If engine
start up is desired, See Starting The Engine. All of
the engine values illustrated on the diagnostic
gauge indicate the engine is running.
For description of trouble codes, see chart in
Troubleshooting Section.
1. Turn the key switch to the ON position. Starting at the
single or four engine parameter display, press the
"Menu" key.
OURGP11,00000AC –19–27JUL06–2/6
RG13168 –UN–02OCT03
Select Stored Codes
2. The main menu will be displayed. Use the "Arrow" keys
to scroll through the menu until "Stored Codes" is
highlighted.
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OURGP11,00000AC –19–27JUL06–3/6
RG13169 –UN–02OCT03
Enter Key
3. Once the "Stored Codes" menu item has been
highlighted press the "Enter" key to view the stored
codes.
OURGP11,00000AC –19–27JUL06–4/6
RG13245 –UN–02OCT03
Use Arrow Keys To Scroll
4. If the word "Next" appears above the "Arrow" keys,
there are more stored codes that may be viewed. Use
the "Arrow" key to scroll to the next stored code.
OURGP11,00000AC –19–27JUL06–5/6
RG13246 –UN–02OCT03
Return To Main Menu
5. Press the "Menu" key to return to the main menu.
Continued on next page
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RG13159 –UN–26SEP03
Exit Main Menu
6. Press the "Menu" key to exit the main menu and return
to the engine parameter display.
OURGP11,00000AD –19–27JUL06–1/7
Accessing Active Trouble Codes
RG13172 –UN–26SEP03
Normal Operation
NOTE: The engine does not need to be running to
navigate the diagnostic gauge screens. If engine
start up is desired, See Starting The Engine. All of
the engine values illustrated on the diagnostic
gauge indicate the engine is running.
For description of trouble codes, see chart in
Troubleshooting Section.
1. During normal operation the single or four parameter
screen will be displayed.
OURGP11,00000AD –19–27JUL06–2/7
RG13240 –UN–30SEP03
Active Trouble Codes Displayed
2. When the diagnostic gauge receives a trouble code
from an engine control unit, the single or four
parameter screen will be replaced with the "Warning"
message. The SPN and FMI number will be displayed
along with a description of the problem and the
corrective action needed.
IMPORTANT: Ignoring active trouble codes can result
in severe engine damage.
Continued on next page
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RG13241 –UN–30SEP03
Use Arrow Keys To Scroll
3. If the word "Next" appears above the arrow keys, there
are more trouble codes that can be viewed by using
the arrow keys to scroll to the next trouble code.
OURGP11,00000AD –19–27JUL06–4/7
RG13242 –UN–30SEP03
Hide Trouble Codes
IMPORTANT: Ignoring active trouble codes can result
in severe engine damage.
4. To acknowledge and hide the code and return to the
single or four parameter display, press the "Enter" Key.
OURGP11,00000AD –19–27JUL06–5/7
RG13176 –UN–26SEP03
Active Trouble Code Icon
5. The display will return to the single or four parameter
display, but the display will contain the warning icon.
Pressing the "Enter" key will redisplay the hidden
trouble code.
OURGP11,00000AD –19–27JUL06–6/7
RG13242 –UN–30SEP03
Enter Key
IMPORTANT: Ignoring active trouble codes can result
in severe engine damage.
6. Pressing the "Enter" key once again will hide the
trouble code and return the screen to the single or four
parameter display.
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OURGP11,00000AD –19–27JUL06–7/7
RG13243 –UN–01OCT03
Active Trouble Code Condition
7. The single or four parameter screen will display the
warning icon until the trouble code condition is
corrected.
OURGP11,00000AE –19–27JUL06–1/6
Engine Shutdown Codes
RG13172 –UN–26SEP03
Normal Operation
1. During normal operation the single or four parameter
screen will be displayed.
OURGP11,00000AE –19–27JUL06–2/6
RG13238 –UN–29SEP03
Shutdown Message
2. When the diagnostic gauge receives a severe trouble
code from an engine control unit, the single or four
parameter screen will be replaced with the "Shutdown"
message. The SPN and FMI number will be displayed
along with a description of the problem and the
corrective action needed.
If the word "Next" appears above the arrow keys, there
are more trouble codes that can be viewed by using
the arrow keys to scroll to the next trouble code.
OURGP11,00000AE –19–27JUL06–3/6
RG13239 –UN–29SEP03
Hide Trouble Code
3. To acknowledge and hide the trouble code and return
to the single or four parameter display, press the
"Enter" key".
IMPORTANT: Ignoring the shutdown message can
result in severe engine damage.
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OURGP11,00000AE –19–27JUL06–4/6
RG13179 –UN–26SEP03
Flashing Shutdown Icon
4. The display will return to the single or four parameter
display, but the display will contain the "Shutdown"
icon. Pressing the "Enter" key will redisplay the hidden
trouble code.
IMPORTANT: Ignoring the shutdown message can
result in severe engine damage.
OURGP11,00000AE –19–27JUL06–5/6
RG13239 –UN–29SEP03
Redisplay Trouble Code
5. Pressing the "Enter" key once again will hide the
trouble code and return the screen to the single or four
parameter display.
OURGP11,00000AE –19–27JUL06–6/6
RG13180 –UN–26SEP03
Shutdown Icon
6. The single or four parameter screen will display the
shutdown icon until the trouble code condition is
corrected.
IMPORTANT: Ignoring the shutdown message can
result in severe engine damage.
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Adjusting Backlighting
RG13159 –UN–26SEP03
Menu Key
1. Turn the key switch to the ON position. Starting at the
single or four engine parameter display, press the
"Menu" key.
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RG13181 –UN–02OCT03
Select Adjust Backlight
2. The main menu will be displayed. Use the "Arrow" keys
to scroll through the menu until "Adjust Backlight" is
highlighted.
OURGP11,0000237 –19–27JUL06–3/6
RG13182 –UN–02OCT03
Press Enter Key
3. Once the "Adjust Backlight" menu item has been
highlighted, press the "Enter" key to activate the
"Adjust Backlight" function.
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RG13183 –UN–29SEP03
Adjust Backlight Intensity
4. Use the "Arrow" keys to select the desired backlight
intensity.
Continued on next page
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OURGP11,0000237 –19–27JUL06–5/6
RG13184 –UN–26SEP03
Return To Main Menu
5. Press the "Menu" key to return to the main menu.
OURGP11,0000237 –19–27JUL06–6/6
RG13159 –UN–26SEP03
Exit Main Menu
6. Press the "Menu" key to exit the main menu and return
to the engine parameter display.
OURGP11,00000AF –19–27JUL06–1/6
Adjusting Contrast
RG13159 –UN–26SEP03
Menu Key
1. Turn the key switch to the ON position. Starting at the
single or four engine parameter display press the
"Menu" key.
Continued on next page
17-15
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PN=78
Instrument Panel - Elect. Cont. Later Engines
OURGP11,00000AF –19–27JUL06–2/6
RG13161 –UN–02OCT03
Select Adjust Contrast
2. The main menu will be displayed. Use the "Arrow" keys
to scroll through the menu until "Adjust Contrast" is
highlighted.
OURGP11,00000AF –19–27JUL06–3/6
RG13185 –UN–02OCT03
Press Enter Key
3. Once the "Adjust Contrast" menu item has been
highlighted, press the "Enter" key to activate the
"Adjust Contrast" function.
OURGP11,00000AF –19–27JUL06–4/6
RG13186 –UN–29SEP03
Adjust Contrast Intensity
4. Use the "Arrow" keys to select the desired contrast
intensity.
17-16
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PN=79
Continued on next page
Instrument Panel - Elect. Cont. Later Engines
OURGP11,00000AF –19–27JUL06–5/6
RG13187 –UN–26SEP03
Return To Main Menu
5. Press the "Menu" key to return to the main menu.
OURGP11,00000AF –19–27JUL06–6/6
RG13159 –UN–26SEP03
Exit Main Menu
6. Press the "Menu" key to exit the main menu and return
to the engine parameter display.
OURGP11,00000B0 –19–27JUL06–1/7
Selecting Units Of Measurement
RG13159 –UN–26SEP03
Menu Key
1. Turn the key switch to the ON position. Starting at the
single or four engine parameter display, press the
"Menu" key.
Continued on next page
17-17
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PN=80
Instrument Panel - Elect. Cont. Later Engines
OURGP11,00000B0 –19–27JUL06–2/7
RG13188 –UN–02OCT03
Select Units
2. The main menu will be displayed. Use the "Arrow" keys
to scroll through the menu until "Select Units" is
highlighted.
OURGP11,00000B0 –19–27JUL06–3/7
RG13189 –UN–02OCT03
Press Enter Key
3. Once the "Select Units" menu item has been
highlighted press the "Enter" key to access the "Select
Units" function.
OURGP11,00000B0 –19–27JUL06–4/7
RG13190 –UN–26SEP03
Select Desired Units
4. There are three choices for units of measurement,
English, Metric kPa or Metric Bar.
English is for Imperial units, with pressures displayed
in PSI and temperatures in °F.
Metric kPa and Metric bar are for IS units, with
pressures displayed in kPa and bar respectively, and
temperatures in °C.
Use the "Arrow" keys to highlight the desired units of
measurement.
17-18
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PN=81
Continued on next page
Instrument Panel - Elect. Cont. Later Engines
OURGP11,00000B0 –19–27JUL06–5/7
RG13191 –UN–30SEP03
Press Enter Key to Select
5. Press the "Enter" key to select the highlighted units.
OURGP11,00000B0 –19–27JUL06–6/7
RG13192 –UN–26SEP03
Return To Main Menu
6. Press the "Menu" key to return to the main menu.
OURGP11,00000B0 –19–27JUL06–7/7
RG13159 –UN–26SEP03
Press Menu Key
7. Press the "Menu" key to return to the engine
parameter display.
17-19
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PN=82
Instrument Panel - Elect. Cont. Later Engines
OURGP11,00000B1 –19–27JUL06–1/18
Setup 1-Up Display
RG13159 –UN–26SEP03
Menu Key
1. Turn the key switch to the ON position. Starting at the
single engine parameter display, press the "Menu" key.
OURGP11,00000B1 –19–27JUL06–2/18
RG13193 –UN–02OCT03
Setup 1-Up Display
2. Use the "Arrow" keys to scroll through the menu until
"Setup 1-Up Display" is highlighted.
OURGP11,00000B1 –19–27JUL06–3/18
RG13194 –UN–02OCT03
Press Enter Key
3. Once "Setup 1-Up Display" menu item has been
highlighted press the "Enter" key to access the "Setup
1-Up Display" function.
Continued on next page
17-20
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PN=83
Instrument Panel - Elect. Cont. Later Engines
OURGP11,00000B1 –19–27JUL06–4/18
RG13196 –UN–26SEP03
1-Up Display Options
4. Three options are available for modification of the 1-Up
Display.
a. Use Defaults – This option contains the following
engine parameters for display: Engine Hours,
Engine Speed, Battery Voltage, % Load, Coolant
Temperature and Oil Pressure.
b. Custom Setup – This option contains a list of
engine parameters. Engine parameters from this list
can be selected to replace any or all of the default
parameters. This option can be used to add
parameters available for scrolling in the 1-Up
Display.
c. Automatic Scan – Selecting the scan function will
allow the 1-Up Display to scroll through the selected
set of parameters one at a time, momentarily
pausing at each.
OURGP11,00000B1 –19–27JUL06–5/18
RG13195 –UN–26SEP03
Select Defaults
5. Use Defaults - To select "Use Defaults" use the Arrow
keys to scroll to and highlight "Use Defaults" in the
menu display.
Continued on next page
17-21
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PN=84
Instrument Panel - Elect. Cont. Later Engines
OURGP11,00000B1 –19–27JUL06–6/18
RG13197 –UN–29SEP03
Defaults Selected
6. Press the "Enter" key to activate the "Use Defaults"
function.
OURGP11,00000B1 –19–27JUL06–7/18
RG13149 –UN–24SEP03
Restored To Defaults
7. The display parameters are reset to the factory
defaults, then the display will return to the "Setup 1-Up
Display" menu.
OURGP11,00000B1 –19–27JUL06–8/18
RG13198 –UN–26SEP03
Select Custom Setup
8. Custom Setup - To perform a custom setup of the
1-Up Display, use the arrow buttons to scroll to and
highlight "Custom Setup" on the display.
17-22
080706
PN=85
Continued on next page
Instrument Panel - Elect. Cont. Later Engines
OURGP11,00000B1 –19–27JUL06–9/18
RG13199 –UN–26SEP03
Engine Parameters
9. Press the "Enter" key to display a list of engine
parameters.
OURGP11,00000B1 –19–27JUL06–10/18
RG13150 –UN–24SEP03
Select Parameters
10. Use the "Arrow" keys to scroll to and highlight a
selected parameter (parameter with a number to right
of it).
OURGP11,00000B1 –19–27JUL06–11/18
RG13219 –UN–26SEP03
Deselect Parameters
11. Press the "Enter" key to deselect the selected
parameter, removing it from the list of parameters
being displayed on the 1-Up Display.
17-23
080706
PN=86
Continued on next page
Instrument Panel - Elect. Cont. Later Engines
OURGP11,00000B1 –19–27JUL06–12/18
RG13151 –UN–24SEP03
Select Desired Parameters
12. Use the "Arrow" keys to scroll and highlight the
desired parameter that has not been selected for
display (parameter without a number to right of it).
OURGP11,00000B1 –19–27JUL06–13/18
RG13220 –UN–26SEP03
Select Parameters For Display
13. Press the "Enter" key to select the parameter for
inclusion in the Single Engine Parameter Display.
14. Continue to scroll through and select additional
parameters for the custom 1-Up Display. Press the
"Menu" key at any time to return to the "Custom
Setup" menu.
OURGP11,00000B1 –19–27JUL06–14/18
RG13221 –UN–26SEP03
Automatic Scan Off
15. Automatic Scan - Selecting the scan function will
allow the 1- Up Display to scroll through the selected
set of parameters one at a time. Use the "Arrow" keys
to scroll to the "Automatic Scan" function.
17-24
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PN=87
Continued on next page
Instrument Panel - Elect. Cont. Later Engines
OURGP11,00000B1 –19–27JUL06–15/18
RG13222 –UN–26SEP03
Automatic Scan On
16. Press the "Enter" key to toggle the "Automatic Scan"
function on.
OURGP11,00000B1 –19–27JUL06–16/18
RG13223 –UN–26SEP03
Automatic Scan Off
17. Press the "Enter" key again to toggle the "Automatic
Scan" function off.
Continued on next page
17-25
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PN=88
Instrument Panel - Elect. Cont. Later Engines
OURGP11,00000B1 –19–27JUL06–17/18
RG13224 –UN–26SEP03
Menu Key
18. Once the "Use Defaults", "Custom Setup" and
"Automatic Scan" functions have been set, press the
"Menu" key to return to the main menu.
OURGP11,00000B1 –19–27JUL06–18/18
RG13159 –UN–26SEP03
Exit Main Menu
19. Press the "Menu" key to exit the main menu and
return to the engine parameter display.
OURGP11,00000B2 –19–27JUL06–1/14
Setup 4-Up Display
RG13159 –UN–26SEP03
Menu Key
1. Turn the key switch to the ON position. From the single
or four engine parameter display, press the "Menu"
key.
Continued on next page
17-26
080706
PN=89
Instrument Panel - Elect. Cont. Later Engines
OURGP11,00000B2 –19–27JUL06–2/14
RG13225 –UN–02OCT03
Select Setup 4-Up Display
2. The main menu will be displayed. Use the "Arrow" keys
to scroll through the menu until "Setup 4-Up Display" is
highlighted.
OURGP11,00000B2 –19–27JUL06–3/14
RG13226 –UN–02OCT03
Press Enter Key
3. Once the "Setup 4-Up Display" menu item has been
highlighted, press the "Enter" key to activate the "Setup
4-Up Display" menu.
Continued on next page
17-27
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PN=90
Instrument Panel - Elect. Cont. Later Engines
OURGP11,00000B2 –19–27JUL06–4/14
RG13244 –UN–02OCT03
Select Factory Defaults
4. Two options are available for the 4-Up Display.
a. Use Defaults – This option contains the following
engine parameters for display: Engine Speed,
Battery Voltage, Coolant Temperature and Oil
Pressure.
b. Custom Setup – This option contains a list of
engine parameters. Engine parameters from this list
can be selected to replace any or all of the default
parameters.
OURGP11,00000B2 –19–27JUL06–5/14
RG13149 –UN–24SEP03
Restored To Defaults
5. To reset the display parameters to the factory defaults,
scroll to and highlight "Use Defaults". Press the "Enter"
key to activate the "Use Defaults" function. A message
indicating the display parameters are reset to the
factory defaults will be displayed, then the display will
return to the "Setup 4-Up Display" menu.
OURGP11,00000B2 –19–27JUL06–6/14
RG13227 –UN–26SEP03
Custom Setup
6. Custom Setup - To perform a custom setup of the
4-Up Display, use the arrow buttons to scroll to and
highlight "Custom Setup" on the display.
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Instrument Panel - Elect. Cont. Later Engines
OURGP11,00000B2 –19–27JUL06–7/14
RG13228 –UN–26SEP03
Select Parameters
7. The quadrant with the highlighted parameter value is
the current selected parameter. Use the "Arrow" keys
to highlight the value in the quadrant you wish to
change to a new parameter.
OURGP11,00000B2 –19–27JUL06–8/14
RG13229 –UN–26SEP03
List Of Engine Parameters
8. Press the "Enter" key and a list of engine parameters
will be displayed.
OURGP11,00000B2 –19–27JUL06–9/14
RG13230 –UN–26SEP03
Select Desired Engine Parameter
9. The parameter that is highlighted is the selected
parameter for the screen. Use the "arrow" keys to
highlight the new parameter to be placed in the "4-Up
Display".
Continued on next page
17-29
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PN=92
Instrument Panel - Elect. Cont. Later Engines
OURGP11,00000B2 –19–27JUL06–10/14
RG13231 –UN–26SEP03
Enter Selected Parameter
10. Press the "Enter" key to change the selected
parameter in the quadrant to the new parameter.
OURGP11,00000B2 –19–27JUL06–11/14
RG13232 –UN–26SEP03
Return To 4-Up Custom Setup
11. Use the "Menu" keys to return to the "4-Up Custom
Setup" screen.
OURGP11,00000B2 –19–27JUL06–12/14
RG13153 –UN–24SEP03
4-Up Display
12. The selected quadrant has now changed to the new
selected parameter.
Continued on next page
17-30
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PN=93
Instrument Panel - Elect. Cont. Later Engines
OURGP11,00000B2 –19–27JUL06–13/14
RG13154 –UN–24SEP03
Return To Main Menu
13. Repeat the parameter selection process until all
spaces are as desired.
14. Press the "Menu" key to return to the main menu.
OURGP11,00000B2 –19–27JUL06–14/14
RG13155 –UN–07OCT03
Select Remaining Parameters
15. Press the "Menu" key to exit the main menu and
return to the engine parameter display.
17-31
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PN=94
Instrument Panel - Mech. Cont. “270” Engines
OURGP11,000018E –19–27JUL06–1/2
Instrument Panel (Earlier 4.5 L “270”
Engines)
RG6574A –UN–07JAN03
Instrument Panel and Gauges (Earlier 4.5 L “270” Engines)
A—Tachometer with Hourmeter
B—Coolant Temperature Gauge
C—Oil Pressure Gauge
D—Pre-Heat Indicator Lamp
E—Charge Indicator Lamp
F—Oil Pressure Indicator Lamp
G—Coolant Temperature Indicator Lamp
H—Key Switch
All controls and gauges are optional equipment for John
Deere 4.5 L suffix “270” OEM Engines. They may be
provided by the equipment manufacturer instead of John
Deere.
IMPORTANT: Any time an electric gauge or meter
does not register correctly, replace it
with a new one. Do not attempt to repair
it.
Following is a brief description of the components on a
basic instrument (gauge) panel:
A—Tachometer with Hourmeter - The optional
tachometer with hourmeter indicates engine speed in
revolutions per minute (rpm) and shows the operating
hours of the engine while key switch is in the “ON”
position. The hour meter should be used as a guide for
scheduling periodic service.
B—Coolant Temperature Gauge - The coolant
temperature gauge indicates the engine coolant
temperature. It is connected to a warning lamp to warn
the operator if coolant temperature rises above the preset,
safe operating temperature.
C—Oil Pressure Gauge - The oil pressure gauge
indicates engine oil pressure. It is connected to a warning
lamp to warn the operator if engine oil pressure falls
below a safe operating pressure.
D—Pre-Heat Indicator Lamp - This indicator lamp is
initially turned on when the key switch is turned to the
“HEAT” position to activate the preheater for cold weather
starting. Lamp is connected to a timer that turns the lamp
off after 15 seconds when the key switch is held at
“HEAT” position. When the lamp goes out, start the
engine.
E—Charge Indicator Lamp - Indicates whether the
charging circuit is adequately replacing battery voltage as
it is used by the electrical system. If the lamp is lit while
the engine is running above 1300 rpm, stop engine
immediately and check charging circuit.
18-1
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PN=95
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Instrument Panel - Mech. Cont. “270” Engines
OURGP11,000018E –19–27JUL06–2/2
RG6574A –UN–07JAN03
Instrument Panel and Gauges (4.5 L “270” Engines)
F—Oil Pressure Indicator Lamp - Warns operator that
engine oil pressure is below a safe operating level. If lamp
stays lit while engine is running faster than slow idle, stop
engine immediately and check engine oil level.
G—Coolant Temperature Indicator Lamp - Warns
operator that engine coolant temperature exceeds safe
operating level. If lamp is lit during full load operation, the
engine is overheated. Stop engine and immediately check
fan belt tension and coolant level in radiator.
H—Key Switch - The key switch controls the electrical
system. Positions of key switch are marked as follows:
OFF, ON, and START. There is also a HEAT position for
cold weather starting.
18-2
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Instrument Panel - Mech. Cont. “270” Engines
OURGP11,0000160 –19–27JUL06–1/2
Instrument Panel (Later 4.5 L “270” Engines)
RG13360 –UN–06FEB04
Instrument Panel and Gauges (Later 4.5 L “270” Engines)
A—Tachometer with Hourmeter (Optional)
B—Oil Pressure Gauge
C—Voltmeter Gauge
D—Coolant Temperature Gauge
E—Preheat Button
F—Reset (Safety) Switch
G—Fuse Holder
H—Key Switch
I—Throttle (Optional)
J—Hourmeter (Optional)
All controls and gauges are optional equipment for John
Deere 4.5 L suffix “270” OEM Engines. They may be
provided by the equipment manufacturer instead of John
Deere.
IMPORTANT: Any time an electric gauge or meter
does not register correctly, replace it
with a new one. Do not attempt to repair
it.
Following is a brief description of the components on a
basic instrument (gauge) panel:
A—Tachometer with Hourmeter (Optional) - The
tachometer with hourmeter indicates engine speed in
revolutions per minute (rpm) and shows the operating
hours of the engine while key switch is in the “ON”
position. The hour meter should be used as a guide for
scheduling periodic service.
B—Oil Pressure Gauge - The oil pressure gauge
indicates engine oil pressure. If the engine oil pressure
falls below a safe operating pressure, the engine will shut
down.
C—Voltmeter Gauge - The voltmeter indicates system
battery voltage.
D—Coolant Temperature Gauge - The coolant
temperature gauge indicates the engine coolant
temperature. If coolant temperature rises above the
preset, safe operating temperature, the engine will shut
down.
E—Pre-Heat Button - Press button to activate the
preheater for cold weather starting.
F—Reset (Safety) Switch- Reset button will pop out and
shut down the engine if the coolant temperature is too
high or oil pressure is too low. Press in and hold while
starting engine until oil pressure is at a safe operating
level.
G—Fuse Holder - Contains 14 amp fuse.
18-3
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Instrument Panel - Mech. Cont. “270” Engines
OURGP11,0000160 –19–27JUL06–2/2
H—Key Switch - The key switch controls the electrical
system. Positions of key switch are marked as follows:
OFF, ON, and START.
I—Throttle (Optional) - The throttle control is used to
control engine speed.
J—Hourmeter (Optional) - The hourmeter indicates the
operating hours of the engine while key switch is in the
“ON” position. The hour meter should be used as a guide
for scheduling periodic service.
18-4
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Engine Operation - Except 4.5L “270” Engines
OURGP11,0000075 –19–27JUL06–1/4
Engine Break-In Service
RG8009 –UN–06JAN99
Check Engine Oil
The engine is ready for normal operation. However, extra
care during the first 100 hours of operation will result in
more satisfactory long-term engine performance and life.
DO NOT exceed 100 hours of operation with break-in oil.
1. This engine is factory-filled with John Deere ENGINE
BREAK-IN OIL (SAE 10W-30). Operate the engine at
heavy loads with minimal idling during the break-in
period.
2. If the engine has significant operating time at idle,
constant speeds, and/or light load usage, or makeup
oil is required in the first 100 hour period, a longer
break-in period may be required. In these situations, an
additional 100 hour break-in period is recommended
using a new change of John Deere ENGINE
BREAK-IN OIL and a new John Deere oil filter.
Continued on next page
19-1
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PN=99
Engine Operation - Except 4.5L “270” Engines
OURGP11,0000075 –19–27JUL06–2/4
RG8028A –UN–15JAN99
Crosshatch Pattern On Dipstick
A—Crosshatch Pattern On Dipstick
IMPORTANT: DO NOT add makeup oil until the oil
level is BELOW the ADD mark on
dipstick. John Deere ENGINE BREAK-IN
OIL (TY22041) should be used to make
up any oil consumed during the
break-in period.
3. Check engine oil level more frequently during engine
break-in period. If oil must be added during this period,
John Deere ENGINE BREAK-IN OIL is preferred. See
ENGINE BREAK-IN OIL, in Fuels, Lubricants, and
Coolant Section.
IMPORTANT: Do not use PLUS-50 oil or engine oils
meeting any of the following during the
first 100 hours of operation of a new or
rebuilt engine:
API CI-4 PLUS ACEA CF
API CI-4 ACEA E7
API CH-4 ACEA E6
API CG-4 ACEA E5
API CF-4 ACEA E4
API CF-2 ACEA E3
These oils will not allow the engine to
break-in properly.
IMPORTANT: DO NOT fill above the crosshatch
pattern (A) or the FULL mark, whichever
is present. Oil levels anywhere within
the crosshatch are considered in the
acceptable operating range.
Specification
Engine—Oil Pressure at Full
Load Rated Speed With Oil
Warmed to 115°C (240°F) 345 ±103 kPa (3.45 ±1.03 bar)
(50 ±15 psi)
.....................
Minimum Oil Pressure at Slow
Idle Speed 105 kPa (1.05 bar) (15 psi)......................................................
Coolant Temperature Range 82°–94°C (180°–202°F)................................
Continued on next page
19-2
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PN=100
Engine Operation - Except 4.5L “270” Engines
OURGP11,0000075 –19–27JUL06–3/4
RG11616 –UN–24OCT01
Engine Oil Filter
A—Engine Oil Filter
4. During the first 20 hours, avoid prolonged periods of
engine idling or sustained maximum load operation. If
engine will idle longer than 5 minutes, stop engine.
5. Before the first 100 hours (maximum), change engine
oil and replace engine oil filter (A). (See CHANGING
ENGINE OIL AND REPLACING FILTER in Lubrication
and Maintenance/500 Hour/12 Month Section.) Fill
crankcase with seasonal viscosity grade oil. (See
DIESEL ENGINE OIL, in Fuels, Lubricants, and
Coolant Section.)
NOTE: Some increase in oil consumption may be
expected when low viscosity oils are used. Check
oil levels more frequently.
If air temperature is below -10
°
C (14
°
F), use an
engine block heater.
OURGP11,0000075 –19–27JUL06–4/4
RG13281 –UN–30OCT03
Watch Coolant Temperature and Oil Pressure On Earlier Panel
(Left) or Later Panel (Right)
A—Engine Oil Pressure Gauge
B—Engine Coolant Temperature Gauge
6. Watch oil pressure gauge (A). Pressure at slow idle
should be at least 103 kPa (1.03 bar) (15 psi) once
engine is warmed up and shouild rise to at least 241
kPa (2.41 bar) (35 psi) at rated speed under full load.
7. Watch coolant temperature gauge (B) closely. If
coolant temperature rises above 112°C (234°F), reduce
load on engine. Unless temperature drops quickly, stop
the engine and determine the cause before resuming
operation.
NOTE: When the coolant temperature gauge reads
approximately 115
°
C (239
°
F), the engine will
shutdown automatically, if equipped with safety
controls.
8. Check poly-vee belt for proper alignment and seating
in pulley grooves.
19-3
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PN=101
Engine Operation - Except 4.5L “270” Engines
OURGP11,0000076 –19–27JUL06–1/3
Starting the Engine
TS220 –UN–23AUG88
Use Proper Ventilation
The following instructions apply to the optional controls
and instruments available through the John Deere Parts
Distribution Network. The controls and instruments for
your engine may be different from those shown here;
always follow manufacturer’s instructions.
CAUTION: Before starting engine in a confined
building, install proper outlet exhaust
ventilation equipment. Always use safety
approved fuel storage and piping.
NOTE: If temperature is below 0
°
C (32
°
F), it may be
necessary to use cold weather starting aids (See
COLD WEATHER OPERATION, later in this
section).
1. Perform all prestarting checks outlined in Lubrication &
Maintenance/Daily Section later in this manual.
2. Open the fuel supply shut-off valve, if equipped.
3. Disengage clutch (if equipped) controlling any engine
drivelines.
Continued on next page
19-4
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PN=102
Engine Operation - Except 4.5L “270” Engines
OURGP11,0000076 –19–27JUL06–2/3
RG13279 –UN–30OCT03
Analog Throttle Control and Speed Select Switch On Earlier Panel
(Left) or Later Panel (Right)
A—Analog Throttle Control (Optional)
B—Speed Select Rocker Switch
4. Set slow idle as follows:
Panels with high-low speed select rocker switch
(B) only: Set slow speed by pressing lower half of
switch.
Panels with optional analog throttle(s) (A) : Set
high-low speed select rocker switch to slow (turtle),
then push in on analog throttle handle or turn full
counterclockwise to set analog throttle(s) to slow
speed.
IMPORTANT: Do not operate the starter for more than
30 seconds at a time. To do so may
overheat the starter. If the engine does
not start the first time, wait at least 2
minutes before trying again. If engine
does not start after four attempts, see
Troubleshooting section.
Continued on next page
19-5
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PN=103
Engine Operation - Except 4.5L “270” Engines
OURGP11,0000076 –19–27JUL06–3/3
RG13280 –UN–30OCT03
Start And Idle Engine On Earlier Panel (Left) or Later Panel
(Right)
A—Key Start Switch
B—High-Low Speed Select Rocker Switch
C—Bump Speed Enable Rocker Switch
D—Speed Select Rocker Switch
E—Analog Throttle Control (Optional)
5. Turn the key start switch (A) clockwise to crank the
engine. When the engine starts, release the key switch
so that it returns to the “ON” position.
IMPORTANT: If the key switch is released before the
engine starts, wait until the starter and
the engine stop turning before trying
again. This will prevent possible
damage to the starter and/or flywheel.
6. After engine starts, idle engine at not more than 1200
rpm until warm. (See WARMING ENGINE later in this
section).
Panels with high-low speed select rocker switch
(B) only: Set rpm using bump speed enable switch (C)
with speed select rocker switch (D).
Panels with optional analog throttle (E): Set either
high-low speed select switch (B) or analog throttle (E)
to slow speed, and set desired speed with remaining
control.
NOTE: Engine control unit (ECU) reads the higher of the
high-low speed select rocker switch or the analog
throttle speed settings.
7. Check all gauges for normal engine operation. If
operation is not normal, stop the engine and determine
the cause. (For normal gauge pressures and
temperatures, see BREAK-IN SERVICE earlier in this
section.)
NOTE: Hand throttle may have an analog potentiometer
(E) for changing engine speeds (See “Changing
Engine Speeds” later in this section).
19-6
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PN=104
Engine Operation - Except 4.5L “270” Engines
OURGP11,0000077 –19–27JUL06–1/1
Normal Engine Operation
Observe engine coolant temperature and engine oil
pressure. Temperatures and pressures will vary
between engines and with changing operating
conditions, temperatures, and loads.
Normal engine coolant operating temperature range is
82°—94°C (180°—202°F). If coolant temperature rises
above 112°C (234°F), reduce load on engine. Unless
temperature drops quickly, stop engine and determine
cause before resuming operation.
Engine oil pressure should be at least 103 kPa (1.03
bar) (15 psi) at slow idle and should reach at least 241
kPa (2.41 bar) (35 psi) at rated speed under full load.
Operate the engine under a lighter load and at slower
than normal speed for first 15 minutes after start-up.
DO NOT run engine at slow idle.
IMPORTANT: Should the engine die while
operating under load, immediately
remove load and restart the engine.
Overheating of the turbocharger
parts may occur when oil flow is
stopped.
Stop engine immediately if there are any signs of part
failure. Symptoms that may be early signs of engine
problems are:
•Sudden drop in oil pressure
•Abnormal coolant temperatures
•Unusual noise or vibration
•Sudden loss of power
•Excessive black exhaust
•Excessive fuel consumption
•Excessive oil consumption
•Fluid leaks
19-7
080706
PN=105
Engine Operation - Except 4.5L “270” Engines
OURGP11,0000137 –19–27JUL06–1/1
Warming Engine
RG13281 –UN–30OCT03
Oil Pressure and Coolant Temperature Gauges On Earlier Panel
(Left) or Later Panel (Right)
A—Engine Oil Pressure Gauge
B—Engine Coolant Temperature Gauge
The electronically-controlled engines will operate at an
accelerated slow idle of 1050 rpm until the engine coolant
warms up to 20°C (68°F).
IMPORTANT: To assure proper lubrication, operate
engine at or below 1200 rpm with no
load for 1–2 minutes. Extend this period
2–4 minutes when operating at
temperatures below freezing.
Engines used in generator set
applications where the governor is
locked at a specified speed may not
have a slow idle function. Operate these
engines at high idle for 1 to 2 minutes
before applying the load. This
procedure does not apply to standby
generator sets where the engine is
loaded immediately upon reaching rated
speed.
1. Check oil pressure gauge (A) as soon as engine starts.
If gauge needle does not rise above minimum oil
pressure specification of 105 kPa (1.05bar) (15.0 psi)
within 5 seconds, stop the engine and determine the
cause. Normal engine oil pressure is 345 ±103 kPa
(3.45 ±1.03 bar) (50 ±15 psi) at rated full load speed
(1800–2500 rpm) with oil at normal operating
temperature of 115°C (240°F).
NOTE: On certain engines, the oil pressure and coolant
temperature gauges are replaced by indicator
warning lights. The lights must be "OFF" when
engine is running.
2. Watch coolant temperature gauge (B). Do not place
engine under full load until it is properly warmed up.
The normal engine coolant temperature range is 82°—
94°C (180°—202°F).
NOTE: It is a good practice to operate the engine under a
lighter load and at lower speeds than normal for
the first few minutes after start-up.
19-8
080706
PN=106
Engine Operation - Except 4.5L “270” Engines
OURGP11,0000078 –19–27JUL06–1/2
Cold Weather Operation
TS1356 –UN–18MAR92
Handle Starting Fluid with Care
RG11521 –19–10JAN01
Cold Weather Starting Guidelines
CAUTION: DO NOT use starting fluid on
engines equipped with air intake heaters or
glow plugs. Ether injector starting fluid is highly
flammable and may explode, causing serious
injury.
DO NOT use starting fluid near fire, sparks, or
flames. DO NOT incinerate or puncture a
starting fluid container.
Engines may be equipped with intake air heaters, coolant
heaters, fuel heaters, or ether injectors as cold weather
starting aids. Later “475” 4-valve cylinder head engines
are equipped with glow plugs as an automatic cold
weather starting aid.
Starting aids are required below 0°C (32°F). They will
enhance starting performance above these temperatures
and may be needed to start applications that have high
parasitic loads during cranking and/or start acceleration to
idle.
Using correct grade of oil (per engine and machine
operator’s manual) is critical to achieving adequate cold
weather cranking speed.
Synthetic oils have improved flow at low temperatures,
especially in arctic conditions.
Other cold weather starting aids are required at
temperatures below -30°C (-22°F) or at altitudes above
1500 m (5000 ft). (See “Using a Booster Battery or
Charger” later in this section.)
1. Follow steps 1—4 as listed under STARTING THE
ENGINE, earlier in this section, then proceed as
follows according to the instrument (gauge) panel on
your engine.
2. 275-Series Engines Without Air Intake Heaters:
Manually activate ether injectors.
19-9
080706
PN=107
Continued on next page
Engine Operation - Except 4.5L “270” Engines
OURGP11,0000078 –19–27JUL06–2/2
NOTE: Air intake heaters (275 engines) and glow plugs
(475 engines) operate automatically through the
ECU. The Engine Preheater Indicator light on
these engines, located above the key switch,
should always illuminate when the switch is turned
ON. In warm weather, the light illuminates briefly
as a light check. In cold weather, the light remains
on during the automatic operation of the air intake
heater or glow plugs. Operating time depends on
temperature. Do not crank engine until light turns
off.
275-Series Engines with Air Intake Heaters and
475-Series Engines with Glow Plugs: Turn key ON,
but DO NOT crank engine until Engine Preheater
Indicator light turns off.
3. Follow remaining steps 5—6 as listed under earlier in
this section.
Additional information on cold weather operation is
available from your authorized servicing dealer.
19-10
080706
PN=108
Engine Operation - Except 4.5L “270” Engines
RG,RG34710,5564 –19–27JUL06–1/2
Using a Booster Battery or Charger
TS204 –UN–23AUG88
Exploding Battery
RG4678 –UN–14DEC88
12-Volt System
RG4698 –UN–14DEC88
24-Volt System
A—12-Volt Machine Battery (ies)
B—12-Volt Booster Battery (ies)
C—Booster Cable
D—Cable to Starting Motor
A 12-volt booster battery can be connected in parallel with
battery (ies) on the unit to aid in cold weather starting.
ALWAYS use heavy duty jumper cables.
CAUTION: Gas given off by battery is explosive.
Keep sparks and flames away from battery.
Before connecting or disconnecting a battery
charger, turn charger off. Make last connection
and first disconnection at a point away from
battery. Always connect NEGATIVE (–) cable
last and disconnect this cable first.
WARNING: Battery posts, terminals, and related
accessories contain lead and lead compounds, chemicals
known to the State of California to cause cancer and
reproductive harm. Wash hands after handling.
IMPORTANT: Be sure polarity is correct before
making connections. Reversed polarity
will damage electrical system. Always
connect positive to positive and
negative to ground. Always use 12-volt
booster battery for 12-volt electrical
systems and 24-volt booster battery
(ies) for 24-volt electrical systems.
1. Connect booster battery or batteries to produce the
required system voltage for your engine application.
NOTE: To avoid sparks, DO NOT allow the free ends of
jumper cables to touch the engine.
2. Connect one end of jumper cable to the POSITIVE (+)
post of the booster battery.
3. Connect the other end of the jumper cable to the
POSITIVE (+) post of battery connected to starter.
4. Connect one end of the other jumper cable to the
NEGATIVE (–) post of the booster battery.
5. ALWAYS complete the hookup by making the last
connection of the NEGATIVE (–) cable to a good
ground on the engine frame and away from the battery
(ies).
19-11
080706
PN=109
Continued on next page
Engine Operation - Except 4.5L “270” Engines
RG,RG34710,5564 –19–27JUL06–2/2
6. Start the engine. Disconnect jumper cables
immediately after engine starts. Disconnect NEGATIVE
(–) cable first.
RG,RG34710,5562 –19–27JUL06–1/1
Avoid Excessive Engine Idling
Prolonged idling may cause the engine coolant
temperature to fall below its normal range. This, in
turn, causes crankcase oil dilution, due to incomplete
fuel combustion, and permits formation of gummy
deposits on valves, pistons, and piston rings. It also
promotes rapid accumulation of engine sludge and
unburned fuel in the exhaust system.
Once an engine is warmed to normal operating
temperatures, engine should be idled at slow idle
speed. Slow idle speed for this engine is 850 rpm at
factory. If an engine will be idling for more than 5
minutes, stop and restart later.
NOTE: Generator set applications where the governor
is locked at a specified speed may not have a
slow idle function. These engines will idle at no
load governed speed (high idle).
19-12
080706
PN=110
Engine Operation - Except 4.5L “270” Engines
OURGP11,0000079 –19–27JUL06–1/3
Changing Engine Speed
RG13282 –UN–30OCT03
Changing Engine Speed On Earlier Panel (Left) or Later Panel
(Right)
A—High-Low Speed Select Rocker Switch
B—Bump Speed Enable Rocker Switch
C—Speed Select Rocker Switch
D—Analog Throttle Control (Optional)
NOTE: Earlier engines have a
2-position
rabbit-turtle
throttle switch, which is not adjustable. These
throttles allows operation only at the preset rated
speed or at idle using the single switch (A).
Changing from slow to fast speed using Standard
High-Low Speed Select Rocker Switch (A) (If
equipped):
•For slow speed, press lower half of switch (indicated by
turtle symbol).
•For fast speed, press upper half of switch (indicated by
rabbit symbol).
NOTE: To adjust preset fast or slow speeds for High-Low
Speed Select Rocker Switch:
1. Select fast (rabbit) or slow (turtle) position on
High-Low Speed Select Rocker Switch (A).
2. Press and hold top or bottom half of Bump
Speed Enable Rocker Switch (B) while using
Speed Select Rocker Switch (C).
3. Use Speed Select Rocker Switch (C) to bump
engine speed up (+) or down (-).
NOTE: Once the speed has been set, the Bump Speed
Enable Switch (B) must be pressed and released
three times within two seconds to commit the new
slow or fast speed to memory. If not done, the
engine’s new slow or fast speed will only be
effective until the key switch is shut off. Then the
speed will revert to its previous setting.
Changing from slow to fast speed using Adjustable
High-Low Speed Select Rocker Switch (A) (If
equipped):
Later engine panels (shown at right) have an adjustable
three-position rocker switch (A) that can be used to
select slow idle, fast idle, or an adjustable (“ADJ”)
intermediate speed.
•For slow speed, press lower half of rocker switch
(indicated by turtle symbol).
19-13
080706
PN=111
Continued on next page
Engine Operation - Except 4.5L “270” Engines
OURGP11,0000079 –19–27JUL06–2/3
•For fast speed, press upper half of rocker switch
(indicated by rabbit symbol).
NOTE: To adjust preset fast or slow speeds with
adjustable High-Low Speed Select Rocker Switch:
1. Select middle position (ADJ) or slow (turtle)
position on the optional Adjustable Three-State
Speed Select Rocker Switch (A).
2. Press and hold top or bottom half of Bump
Speed Enable Rocker Switch (B) while using
Speed Select Rocker Switch (C).
3. Use Speed Select Rocker Switch (C) to bump
engine speed up (+) or down (-).
NOTE: Slow (turtle) position is factory preset at low
engine idle, while middle (ADJ) position is factory
set at high engine idle.
NOTE: Once the speed has been set, the Bump Speed
Enable Switch (B) must be pressed and released
three times within two seconds to commit the new
slow or fast speed to memory. If not done, the
engine’s new slow or fast speed will only be
effective until the key is shut off. Then the speed
will revert to its previous setting.
Changing engine speed using optional analog
potentiometer throttle (D)
NOTE: Pushing in on analog potentiometer will
immediately take engine to slow idle speed.
1. Set High-Low Speed Select Rocker Switch (A) to low
speed position.
2. Turn potentiometer throttle clockwise to increase speed
or counterclockwise to decrease speed.
NOTE: Engine Control Unit (ECU) reads the higher of the
High-Low Speed Select Rocker Switch or the
Analog Throttle(s) Speed Settings. With High-Low
switch at low speed, Analog Throttle(s) will control
speed higher than low idle setting.
19-14
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PN=112
Continued on next page
Engine Operation - Except 4.5L “270” Engines
OURGP11,0000079 –19–27JUL06–3/3
RG13289 –UN–30OCT03
Changing Engine Speed With Basic Panel
E—High-Low Speed Select Rocker Switch
Changing engine speeds on later engines equipped
with the Basic Instrument Panel
The basic instrument panel has a “ramp” throttle switch
(E) with a spring loaded return to the center rest position
(Off).
To increase the engine speed, press and hold upper half
of rocker switch (E) (indicated by rabbit symbol) to
increase or ramp up the engine speed to desired speed.
Release the rocker switch.
Press lower half of rocker switch (indicated by turtle
symbol) to decrease or ramp down the engine speed to
desired speed. Release the rocker switch.
The settings will not be stored.
19-15
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PN=113
Engine Operation - Except 4.5L “270” Engines
OURGP11,0000139 –19–27JUL06–1/1
Stopping The Engine
RG13280 –UN–30OCT03
Stopping the Engine On Earlier Panel (Left) or Later Panel (Right)
RG9933 –UN–18NOV99
Exhaust Stack Rain Cap
A—Key Switch
B—High-Low Speed Select Rocker Switch
C—Bump Speed Enable Switch
D—Speed Select Rocker Switch
E—Analog Throttle (Optional)
F—Exhaust Stack Rain Cap
1. Disengage clutch, if equipped, controlling engine power
driveline.
IMPORTANT: Before stopping an engine that has
been operating at working load, idle
engine at least 2 minutes at 1000—1200
rpm to cool hot engine parts.
Engines in generator set applications
where the ECU is locked at a specified
speed and no slow idle function is
available, run engine for at least 2
minutes at fast idle and no load.
2. Run engine at 1000—1200 rpm for at least 2 minutes
to cool.
Panels with High-Low Speed Select Rocker Switch (B)
only: Set rpm using Bump Speed Enable Switch (C) with
Speed Select Rocker Switch (D).
Panels with optional Analog Throttle (E): Set either
High-Low Speed Select Switch (B) or Analog Throttle (E)
to low idle, and set desired speed with remaining control.
NOTE: Engine Control Unit (ECU) reads the higher of the
High-Low Speed Select Rocker Switch or the
Analog Throttle(s) Speed settings.
3. Push in on analog throttle potentiometer handle (if
equipped) so that engine goes to slow idle, or set slow
speed with High-Low Speed Select Rocker Switch.
4. Turn key switch (A) to “OFF” position to stop the
engine. Remove ignition key.
IMPORTANT: Make sure that exhaust stack rain cap
(F) is installed when engine is not
running. This will prevent water and dirt
from entering engine.
19-16
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PN=114
Engine Operation - Except 4.5L “270” Engines
RG,RG34710,5555 –19–27JUL06–1/1
Auxiliary Gear Drive Limitations
RG7634A –UN–22JAN99
Auxiliary Gear Drive
A—Auxiliary Gear Drive
IMPORTANT: When attaching an air compressor,
hydraulic pump, or other accessory to
be driven by the auxiliary gear drive (A)
(engine timing gear train at front of
engine), power requirements of the
accessory must be limited to values
listed below:
•30 kW (40 hp) Continuous Operation at 2500 rpm
•37 kW (50 hp) Intermittent Operation at 2500 rpm
RG,RG34710,5556 –19–27JUL06–1/1
Generator Set (Standby) Applications
To assure that your engine will deliver efficient standby
operation when needed, start engine and run at rated
speed (with 50%—70% load) for 30 minutes every 2
weeks. DO NOT allow engine to run extended period of
time with no load.
19-17
080706
PN=115
Engine Operation- 4.5 L “270” Engines
OURGP11,000007A –19–27JUL06–1/1
Normal Engine Operation
RG13343 –UN–24NOV03
Instrument Panel (Earlier 4.5 L “270” Engines)
RG13359 –UN–06FEB04
Instrument Panel (Later 4.5 L “270” Engines)
Before starting, fill engine with oil and coolant meeting
specifications. (See DIESEL ENGINE BREAK-IN OIL and
DIESEL ENGINE COOLANT SPECIFICATIONS in Fuels,
Lubricants, and Coolant section.)
•Observe engine coolant temperature and engine oil
pressure. Temperatures and pressures will vary
between engines and with changing operating
conditions, temperatures, and loads.
•Normal engine coolant operating temperature range is
90°– 100°C (194°– 212°F). If coolant temperature
rises above 105°C (221°F), reduce load on engine.
Unless temperature drops quickly, stop engine and
determine cause before resuming operation.
•Engine oil pressure should be at least 103 kPa (1.03
bar) (15 psi) at slow idle and should reach at least 241
kPa (2.41 bar) (35 psi) at rated speed under full load.
•Operate the engine under a lighter load and at slower
than normal speed for first 15 minutes after start-up. DO
NOT run engine at slow idle.
•Stop engine immediately if there are any signs of part
failure. Symptoms that may be early signs of engine
problems are:
– Sudden drop in oil pressure
– Abnormal coolant temperatures
– Unusual noise or vibration
– Sudden loss of power
– Excessive black exhaust
– Excessive fuel consumption
– Excessive oil consumption
– Fluid leaks
20-1
080706
PN=116
Engine Operation- 4.5 L “270” Engines
OURGP11,0000169 –19–27JUL06–1/3
Break-In Service
RG12692 –UN–07FEB03
Check Engine Oil Level Daily
Before starting, fill engine with seasonal viscosity grade oil
and with coolant meeting specifications. (See DIESEL
ENGINE OIL and DIESEL ENGINE COOLANT
SPECIFICATIONS in Fuels, Lubricants, and Coolant
Section.)
1. During the first 20 hours, avoid prolonged periods of
engine idling or sustained maximum load operation.
Warm-up engine carefully and operate at normal loads.
If engine will idle longer than 5 minutes, stop engine.
2. Check oil level daily or every 10 hours during engine
break-in period. If oil must be added during this period,
use seasonal viscosity grade oil. (See DIESEL
ENGINE OIL in Fuels, Lubricants, and Coolant
section.)
OURGP11,0000169 –19–27JUL06–2/3
RG6574 –UN–17FEB03
Oil Pressure and Coolant Temperature Gauges (Earlier Engines)
RG13361 –UN–06FEB04
Oil Pressure and Coolant Temperature Gauges (Later Engines)
A—Oil Pressure Gauge
B—Coolant Temperature Gauge
3. Watch oil pressure (A) and coolant temperature (B)
closely during break-in period. Also check coolant level
daily or every 10 hours and check for leaks.
4. Check poly-vee belt for proper alignment and seating
in pulley grooves.
20-2
080706
PN=117
Continued on next page
Engine Operation- 4.5 L “270” Engines
OURGP11,0000169 –19–27JUL06–3/3
RG11616 –UN–24OCT01
Engine Oil Filter
5. Change engine oil and oil filter after the first 100 hours
of use. After break-in period, change oil and filter every
500 hours/12 months. (See CHANGE ENGINE OIL
AND FILTER in Lubrication and Maintenance/500 Hour
Section.) Fill crankcase with seasonal viscosity grade
oil. (See DIESEL ENGINE OIL, in Fuels, Lubricants,
and Coolant Section.)
IMPORTANT: DO NOT operate engine when oil level
is below ADD mark on dipstick. Check
oil level before starting engine for the
first time.
RG,RG34710,5555 –19–27JUL06–1/1
Auxiliary Gear Drive Limitations
RG7634A –UN–22JAN99
Auxiliary Gear Drive
A—Auxiliary Gear Drive
IMPORTANT: When attaching an air compressor,
hydraulic pump, or other accessory to
be driven by the auxiliary gear drive (A)
(engine timing gear train at front of
engine), power requirements of the
accessory must be limited to values
listed below:
•30 kW (40 hp) Continuous Operation at 2500 rpm
•37 kW (50 hp) Intermittent Operation at 2500 rpm
20-3
080706
PN=118
Engine Operation- 4.5 L “270” Engines
RG41183,000002F –19–27JUL06–1/1
Generator Set (Standby) Power Units
To assure that your engine will deliver efficient standby
operation when needed, start engine and run at rated
speed (with 50%—70% load) for 30 minutes every 2
weeks. DO NOT allow engine to run extended period of
time with no load.
OURGP11,000016A –19–27JUL06–1/2
Starting The Engine
TS220 –UN–23AUG88
Use Proper Ventilation
The controls and instruments for your engine may be
different from those shown here. Always follow
manufacturer’s instructions and familiarize yourself with
the correct starting procedure.
CAUTION: Before starting engine in a confined
building, install proper outlet exhaust
ventilation equipment. Always use safety
approved fuel storage and piping.
NOTE: If temperature is below 0
°
C (32
°
F), it may be
necessary to use cold weather starting aids. (See
COLD WEATHER OPERATION, later in this
section).
1. Perform all prestarting checks outlined in Lubrication &
Maintenance/Daily Section later in this manual.
2. Disengage engine rear driveline (if equipped) or gen
set drive.
3. Open the fuel supply shut-off valve, if equipped.
4. Place the speed control lever in the “START” position,
if equipped.
Continued on next page
20-4
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PN=119
Engine Operation- 4.5 L “270” Engines
OURGP11,000016A –19–27JUL06–2/2
RG6580 –UN–20JAN93
Starting Engine Using Key Switch (Earlier Engines)
RG13366 –UN–12FEB04
Starting Engine Using Reset Button and Key Switch (Later
Engines)
A—Reset Button
B—Key Switch
IMPORTANT: Do not operate the starter for more than
15 seconds at a time. To do so may
overheat the starter. If the engine does
not start the first time, wait at least 2
minutes before trying again. If engine
does not start after four attempts, see
Troubleshooting Section.
5. Earlier Engines: Turn key switch to “START” position
as shown and hold until engine starts. Release key
once engine starts; key automatically returns to “ON”
position and instrument panel gauges start operating.
Later Engines: Press and hold in the reset button (A)
while turning key switch (B) to “START” position and
hold until engine starts. Release key once engine
starts; key automatically returns to “ON” position and
instrument panel gauges start operating. Continue to
hold in the reset button until the oil pressure is at a
safe operating level.
6. Warm-up engine for at least 5 minutes before applying
a load. (See WARMING-UP ENGINE, later in this
section.)
7. Check all gauges for normal operation. If operation is
not normal, stop engine immediately and determine
cause.
20-5
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PN=120
Engine Operation- 4.5 L “270” Engines
OURGP11,000007B –19–27JUL06–1/2
Cold Weather Starting
When outside temperatures fall below 0°C (32°F) it may
be necessary to consider using cold weather starting aids.
Your PowerTechEngines may be fitted with a block
heater, glow plugs, air intake heater and increased
capacity battery and/or lower viscosity oil may also be
used. See your local John Deere engine distributor or
servicing dealer for recommendations. (Also see “Using a
Booster Battery or Charger” later in this section.)
1. Perform all prestarting checks outlined in Lubrication &
Maintenance/Daily Section later in this manual.
2. Disengage engine rear driveline (if equipped) or gen
set drive.
3. Open the fuel supply shut-off valve, if equipped.
4. Place the speed control lever in the “START” position,
if equipped.
POWERTECH is a trademark of Deere & Company
Continued on next page
20-6
080706
PN=121
Engine Operation- 4.5 L “270” Engines
OURGP11,000007B –19–27JUL06–2/2
RG6580 –UN–20JAN93
Starting Engine
IMPORTANT: Do not operate the starter for more than
15 seconds at a time. To do so may
overheat the starter. If the engine does
not start the first time, wait at least 2
minutes before trying again. If engine
does not start after four attempts, see
Troubleshooting Section.
5. Earlier Engines (Shown) - Turn key switch to “HEAT”
position and hold until heat indicator lamp on
instrument panel goes out. Turn key switch to “START”
and hold until engine starts. Release key switch once
engine starts; key automatically returns to “ON”
position and instrument panel gauges start operating.
Later Engines - Turn key switch to “ON” position and
hold “PREHEAT” button (if equipped with preheat
option) in for up to 30 seconds. Turn key switch to
“START” while continuing to hold the “PREHEAT”
button and the reset button. Hold until engine starts.
Release key and “PREHEAT” button once engine
starts; key automatically returns to “ON” position and
instrument panel gauges start operating. Release reset
button when oil pressure is at a safe operating level.
6. Warm-up engine for at least 5 minutes before applying
a load. (See WARMING ENGINE, later in this section.)
20-7
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PN=122
Engine Operation- 4.5 L “270” Engines
OURGP11,000007C –19–27JUL06–1/1
Warming Engine
RG6574 –UN–17FEB03
Oil Pressure and Coolant Temperature Gauges (Earlier Engines)
RG13361 –UN–06FEB04
Oil Pressure and Coolant Temperature Gauges (Later Engines)
A—Oil Pressure Gauge
B—Coolant Temperature Gauge
IMPORTANT: To assure proper lubrication, operate
engine at or below 1200 rpm with no
load for 1–2 minutes. Extend this period
2–4 minutes when operating at
temperatures below freezing.
Engines used in generator set
applications where the governor is
locked at a specified speed may not
have a slow idle function. Operate these
engines at high idle for 1 to 2 minutes
before applying the load. This
procedure does not apply to standby
generator sets where the engine is
loaded immediately upon reaching rated
speed.
1. Check oil pressure gauge (A) as soon as engine starts.
If gauge needle does not rise above minimum oil
pressure specification of 103 kPa (1.03 bar) (15.0 psi)
within 5 seconds, stop the engine and determine the
cause. Normal engine oil pressure is 345 ±103 kPa
(3.45 ±1.03 bar) (50 ±15 psi) at rated full load speed
(1800–2500 rpm) with oil at normal operating
temperature of 115°C (240°F). Engine oil pressure at
rated speed can as high as 586 kPa (5.86 bar) (85
psi). This not detrimental to the engine.
NOTE: On certain engines, the oil pressure and coolant
temperature gauges are replaced by indicator
warning lights. The lights must be "OFF" when
engine is running.
2. Watch coolant temperature gauge (B). Do not place
engine under full load until it is properly warmed up.
The normal engine coolant temperature range is 90°–
100°C (194°–212°F).
NOTE: It is a good practice to operate the engine under a
lighter load and at lower speeds than normal for
the first few minutes after start-up.
20-8
080706
PN=123
Engine Operation- 4.5 L “270” Engines
OURGP11,000007D –19–27JUL06–1/1
Avoid Excessive Engine Idling
Avoid excessive engine idling. Prolonged idling may cause
the engine coolant temperature to fall below its normal
range. This, in turn, causes crankcase oil dilution, due to
incomplete fuel combustion, and permits formation of
gummy deposits on valves, pistons, and piston rings. It
also promotes rapid accumulation of engine sludge and
unburned fuel in the exhaust system.
Once an engine is warmed to normal operating
temperatures, engine should be idled at slow idle speed.
Slow idle speed for this engine is 850 rpm at factory. If an
engine will be idling for more than 5 minutes, stop and
restart later.
NOTE: Generator set applications where the governor is
locked at a specified speed may not have a slow
idle function. These engines will idle at no load
governed speed (high idle).
20-9
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Engine Operation- 4.5 L “270” Engines
OURGP11,0000134 –19–27JUL06–1/2
Stopping the Engine
RG6574B –UN–07JAN03
Key Switch on Instrument Panel (Earlier Engines)
RG13362 –UN–06FEB04
Key Switch on Instrument Panel (Later Engines)
IMPORTANT: Stopping the engine immediately when
it has been working under load, can
result in overheating and accelerated
wear of the engine components.
ALWAYS run the engine at slow idle
and no load to allow hot engine parts to
cool before shutdown (if possible).
On engines with variable speed
governors, remove load from engine
and run engine for at least 2 minutes
Run turbocharged engines for 3 to 5
minutes.
On generator set engines with
governors locked at a specific speed,
remove electrical load from engine (if
possible) and run at fast idle and no
load for at least 2 minutes.
1. Reduce engine speed to slow idle (variable speed
governors only).
2. Turn key switch (A) to "OFF" position to stop the
engine. After engine stops, close valve on fuel supply
to prevent accidental starting.
OURGP11,0000134 –19–27JUL06–2/2
RG10616 –UN–16JUN00
Exhaust Stack Rain Cap
IMPORTANT: Make sure that exhaust stack cap (rain
cap) is in place when engine is not
running. This will prevent water and dirt
from entering engine.
3. Fill fuel tank to minimize possible water condensation
problems. Filling tanks at end of day drives out
moisture-laden air.
20-10
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Engine Operation- 4.5 L “270” Engines
RG,RG34710,5564 –19–27JUL06–1/2
Using a Booster Battery or Charger
TS204 –UN–23AUG88
Exploding Battery
RG4678 –UN–14DEC88
12-Volt System
RG4698 –UN–14DEC88
24-Volt System
A—12-Volt Machine Battery (ies)
B—12-Volt Booster Battery (ies)
C—Booster Cable
D—Cable to Starting Motor
A 12-volt booster battery can be connected in parallel with
battery (ies) on the unit to aid in cold weather starting.
ALWAYS use heavy duty jumper cables.
CAUTION: Gas given off by battery is explosive.
Keep sparks and flames away from battery.
Before connecting or disconnecting a battery
charger, turn charger off. Make last connection
and first disconnection at a point away from
battery. Always connect NEGATIVE (–) cable
last and disconnect this cable first.
WARNING: Battery posts, terminals, and related
accessories contain lead and lead compounds, chemicals
known to the State of California to cause cancer and
reproductive harm. Wash hands after handling.
IMPORTANT: Be sure polarity is correct before
making connections. Reversed polarity
will damage electrical system. Always
connect positive to positive and
negative to ground. Always use 12-volt
booster battery for 12-volt electrical
systems and 24-volt booster battery
(ies) for 24-volt electrical systems.
1. Connect booster battery or batteries to produce the
required system voltage for your engine application.
NOTE: To avoid sparks, DO NOT allow the free ends of
jumper cables to touch the engine.
2. Connect one end of jumper cable to the POSITIVE (+)
post of the booster battery.
3. Connect the other end of the jumper cable to the
POSITIVE (+) post of battery connected to starter.
4. Connect one end of the other jumper cable to the
NEGATIVE (–) post of the booster battery.
5. ALWAYS complete the hookup by making the last
connection of the NEGATIVE (–) cable to a good
ground on the engine frame and away from the battery
(ies).
20-11
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Continued on next page
Engine Operation- 4.5 L “270” Engines
RG,RG34710,5564 –19–27JUL06–2/2
6. Start the engine. Disconnect jumper cables
immediately after engine starts. Disconnect NEGATIVE
(–) cable first.
20-12
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Lubrication and Maintenance
OURGP11,0000241 –19–27JUL06–1/1
Observe Service Intervals
RG13283 –UN–30OCT03
Hour Meter On Earlier Panel (Left) or Later Panel (Right) (Except
4.5 L “270” Engines)
A—Hour Meter
Using hour meter (A) on diagnostic gauge as a guide,
perform all services at the hourly intervals indicated on
following pages. At each scheduled maintenance interval,
perform all previous maintenance operations in addition to
the ones specified. Keep a record of hourly intervals and
services performed, using charts provided in Lubrication
and Maintenance Records section.
IMPORTANT: Recommended service intervals are for
normal operating conditions. Service
MORE OFTEN if engine is operated
under adverse conditions. Neglecting
maintenance can result in failures or
permanent damage to the engine.
DPSG,OUOE003,20 –19–27JUL06–1/1
Use Correct Fuels, Lubricants, and Coolant
TS100 –UN–23AUG88
John Deere Parts Network
IMPORTANT: Use only fuels, lubricants, and coolants
meeting specifications outlined in
Fuels, Lubricants, and Coolant Section
when servicing your John Deere
Engine.
Consult your John Deere engine distributor, servicing
dealer or your nearest John Deere Parts Network for
recommended fuels, lubricants, and coolant. Also
available are necessary additives for use when operating
engines in tropical, arctic, or any other adverse conditions.
21-1
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PN=128
Lubrication and Maintenance
OURGP11,000007E –19–27JUL06–1/2
Lubrication and Maintenance Service Interval
Chart—Standard Industrial Engines
NOTE: The service intervals below are for standard
industrial engines. See details in Sections which
follow these charts.
Lubrication and Maintenance Service Intervals
500 Hour/ 2000 Hour/
Item Daily 12 Month 24 Month As Required
Check Engine Oil and Coolant Level •
Check Fuel Filter/Water Bowl •
Check Air Cleaner Dust Unloader Valve & Restriction Indicator •
Gauge
a
Visual Walk Around Inspection •
Check Lamps (4045DF/TF270) •
Service Fire Extinguisher •
Check Engine Mounts •
Service Battery •
Check Manual Belt Tensioner and Belt Wear •
Change Engine Oil And Replace Oil Filter
b, c
•
Check Crankcase Vent System •
Check Air Intake Hoses, Connections, & System •
Replace Fuel Filter Elements •
Check Automatic Belt Tensioner and Belt Wear •
Check Engine Electrical Ground Connection •
Check Cooling System •
Coolant Solution Analysis-Add SCAs as required •
Pressure Test Cooling System •
Check Engine Speeds •
Check Crankshaft Vibration Damper
(6.8 L Engines)
d
•
Flush and Refill Cooling System
e
•
Test Thermostats •
Check and Adjust Engine Valve Clearance •
a
Replace primary air cleaner element when restriction indicator shows a vacuum of 625 mm (25 in.) H2O.
b
During engine break-in, change the oil and filter for the first time before 100 hours of operation.
c
If the recommended engine oils, John Deere PLUS-50or ACEA-E7, ACEA E6, ACEA E5 or ACEA E4, are not used, the oil and filter
change interval is reduced (see DIESEL ENGINE OIL AND FILTER INTERVALS chart). If diesel fuel with a sulfur content greater than 0.05%
is used, the oil and filter change interval is also reduced. 6-Cylinder engines with oil pan option codes 1907, 1908, and 1909 require the oil to
be changed at every 250 hours or less regardless of oil specification used.
d
Replace crankshaft damper every 4500 hours or 60 months, whichever occurs first.
e
If John Deere COOL-GARD is used, the flushing interval may be extended to 3000 hours or 36 months. If John Deere COOL-GARD is used
and the coolant is tested annually AND additives are replenished as needed by adding a supplemental coolant additive, the flushing interval
may be extended to 5000 hours or 60 months, whichever occurs first.
21-2
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PN=129
Continued on next page
Lubrication and Maintenance
OURGP11,000007E –19–27JUL06–2/2
Lubrication and Maintenance Service Intervals
500 Hour/ 2000 Hour/
Item Daily 12 Month 24 Month As Required
Test Glow Plugs (4045HF475, 6068HF475) •
Add Coolant •
Replace Air Cleaner Elements •
Replace Fan and Alternator Belts •
Check Fuses •
Check Air Compressor (If Equipped) •
Bleed Fuel System •
21-3
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Lubrication and Maintenance
OURGP11,000007F –19–27JUL06–1/2
Lubrication and Maintenance Service Interval
Chart—Generator (Standby) Applications
NOTE: Use service intervals listed below for generator
(standby) applications. Match service items below
to titles in Lubrication and Maintenance Sections
for procedures.
Lubrication and Maintenance Service Intervals
500 Hours or 2000 Hours or
Item Every 2 Weeks 12 Months 24 Months As Required
Operate Engine at Rated Speed and 50%–70% Load a Minimum •
of 30 Minutes
Check Engine Oil and Coolant Level •
Check Fuel Filter/Water Bowl •
Check Air Cleaner Dust Unloader Valve & Restriction Indicator •
Gauge
a
Visual Walk Around Inspection •
Check Lamps (4045DF/TF270) •
Service Fire Extinguisher •
Check Engine Mounts •
Service Battery •
Check Manual Belt Tensioner and Belt Wear •
Change Engine Oil And Replace Oil Filter
b, c
•
Check Crankcase Vent System •
Check Air Intake Hoses, Connections, & System •
Replace Fuel Filter Elements •
Check Automatic Belt Tensioner and Belt Wear •
Check Engine Electrical Ground Connection •
Check Cooling System •
Coolant Solution Analysis-Add SCAs as required •
Pressure Test Cooling System •
Check Engine Speeds •
Adjust Variable Speed (Droop) (4.5 L “270” Engines) •
Check Crankshaft Vibration Damper
(6.8 L Engines)
d
•
Flush and Refill Cooling System •
Test Thermostats •
a
Replace primary air cleaner element when restriction indicator shows a vacuum of 625 mm (25 in.) H2O.
b
During engine break-in, change the oil and filter for the first time before 100 hours of operation.
c
If the recommended engine oils, John Deere PLUS-50or ACEA-E7, ACEA E6, ACEA E5 or ACEA E4, are not used, the oil and filter
change interval is reduced (see DIESEL ENGINE OIL AND FILTER INTERVALS chart). If diesel fuel with a sulfur content greater than 0.05%
is used, the oil and filter change interval is also reduced. 6-Cylinder engines with oil pan option codes 1907, 1908, and 1909 require the oil to
be changed at every 250 hours or less regardless of oil specification used.
d
Replace crankshaft damper every 4500 hours or 60 months, whichever occurs first.
21-4
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Continued on next page
Lubrication and Maintenance
OURGP11,000007F –19–27JUL06–2/2
Lubrication and Maintenance Service Intervals
500 Hours or 2000 Hours or
Item Every 2 Weeks 12 Months 24 Months As Required
Check and Adjust Engine Valve Clearance •
Test Glow Plugs (4045HF475, 6068HF475) •
Add Coolant •
Replace Air Cleaner Elements •
Replace Fan and Alternator Belts •
Check Fuses •
Check Air Compressor (If Equipped) •
Bleed Fuel System •
21-5
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Lubrication & Maintenance/Daily
OURGP11,000018F –19–27JUL06–1/5
Daily Prestarting Checks
RG8009A –UN–16JUN00
Left Side Oil Filler Cap
RG8054A –UN–16JUN00
Right Side Oil Filler Cap
RG8025B –UN–16JUN00
Rocker Arm Cover Filler Cap
RG8028B –UN–15JAN99
Crosshatch on Dipstick
A—Left Side Oil Filler Cap
B—Right Side Oil Filler Cap
C—Cover Oil Filler Cap
D—Crosshatch On Dipstick
Do the following BEFORE STARTING THE ENGINE for
the first time each day:
IMPORTANT: DO NOT add makeup oil until the oil
level is BELOW the crosshatch marks
on the dipstick.
1. Check engine oil level on dipstick. Add as required,
using seasonal viscosity grade oil. (See DIESEL
ENGINE OIL in Fuels, Lubricants, and Coolant Section
for oil specifications.)
Depending on application, oil may be added at left (A)
or right (B) side oil filler cap and rocker arm cover filler
cap (C) locations.
IMPORTANT: DO NOT fill above the top mark on the
dipstick. Oil levels anywhere within
crosshatch (D) are considered in the
acceptable operating range.
Continued on next page
25-1
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Lubrication & Maintenance/Daily
OURGP11,000018F –19–27JUL06–2/5
TS281 –UN–23AUG88
High-Pressure Fluids
RG4675 –UN–14DEC88
Fill Radiator
A—Fill Radiator
CAUTION: Explosive release of fluids from
pressurized cooling system can cause serious
burns.
Only remove filler cap when engine is cold or
when cool enough to touch with bare hands.
Slowly loosen cap to first stop to relieve
pressure before removing completely.
2. Check the coolant level when engine is cold. Coolant
level should be at bottom of filler neck. Fill radiator (A)
with proper coolant solution if level is low. (See
ADDING COOLANT in Service As Required Section.)
Check overall cooling system for leaks.
NOTE: Refer to your vehicle’s operator’s manual for
recommendations for non-John Deere supplied
accessories.
Continued on next page
25-2
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Lubrication & Maintenance/Daily
OURGP11,000018F –19–27JUL06–3/5
RG12222 –UN–24MAY02
Drain Final Fuel Filter
RG11955 –UN–05DEC01
Drain Primary Fuel Filter (If Equipped)
A—Drain Plug
B—Air Bleed Plug
NOTE: Engine may be equipped with a water sensor at
the fuel filter. In this case, an indicator light will
signal the operator that water should be drained
from the filter bowl.
3. Check the fuel filters for water or debris. If filter is fitted
with a see-through bowl, drain as needed based on a
daily visual inspection.
IMPORTANT: Drain water into a suitable container
and dispose of properly.
a. Loosen drain plugs (A) at bottom of fuel filters or
bowls, if equipped, two or three turns.
b. Loosen air bleed plug (B) two full turns on fuel filter
mounting and drain water from bottom until fuel
starts to drain out.
c. When fuel starts to drain out, tighten drain plugs
securely.
After draining water from the fuel filters, the filters must
be primed by bleeding all air from the fuel system. See
BLEEDING FUEL SYSTEM in Service As Required
Section, later in this manual
Continued on next page
25-3
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PN=135
Lubrication & Maintenance/Daily
OURGP11,000018F –19–27JUL06–4/5
RG7332A –UN–22JAN99
Dust Unloader Valve and Indicator Gauge
A—Dust Unloader Valve
B—Air Restriction Indicator
4. If the air cleaner has an automatic dust unloader valve
(A), squeeze the unloader valve on air cleaner
assembly to clear away any dust buildup.
If equipped with air intake restriction indicator gauge
(B), check gauge to determine if air cleaner needs to
be serviced.
IMPORTANT: Maximum air intake restriction is 6.25
kPa (0.06 bar) (1.0 psi) (25 in. H
2
O). A
clogged air cleaner element will cause
excessive intake restriction and a
reduced air supply to the engine.
5. Make a thorough inspection of the engine
compartment. Look for oil or coolant leaks, worn fan
and accessory drive belts, loose connections and trash
build-up. Remove trash buildup and have repairs made
as needed if leaks are found.
NOTE: Wipe all fittings, caps, and plugs before
performing any maintenance to reduce the chance
of system contamination.
Inspect:
•Radiator for leaks and trash build-up.
•Air intake system hoses and connections for cracks
and loose clamps.
•Fan, alternator, and accessory drive belts for cracks,
breaks or other damage.
•Coolant pump for coolant leaks.
NOTE: It is normal for a small amount of leakage to occur
as the engine cools down and parts contract.
Excessive coolant leakage may indicate the need
to replace the coolant pump seal. Contact your
engine distributor or servicing dealer for repairs.
Continued on next page
25-4
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Lubrication & Maintenance/Daily
OURGP11,000018F –19–27JUL06–5/5
RG6578 –UN–29JAN93
Key Switch in "ON" Position (4.5 L “270” Engines)
6. 4.5 L Suffix “270” Earlier Engines Only: Turn key
switch to “ON” position and check lamps. “WATER”
lamp should be off, while “OIL” and “CHG” lamps
should be lit.
Replace lamps as needed. If this does not solve any
problems, see your John Deere dealer or distributor.
25-5
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PN=137
Lubrication & Maintenance/500 Hour/12 Month
OURGP11,000015F –19–27JUL06–1/1
Servicing Fire Extinguisher
RW4918 –UN–15DEC88
Fire Extinguisher
A—Fire Extinguisher
A fire extinguisher (A) is available from your authorized
servicing dealer or engine distributor.
Read and follow the instructions which are packaged with
it. The extinguisher should be inspected at least every 500
hours of engine operation or every 6 months. Once
extinguisher is operated, no matter how long, it must be
recharged. Keep record of inspections on the tag which
comes with the extinguisher instruction booklet.
OURGP11,0000110 –19–27JUL06–1/1
Checking Engine Mounts
RG9905 –UN–06JAN99
Engine Mounting
A—Mounting Bracket
Engine mounting is the responsibility of the vehicle or
generator manufacturer. Follow manufacturer’s guidelines
for mounting specifications.
IMPORTANT: Use only Grade SAE 8 or higher grade
of hardware for engine mounting.
1. Check the engine mounting brackets (A), vibration
isolators, and mounting bolts on support frame and
engine block for tightness. Tighten as necessary.
2. Inspect overall condition of vibration isolators, if
equipped. Replace isolators, as necessary, if rubber
has deteriorated or mounts have collapsed.
30-1
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PN=138
Lubrication & Maintenance/500 Hour/12 Month
RG,RG34710,5568 –19–27JUL06–1/2
Servicing Battery
TS204 –UN–23AUG88
Exploding Battery
CAUTION: Battery gas can explode. Keep
sparks and flames away from batteries. Use a
flashlight to check battery electrolyte level.
Never check battery charge by placing a metal
object across the posts. Use a voltmeter or
hydrometer.
Always remove grounded NEGATIVE (–) battery
clamp first and replace it last.
WARNING: Battery posts, terminals, and related
accessories contain lead and lead compounds, chemicals
known to the State of California to cause cancer and
reproductive harm. Wash hands after handling.
1. On regular batteries, check electrolyte level. Fill each
cell to bottom of filler neck with distilled water.
NOTE: Low-maintenance or maintenance-free batteries
should require little additional service. However,
electrolyte level can be checked by cutting the
center section of decal on dash-line, and
removing cell plugs. If necessary, add clean, soft
water to bring level to bottom of filler neck.
2. Keep batteries clean by wiping them with a damp cloth.
Keep all connections clean and tight. Remove any
corrosion, and wash terminals with a solution of 1 part
baking soda and 4 parts water. Tighten all connections
securely.
NOTE: Coat battery terminals and connectors with a
mixture of petroleum jelly and baking soda to
retard corrosion.
3. Keep battery fully charged, especially during cold
weather. If a battery charger is used, turn charger off
before connecting charger to battery(ies). Attach
POSITIVE (+) battery charger lead to POSITIVE (+)
battery post. Then attach NEGATIVE (–) battery
charger lead to a good ground.
30-2
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Continued on next page
Lubrication & Maintenance/500 Hour/12 Month
RG,RG34710,5568 –19–27JUL06–2/2
TS203 –UN–23AUG88
Sulfuric Acid
CAUTION: Sulfuric acid in battery electrolyte is
poisonous. It is strong enough to burn skin, eat
holes in clothing, and cause blindness if
splashed into eyes.
Avoid the hazard by:
1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is
added.
4. Avoiding spilling or dripping electrolyte.
5. Use proper jump start procedure.
If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize
the acid.
3. Flush your eyes with water for 10–15
minutes. Get medical attention immediately.
If acid is swallowed:
1. Drink large amounts of water or milk.
2. Then drink milk of magnesia, beaten eggs, or
vegetable oil.
3. Get medical attention immediately.
In freezing weather, run engine at least 30 minutes to
assure thorough mixing after adding water to battery.
If necessary to replace battery(ies), replacements must
meet or exceed the following recommended capacities at
-18°C(0°F):
Specification
12 Volt Standard Duty Starter—
Cold Cranking Amps 640............................................................................
12 Volt Heavy Duty Starter—Cold
Cranking Amps 800.....................................................................................
24 Volt Standard Duty Starter—
Cold Cranking Amps 570............................................................................
30-3
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Lubrication & Maintenance/500 Hour/12 Month
DPSG,RG41165,128 –19–27JUL06–1/1
Manual Belt Tensioner Adjustment
RG10556 –UN–21DEC99
Check Belt Tension
RG10557 –UN–21DEC99
Adjust Belt Tension
A—Belt Tension Gauge
B—Cap Screw
C—Cap Screw
D—Tensioner Bracket
NOTE: Two types of manual tensioners shown.
NOTE: Inspect belts for cracks, fraying, or stretched-out
areas. Replace if necessary.
As a reference check, twist belt in the middle of a
254—305 mm (10—12 in.) span with two fingers.
A properly tensioned belt will turn 75—85
degrees. If belt turns more, it needs to be
tightened. If belt turns less, it needs to be
loosened.
NOTE: If timing gear cover or alternator bracket interfere
with installation/centering of belt tension gauge
(A), install gauge with face toward engine.
1. Install JDG1341 Belt Tension Gauge (A) on belt,
halfway between pulleys as shown. (JDG1341 Belt
Tension Gauge available from local John Deere Dealer
or Distributor.)
2. Loosen cap screws (B) and (C).
3. Slide alternator or tensioner bracket (D) in slot by hand
to remove all excess slack in belt.
IMPORTANT: Do not pry against alternator rear frame.
4. Stretch belt by prying outward on alternator front frame
or tensioner bracket. Observing tension gauge, stretch
the belt until specified tension is achieved.
Specification
New Belt—Tension 470—650 N (105—145 lb-force).................................
Used Belt—Tension 400—580 N (90—130 lb-force)..................................
5. Tighten cap screws (B) and (C).
NOTE: After ten minutes run-in, new belts are considered
used. Belt tension must then be rechecked per
used belt specifications.
6. Run engine for ten minutes and immediately re-check
belt tension per used belt specification above.
7. Reset belt tension as necessary.
30-4
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PN=141
Lubrication & Maintenance/500 Hour/12 Month
OUOD002,000016D –19–27JUL06–1/2
Manual Belt Tensioner Adjustment Using
Belt Tension Tool (Alternate Method For
Engines Without Auxiliary Drive)
RG11812 –UN–31OCT01
Alternator Bracket and Cap Screws
RG11813 –UN–31OCT01
Belt Tension Tool
A—Upper Alternator Bracket Cap Screw
B—Lower Alternator Bracket Cap Screw
C—JDG1520 Belt Tension Tool
D—Belt
NOTE: The JD1520 Belt Tension Tool may not be
compatible with all alternators. In that case, use
the preceding method for belt tensioning.
NOTE: Inspect belts for cracks, fraying, or stretched-out
areas. Replace if necessary.
As a reference check, twist belt in the middle of a
254—305 mm (10—12 in.) span with two fingers.
A properly tensioned belt will turn 75—85
degrees. If belt turns more, it needs to be
tightened. If belt turns less, it needs to be
loosened.
1. Loosen upper (A) and lower (B) alternator bracket cap
screws. Lower cap screw must remain tight enough to
prevent excessive alternator play but allow alternator to
pivot by hand.
2. Insert JDG1520 Belt Tension Tool (C) behind belt (D)
and over alternator mounting screw.
Continued on next page
30-5
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Lubrication & Maintenance/500 Hour/12 Month
OUOD002,000016D –19–27JUL06–2/2
RG11814 –UN–31OCT01
Belt Tension Tool and Torque Wrench
RG11815 –UN–31OCT01
Scribe Reference Mark
A—Alternator
B—Belt Tensioning Tool
C—Torque Wrench
D—Reference Mark
E—Alternator Upper Bracket Notch
3. Place torque wrench (C) on belt tensioning tool (B) at
90°to tool. Pivot alternator (A) until desired torque is
achieved according to specification using the following
table.
Specification
New Belt—Tension 470—650 N (105—145 lb-force).................................
Used Belt—Tension 400—580 N (90—130 lb-force)..................................
JDG1520 Belt Tensioning Tool Torque Table
Desired Belt Tension N Applied Torque N•m (lb-ft)
(lb-force)
445 (100) 108 (90)
489 (110) 115 (85)
534 (120) 122 (90)
623 (140) 135 (100)
4. While holding tension with torque wrench (B), scribe a
reference mark (D) on alternator in line with notch (E)
on upper alternator bracket.
5. Continue to hold tension with torque wrench and
tighten upper alternator bracket cap screw.
6. Check position of reference mark to see if alternator
moved while tightening. If alternator moved, loosen
upper alternator bracket cap screw and repeat the
tension adjustment procedure.
7. Remove belt tension tool and tighten lower alternator
bracket cap screw.
30-6
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Lubrication & Maintenance/500 Hour/12 Month
OURGP11,000008C –19–27JUL06–1/4
Changing Engine Oil and Replacing Filter
RG11616 –UN–24OCT01
Special Oil Filter
RG4881 –UN–29NOV88
Oil Pan Drain Plug
A—Oil Filter Element
IMPORTANT: 6-Cylinder engines with oil pan option
codes 1907, 1908, and 1909 require the
oil to be changed at every 250 hours or
less regardless of oil specification
used.
Your engine is equipped with a special oil filter (A).
NOTE: During break-in, change engine oil and filter for
the first time before 100 hours maximum of
operation.
After break-in, if John Deere PLUS-50or ACEA-E7, E6,
E5, E4 engine oil and a John Deere special oil filter are
used along with a large-sump oil pan, the oil and filter
change interval is 500 hours or every 12 months,
whichever comes first.
NOTE: If the above recommendations are not followed,
the oil and filter change interval is every 250
hours/6 months or less. If diesel fuel with a high
sulfur content is used, the oil and filter change
interval is also reduced. (See DIESEL ENGINE
OIL in the “Fuels, Lubricants, and Coolant”
section.
OILSCANor OILSCAN PLUSis a John Deere
sampling program to help you monitor machine
performance and identify potential problems before they
cause serious damage. OILSCANand OILSCAN
PLUSkits are available from your John Deere engine
distributor or servicing dealer. Oil samples should be
taken prior to the oil change. Refer to instructions
provided with kit.
To change engine oil and oil filter:
1. Run engine approximately 5 minutes to warm up oil.
Shut engine off.
2. Remove oil pan drain plug (arrow).
PLUS-50 is a trademark of Deere & Company.
OILSCAN is a trademark of Deere & Company.
OILSCAN PLUS is a trademark of Deere & Company.
30-7
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Continued on next page
Lubrication & Maintenance/500 Hour/12 Month
OURGP11,000008C –19–27JUL06–2/4
3. Drain crankcase oil from engine while warm.
NOTE: Drain plug location may vary, depending on the
application.
OURGP11,000008C –19–27JUL06–3/4
RG11616 –UN–24OCT01
Oil Filter And Mounting Header
RG11617 –UN–24OCT01
Oil Filter Seals
RG11618 –UN–24OCT01
Filter And Mounting Header
A—Oil Filter Element
B—Inner Seal
C—Outer Seal
D—Sealing Surface On Header
E—Sealing Surface On Header
F—Dust Seal
4. Turn filter element (A) using a suitable filter wrench to
remove. Discard oil filter element.
NOTE: Depending on engine application, oil filter may be
located on either side of the engine in a high- or
low-mount location.
IMPORTANT: Filtration of oils is critical to proper
lubrication. Always change filter
regularly. Use filter meeting John Deere
performance specifications.
5. Apply clean engine oil to the new filter at the inner (B)
and outer (C) seals and to filter threads.
6. Wipe both sealing surfaces of the header (D, E) with a
clean rag. Ensure notches in dust seal (F) are properly
installed in the slots in the housing. Replace dust seal
if damaged.
IMPORTANT: When installing filter element, HAND
TIGHTEN only. A filter wrench may be
used for REMOVAL ONLY. Be sure
notches in dust seal (F) are properly
installed in the slots in the housing.
7. Install and tighten oil filter by hand until firmly against
dust seal (F). DO NOT apply an extra 3/4 to 1-1/4 turn
after gasket contact as done with standard filters.
8. Tighten drain plug to specifications.
Specification
Oil Pan Drain Plug With Copper
Washer—Torque 70 N•m (52 lb ft).............................................................
Oil Pan Drain Plug With O-Ring—
Torque 50 N•m (37 lb ft).............................................................................
Oil Pan Drain Plug With Packing
(6068 Engine Code 1961, Steel
Oil Pan)—Torque 40 N•m (29 lb ft).............................................................
30-8
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Continued on next page
Lubrication & Maintenance/500 Hour/12 Month
OURGP11,000008C –19–27JUL06–4/4
RG11619 –UN–24OCT01
Rocker Arm Cover Oil Filler Opening
RG11942 –UN–24OCT01
Oil Filler At Side Of Engine
A—Rocker Arm Cover Oil Filler Opening
B—Oil Filler At Side Of Engine
9. Fill engine crankcase with correct John Deere engine
oil through rocker arm cover opening (A) or either side
oil filler (B) depending on engine application. (See
DIESEL ENGINE OIL in Fuels, Lubricants, and Coolant
Section for determining correct engine oil.)
To determine the correct oil fill quantity for your engine,
see ENGINE CRANKCASE OIL FILL QUANTITIES in
the Specifications Section of this manual.
IMPORTANT: Immediately after completing any oil
change, crank engine for 30 seconds
without permitting engine to start. This
will help insure adequate lubrication to
engine components before engine
starts.
NOTE: Crankcase oil capacity may vary slightly.
ALWAYS fill crankcase within crosshatch marks
on dipstick. DO NOT overfill.
10. Start engine and run to check for possible leaks.
11. Stop engine and check oil level after 10 minutes. Oil
level reading should be within crosshatch of dipstick.
OURGP11,000014F –19–27JUL06–1/2
Checking Crankcase Vent System
RG8017A –UN–19JUN00
Crankcase Vent Tube
A—Crankcase Vent Tube
Crankcase Vent Tube (If Equipped)
If you operate the engine in dusty conditions, check the
system at shorter intervals.
1. If equipped, remove and clean crankcase vent tube
(A).
2. Install the vent tube. Be sure the O-ring fits correctly in
the rocker arm cover for elbow adapter. Tighten hose
clamp securely.
30-9
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Continued on next page
Lubrication & Maintenance/500 Hour/12 Month
OURGP11,000014F –19–27JUL06–2/2
RG12426 –UN–20NOV03
Closed Crankcase Vent
RG12427 –UN–03FEB04
Closed Crankcase Vent
A—Closed Crankcase Ventilation (CCV) Valve
B—Hose, CCV Valve to Intake Manifold
C—Hose, Valve Cover to CCV Valve
D—Valve Cover Vent Fitting
E—Intake Manifold Fitting
F—Cap Screw, CCV Valve to Bracket
G—Oil Drain Hose
H—Check Valve
I—Crankcase Oil Drain Tube
Closed Crankcase Ventilation System (If Equipped)
1. Inspect hoses (C, D and G) for kinks, blockage, or
other damage.
2. Inspect check valve (H) for damage. (Valve is installed
with black end toward crankcase).
3. Verify that crankcase oil drain tube (I) is not plugged.
4. Inspect CCV valve (A) for cracks or other damage.
30-10
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Lubrication & Maintenance/500 Hour/12 Month
RG,RG34710,5575 –19–27JUL06–1/1
Checking Air Intake System
RG4689 –UN–20DEC88
Check Clamps
RG7332B –UN–22JAN99
Underloader Valve and Air Restriction Indicator
A—Clamps
B—Dust Unloader Valve
C—Air Restriction Indicator
IMPORTANT: The air intake system must not leak.
Any leak, no matter how small, may
result in internal engine damage due to
abrasive dirt and dust entering the
intake system.
1. Inspect all intake hoses (piping) for cracks. Replace as
necessary.
2. Check clamps (A) on piping which connect the air
cleaner, engine and, if present, turbocharger. Tighten
clamps as necessary. This will help prevent dirt from
entering the air intake system through loose
connections causing internal engine damage.
3. If engine has a rubber dust unloader valve (B), inspect
the valve on bottom of air cleaner for cracks or
plugging. Replace as necessary.
IMPORTANT: ALWAYS REPLACE primary air cleaner
element when air restriction indicator
shows a vacuum of 625 mm (25 in.)
H
2
O, is torn, or visibly dirty.
4. Test air restriction indicator (C) for proper operation.
Replace indicator as necessary.
IMPORTANT: If not equipped with air restriction
indicator, replace air cleaner elements
at 500 Hours or 12 Months, whichever
occurs first.
30-11
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PN=148
Lubrication & Maintenance/500 Hour/12 Month
OURGP11,000021F –19–27JUL06–1/2
Replacing Fuel Filter Elements
X9811 –UN–23AUG88
High-Pressure Fluids
RG7721 –UN–15JAN99
Final Fuel Filter
RG11954 –UN–05DEC01
Primary Fuel Filter (or Pre-Filter, If Equipped)
A—Retaining Ring
B—Filter Element
C—Drain Plug
D—Bleed Plug
E—Water Bowl
Engines may be equipped with either a primary fuel filter
(or pre-filter) with water bowl and a final filter, or only a
final filter including water bowl. Both filters are replaced at
the same 500-hour interval.
CAUTION: Escaping fluid under pressure can
penetrate the skin causing serious injury.
Relieve pressure before disconnecting fuel or
other lines. Tighten all connections before
applying pressure. Keep hands and body away
from pinholes and nozzles which eject fluids
under high pressure. Use a piece of cardboard
or paper to search for leaks. Do not use your
hand.
If any fluid is injected into the skin, it must be
surgically removed within a few hours by a
doctor familiar with this type injury or gangrene
may result. Doctors unfamiliar with this type of
injury may call the Deere & Company Medical
Department in Moline, Illinois, or other
knowledgeable medical source.
1. Close fuel shut-off valve, if equipped.
2. Thoroughly clean fuel filter assemblies and surrounding
areas.
3. Disconnect water sensor wiring (if equipped).
4. Loosen drain plugs (C) and drain fuel into a suitable
container.
NOTE: Lifting up on retaining ring (A) as it is rotated
helps to get it past raised locators.
5. Firmly grasp the retaining ring (A) and rotate it
clockwise 1/4 turn (when viewed from the top).
Remove ring with filter element (B).
6. Inspect filter mounting base for cleanliness. Clean as
required.
30-12
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Lubrication & Maintenance/500 Hour/12 Month
OURGP11,000021F –19–27JUL06–2/2
NOTE: Raised locators on fuel filter canisters must be
indexed properly with slots in mounting base for
correct installation.
7. Install new filter elements onto mounting bases. Be
sure elements are properly indexed and firmly seated
on bases. It may be necessary to rotate filters for
correct alignment.
If equipped with water separator bowl (E), remove filter
element from separator bowl. Drain and clean
separator bowl. Dry with compressed air. Install bowl
onto new element. Tighten securely.
8. Align keys on filter element with slots in filter base.
9. Install retaining ring onto mounting base making certain
dust seal is in place on filter base. Hand tighten ring
counterclockwise (about 1/3 turn) until it “snaps” into
the detent. DO NOT overtighten retaining ring.
NOTE: The proper installation is indicated when a "click"
is heard and a release of the retaining ring is felt.
A plug is provided with the new element for
plugging the used element.
10. Reconnect water sensor wiring (if equipped).
11. Open fuel shut-off valve and bleed the fuel system.
(See BLEEDING FUEL SYSTEM in Service As
Required Section.) Tighten bleed plug (D).
30-13
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Lubrication & Maintenance/500 Hour/12 Month
OURGP11,0000080 –19–27JUL06–1/3
Checking Belt Tensioner Spring Tension and
Belt Wear (Automatic Tensioner)
Belt drive systems equipped with automatic (spring) belt
tensioners cannot be adjusted or repaired. The automatic
belt tensioner is designed to maintain proper belt tension
over the life of the belt. If tensioner spring tension is not
within specification, replace tensioner assembly.
OURGP11,0000080 –19–27JUL06–2/3
RG8098 –UN–18NOV97
Belt Tensioner - Earlier Engines
RG13744 –UN–11NOV04
Belt Tensioner - Later Engines
A—Cast Stop
B—Cast Stop
Checking Belt Wear
The belt tensioner is designed to operate within the limit
of arm movement provided by the cast stops (A and B)
when correct belt length and geometry is used.
Visually inspect cast stops (A and B) on belt tensioner
assembly.
If the tensioner stop on swing arm (A) is hitting the fixed
stop (B), check mounting brackets (alternator, belt
tensioner, idler pulley, etc.) and the belt length. Replace
belt as needed ( see REPLACING FAN AND
ALTERNATOR BELTS in Service As Required Section).
Continued on next page
30-14
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Lubrication & Maintenance/500 Hour/12 Month
OURGP11,0000080 –19–27JUL06–3/3
RG7977 –UN–14NOV97
Marks on Tensioner
RG8037C –UN–11SEP00
Align Marks
RG12065 –UN–28JAN02
Align Torque Wrench With Pulley and Tensioner
A—Mark On Swing Arm
B—Mark On Tensioner Mounting Base
C—Torque Wrench
Checking Tensioner Spring Tension
A belt tension gauge will not give an accurate measure of
the belt tension when automatic spring tensioner is used.
Measure tensioner spring tension using a torque wrench
and procedure outlined below:
NOTE: Later engines have a 12.7 mm (1/2 in.) square
hole in tensioner so no socket drive is required.
1. Release tension on belt using a breaker bar and
socket (if required) on tension arm. Remove belt from
pulleys.
NOTE: While belt is removed, inspect pulleys and
bearings. Rotate and feel for hard turning or any
unusual sounds. If pulleys or bearings need
replacement, see your John Deere dealer.
2. Release tension on tension arm and remove breaker
bar.
3. Put a mark (A) on swing arm of tensioner as shown.
4. Measure 21 mm (0.83 in.) from (A) and put a mark (B)
on tensioner mounting base.
5. Install torque wrench (C) so that it is aligned with
centers of pulley and tensioner. Rotate the swing arm
using a torque wrench until marks (A and B) are
aligned.
6. Record torque wrench measurement and compare with
specification below. Replace tensioner assembly as
required.
Specification
Spring Tension—Torque 18-22 N•m (13-16 lb-ft).......................................
NOTE: Threads on belt tensioner roller cap screw are
LEFT-HAND threads
30-15
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PN=152
Lubrication & Maintenance/500 Hour/12 Month
OUOD002,0000169 –19–27JUL06–1/1
Checking Engine Electrical Ground
Connections
Keep all engine ground connections clean and tight to
prevent electrical arcing which can damage electronic
components.
Also see precautions in Troubleshooting Section when
welding on engine or machine.
OURGP11,0000151 –19–27JUL06–1/1
Checking Cooling System
TS281 –UN–23AUG88
High-Pressure Fluids
CAUTION: Explosive release of fluids from
pressurized cooling system can cause serious
burns.
Shut off engine. Only remove filler cap when
cool enough to touch with bare hands. Slowly
loosen cap to first stop to relieve pressure
before removing completely.
IMPORTANT: Air must be expelled from cooling
system when system is refilled. Loosen
temperature sending unit fitting at rear
of cylinder head or plug in thermostat
housing to allow air to escape when
filling system. Retighten fitting or plug
when all the air has been expelled.
1. Visually check entire cooling system for leaks. Tighten
all clamps securely.
2. Thoroughly inspect all cooling system hoses for hard,
flimsy, or cracked condition. Replace hoses if any of
the above conditions are found.
3. Inspect the coolant pump for wear or leakage.
30-16
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Lubrication & Maintenance/500 Hour/12 Month
DPSG,OUOD002,1921 –19–27JUL06–1/2
Replenishing Supplemental Coolant
Additives (SCAs) Between Coolant Changes
RG6261 –UN–08DEC97
Radiator Coolant Check
RG6262 –UN–05DEC97
JT07298 Coolant/Battery Tester
IMPORTANT: Do not add supplemental coolant
additives when the cooling system is
drained and refilled with John Deere
COOL-GARD
NOTE: If system is to be filled with coolant that does not
contain SCAs, the coolant must be precharged.
Determine the total system capacity and premix
with 3% John Deere Coolant Conditioner.
Through time and use, the concentration of coolant
additives is gradually depleted during engine operation.
Periodic replenishment of inhibitors is required, even when
John Deere COOL-GARDis used. The cooling system
must be recharged with additional supplemental coolant
additives available in the form of liquid coolant conditioner.
Maintaining the correct coolant conditioner concentration
(SCAs) and freeze point is essential in your cooling
system to protect against rust, liner pitting and corrosion,
and freeze-ups due to incorrect coolant dilution.
John Deere LIQUID COOLANT CONDITIONER is
recommended as a supplemental coolant additive in
John Deere engines.
DO NOT mix one brand of SCA with a different brand.
Test the coolant solution at 500 hours or 12 months of
operation using either John Deere coolant test strips or a
COOLSCANor COOLSCAN PLUSanalysis. If a
COOLSCANor COOLSCAN PLUSanalysis is not
available, recharge the system per instructions printed on
label of John Deere Liquid Coolant Conditioner.
COOL-GARD is a trademark of Deere & Company
COOLSCAN is a trademark of Deere & Company
COOLSCAN PLUS is a trademark of Deere & Company
Continued on next page
30-17
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Lubrication & Maintenance/500 Hour/12 Month
DPSG,OUOD002,1921 –19–27JUL06–2/2
IMPORTANT: ALWAYS maintain coolant at correct
level and concentration. DO NOT
operate engine without coolant even for
a few minutes.
If frequent coolant makeup is required,
the glycol concentration should be
checked with JT07298 Coolant/Battery
Tester to ensure that the desired freeze
point is maintained. Follow
manufacturer’s instructions provided
with Coolant/Battery Tester.
Add the manufacturer’s recommended concentration of
supplemental coolant additive. DO NOT add more than
the recommended amount.
The use of non-recommended supplemental coolant
additives may result in additive drop-out and gelation of
the coolant.
If other coolants are used, consult the coolant supplier
and follow the manufacturer’s recommendation for use of
supplemental coolant additives.
See DIESEL ENGINE COOLANTS AND
SUPPLEMENTAL ADDITIVE INFORMATION for proper
mixing of coolant ingredients before adding to the cooling
system.
30-18
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Lubrication & Maintenance/500 Hour/12 Month
OUOD002,0000175 –19–27JUL06–1/1
Testing Diesel Engine Coolant
Maintaining adequate concentrations of glycol and
inhibiting additives in the coolant is critical to protect
the engine and cooling system against freezing,
corrosion, and cylinder liner erosion and pitting.
Test the coolant solution at intervals of 12 months or
less and whenever excessive coolant is lost through
leaks or overheating.
Coolant Test Strips
Coolant test strips are available from your John Deere
dealer. These test strips provide a simple, effective
method to check the freeze point and additive levels of
your engine coolant.
Compare the results to the supplemental coolant
additive (SCA) chart to determine the amount of
inhibiting additives in your coolant and whether more
John Deere COOLANT CONDITIONER should be
added.
COOLSCAN Or COOLSCAN PLUS
For a more thorough evaluation of your coolant,
perform a COOLSCAN or COOLSCAN PLUS analysis.
See your John Deere dealer for information about
COOLSCAN or COOLSCAN PLUS.
30-19
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Lubrication & Maintenance/500 Hour/12 Month
OURGP11,0000220 –19–27JUL06–1/1
Pressure Testing Cooling System
RG6557 –UN–20JAN93
Test Radiator Cap
RG6558 –UN–20JAN93
Test Cooling System
CAUTION: Explosive release of fluids from
pressurized cooling system can cause
serious burns.
Shut off engine. Only remove filler cap when
cool enough to touch with bare hands.
Slowly loosen cap to first stop to relieve
pressure before removing completely.
NOTE: These tests apply only to John Deere
radiators. For other brands, see manufacturers
literature.
Test Radiator Cap
1. Remove radiator cap and attach to D05104ST
Tester as shown.
2. Pressurize cap to specification listed. Gauge should
hold pressure for 10 seconds at least to pressure
listed if cap is acceptable.
If gauge does not hold pressure, replace radiator
cap.
Specification
Radiator Cap Holding Pressure
(Not Opening For 10
Seconds)—Pressure 70 kPa (0.7 bar) (10 psi)....................................
3. Remove the cap from gauge, turn it 180°, and
retest cap. This will verify that the first
measurement was accurate.
Test Cooling System
NOTE: Engine should be warmed up to test overall
cooling system.
1. Allow engine to cool, then carefully remove radiator
cap.
2. Fill radiator with coolant to the normal operating
level.
IMPORTANT: DO NOT apply excessive pressure to
cooling system, doing so may
damage radiator and hoses.
3. Connect gauge and adapter to radiator filler neck.
Pressurize cooling system to specification listed for
radiator cap.
4. With pressure applied, check all cooling system
hose connections, radiator, and overall engine for
leaks.
If leakage is detected, correct as necessary and
pressure test system again.
If no leakage is detected, but the gauge indicated a
drop in pressure, coolant may be leaking internally
within the system or at the block-to-head gasket.
Have your engine distributor or servicing dealer
correct this problem immediately.
30-20
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Lubrication & Maintenance/500 Hour/12 Month
OURGP12,00001DB –19–27JUL06–1/1
Checking and Adjusting Engine Speeds
RG12607 –UN–24OCT02
Using Tachometer to Check Engine Speeds
A—Tachometer
If equipped with a tachometer (A) on the instrument panel,
observe tachometer reading to verify engine speeds.
(Refer to ENGINE POWER RATINGS AND FUEL
SYSTEM SPECIFICATIONS in Specifications Section
later in this manual for engine speed specifications.) If
engine speed adjustment is required, see your authorized
servicing dealer or engine distributor.
30-21
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Lubrication & Maint./2000 Hour/24 Month
OURGP12,00001ED –19–27JUL06–1/1
Adjusting Variable Speed (Droop) — 4.5 L
“270” Generator Set Engines Only
RG12066 –UN–29JAN02
Droop Adjustment Screw
A—Adjustment Screw
B—Fast Idle Adjustment
C—Slow Idle Adjustment
1. Warm engine to normal operating temperature.
2. When necessary, disconnect throttle linkage or cable.
3. Adjust slow idle (C) and adjust fast idle (B) speed
when necessary.
4. Run engine at fast idle, then apply load until reaching
rated speed.
5. Check power. Adjust with the screw (A) if needed.
6. Remove load from engine.
7. Again check and adjust fast idle if screw (A) has been
turned.
8. Repeat procedure until both the engine power and the
fast idle speed are correct.
9. Reinstall throttle linkage if previously removed.
35-1
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Lubrication & Maint./2000 Hour/24 Month
RG,RG34710,5585 –19–27JUL06–1/1
Checking Crankshaft Vibration Damper
(6-Cylinder Engine Only)
RG8018 –UN–15JAN99
Grasp Vibration Damper
RG7508 –UN–23NOV97
Check Runout
1. Remove belts (shown removed).
2. Grasp vibration damper with both hands and attempt to
turn it in both directions. If rotation is felt, damper is
defective and should be replaced.
IMPORTANT: The vibration damper assembly is not
repairable and should be replaced every
4500 hours or 60 months, whichever
occurs first.
3. Check vibration damper radial runout by positioning a
dial indicator (A) so probe contacts damper outer
diameter.
4. With engine at operating temperature, rotate crankshaft
using either JD281A, JDE81-4, or JDE83 Flywheel
Turning Tool.
5. Note dial indicator reading. If runout exceeds
specifications given below, replace vibration damper.
Specification
Vibration Damper—Maximum
Radial Runout 1.50 mm (0.060 in.).............................................................
35-2
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Lubrication & Maint./2000 Hour/24 Month
OURGP11,0000081 –19–27JUL06–1/4
Flushing and Refilling Cooling System
TS281 –UN–23AUG88
High-Pressure Fluids
RG12833 –UN–13FEB03
Radiator Cap
CAUTION: Explosive release of fluids from
pressurized cooling system can cause serious
burns.
Shut off engine. Only remove filler cap when
cool enough to touch with bare hands. Slowly
loosen cap to first stop to relieve pressure
before removing completely.
NOTE: When John Deere COOL-GARD is used, the drain
interval is 3000 hours or 36 months. The drain
interval may be extended to 5000 hours or 60
months of operation, provided that the coolant
is tested annually AND additives are
replenished, as needed, by adding a
supplemental coolant additive (SCA).
If COOL-GARD is not used, the flushing interval is
2000 hours or 24 months of operation.
Drain old coolant, flush the entire cooling system, test
thermostats, and fill with recommended clean coolant per
the following procedure.
1. Pressure test entire cooling system and pressure cap if
not previously done. (See PRESSURE TESTING
COOLING SYSTEM, in the Lubrication and
Maintenance/500 Hour/12 Month Section.)
2. Slowly open the engine cooling system filler cap or
radiator cap (A) to relieve pressure and allow coolant
to drain faster.
Continued on next page
35-3
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Lubrication & Maint./2000 Hour/24 Month
OURGP11,0000081 –19–27JUL06–2/4
RG8019A –UN–19JUN00
Engine Block Drain Valve- Except 475 Engines
RG12223 –UN–11JUN02
Engine Block Coolant Drain Plug- 475 Engines
A—Engine Block Drain Valve
B—Engine Block Drain Plug
C—Engine Block Drain Plug
3. All Except 4045HF475 and 6068HF475 Engines:
Open engine block drain valve (A) on left side of
engine. Drain all coolant from engine block.
NOTE: On earlier “475” engines, the engine block drain
valve is located behind the fuel rail, and is not
easily accessible.
4045HF475 and 6068HF475 Engines: Open drain
plug (B) or (C) on oil cooler housing. Drain all coolant
from engine block.
NOTE: These engines use several different oil filter
adapters. Use either drain plug (B) or (C) to drain
coolant, whichever is more accessible for the oil
filter adapter on your engine.
4. Open radiator drain valve. Drain all coolant from
radiator.
5. Remove thermostats at this time, if not previously
done. Install cover (without thermostats) using old
gasket and tighten cap screws to 47 N•m (35 lb-ft).
6. Test thermostat opening temperature. (See Inspecting
Thermostats And Testing Opening Temperature in
Service As Required Section.)
7. Close all drain valves after coolant has drained.
CAUTION: Do not run engine longer than 10
minutes. Doing so may cause engine to
overheat which may cause burns when radiator
water is draining.
8. Fill the cooling system with clean water. Run the
engine about 10 minutes to stir up possible rust or
sediment.
9. Stop engine, pull off lower radiator hose and remove
radiator cap. Immediately drain the water from system
before rust and sediment settle.
35-4
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Continued on next page
Lubrication & Maint./2000 Hour/24 Month
OURGP11,0000081 –19–27JUL06–3/4
10. After draining water, close drain valves. Reinstall
radiator cap and radiator hose and clamp. Fill the
cooling system with clean water and a heavy duty
cooling system cleaner such as Fleetguard
RESTOREand RESTORE PLUS. Follow
manufacturer’s directions on label.
11. After cleaning the cooling system, drain cleaner and
fill with water to flush the system. Run the engine
about 10 minutes, remove radiator cap and pull off
lower radiator hose to drain out flushing water.
12. Close all drain valves on engine and radiator.
Reinstall radiator hose and tighten clamps securely.
Install thermostats using a new gasket. (See
TESTING THERMOSTATS OPENING
TEMPERATURE later in this section.)
IMPORTANT: Air must be expelled from cooling
system when system is refilled. Loosen
temperature sending unit fitting at rear
of cylinder head or plug in thermostat
housing to allow air to escape when
filling system. Retighten fitting or plug
after filling cooling system.
13. Add coolant to radiator until coolant touches bottom of
filler neck. (See specification for capacity.) Install
radiator cap.
Specification
4.5 L Engine— Coolant Capacity 8.5 L (9 qt).............................................
6.8 L Engine—Coolant Capacity 11.3 L (12 qt)..........................................
14. Run engine until it reaches operating temperature.
This mixes the solution uniformly and circulates it
through the entire system. The normal engine coolant
temperature range is 82°—94°C (180°—202°F).
15. After running engine, check coolant level and entire
cooling system for leaks.
Fleetguard is a trademark of Cummins Engine Company, Inc.
RESTORE is a trademark of Fleetguard.
RESTORE PLUS is a trademark of Fleetguard.
35-5
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Continued on next page
Lubrication & Maint./2000 Hour/24 Month
OURGP11,0000081 –19–27JUL06–4/4
16. Inspect the fan belt for wear and check belt tension.
(See Checking Belt Tensioner Spring Tension and
Belt Wear in Lubrication and Maintenance 500
Hour/12 Month section.
DPSG,RG34710,112 –19–27JUL06–1/5
Testing Thermostats Opening Temperature
TS281 –UN–23AUG88
High Pressure Fluids
RG8115A –UN–15JAN98
Thermostat Cover-to-Coolant Pump Tube
A—Cover-To-Coolant Pump Tube
To Remove Thermostat(s)
CAUTION: Explosive release of fluids from
pressurized cooling system can cause serious
burns. DO NOT drain coolant until it has cooled
below operating temperature. Always loosen
radiator pressure cap or drain valve slowly to
relieve pressure.
1. Visually inspect area around thermostat housing for
leaks.
2. Remove radiator pressure cap and partially drain
cooling system.
3. Remove thermostat cover-to-coolant pump tube (A)
and seal.
DPSG,RG34710,112 –19–27JUL06–2/5
RG7921A –UN–13NOV97
Thermostat Cover
B—Thermostat Cover
4. Remove thermostat cover (B) with gasket.
5. Remove thermostat(s)
6. Remove and discard all gasket material. Clean gasket
surfaces.
7. Clean and check cover for cracks or damage.
35-6
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Continued on next page
Lubrication & Maint./2000 Hour/24 Month
DPSG,RG34710,112 –19–27JUL06–3/5
RG5971 –UN–23NOV97
Testing Thermostat Opening Temperature
Testing Thermostats Opening Temperature
1. Remove thermostat(s).
2. Visually inspect thermostat(s) for corrosion or damage.
If dual thermostats, replace as a matched set as
necessary.
CAUTION: DO NOT allow thermostat or
thermometer to rest against the side or bottom
of container when heating water. Either may
rupture if overheated.
3. Suspend thermostat and a thermometer in a container
of water.
4. Stir the water as it heats. Observe opening action of
thermostat and compare temperatures with the
specification given in chart below.
NOTE: Due to varying tolerances of different suppliers,
initial opening and full open temperatures may
vary slightly from specified temperatures.
THERMOSTAT TEST SPECIFICATIONS
Rating Initial Opening (Range) Full Open
(Nominal)
71°C (160°F) 69—72°C (156—162°F) 84°C (182°F)
77°C (170°F) 74—78°C (166—172°F) 89°C (192°F)
82°C (180°F) 80—84°C (175—182°F) 94°C (202°F)
89°C (192°F) 86—90°C (187—194°F) 101°C(214°F)
90°C (195°F) 89—93°C (192—199°F) 103°C(218°F)
92°C (197°F) 89—93°C (193—200°F) 105°C(221°F)
96°C (205°F) 94—97°C (201—207°F) 100°C(213°F)
99°C (210°F) 96—100°C (205—212°F) 111°C(232°F)
5. Remove thermostat and observe its closing action as it
cools. In ambient air the thermostat should close
completely. Closing action should be smooth and slow.
6. Replace any defective thermostat. On a dual
thermostat engine, replace both thermostats.
Continued on next page
35-7
080706
PN=165
Lubrication & Maint./2000 Hour/24 Month
DPSG,RG34710,112 –19–27JUL06–4/5
RG7614A –UN–06NOV97
Installing Thermostat Cover
RG7921B –UN–13NOV97
Thermostat Cover Seal
A—Guide Studs
B—Seal
To Install Thermostats
IMPORTANT: Install manifold gasket so that smaller
(round) holes are at lower left and
upper right corners of manifold
(matching studs A).
1. Clean all gasket material from thermostat cover and
housing mounting surfaces.
2. Using guide studs (A) to keep gasket in place, install a
new gasket on cylinder head.
3. Install thermostat(s) with jiggle wire facing up in the 12
o’clock position.
4. Using a screwdriver to hold thermostat(s) in place,
install thermostat(s) and coolant manifold/thermostat
cover.
5. Tighten cover cap screws to 70 N•m (52 lb-ft).
6. Lubricate new O-ring with PT507 Multi-Purpose
Grease. Install seal (B) in thermostat cover.
DPSG,RG34710,112 –19–27JUL06–5/5
RG8115B –UN–15JAN98
Cover-To-Coolant Pump Tube
C—Cover-To-Coolant Pump Tube
7. Install coolant manifold/thermostat cover-to-coolant
pump tube (C). Tighten clamps.
8. If not already done, fill cooling system and check for
leaks.
IMPORTANT: Air must be expelled from cooling
system when filling. Loosen
temperature sending unit fitting at rear
of cylinder head or plug in thermostat
housing to allow air to escape when
filling system. Tighten fitting or plug
when all air has been expelled.
35-8
080706
PN=166
Lubrication & Maint./2000 Hour/24 Month
DPSG,RG41165,137 –19–27JUL06–1/5
Check and Adjust Valve Clearance (All
Engines Except 4045HF475 And 6068HF475)
RG7408 –UN–06AUG96
Flywheel Housing Timing Holes
A—Timing/Rotation Hole
B—Timing Pin Hole
CAUTION: To prevent accidental starting of
engine while performing valve adjustments,
always disconnect NEGATIVE (—) battery
terminal.
IMPORTANT: Valve clearance MUST BE checked and
adjusted with engine COLD.
1. Remove rocker arm cover and crankcase ventilator
tube.
IMPORTANT: Visually inspect contact surfaces of
valve tips and rocker arm wear pads.
Check all parts for excessive wear,
breakage, or cracks. Replace parts that
show visible damage.
Rocker arms that exhibit excessive
valve clearance should be inspected
more thoroughly to identify damaged
parts.
2. Remove plastic plugs or cover plate from engine
timing/rotation hole (A) and timing pin hole (B).
NOTE: Some engines are equipped with flywheel
housings which do not allow use of an engine
flywheel rotation tool. These engines may be
rotated from front nose of engine, using JDG966
Crankshaft Front/Rear Rotation Adapter.
3. Using JDE83 or JDG281AFlywheel Turning Tool, rotate
engine flywheel in running direction (clockwise viewed
from front) until No. 1 cylinder is at TDC compression
stroke. Insert JDG1571 Timing Pin in flywheel.
If No.1 cylinder rocker arms are loose, the engine is at
No. 1 TDC compression.
If No. 1 cylinder rocker arms are not loose, rotate
engine one full revolution (360°)toNo.1TDC
compression.
35-9
080706
PN=167
Continued on next page
Lubrication & Maint./2000 Hour/24 Month
DPSG,RG41165,137 –19–27JUL06–2/5
4. With engine lock-pinned at TDC of No. 1 piston’s
compression stroke, check valve clearance to following
specifications. (Use sequence for 4-cylinder or
6-cylinder engines as outlined on next page.)
Specification
Intake Valve Clearance For
Checking (Rocker Arm-to-Valve
Tip) (Engine Cold)—Clearance 0.31—0.38 mm
(0.012—0.015 in.)
.........................................
Exhaust Valve Clearance For
Checking (Rocker Arm-to-Valve
Tip) (Engine Cold)—Clearance 0.41—0.48 mm
(0.016—0.019 in.)
.........................................
DPSG,RG41165,137 –19–27JUL06–3/5
RG7409 –UN–06AUG96
Adjusting Valves
A—Adjusting Screw Jam Nut
5. If valves need adjusting, use the appropriate valve
clearance adjustment procedure on the next page and
adjust to specifications below. Loosen the jam nut (A)
on rocker arm adjusting screw. Turn adjusting screw
until feeler gauge slips with a slight drag. Hold the
adjusting screw from turning with screwdriver and
tighten jam nut to specifications. Recheck clearance
again after tightening jam nut. Readjust clearance as
necessary.
Specification
Intake Valve Clearance For
Adjusting (Rocker Arm-to-Valve
Tip) (Engine Cold)—Clearance 0.36 mm (0.014 in.)..................................
Exhaust Valve Clearance For
Adjusting (Rocker Arm-to-Valve
Tip) (Engine Cold)—Clearance 0.46 mm (0.018 in.)..................................
Rocker Arm Adjusting Screw Jam
Nut—Torque 27 N•m (20 lb-ft)....................................................................
6. Replace rocker arm cover and crankcase ventilator
tube.
Continued on next page
35-10
080706
PN=168
Lubrication & Maint./2000 Hour/24 Month
DPSG,RG41165,137 –19–27JUL06–4/5
RG4776 –UN–31OCT97
4-Cylinder Engine Valve Adjustment
A—Front of Engine
B—No. 1 Piston TDC Compression
C—No. 4 Piston TDC Compression
E—Exhaust Valve
I—Intake Valve
4-Cylinder Engine:
NOTE: Firing order is 1-3-4-2.
1. Using JDE81-4 Timing Pin, lock No. 1 piston at TDC
compression stroke (B).
2. Adjust valve clearance on No. 1 and 3 exhaust valves
and No. 1 and 2 intake valves.
3. Turn crankshaft 360°. Lock No. 4 piston at TDC
compression stroke (C).
4. Adjust valve clearance on No. 2 and 4 exhaust valves
and No. 3 and 4 intake valves.
DPSG,RG41165,137 –19–27JUL06–5/5
RG4777 –UN–31OCT97
6-Cylinder Engine Valve Adjustment
A—Front of Engine
B—No. 1 Piston TDC Compression
C—No. 6 Piston TDC Compression
E—Exhaust Valve
I—Intake Valve
6-Cylinder Engine:
NOTE: Firing order is 1-5-3-6-2-4.
1. Lock No. 1 piston at TDC compression stroke (B).
2. Adjust valve clearance on No. 1, 3 and 5 exhaust
valves and No. 1, 2, and 4 intake valves.
3. Turn crankshaft 360°. Lock No. 6 piston at TDC
compression stroke (C).
4. Adjust valve clearance on No. 2, 4 and 6 exhaust
valves and No. 3, 5, and 6 intake valves.
35-11
080706
PN=169
Lubrication & Maint./2000 Hour/24 Month
OUO1089,0000208 –19–27JUL06–1/5
Check and Adjust Valve Clearance
(4045HF475 And 6068HF475 Engines)
RG12168 –UN–03JUL02
Flywheel Housing Timing Holes
A—Timing/Rotation Hole
B—Timing Pin Hole
CAUTION: To prevent accidental starting of
engine while performing valve adjustments,
always disconnect NEGATIVE (—) battery
terminal.
IMPORTANT: Valve clearance MUST BE checked and
adjusted with engine COLD.
1. Remove rocker arm cover and crankcase ventilator
tube.
IMPORTANT: Visually inspect contact surfaces of
valve tips, bridges and rocker arm wear
pads. Check all parts for excessive
wear, breakage, or cracks. Replace
parts that show visible damage.
Rocker arms that exhibit excessive
valve clearance should be inspected
more thoroughly to identify damaged
parts.
2. Remove plastic plugs or cover plate from engine
timing/rotation hole (A) and timing pin hole (B).
NOTE: Some engines are equipped with flywheel
housings which do not allow use of an engine
flywheel rotation tool. These engines with straight
nose crankshafts may be rotated from front nose
of engine, using JDG966 Crankshaft Front/Rear
Rotation Adapter.
3. Using JDE83 or JDG820 Flywheel Turning Tool, rotate
engine flywheel in running direction (clockwise viewed
from front) until No. 1 (front) cylinder is at TDC
compression stroke. Insert JDG1571 or JDE81-4
Timing Pin in flywheel.
If No. 1 cylinder rocker arms are loose, the engine is at
No. 1 TDC compression.
If No. 1 cylinder rocker arms are not loose, rotate
engine one full revolution (360°)toNo.1TDC
compression.
35-12
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PN=170
Continued on next page
Lubrication & Maint./2000 Hour/24 Month
OUO1089,0000208 –19–27JUL06–2/5
4. With engine lock-pinned at TDC of No. 1 piston’s
compression stroke, check valve clearance to following
specifications. (Use sequence for 4-cylinder or
6-cylinder engines as outlined on next page.)
Specification
Intake Valve Clearance Checking
(Rocker Arm-to-Bridge) (Engine
Cold)—Clearance 0.31—0.38 mm (0.012—0.015 in.)................................
Exhaust Valve Clearance
Checking (Rocker Arm-to-Bridge)
(Engine Cold)—Clearance 0.41—0.48 mm (0.016—0.019 in.)...................
OUO1089,0000208 –19–27JUL06–3/5
RG12169 –UN–03JUL02
Adjusting Valves
A—Adjusting Screw Jam Nut
5. If valves need adjusting, use the appropriate valve
clearance adjustment procedure on the next page and
adjust to specifications below. Loosen the jam nut (A)
on rocker arm adjusting screw. Turn adjusting screw
until feeler gauge slips with a slight drag. Hold the
adjusting screw from turning with screwdriver and
tighten jam nut to specifications. Recheck clearance
again after tightening jam nut. Readjust clearance as
necessary.
Specification
Intake Valve Clearance
Adjustment (Rocker
Arm-to-Bridge) (Engine Cold)—
Clearance 0.36 mm (0.014 in.)...................................................................
Exhaust Valve Clearance
Adjustment (Rocker
Arm-to-Bridge) (Engine Cold)—
Clearance 0.46 mm (0.018 in.)...................................................................
Rocker Arm Adjusting Screw Jam
Nut—Torque 27 N•m (20 lb-ft)....................................................................
NOTE: While rocker arm cover is removed, test glow
plugs. (See following procedure.)
6. Install rocker arm cover and crankcase ventilator tube.
7. Reconnect battery terminal.
35-13
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PN=171
Continued on next page
Lubrication & Maint./2000 Hour/24 Month
OUO1089,0000208 –19–27JUL06–4/5
A
B
EI
4E3
IE2
IE1
I
E4
IE3
IE2
IE1
I
C
RG12357 –UN–29MAY02
4-Cylinder Valve Adjustment
A—Front of Engine
B—No. 1 Piston TDC Compression
C—No. 4 Piston TDC Compression
E—Exhaust Valve
I—Intake Valve
4-Cylinder Engine:
NOTE: Firing order is 1-3-4-2.
1. Using JDG1571 or JDE81-4 Timing Pin, lock No. 1
piston at TDC compression stroke (B).
2. Adjust valve clearance on No. 1 and 3 exhaust valves
and No. 1 and 2 intake valves.
3. Turn crankshaft 360°. Lock No. 4 piston at TDC
compression stroke (C).
4. Adjust valve clearance on No. 2 and 4 exhaust valves
and No. 3 and 4 intake valves.
OUO1089,0000208 –19–27JUL06–5/5
A
B
E6
IE5
IE4
IE3
IE2
IE1
I
E6
IE5
IE4
IE3
IE2
IE1
I
C
RG12170 –UN–21MAY02
6-Cylinder Valve Adjustment
A—Front of Engine
B—No. 1 Piston TDC Compression
C—No. 6 Piston TDC Compression
E—Exhaust Valve
I—Intake Valve
6-Cylinder Engine:
NOTE: Firing order is 1-5-3-6-2-4.
1. Lock No. 1 piston at TDC compression stroke (B).
2. Adjust valve clearance on No. 1, 3 and 5 exhaust
valves and No. 1, 2, and 4 intake valves.
3. Turn crankshaft 360°. Lock No. 6 piston at TDC
compression stroke (C).
4. Adjust valve clearance on No. 2, 4 and 6 exhaust
valves and No. 3, 5, and 6 intake valves.
35-14
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PN=172
Lubrication & Maint./2000 Hour/24 Month
OURGP11,0000082 –19–27JUL06–1/1
Test Glow Plugs for Continuity (4045HF475
And 6068HF475 Engines)
RG13802 –UN–18NOV04
Test Glow Plugs for Continuity
A—Glow Plug
CAUTION: To prevent accidental starting of
engine while performing this test, always
disconnect NEGATIVE (—) battery terminal.
While checking valve clearance with rocker arm cover
removed, check each glow plug (A) for continuity using a
multimeter.
Check continuity between glow plug and ground on
cylinder head. If resistance is infinite (no current), the glow
plug is damaged and must be replaced.
Install new glow plugs and torque to specifications.
Specification
Glow Plug—Torque 12—18 N•m (9—13 lb-ft)............................................
Reinstall rocker arm cover and crankcase ventilator tube.
35-15
080706
PN=173
Service as Required
RG,RG34710,5591 –19–27JUL06–1/1
Additional Service Information
RG4624 –UN–15DEC88
Component Technical Manual
This is not a detailed service manual. If you want more
detailed service information, use the Publications
Information in the back of this manual to order a
component technical manual.
40-1
080706
PN=174
Service as Required
OURGP11,0000083 –19–27JUL06–1/1
Do Not Modify Fuel System
TS1343 –UN–18MAR92
High-Pressure Fuel Lines
RG11953 –UN–26NOV01
Fuel Injection Pump
CAUTION: Do not open high-pressure fuel
system.
High-pressure fluid remaining in fuel lines can
cause serious injury. Do not disconnect or
attempt repair of fuel lines, sensors, or any
other components between the high-pressure
fuel pump and nozzles on engines with High
Pressure Common Rail (HPCR) fuel system.
Only technicians familiar with this type of
system can perform repairs. (See your John
Deere dealer.)
IMPORTANT: Never steam clean or pour cold water
on an injection pump while it is still
warm. To do so may cause seizure of
pump parts.
Modification or alteration of the
injection pump (arrow), the injection
pump timing, or the fuel injectors in
ways not recommended by the
manufacturer will terminate the
warranty obligation to the purchaser.
In addition, tampering with fuel system
which alters emission-related
equipment on engines may result in
fines or other penalties, per EPA
regulations or other local emission
laws.
Do not attempt to service injection
pump or fuel injectors yourself. Special
training and special tools are required.
(See your authorized servicing dealer or
engine distributor.)
40-2
080706
PN=175
Service as Required
OURGP11,0000222 –19–27JUL06–1/2
Adding Coolant
TS281 –UN–23AUG88
High-Pressure Fluids
RG13295 –UN–20NOV03
Radiator and Coolant
A—Radiator Filler Neck
B—Radiator
CAUTION: Explosive release of fluids from
pressurized cooling system can cause serious
burns.
Shut off engine. Only remove filler cap when
cool enough to touch with bare hands. Slowly
loosen cap to first stop to relieve pressure
before removing completely.
IMPORTANT: Never pour cold liquid into a hot
engine, as it may crack cylinder head or
block. DO NOT operate engine without
coolant for even a few minutes.
John Deere TY15161 Cooling System
Sealer may be added to the radiator to
stop leaks. DO NOT use any other
stop-leak additives in the cooling
system.
Air must be expelled from cooling
system when coolant is added.
Coolant level should be maintained to the bottom of the
radiator filler neck (A). If needed, as coolant as follows.
1. Loosen temperature sending unit fitting at rear of
cylinder head or plug in side of thermostat housing to
allow air to escape when filling system.
IMPORTANT: When adding coolant to the system, use
the appropriate coolant solution. ( See
ENGINE COOLANT SPECIFICATIONS in
Fuels, Lubricants, and Coolant Section
for mixing of coolant ingredients before
adding to cooling system.)
Do not overfill cooling system. A
pressurized system needs space for
heat expansion without overflowing at
top of radiator.
2. Fill radiator (B) until coolant level touches bottom of
radiator filler neck (A).
40-3
080706
PN=176
Continued on next page
Service as Required
OURGP11,0000222 –19–27JUL06–2/2
3. Tighten plugs and fittings when air has been expelled
from system.
4. Run engine until it reaches operating temperature.
40-4
080706
PN=177
Service as Required
RG,RG34710,5594 –19–27JUL06–1/1
Replacing Single Stage Air Cleaner
RG11319A –UN–06SEP00
Single Stage Air Filter
RG11320 –UN–07SEP00
Installation of Single Stage Air Cleaner
A—Outlet Neck Clamp
B—Filter to Engine Overlap
IMPORTANT: ALWAYS REPLACE air cleaner when air
restriction indicator shows a vacuum of
625 mm (25 in.) H
2
O, is torn, or visibly
dirty.
NOTE: This procedure applies to John Deere single stage
air cleaner kits. Refer to manufacturers’
instructions for servicing air cleaners not supplied
by John Deere.
1. If equipped, loosen body clamp.
2. Loosen clamp around outlet neck (A).
3. Remove air cleaner.
4. Install new filter so that overlap (B) of air cleaner outlet
neck and engine intake pipe is to specification below.
Specification
Air Cleaner Neck to Engine
Intake—Overlap 38 mm (1.5 in)..................................................................
5. Tighten neck clamp (A) to specification below.
Specification
Air Cleaner Neck Clamp—Torque 6.8 N•m (60 lb-in.).................................
IMPORTANT: Do NOT overtighten body clamp.
Overtightening may cause crushing of
air cleaner body. Tighten body clamp
only until snug.
6. If equipped, tighten body clamp until snug.
IMPORTANT: Whenever the air cleaner has been
serviced or removed, ALWAYS fully
depress the air restriction indicator
reset button (if equipped) to assure
accurate readings.
7. If equipped, fully depress air restriction indicator reset
button and release to reset indicator.
40-5
080706
PN=178
Service as Required
OURGP11,000013A –19–27JUL06–1/2
Replacing Axial Seal Air Cleaner Filter
Element
RG8719B –UN–03SEP99
Air restriction Indicator
IMPORTANT: ALWAYS REPLACE primary air cleaner
element when air restriction indicator
(A) shows a vacuum of 625 mm (25 in.)
H
2
O, is torn, or visibly dirty.
NOTE: This procedure applies to John Deere 2-stage
axial seal air cleaner kits. Refer to manufacturers’
instructions for servicing air cleaners not supplied
by John Deere.
Continued on next page
40-6
080706
PN=179
Service as Required
OURGP11,000013A –19–27JUL06–2/2
RG4686 –UN–20DEC88
Wing Nut and Primary Element
RG4687 –UN–20DEC88
Dust Unloader Valve and Restriction Indicator
RG11068 –UN–26JUN00
Retaining Nut and Secondary Element
A—Wing Nut
B—Primary Element
C—Dust Unloader Valve
D—Retaining Nut
E—Secondary Element
1. Remove wing nut and remove canister cover shown in
small illustration inset.
2. Remove wing nut (A) and remove primary element (B)
from canister.
3. Thoroughly clean all dirt from inside canister.
NOTE: Some engines may have a dust unloader valve
(C) on the air cleaner. If equipped, squeeze valve
tip to release any trapped dirt particles.
IMPORTANT: Remove secondary (safety) element (E)
ONLY for replacement. DO NOT attempt
to clean, wash, or reuse secondary
element. Replacement of secondary
element is usually necessary ONLY
when primary element has a hole in it.
4. To replace secondary element, remove retaining nut
(D) and secondary element (E). Immediately replace
secondary element with new element to prevent dust
from entering air intake system.
5. Install new primary element and tighten wing nut
securely. Install cover assembly and tighten retaining
wing nut securely.
IMPORTANT: Whenever the air cleaner has been
serviced or had cover removed,
ALWAYS fully depress the air
restriction indicator reset button (if
equipped) to assure accurate readings.
6. If equipped, fully depress air restriction indicator reset
button and release to reset indicator.
40-7
080706
PN=180
Service as Required
RG41165,000008B –19–27JUL06–1/2
Replacing Radial Seal Air Cleaner Filter
Element
RG11321A –UN–08SEP00
Dust Cup/Cover
RG11322A –UN–08SEP00
Primary Filter Element
RG11327A –UN–08SEP00
Secondary Filter Element
A—Dust Cap/Cover
B—Primary Filter Element
C—Secondary Filter Element
IMPORTANT: ALWAYS REPLACE primary air cleaner
element when air restriction indicator
shows a vacuum of 625 mm (25 in.)
H
2
O, is torn, or visibly dirty.
NOTE: This procedure applies to John Deere 2-stage
radial seal air cleaner kits. Refer to manufacturers’
instructions for servicing air cleaners not supplied
by John Deere.
1. Unlatch and remove dust cup/cover (A) of air cleaner.
2. Move end of filter (B) back and forth gently to break
seal.
3. Pull filter (B) off outlet tube and out of housing.
4. Thoroughly clean all dirt from inside housing and from
outlet bore.
IMPORTANT: Remove secondary (safety) element (C)
ONLY for replacement. DO NOT attempt
to clean, wash, or reuse secondary
element. Replacement of secondary
element is usually necessary ONLY
when primary element has a hole in it.
5. To replace secondary element (C), pull filter element
out gently. Immediately replace secondary element
with new element to prevent dust from entering air
intake system.
6. Install new primary filter element. Apply pressure by
hand at outer rim of filter.
IMPORTANT: Do NOT use latches on cover to force
filter into air cleaner. Using cover to
force filter will damage cleaner housing.
7. Close housing with dust unloader valve aimed down
and latch latches.
40-8
080706
PN=181
Continued on next page
Service as Required
RG41165,000008B –19–27JUL06–2/2
IMPORTANT: Whenever the air cleaner has been
serviced or cover has been removed,
ALWAYS fully depress the air
restriction indicator reset button (if
equipped) to assure accurate readings.
8. If equipped, fully depress air restriction indicator reset
button and release to reset indicator.
40-9
080706
PN=182
Service as Required
OURGP11,000013B –19–27JUL06–1/1
Replacing Fan and Alternator Belts
RG11950 –UN–07NOV01
290 mm (11.4 in.) Fan Height and Lower*
RG11951 –UN–07NOV01
338 mm (13.3 in.) Fan Height and Higher Without Freon
Compressor*
RG11952 –UN–07NOV01
402 mm (15.8 in.) Fan Height With Freon Compressor*
A—Alternator
CSP—Crankshaft Pulley
FC—Freon (A/C) Compressor
FD—Fan Drive
I—Idler Pulley
T—Tensioner
CP—Coolant Pump
Refer to CHECKING BELT TENSIONER SPRING
TENSION AND BELT WEAR in Lubrication and
Maintenance/500 Hour/12 Month Section for additional
information on the belt tensioner.
1. Inspect belts for cracks, fraying, or stretched out areas.
Replace if necessary.
2. To replace belt with automatic tensioner, release
tension on belt using a breaker bar and socket on
tension arm.
To replace belt with manual tensioner, release tension
at belt tensioner (See MANUAL BELT TENSIONER
ADJUSTMENT in Lubrication and Maintenance/500
Hour/12 Month Section.)
3. Remove poly-vee belt from pulleys and discard belt.
NOTE: While belt is removed, inspect pulleys and
bearings. Rotate and feel for hard turning or any
unusual sounds. If pulleys or bearings need
replacement, see your John Deere dealer.
4. Install new belt, making sure belt is correctly seated in
all pulley grooves. Refer to belt routing at right for your
application.
5. Apply tension to belt with tensioner. Remove socket.
6. Install fan guard if removed.
7. Start engine and check belt alignment.
*Measured from crank centerline to fan drive center.
40-10
080706
PN=183
Service as Required
OURGP11,000013C –19–27JUL06–1/1
Checking Fuses
RG11938 –UN–06NOV01
Early Engines with Electronic Instrument Panel
A—5 Amp Fuse
NOTE: The instrument panels for later electronically
controlled engines as described in Section 17 do
not have this fuse.
Check fuse (A) located in fuse holder on face of
instrument panel. If defective, replace with a 5-amp fuse.
A separate wiring harness fuse (10 amp) and a main
system fuse (20 amp) are shown in the Wiring Diagrams
in the Troubleshooting Section.
On 4045HF475 and 6068HF475 engines, a separate
wiring harness for glow plugs (not shown) has fuse
protection. To replace fuse, remove cap from holder on
jumper cable and replace with a 50-amp fuse.
NOTE: On 4045DF/TF 270 engines, refer to supplier’s
instructions and diagrams for fuse location and
type.
OURGP12,00001E0 –19–27JUL06–1/1
Checking Air Compressors (If Equipped)
RG12836 –UN–27FEB03
Air Compressor (Optional)
Air compressors are offered as options with John Deere
OEM engines to provide compressed air to operate
air-powered devices like vehicle air brakes.
Air compressors are engine-driven piston types. They are
either air cooled or cooled with engine coolant. The
compressors are lubricated with engine oil. The
compressor runs continuously as gear or spline driven by
the auxiliary drive of the engine but has “loaded” and
“unloaded” operating modes. This is controlled by the
vehicle’s air system (refer to vehicle technical manual for
complete air system checks and services).
See your John Deere engine distributor or servicing dealer
for diagnostic and troubleshooting information. If diagnosis
leads to an internal fault in the compressor, replace the
complete compressor as a new or remanufactured unit.
40-11
080706
PN=184
Service as Required
OURGP11,000000E –19–27JUL06–1/3
Bleeding the Fuel System (Engines With
Electronic Fuel Systems And Bosch VP44
Pump)
X9811 –UN–23AUG88
High-Pressure Fluids
CAUTION: Escaping fluid under pressure can
penetrate the skin causing serious injury.
Relieve pressure before disconnecting fuel or
other lines. Tighten all connections before
applying pressure. Keep hands and body away
from pinholes and nozzles which eject fluids
under high pressure. Use a piece of cardboard
or paper to search for leaks. Do not use your
hand.
If ANY fluid is injected into the skin, it must be
surgically removed within a few hours by a
doctor familiar with this type injury or gangrene
may result. Doctors unfamiliar with this type of
injury may call the Deere & Company Medical
Department in Moline, Illinois, or other
knowledgeable medical source.
Bleed the fuel system anytime the fuel system has been
opened up. This includes:
•After fuel filter changes.
•After pump or nozzle replacement.
•Anytime fuel lines have been disconnected.
•After engine has run out of fuel.
This fuel system can only be bled by the electronic
transfer pump or at the injection nozzles. BLEEDING
SHOULD NOT BE PERFORMED at any location on the
Bosch VP44 injection pump.
Continued on next page
40-12
080706
PN=185
Service as Required
OURGP11,000000E –19–27JUL06–2/3
RG11719A –UN–20JUN01
Bleed Fuel System
A—Bleed Orifice in Final Fuel Filter Base
B—Fuel Return Line
IMPORTANT: NEVER pressurize the fuel tank to prime
the fuel system as it could rupture seals
in the injection pump.
Bleed Using Electronic Transfer Pump
The bleed is automatically performed by a small orifice (A)
inside the final fuel filter base connected to the overflow
valve on injection pump. The system allows air to escape
continually through the fuel return line (B) when ignition is
ON.
1. Ignition ON.
2. Allow 40 seconds for electronic transfer pump to
complete priming.
3. If additional system bleeding is required, bleed the
circuit by loosening fuel line connections at injection
nozzles. See the next procedure, BLEED FUEL SYSTEM
AT FUEL INJECTION NOZZLES.
OURGP11,000000E –19–27JUL06–3/3
RG7725 –UN–08JAN97
Bleed At Fuel Injection Nozzles
Bleed Fuel System at Fuel Injection Nozzles
IMPORTANT: Always use a backup wrench when
loosening or tightening fuel lines at
nozzles and/or injection pump to avoid
damage.
1. Using two open-end wrenches, loosen two fuel line
connections at injection nozzles.
2. Crank engine over with starter motor for 15 seconds
(but do not start engine) until fuel free from bubbles
flows out of loosened connection. Retighten connection
to specifications.
Specification
Fuel Injection Nozzle Delivery
Line—Torque 27 N•m (20 lb-ft)...................................................................
3. Repeat procedure for remaining injection nozzles (if
necessary) until all air has been removed from fuel
system.
40-13
080706
PN=186
Service as Required
OUOD002,000016F –19–27JUL06–1/5
Bleed the Fuel System (Engines with
Electronic Fuel Systems and Stanadyne
DE10 Pump)
X9811 –UN–23AUG88
High Pressure Fluids
CAUTION: Escaping fluid under pressure can
penetrate the skin causing serious injury. Avoid
hazards by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure
fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be
surgically removed within a few hours or
gangrene may result. Doctors unfamiliar with
this type of injury may call the Deere &
Company Medical Department in Moline, Illinois,
or other knowledgeable medical source.
Bleed the fuel system anytime the fuel system has been
opened up. This includes:
•After fuel filter changes.
•After pump or nozzle replacement.
•Anytime fuel lines have been disconnected.
•After engine has run out of fuel.
The fuel system may be bled at one of several locations.
Choose the best location for your engine/machine
application.
Continued on next page
40-14
080706
PN=187
Service as Required
OUOD002,000016F –19–27JUL06–2/5
RG11805 –UN–25OCT01
Final Fuel Filter Bleed Vent Screw
A—Bleed Vent Screw
1. Loosen the air bleed vent screw (A) two full turns by
hand on fuel filter base.
OUOD002,000016F –19–27JUL06–3/5
RG11806 –UN–25OCT01
Fuel Supply Pump Primer Lever
B—Primer Lever
2. Operate fuel supply pump primer lever (B) or primer
button on fuel filter base (if equipped).
3. Tighten bleed plug securely, continue operating primer
until pumping action is not felt
4. Start engine and check for leaks.
If engine will not start, it may be necessary to bleed air
from fuel system at fuel injection pump or injection
nozzles as explained next.
Continued on next page
40-15
080706
PN=188
Service as Required
OUOD002,000016F –19–27JUL06–4/5
RG11807 –UN–25OCT01
Fuel Injection Pump Return Line
A—Fuel Return Line
At Fuel Injection Pump
1. Loosen fuel return line (A) at fuel injection pump.
2. Operate fuel supply pump primer lever or primer button
on fuel filter base (if equipped).
3. As soon as fuel flow is free from air bubbles, tighten
fuel return line to specifications. Primer lever is
spring-loaded and will return to normal position.
Specification
Fuel Injection Pump Return
Line—Torque 27 N•m (20 lb-ft)...................................................................
OUOD002,000016F –19–27JUL06–5/5
RG11808 –UN–25OCT01
Nozzle Fuel Pressure Line
At Fuel Injection Nozzles
IMPORTANT: Always use a backup wrench when
loosening or tightening fuel lines at
nozzles and/or injection pump to avoid
damage.
1. Using two open-end wrenches, loosen two fuel line
connections at injection nozzles.
2. Crank engine over with starter motor for 15 seconds
(but do not start engine) until fuel free from bubbles
flows out of loosened connection. Retighten connection
to specifications.
Specification
Fuel Injection Nozzle Delivery
Lines—Torque 27 N•m (20 lb-ft).................................................................
3. Repeat procedure for remaining injection nozzles (if
necessary) until all air has been removed from fuel
system.
If engine still will not start, see your authorized servicing
dealer or engine distributor.
40-16
080706
PN=189
Service as Required
OURGP11,000000F –19–27JUL06–1/3
Bleed the Fuel System (Engines with
Electronic Fuel Systems and Denso High
Pressure Common Rail) (4045HF475,
6068HF475)
TS1343 –UN–18MAR92
High-Pressure Fuel Lines
X9811 –UN–23AUG88
High Pressure Fluids
CAUTION: High-pressure fluid remaining in fuel
lines can cause serious injury. Do not
disconnect or attempt repair of fuel lines,
sensors, or any other components between the
high-pressure fuel pump and nozzles on
engines with High Pressure Common Rail
(HPCR) fuel system. Only technicians familiar
with this type of system can perform repairs.
(See your John Deere dealer.)
Escaping fluid under pressure can penetrate the
skin causing serious injury. Avoid hazards by
relieving pressure before disconnecting
hydraulic or other lines. Tighten all connections
before applying pressure. Search for leaks with
a piece of cardboard. Protect hands and body
from high pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be
surgically removed within a few hours or
gangrene may result. Doctors unfamiliar with
this type of injury may call the Deere &
Company Medical Department in Moline, Illinois,
or other knowledgeable medical source.
Any time the fuel system has been opened up for service
(lines disconnected or filters removed), it will be necessary
to bleed air from the system.
Continued on next page
40-17
080706
PN=190
Service as Required
OURGP11,000000F –19–27JUL06–2/3
RG12220 –UN–24MAY02
Final Fuel Filter Bleed Vent Screw
A—Bleed Vent Screw
IMPORTANT: NEVER pressurize the fuel tank to prime
the fuel system as it could rupture seals
in the injection pump.
NOTE: These are the 4-valve cylinder head 4.5 L and 6.8
L “475” model engines with Denso HP3 pumps
and High Pressure Common Rail (HPCR) fuel
systems (decal on rocker arm cover marked “16V”
or “24V”).
IMPORTANT: Four valve cylinder head engines are
especially sensitive to fuel
contamination. Do not crack any fuel
lines to bleed the fuel system.
1. Loosen the air bleed vent screw (A) two full turns by
hand on fuel filter base.
OURGP11,000000F –19–27JUL06–3/3
RG12221 –UN–24MAY02
Fuel Supply Pump Primer Lever
B—Primer Lever
2. Operate fuel supply pump primer lever (B), or primer
button on fuel filter base (if equipped), until fuel flows
out of bleed vent screw.
3. Tighten bleed vent screw securely. Continue operating
primer until pumping action is not felt.
4. Start engine and check for leaks.
If engine will not start, repeat steps 1-4.
40-18
080706
PN=191
Service as Required
OURGP11,0000010 –19–27JUL06–1/5
Bleed the Fuel System (4045DF270,
4045TF270)
X9811 –UN–23AUG88
High-Pressure Fluids
CAUTION: Escaping fluid under pressure can
penetrate the skin causing serious injury.
Relieve pressure before disconnecting fuel or
other lines. Tighten all connections before
applying pressure. Keep hands and body away
from pinholes and nozzles which eject fluids
under high pressure. Use a piece of cardboard
or paper to search for leaks. Do not use your
hand.
If ANY fluid is injected into the skin, it must be
surgically removed within a few hours by a
doctor familiar with this type injury or gangrene
may result. Doctors unfamiliar with this type of
injury may call the Deere & Company Medical
Department in Moline, Illinois, or other
knowledgeable medical source.
IMPORTANT: Do not operate the engine at high
speeds or full loads just before
bleeding the fuel system as this may
cause fuel injection pump failure.
Bleed the fuel system anytime the fuel system has been
opened up. This includes:
•After fuel filter changes.
•After pump or nozzle replacement.
•Anytime fuel lines have been disconnected.
•After engine has run out of fuel.
Continued on next page
40-19
080706
PN=192
Service as Required
OURGP11,0000010 –19–27JUL06–2/5
RG7947 –UN–13NOV97
Air Bleed Vent Screw
A—Vent Screw
IMPORTANT: NEVER pressurize the fuel tank to prime
the fuel system as it could rupture seals
in the injection pump.
1. Loosen the air bleed vent screw (A) two full turns by
hand on fuel filter base.
OURGP11,0000010 –19–27JUL06–3/5
RG8013A –UN–15JAN99
Fuel Supply Pump Primer Lever
B—Fuel Supply Pump Primer Lever
2. Operate supply pump primer lever (B) until fuel flow is
free from air bubbles.
3. Tighten bleed plug securely, continue operating hand
primer until pumping action is not felt. Push hand
primer inward (toward engine) as far as it will go.
4. Start engine and check for leaks.
If engine will not start, it may be necessary to bleed air
from fuel system at fuel injection pump or injection
nozzles as explained next.
Continued on next page
40-20
080706
PN=193
Service as Required
OURGP11,0000010 –19–27JUL06–4/5
RG6264 –UN–03NOV97
Stanadyne Rotary Fuel Injection Pump
A—Fuel Return Line Connector
At Fuel Injection Pump
1. Slightly loosen fuel return line connector (A) at fuel
injection pump.
2. Operate fuel supply pump primer lever until fuel,
without air bubbles, flows from fuel return line
connection.
3. Tighten return line connector to 27 N•m (20 lb-ft).
4. Primer lever is spring-loaded and will return to normal
position.
OURGP11,0000010 –19–27JUL06–5/5
RG7725 –UN–08JAN97
Fuel Line Connection
At Fuel Injection Nozzles
1. Move the engine speed control lever to half throttle
position. On engines equipped with electronic fuel
shut-off solenoid, energize solenoid.
2. Using two open-end wrenches, loosen fuel line
connection at injection nozzle as shown.
3. Crank engine over with starter motor, (but do not start
engine), until fuel free from bubbles flows out of
loosened connection.
4. Retighten connection to 23 N•m (17 lb-ft).
5. Repeat procedure for remaining injection nozzles (if
necessary) until all air has been removed from fuel
system.
If engine still will not start, see your authorized
servicing dealer or engine distributor.
40-21
080706
PN=194
Troubleshooting
RG,RG34710,5605 –19–27JUL06–1/1
General Troubleshooting Information
Troubleshooting engine problems can be difficult. An
engine wiring diagram is provided in this section to
help isolate electrical problems on power units using
John Deere wiring harness and instrument (gauge)
panel.
Wiring diagrams are shown for the electronic
instrument panel and harness offered for these
engines.
Later in this section is a list of possible engine
problems that may be encountered accompanied by
possible causes and corrections. The illustrated
diagrams and troubleshooting information are of a
general nature; final design of the overall system for
your engine application may be different. See your
engine distributor or servicing dealer if you are in
doubt.
A reliable program for troubleshooting engine problems
should include the following basic diagnostic thought
process:
•Know the engine and all related systems.
•Study the problem thoroughly.
•Relate the symptoms to your knowledge of engine
and systems.
•Diagnose the problem starting with the easiest
things first.
•Double-check before beginning the disassembly.
•Determine cause and make a thorough repair.
•After making repairs, operate the engine under
normal conditions to verify that the problem and
cause was corrected.
NOTE: The engines covered in this manual have
electronic control systems which send
diagnostic trouble codes to signal problems
(see DIAGNOSTIC TROUBLE CODE
PROCEDURE, later in this section).
45-1
080706
PN=195
Troubleshooting
OUOD002,000016B –19–27JUL06–1/1
Precautions For Welding On Engines
Equipped With Electronic Engine Control
Unit (ECU)
IMPORTANT: ALWAYS disconnect Electronic Control
Unit (ECU) connectors and engine
control system-to-machine ground
before welding on engine or machine.
High currents or electro-static
discharge in electronic components
from welding may cause permanent
damage.
1. Remove the ground connection for the engine control
system-to-machine frame.
2. Disconnect the connectors from the ECU.
3. Connect the welder ground close to the welding point
and be sure ECU or other electronic components are not
in the ground path.
OURGP11,000012A –19–27JUL06–1/1
Precautions for Electrical System When
Steam Cleaning Engine
IMPORTANT: Do not steam clean any electrical or
electronic components while steam
cleaning the engine as it could damage
sensitive parts.
45-2
080706
PN=196
Troubleshooting
OURGP11,0000276 –19–27JUL06–1/1
Engine Wiring Layout (Electronic Fuel System With Stanadyne DE10 Injection Pump)
RG12201 –UN–24MAY02
A—Coolant Temperature G—Starter Relay Connector M—Remote ON/ OFF R—Engine Wiring Harness
Sensor Connector H—Oil Pressure Sensor Connector S—Fuel Heater Connector
B—Fuel Temperature Sensor Connector N—CAN Network Diagnostic T—Manifold Air Temperature
Connector I—Main System Fuse (10 amp) Connector (MAT) Sensor Connector
C—Injection Pump Solenoid J—Power and Ground Battery O—Instrument Panel U—Alternator Ignition
Connector Connections Connector Harness Connector
D—SAE 1939 CAN Connector K—Fuse Holder P—23-pin Optional Feature V—Optional Instrument Panel
E—Crankshaft Position Sensor L—Transient Voltage Connector (Extended- (Earlier Version Shown)
Connector Protection (TVP) Module feature ECU only)
F—ECU Connector Connector Q—21-pin Instrument Panel
Connector
45-3
080706
PN=197
Troubleshooting
OURGP11,0000277 –19–27JUL06–1/1
Engine Wiring Layout (Electronic Fuel System With Bosch VP44 Injection Pump)
RG11939A –UN–05JUN02
A—Oil Pressure Sensor I—Manifold Air Temperature Q—Engine Control Unit (ECU) W—Remote ON/OFF
B—Fuel Pump Relay (MAT) Sensor R—ECU Connector Connector
C—Fuel Pump Relay Fuse J—Fuel Transfer Pump S—System Ground (ECU must X—Instrument Panel
D—Crankshaft Position Sensor K—Fuel Heater also be grounded to frame) Connector
E—Fuel Injection Pump Event L—Fuel Temperature Sensor T—CAN Network Diagnostic Y—Optional Instrument Panel
Sensor M—Network CAN Connector Connector (Earlier Version Shown)
F—Coolant Temperature N—Isochronous Governor U—Blink-Code Diagnostic Z—Starter Relay Connections
Sensor Select Connector Connector AA—Power and Ground
G—Fuel Injection Pump O—Transient Voltage V—Secondary Analog Throttle Battery Connections
Connector Protection (TVP) Module Connector BB—Optional Wire Extensions
H—Alternator Ignition P—Main System Fuse (20
Connector Amp)
45-4
080706
PN=198
Troubleshooting
OURGP11,0000278 –19–27JUL06–1/1
Engine Wiring Layout (Electronic Fuel System With Denso High Pressure Common
Rail)(4045HF475,6068HF475)
RG12224 –UN–19JUN02
6068HF475 Engine Shown
A—Engine Coolant D—(ECU) Connector H—Power and Ground Battery K—Pump Position Sensor
Temperature (ECT) Sensor E—Optional Instrument Panel Connections L—Pump Control Valve
B—Electronic Injector (Earlier Version Shown) I—Fuel Rail Pressure Sensor Solenoid
Connector F—Engine Wiring Harness J—Crankshaft Position Sensor M—Fuel Temperature Sensor
C—Manifold Air Temperature G—Engine Oil Pressure
(MAT) Sensor Sensor Connector
45-5
080706
PN=199
Troubleshooting
OURGP11,000026F –19–27JUL06–1/1
Engine Wiring Diagram (With Earlier Electronic Instrument Panel)
414
BAT
B
BA
BA
X6
REMOTE ON/OFF
PLUG
022
032
032
022
A
B
C
905 CAN L
012 IGN +12V OR +24V
412 ACC
422 STARTER RELAY SOLENOID
002 BAT
904 CAN H
020 CAN SHIELD
464 SENSOR RETURN 2
911
915
414
SE-2 INSTRUMENT PANEL (CONTINUED NEXT PAGE)
SE-1 ENGINE START COMPONENTS
923
OFF
OVERRIDE
SHUTDOWN
B
OFF
A
918
S5
464
TO
ECU
HIGH IDLE
LOW IDLE
B
ALL A
C
TO
ECU
TO
ECU
947
S4
947
BA
TO
ECU
TO
ECU
BUMP UP
OFF
BUMP DN
OFF
A
B
C
BUMP
ENABLE
BUMP
ENABLE
OFF
OFF
A
B
C
012
012
012
S1
OFF
RUN
START
RUN
ST
IGN
ACC
GND
422
012
ACC.
422
002
A
BTVP
(12V
OR 24V)
002
050
012
IGN
OUTPUT
N1
V1
G1 M1
050
TO
ECU
012
SINGLE
POINT
GROUND
F1
10A
G1 M1
K1
B
OUT
2
X3
X2
S2
S3
A
B
A
002
X1
923
955
936
422
022
050 050
+12V
002
A
A
TO
ECU
S
BAT
S
409
X5
ABC
ACB
B1
ANALOG THROTTLE
EMULATOR
4700
OHM 510
OHM
ANALOG
THROTTLE A
TO
ECU
RG11568 –19–24OCT01
B1—Analog Throttle or N1—Transient Voltage S1—Ignition Key Switch V1—Diode
Emulator Protector S2—Speed Select Switch X1—Vehicle Harness
E1—Back Light Regulator N2—Voltage Regulator (for (Momentary) Connector
(24V) or Plug (12V) 24V Operation) S3—Bump Enable Switch X2—Alternator Harness
F1—Fuse (10 Amp) (for P1—Optional Gauge (Momentary) X3—Single Point Ground
harness) P2—Optional Gauge S4—High Low Speed Switch X4—CAN Terminator
F2—Fuse (5 Amp) (for P3—Oil Pressure Gauge S5—Override Shutdown X5—Analog Throttle
instrument panel) P4—Coolant Temperature Switch (Momentary) Connector
G1—Alternator Gauge S6—Dimmer Control or X6—Remote On-Off Plug
K1—Starter Relay P5—Tachometer Display Jumper Plug
M1—Starter Motor P6—Hourmeter/Diagnostic
Meter
45-6
080706
PN=200
Troubleshooting
OURGP11,0000270 –19–27JUL06–1/1
Engine Wiring Diagram (With Earlier Electronic Instrument Panel)—Continued
RG10040 –19–18MAY99
B1—Analog Throttle or N1—Transient Voltage S1—Ignition Key Switch V1—Diode
Emulator Protector S2—Speed Select Switch X1—Vehicle Harness
E1—Back Light Regulator N2—Voltage Regulator (for (Momentary) Connector
(24V) or Plug (12V) 24V Operation) S3—Bump Enable Switch X2—Alternator Harness
F1—Fuse (10 Amp) (for P1—Optional Gauge (Momentary) X3—Single Point Ground
harness) P2—Optional Gauge S4—High Low Speed Switch X4—CAN Terminator
F2—Fuse (5 Amp) (for P3—Oil Pressure Gauge S5—Override Shutdown X5—Analog Throttle
instrument panel) P4—Coolant Temperature Switch (Momentary) Connector
G1—Alternator Gauge S6—Dimmer Control or X6—Remote On-Off Plug
K1—Starter Relay P5—Tachometer Display Jumper Plug
M1—Starter Motor P6—Hourmeter/Diagnostic
Meter
45-7
080706
PN=201
Troubleshooting
OURGP11,0000271 –19–27JUL06–1/1
Engine Wiring Diagram (With Later Full-Featured Electronic Instrument Panel)
RG13354 –UN–22JAN04
B1—Analog Throttle P3—Oil Pressure Gauge S3—Bump Enable Switch X2—Alternator Harness
F1—Fuse (30 Amp) (Harness) P4—Coolant Temperature (Momentary) Connector
G1—Alternator Gauge S4—High-Low Speed Select X3—Single Point Ground
K1—Starter Relay P5—Tachometer Display Switch X4—CAN Terminator
M1—Starter Motor P6—Hour Meter/Diagnostic S5—Override Shutdown X5—Analog Throttle
N1—Transient Voltage Gauge Switch (Momentary) Connector
Protector S1—Ignition Key Switch V1—Diode
P1—Optional Gauge S2—Speed Select Switch X1—Vehicle Harness
P2—Optional Gauge (Momentary) Connector
45-8
080706
PN=202
Troubleshooting
OURGP11,0000272 –19–27JUL06–1/1
Engine Wiring Diagram (With Later Full-Featured Electronic Instrument Panel)—
Continued
RG13272 –UN–26JAN04
B1—Analog Throttle P3—Oil Pressure Gauge S3—Bump Enable Switch X2—Alternator Harness
F1—Fuse (30 Amp) (Harness) P4—Coolant Temperature (Momentary) Connector
G1—Alternator Gauge S4—High-Low Speed Select X3—Single Point Ground
K1—Starter Relay P5—Tachometer Display Switch X4—CAN Terminator
M1—Starter Motor P6—Hour Meter/Diagnostic S5—Override Shutdown X5—Analog Throttle
N1—Transient Voltage Gauge Switch (Momentary) Connector
Protector S1—Ignition Key Switch V1—Diode
P1—Optional Gauge S2—Speed Select Switch X1—Vehicle Harness
P2—Optional Gauge (Momentary) Connector
45-9
080706
PN=203
Troubleshooting
RG,RG34710,5608 –19–27JUL06–1/8
Engine Troubleshooting
Symptom Problem Solution
Engine cranks but will not start Incorrect starting procedure. Verify correct starting procedure.
No fuel. Check fuel in tank.
Exhaust restricted. Check and correct exhaust
restriction.
Fuel filter plugged or full of water. Replace fuel filter or drain water
from filter.
Injection pump not getting fuel or air Check fuel flow at supply pump or
in fuel system. bleed fuel system.
Faulty injection pump or nozzles. Consult authorized diesel repair
station for repair or replacement.
Continued on next page
45-10
080706
PN=204
Troubleshooting
RG,RG34710,5608 –19–27JUL06–2/8
Symptom Problem Solution
Engine hard to start or will not Engine starting under load. Disengage PTO.
start
Improper starting procedure. Review starting procedure.
No fuel. Check fuel tank.
Air in fuel line. Bleed fuel line.
Cold weather. Use cold weather starting aids.
Slow starter speed. See “Starter Cranks Slowly”.
Crankcase oil too heavy. Use oil of proper viscosity.
Improper type of fuel. Consult fuel supplier; use proper
type fuel for operating conditions.
Water, dirt, or air in fuel system. Drain, flush, fill, and bleed system.
Clogged fuel filter. Replace filter element.
Dirty or faulty injection nozzles. Have authorized servicing dealer or
engine distributor check injectors.
Defective glow plugs (Cold weather Test glow plugs (See 2000 hour/24
starting-4045HF475, 6068HF475) month maintenance section)
Electronic fuel system problem (if See your John Deere distributor or
equipped) servicing dealer.
Engine knocks Low engine oil level. Add oil to engine crankcase.
Low coolant temperature. Remove and check thermostat.
Engine overheating. See “Engine Overheats”.
Engine cold Wrong or defective thermostat.
Remove and check thermostat.
Continued on next page
45-11
080706
PN=205
Troubleshooting
RG,RG34710,5608 –19–27JUL06–3/8
Symptom Problem Solution
Engine runs irregularly or stalls Low coolant temperature. Remove and check thermostat.
frequently
Clogged fuel filter. Replace fuel filter element.
Water, dirt, or air in fuel system. Drain, flush, fill, and bleed system.
Dirty or faulty injection nozzles. Have authorized servicing dealer or
engine distributor check injectors.
Electronic fuel system problem See your John Deere distributor or
servicing dealer.
Below normal engine Defective thermostat. Remove and check thermostat.
temperature
Defective temperature gauge or Check gauge, sender, and
sender. connections.
Continued on next page
45-12
080706
PN=206
Troubleshooting
RG,RG34710,5608 –19–27JUL06–4/8
Symptom Problem Solution
Lack of power Engine overloaded. Reduce load.
Intake air restriction. Service air cleaner.
Clogged fuel filter. Replace filter elements.
Improper type of fuel. Use proper fuel.
Overheated engine. See “Engine Overheats”.
Below normal engine temperature. Remove and check thermostat.
Improper valve clearance. See your authorized servicing dealer
or engine distributor.
Dirty or faulty injection nozzles. Have authorized servicing dealer or
engine distributor check injectors.
Injection pump out of time. See your authorized servicing dealer
or engine distributor.
Electronic fuel system problem See your John Deere distributor or
servicing dealer.
Turbocharger not functioning. See your authorized servicing dealer
(Turbocharger engines only.) or engine distributor.
Leaking exhaust manifold gasket. See your authorized servicing dealer
or engine distributor.
Defective aneroid control line. See your authorized servicing dealer
or engine distributor.
Restricted fuel hose. Clean or replace fuel hose.
Low fast idle speed. See your authorized servicing dealer
or engine distributor.
Low oil pressure Low oil level. Add oil.
Improper type of oil. Drain, fill crankcase with oil of proper
viscosity and quality.
45-13
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Continued on next page
Troubleshooting
RG,RG34710,5608 –19–27JUL06–5/8
Symptom Problem Solution
High oil consumption Crankcase oil too light. Use proper viscosity oil.
Oil leaks. Check for leaks in lines, gaskets,
and drain plug.
Restricted crankcase vent tube. Clean vent tube.
Defective turbocharger. See your authorized servicing dealer
or engine distributor.
Engine emits white smoke Improper type of fuel. Use proper fuel.
Low engine temperature. Warm up engine to normal operating
temperature.
Defective thermostat. Remove and check thermostat.
Defective injection nozzles. See your authorized servicing dealer
or engine distributor.
Defective glow plugs (4045HF475, Test glow plugs (See 2000 hour/24
6068HF475) month maintenance section)
Engine emits black or gray Improper type of fuel. Use proper fuel.
exhaust smoke
Clogged or dirty air cleaner. Service air cleaner.
Engine overloaded. Reduce load.
Injection nozzles dirty. See your authorized servicing dealer
or engine distributor.
Electronic fuel system problem See your authorized servicing dealer
or engine distributor.
Turbocharger not functioning. See your authorized servicing dealer
or engine distributor.
Continued on next page
45-14
080706
PN=208
Troubleshooting
RG,RG34710,5608 –19–27JUL06–6/8
Symptom Problem Solution
Engine overheats Engine overloaded. Reduce load.
Low coolant level. Fill radiator to proper level, check
radiator and hoses for loose
connections or leaks.
Faulty radiator cap. Have technician check.
Stretched poly-vee belt or defective Check automatic belt tensioner and
belt tensioner. check belts for stretching. Replace
as required.
Low engine oil level. Check oil level. Add oil as required.
Cooling system needs flushing. Flush cooling system.
Defective thermostat. Remove and check thermostat.
Defective temperature gauge or Check coolant temperature with
sender. thermometer and replace, if
necessary.
Incorrect grade of fuel. Use correct grade of fuel.
High fuel consumption Improper type of fuel. Use proper type of fuel.
Clogged or dirty air cleaner. Service air cleaner.
Engine overloaded. Reduce load.
Improper valve clearance. See your authorized servicing dealer
or engine distributor.
Injection nozzles dirty. See your authorized servicing dealer
or engine distributor.
Electronic fuel system problem See your authorized servicing dealer
or engine distributor.
Defective turbocharger. See your authorized servicing dealer
or engine distributor.
Low engine temperature. Check thermostat.
45-15
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Continued on next page
Troubleshooting
RG,RG34710,5608 –19–27JUL06–7/8
Symptom Problem Solution
Undercharged electrical system Excessive electrical load from added Remove accessories or install higher
accessories. output alternator.
Excessive engine idling. Increase engine rpm when heavy
electrical load is used.
Poor electrical connections on Inspect and clean as necessary.
battery, ground strap, starter, or
alternator.
Defective battery. Test battery.
Defective alternator. Test charging system.
Battery uses too much water Cracked battery case. Check for moisture and replace as
necessary.
Defective battery. Test battery.
Battery charging rate too high. Test charging system.
Batteries will not charge Loose or corroded connections. Clean and tighten connections.
Sulfated or worn-out batteries. See your authorized servicing dealer
or engine distributor.
Stretched poly-vee belt or defective Adjust belt tension or replace belts.
belt tensioner.
Starter will not crank PTO engaged. Disengage PTO.
Loose or corroded connections. Clean and tighten loose connections.
Low battery output voltage. See your authorized servicing dealer
or engine distributor.
Faulty start circuit relay. See your authorized servicing dealer
or engine distributor.
Blown main system fuse (MDL-25) Replace fuse.
Starter cranks slowly Low battery output. See your authorized servicing dealer
or engine distributor.
Crankcase oil too heavy. Use proper viscosity oil.
Loose or corroded connections. Clean and tighten loose connections.
45-16
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Continued on next page
Troubleshooting
RG,RG34710,5608 –19–27JUL06–8/8
Symptom Problem Solution
Starter and hour meter functions; Blown fuse on magnetic switch. Replace fuse.
rest of electrical system does not
function
Entire electrical system does not Faulty battery connection. Clean and tighten connections.
function
Sulfated or worn-out batteries. See your authorized servicing dealer
or engine distributor.
Blown main system fuse. Replace fuse.
OURGP11,0000085 –19–27JUL06–1/1
Blink Code Method for Retrieving Diagnostic Trouble Codes (All Except Early VP44 Pump
Engines)
NOTE: If engine has an electronic instrument panel
with diagnostic gauge, refer to “Instrument
Panel Method for Retrieving Diagnostic
Trouble Codes” later in this section.
On OEM applications that have a Fault Lamp, the ECU
has the ability to display DTCs using blinking
sequence of the fault lamp. To retrieve DTCs from the
ECU using the “blink code” method:
NOTE: The ECU blinks the codes in 2-digit codes
only. See LISTING OF DIAGNOSTIC
TROUBLE CODES (DTCS) later in this Group.
1. Press down Override Shutdown Switch while
turning the ignition switch “ON”.
2. The Fault Lamp will begin to flash a code number.
For example, flash three times...short pause...flash
two times...long pause. This example is code 32.
3. The ECU begins the flashing sequence by flashing
a code 32, this indicates the start of blinking active
codes. If there are any active DTCs, the ECU will
flash it’s 2–digit number. If there is more than one
active DTC, the ECU will flash each code in
numerical order. If there are no active DTCs, the
Fault Lamp will flash a code 88.
4. Following the active codes, the Fault Lamp will
flash a code 33. This indicates the start of blinking
stored codes. If there are any stored DTCs, the
Fault Lamp will flash its 2–digit number. If there is
more than one stored DTC, the ECU will flash each
code in numerical order. If there are no stored
DTCs, the Fault Lamp will flash a code 88.
5. Once complete, this sequence will repeat.
6. When complete, turn ignition “OFF”.
As an example, if an engine had an active DTC 18
and stored DTC 53, the flashing sequence would be:
flash three times...short pause...flash two times...long
pause...flash one time...short pause...flash eight
times...long pause...flash three times...short
pause...flash three times...long pause...flash five
times...short pause...flash three times.
45-17
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Troubleshooting
OURGP12,00001EA –19–27JUL06–1/2
Blink Code Method for Retrieving Diagnostic
Trouble Codes (Early VP44 Pump Engines
Only)
RG11754A –UN–13JUL01
Diagnostic Blink Code Connector
A—Diagnostic Blink Code Connector
B—Diagnostic Connector
C—ECU
On OEM applications that have a Fault Lamp, the ECU
has the ability to display Diagnostic Trouble Codes
(DTCs) using blinking sequence of the fault lamp. To
retrieve DTCs from the ECU using the “blink code”
method:
NOTE: The ECU blinks the codes in 2-digit codes only.
See LISTING OF DIAGNOSTIC TROUBLE
CODES (DTCS) later in this Group.
1. Locate and uncap the 4–way METRI-PACK
diagnostic blink code connector (A).
2. Using a short piece of wire, jump terminals A and B in
the diagnostic blink code connector together.
3. Turn the ignition switch “ON”.
4. The Fault Lamp will begin to flash a code number. For
example, flash three times...short pause...flash two
times...long pause. This example is code 32.
5. The ECU begins the flashing sequence by flashing a
code 32, this indicates the start of blinking active
codes. If there are any active DTCs, the ECU will flash
it’s 2–digit number. If there is more than one active
DTC, the ECU will flash each code in numerical order.
If there are no active DTCs, the Fault Lamp will flash a
code 88.
6. Following the active codes, the Fault Lamp will flash a
code 33, this indicates the start of blinking stored
codes. If there are any stored DTCs, the Fault Lamp
will flash its 2–digit number. If there is more than one
stored DTC, the ECU will flash each code in numerical
order. If there are no stored DTCs, the Fault Lamp will
flash a code 88.
7. Once complete, this sequence will repeat.
METRI-PACK is a trademark of Packard Electric Inc.
45-18
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Continued on next page
Troubleshooting
OURGP12,00001EA –19–27JUL06–2/2
8. When complete, turn ignition “OFF”, remove jumper
wire, and recap the diagnostic reader connector.
As an example, if an engine had an active DTC 18 and
stored DTC 53, the flashing sequence would be: flash
three times...short pause...flash two times...long
pause...flash one time...short pause...flash eight
times...long pause...flash three times...short pause...flash
three times...long pause...flash five times...short
pause...flash three times.
45-19
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Troubleshooting
OURGP11,0000279 –19–27JUL06–1/1
Instrument Panel Method for Retrieving
Diagnostic Trouble Codes
RG13287 –UN–30OCT03
Trouble Code Display On Earlier Panel (Left) or Later Panel
(Right)
A—Diagnostic Gauge
IMPORTANT: Care should be used during diagnostic
procedures to avoid damaging the
terminals of connectors, sensors, and
actuators. Probes should not be poked
into or around the terminals or damage
will result. Probes should only be
touched against the terminals to make
measurements.
Diagnosis of the Deere electronic control system on
engines with Deere electronic instrument panel (shown)
should be performed as follows:
1. Make sure all engine mechanical and other systems not
related to the electronic control system are operating
properly.
NOTE: Liquid Crystal Display [LCD] will always default to
last menu item. If an active Diagnostic Trouble
Code (DTC) is present, display will alternately
flash from the hour meter reading to DTC(s).
The code number will appear on the first line and
the words SrvcCode on the second line. Active
DTC(s) can be viewed by selecting “SrvcCode” on
the menu and pressing both touch switches at the
same time. Pressing touch switches (B) and (C)
scrolls through various engine parameters and
diagnostic trouble codes.
2. Read and record DTC(s) displayed on LCD of
diagnostic gauge (A). For procedure to access diagnostic
trouble codes, refer to “Using Diagnostic Gauge to Access
Engine Information”, earlier in this manual.
3. Go to the LISTING OF DIAGNOSTIC TROUBLE
CODES (DTCs) later in this section, to interpret to the
DTC(s) present.
4. Contact your nearest engine distributor or servicing
dealer with a list of DTC(s) so that necessary repairs can
be made.
45-20
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Troubleshooting
DPSG,OUOD002,1591 –19–27JUL06–1/1
Displaying Of Diagnostic Trouble Codes (DTCs)
There are several different methods for displaying both
stored and active DTCs from the ECU via a fault lamp
or a diagnostic gauge on the electronic instrument
panel.
2-DIGIT CODES
Some engines display Service Codes or DTCs as
2-digit codes read from a fault lamp which gives blink
codes.
SPN/FMI CODES
Stored and active diagnostic trouble codes are output
on the diagnostic gauge on the Deere electronic
instrument panel according to the J1939 standard as a
two-part code as shown on the tables on the following
pages.
The first part is a six-digit Suspect Parameter Number
(SPN) followed by a two-digit Failure Mode Identifier
(FMI) code. In order to determine the exact failure,
both parts (SPN and FMI) of the code are needed.
The SPN identifies the system or the component that
has the failure; for example SPN 000110 indicates a
failure in the engine coolant temperature circuit.
The FMI identifies the type of failure that has occurred;
for example FMI 03 indicates value above normal.
Combining SPN 000110 with FMI 03 yields engine
coolant temperature input voltage too high, or the
equivalent of 2-digit fault code 18.
If diagnosing an application that shows DTCs as SPNs
and FMIs, using the following list, determine the
equivalent 2-digit code and have your dealer use the
diagnostic procedure in the component technical
manual for that 2-digit code.
Always contact your servicing dealer for help in
correcting diagnostic trouble codes which are
displayed for your engine.
45-21
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Troubleshooting
OURGP11,0000086 –19–27JUL06–1/2
Listing of Diagnostic Trouble Codes (DTCs)
(Engines With Electronic Fuel Systems And
Stanadyne DE10 Pump)
NOTE: Not all of these codes are used on all OEM
engine applications.
Third column below is for Blink Code retrieval
method only.
Trouble Codes
DTC’s Listing in Ascending SPN/FMI Codes
SPN FMI Blink Codes Description of Fault
000028 03 13 Throttle Voltage High
04 14 Throttle Voltage Low
000029 03 15 Throttle Voltage High
04 16 Throttle Voltage Low
14 — Throttle Voltage Out of Range
000084 31 — Vehicle Speed Mismatch
000091 03 11 Throttle Voltage High
04 12 Throttle Voltage Low
07 — Throttle Calibration Invalid
10 — Throttle Voltage Low
13 — Throttle Calibration Invalid
14 — Throttle Voltage Out of Range
000097 00 — Water in Fuel Input Voltage High
03 — Water in Fuel Signal Voltage High
04 — Water in Fuel Signal Voltage Low
16 — Water in Fuel Detected
31 — Water in Fuel Detected, Condition Exists
000100 01 65 Engine Oil Pressure Extremely Low
03 23 Engine Oil Pressure Input Voltage High
04 24 Engine Oil Pressure Input Voltage Low
16 — Engine Oil Pressure, Reading Incorrect
18 64 Engine Oil Pressure Moderately Low
000105 03 25 Manifold Air Temperature Input Voltage High
04 26 Manifold Air Temperature Input Voltage Low
16 66 Manifold Air Temperature Moderately High
000107 00 — Air Filter Restricted
000110 00 69 Engine Coolant Temperature Extremely High
03 18 Engine Coolant Temperature Input Voltage High
04 19 Engine Coolant Temperature Input Voltage Low
15 62 Engine Coolant Temperature High Least Severe
16 63 Engine Coolant Temperature Moderately High
000111 00 — Loss of Coolant Temperature Extremely High
03 — Loss of Coolant Temperature Input Voltage High
04 — Loss of Coolant Temperature Input Voltage Low
000158 17 54 ECU Power Down Error
17 84 ECU Power Down Error
000171 03 — Ambient Air Temperature, Voltage Out of Range, High
03 — Ambient Air Temperature, Voltage Out of Range, Low
000174 03 37 Fuel Temperature Input Voltage High
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Continued on next page
Troubleshooting
OURGP11,0000086 –19–27JUL06–2/2
SPN FMI Blink Codes Description of Fault
04 38 Fuel Temperature Input Voltage Low
16 81 Fuel Temperature High Moderately Severe
000189 00 — Engine Speed Derate
000190 00 42 Engine Overspeed Extreme
01 — Engine Speed, Below Normal, Most Severe
16 42 Engine Overspeed Moderate
000620 03 21 Sensor Supply Voltage High
04 22 Sensor Supply Voltage Low
000627 04 — ECU Unswitched Power Missing
000629 13 28 ECU Error
000636 02 — Engine Position Sensor Noise Detected
08 — Engine Position Sensor Signal Missing
10 — Engine Position Sensor Pattern Error Detected
000637 01 — Timing (Crank) Sensor, Signal Pattern Error
02 39 Crank Position Input Noise
10 39 Crank Position Input Pattern Error
000639 13 55 CAN Bus Error
000729 03 — Inlet Air Heater Signal High
05 — Inlet Air Heater Signal Low
000970 31 83 Auxiliary Engine Shutdown Switch Active
000971 31 84 External Engine Derate Switch Active
001076 00 71 Pump Control Valve Closure Too Long
01 72 Pump Control Valve Closure Too Short
03 77 Pump Solenoid Current High
05 73 Pump Solenoid Circuit Open
06 74 Pump Solenoid Circuit Severely Shorted
07 75 Pump Control Valve Closure Not Detected
10 76 Pump Solenoid Circuit Moderately Shorted
13 — Pump Current Decay Time Invalid
001079 03 — Sensor Supply Voltage High
04 — Sensor Supply Voltage Low
001109 31 — Engine Shutdown Warning
001110 31 82 Engine Shutdown
001568 04 — Torque Curve Selection Input Voltage Low
001569 31 68 Fuel Derate
002000 06 79 Internal ECU Failure
13 78 Security Violation
N/A N/A 32 When reading blink codes, signifies the start of active codes.
N/A N/A 33 When reading blink codes, signifies the start of previously active codes.
N/A N/A 88 When reading blink codes, signifies that no fault codes are in the buffer.
45-23
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Troubleshooting
OURGP11,0000087 –19–27JUL06–1/2
Listing of Diagnostic Trouble Codes (DTCs)
(Engines With Electronic Fuel Systems And
Bosch VP44 Pump)
NOTE: Not all of these codes are used on all OEM
engine applications
Third column below is for Blink Code retrieval
method only.
Trouble Codes
DTC’s Listing in Ascending SPN/FMI Codes
SPN FMI Blink Code Description of Fault
000028 03 13 Throttle Volts High
04 14 Throttle Volts Low
000029 03 15 Throttle Volts High
04 16 Throttle Volts Low
000084 02 91 Vehicle Speed Mismatch
000091 03 11 Throttle Volts High
04 12 Throttle Volts Low
09 — Throttle Invalid
000094 01 58 Fuel Supply Pressure Extremely Low
03 27 Fuel Supply Pressure Input Voltage High
04 28 Fuel Supply Pressure Input Voltage Low
18 57 Fuel Supply Pressure Moderately Low
000097 00 — Water in Fuel Continuously Detected
16 — Water in Fuel Detected
000100 01 75 Engine Oil Pressure Extremely Low
03 23 Engine Oil Pressure Input Voltage High
04 24 Engine Oil Pressure Input Voltage Low
18 74 Engine Oil Pressure Moderately Low
000105 00 56 Manifold Air Temperature Extremely High
03 25 Manifold Air Temperature Input Voltage High
04 26 Manifold Air Temperature Input Voltage Low
16 55 Manifold Air Temperature Moderately High
000107 00 — Air Filter Differential Pressure
000110 00 63 Engine Coolant Temperature Extremely High
03 18 Engine Coolant Temperature Input Voltage High
04 19 Engine Coolant Temperature Input Voltage Low
15 61 Engine Coolant Temperature High Least Severe
16 62 Engine Coolant Temperature Moderately High
000111 01 64 Engine Coolant Level Low
000158 17 54 ECU Power Down Error
000174 00 67 Fuel Temperature High Most Severe
15 53 Fuel Temperature High Least Severe
16 71 Fuel Temperature High Moderately Severe
31 98 Fuel Temperature Sensor Faulty
000189 00 — Engine Speed Derate
31 48 Engine Speed Derate
000190 00 42 Engine Overspeed Extreme
16 42 Engine Overspeed Moderate
000620 03 21 Sensor Supply Voltage High
45-24
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Continued on next page
Troubleshooting
OURGP11,0000087 –19–27JUL06–2/2
SPN FMI Blink Code Description of Fault
04 22 Sensor Supply Voltage Low
000627 04 76 ECU Unswitched Power Missing
000629 13 34 ECU Error
19 34 ECU to Pump Communication Error
000632 02 37 Fuel Shutoff Error
05 86 Fuel Shutoff Non-Functional
000636 02 44 Pump Position Input Noise
08 43 Pump Position Input Missing
10 44 Pump Position Input Pattern Error
000637 02 39 Crank Position Input Noise
08 38 Crank Position Input Missing
10 39 Crank Position Input Pattern Error
000729 03 — Inlet Air Heater Signal High
05 — Inlet Air Heater Signal Low
000810 02 92 Calculated Vehicle Speed Input Noise
000898 09 77 Vehicle Speed Invalid/Missing
000970 02 — Auxiliary Engine Shutdown Switch Signal Invalid
31 83 Auxiliary Engine Shutdown Switch Active
000971 31 84 External Engine Derate Switch Active
001069 02 93 Tire Size Error
001076 02 66 Pump Detected Defect
001077 07 35 Attempting to Fuel Without Command
11 68 Pump Supply Voltage Out of Range
12 97 Pump Self Test Error
19 96 Pump Detected Communication Error
31 36 Pump Initiated Engine Protection
001078 07 95 ECU/Pump Timing Moderately Out of Sync
11 87 ECU/Pump Speed Out of Sync
31 94 ECU/Pump Timing Extremely Out of Sync
001079 03 21 Sensor Supply 1 Voltage High
04 22 Sensor Supply 1 Voltage Low
001080 03 51 Sensor Supply 2 Voltage High
04 52 Sensor Supply 2 Voltage Low
001109 31 — Engine Shutdown Warning
001110 31 82 Engine Shutdown
001485 02 89 Pump Power Relay Fault
001569 31 47 Fuel Derate
002000 13 — Security Violation
45-25
080706
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Troubleshooting
OURGP11,0000088 –19–27JUL06–1/3
Listing of Diagnostic Trouble Codes (DTCs)
(Engines With Electronic Fuel Systems And
Denso High Pressure Common Rail) (“475”
Engines)
NOTE: Not all of these codes are used on all OEM
engine applications
Third column below is for Blink Code retrieval
method only.
Trouble Codes
DTC’s Listing in Ascending SPN/FMI Codes
SPN FMI Blink Code Description of Fault
000028 03 15 Analog Throttle (B) Voltage High
04 — Analog Throttle (B) Voltage Low
000029 03 13 Analog Throttle (A) Voltage High
04 — Analog Throttle (A) Voltage Low
000084 31 — Vehicle Speed Mismatch
000091 03 11 Multi-state Throttle Voltage High
04 12 Multi-state Throttle Voltage Low
09 — Throttle Invalid
000094 03 27 Fuel Rail Pressure Input Voltage High
04 28 Fuel Rail Pressure Input Voltage Low
10 86 Fuel Rail Pressure Loss Detected
13 — Fuel Rail Pressure Higher Than Expected
17 85 Fuel Rail Pressure Not Developed
000097 00 — Water in Fuel Continuously Detected
03 — Water in Fuel Signal Voltage High
04 — Water in Fuel Signal Voltage Low
16 — Water in Fuel Detected
000100 01 75 Engine Oil Pressure Extremely Low
03 23 Engine Oil Pressure Input Voltage High
04 24 Engine Oil Pressure Input Voltage Low
18 74 Engine Oil Pressure Moderately Low
000105 00 — Manifold Air Temperature Extremely High
03 25 Manifold Air Temperature Input Voltage High
04 26 Manifold Air Temperature Input Voltage Low
16 55 Manifold Air Temperature Moderately High
000107 00 — Air Filter Differential Pressure
000110 00 63 Engine Coolant Temperature High Most Severe
03 18 Engine Coolant Temperature Input Voltage High
04 19 Engine Coolant Temperature Input Voltage Low
15 61 Engine Coolant Temperature High Least Severe
16 62 Engine Coolant Temperature High Moderately Severe
000111 01 64 Engine Coolant Level Low
000158 17 54 ECU Power Down Error
000160 02 — Wheel Speed Input Noise
000174 00 — Fuel Temperature High Most Severe
03 37 Fuel Temperature Input Voltage High
04 38 Fuel Temperature Input Voltage Low
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Continued on next page
Troubleshooting
OURGP11,0000088 –19–27JUL06–2/3
SPN FMI Blink Code Description of Fault
16 71 Fuel Temperature High Moderately Severe
000189 00 — Engine Speed Derate
000190 00 42 Engine Overspeed Extreme
16 42 Engine Overspeed Moderate
000611 03 98 Electronic Injector Wiring Shorted to Power Source
04 99 Electronic Injector Wiring Shorted to Ground
000620 03 21 Sensor Supply 2 Voltage High
04 22 Sensor Supply 2 Voltage Low
000627 01 97 Electronic Injector Supply Voltage Problem
000629 13 — ECU Error
000636 02 44 Pump Position Sensor Input Noise
08 43 Pump Position Sensor Input Missing
10 44 Pump Position Sensor Input Pattern Error
000637 02 39 Crank Position Input Noise
07 45 Crank/Pump Timing Moderately Out of Sync
08 41 Crank Position Input Missing
10 39 Crank Position Input Pattern Error
000639 13 — CAN Bus Error
000651 05 31 Cylinder #1 EI Circuit Open
06 91 Cylinder #1 EI Circuit Shorted
07 65 Cylinder #1 EI Delivery Failure
000652 05 29 Cylinder #2 EI Circuit Open
06 92 Cylinder #2 EI Circuit Shorted
07 66 Cylinder #2 EI Delivery Failure
000653 05 17 Cylinder #3 EI Circuit Open
06 93 Cylinder #3 EI Circuit Shorted
07 59 Cylinder #3 EI Delivery Failure
000654 05 34 Cylinder #4 EI Circuit Open
06 94 Cylinder #4 EI Circuit Shorted
07 67 Cylinder #4 EI Delivery Failure
000655 05 35 Cylinder #5 EI Circuit Open
06 95 Cylinder #5 EI Circuit Shorted
07 56 Cylinder #5 EI Delivery Failure
000656 05 36 Cylinder #6 EI Circuit Open
06 96 Cylinder #6 EI Circuit Shorted
07 68 Cylinder #6 EI Delivery Failure
000676 03 — Glow Plug Relay Voltage High
05 — Glow Plug Relay Voltage Low
000898 09 — Vehicle Speed or Torque Message Invalid
000970 31 83 Engine Shutdown - Auxiliary Request
000971 31 84 External Fuel Derate Switch Active
001069 09 — Tire Size Invalid
31 — Tire Size Error
001079 03 51 Sensor Supply 1 Voltage High
04 52 Sensor Supply 1 Voltage Low
001080 03 49 Fuel Rail Pressure Sensor Supply Voltage High
04 48 Fuel Rail Pressure Sensor Supply Voltage Low
001109 31 — Engine Protection Shutdown Warning
001110 31 82 Engine Protection Shutdown
001347 03 79 Pump Return Shorted High
05 77 Pump Control Valve Error
07 78 Fuel Rail Pressure Control Error
001568 02 — Torque Curve Selection Invalid
001569 31 — Fuel Derate
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Troubleshooting
OURGP11,0000088 –19–27JUL06–3/3
SPN FMI Blink Code Description of Fault
002000 13 — Security Violation
N/A N/A 32 When reading blink codes, signifies the start of active codes.
N/A N/A 33 When reading blink codes, signifies the start of stored codes.
N/A N/A 88 When reading blink codes, signifies that no fault codes are in the buffer.
OURGP11,0000152 –19–27JUL06–1/1
Error Codes Displayed (With Early Electronic
Panels)
NOTE: The Diagnostic Gauge on the earlier electronic
instrument panel can have communication
problems that result in Error Codes being shown
on its LCD display window. The following Error
Codes all indicate that there is a Diagnostic
Gauge communication error with the ECU.
Contact your servicing dealer for help in correcting
these codes:
EE—Error XXXXX—EP
No Data
ACP—Err XXXXX—BO
No Addr No Data
ACP—Err XXXXX—BR
BUS—EP No Data
NOTE: Later instrument panels will display text for
communication faults, such as “CAN BUS
FAILURE”.
45-28
080706
PN=222
Troubleshooting
OUOD007,0000036 –19–27JUL06–1/1
Intermittent Fault Diagnostics (With Electronic Controls)
Intermittent faults are problems that periodically “go
away”. A problem such as a terminal that intermittently
doesn’t make contact can cause an intermittent fault.
Other intermittent may be set only under certain
operating conditions such as heavy load, extended
idle, etc. When diagnosing intermittent faults, take
special note of the condition of wiring and connectors,
since a high percentage of intermittent problems
originate here. Check for loose, dirty or disconnected
connectors. Inspect the wiring routing, looking for
possible shorts caused by contact with external parts
(for example, rubbing against sharp sheet metal
edges). Inspect the connector vicinity, looking for wires
that have pulled out of connectors, poorly positioned
terminals, damaged connectors and corroded or
damaged splices and terminals. Look for broken wires,
damaged splices, and wire-to-wire shorts. Use good
judgement if component replacement is thought to be
required.
NOTE: The engine control unit (ECU) is the
component LEAST likely to fail.
Suggestions for diagnosing intermittent faults:
•If the problem is intermittent, try to reproduce the
operating conditions that were present when the
diagnostic trouble code (DTC) set.
•If a faulty connection or wire is suspected to be the
cause of the intermittent problem: clear DTCs, then
check the connection or wire by wiggling it while
watching the diagnostic gauge to see if the fault
resets.
Possible causes of intermittent faults:
•Faulty connection between sensor or actuator
harness.
•Faulty contact between terminals in connector.
•Faulty terminal/wire connection.
•Electromagnetic interference (EMI) from an
improperly installed 2-way radio, etc., can cause
faulty signals to be sent to the ECU.
NOTE: Refer to wiring diagrams earlier in this section
as a guide to connection and wiring.
OURGP11,000012B –19–27JUL06–1/4
Displaying Diagnostic Gauge Software (Later
Engines)
RG13159 –UN–26SEP03
Menu Key
NOTE: The following steps can be used to display the
software version of the diagnostic gauge if needed
by your dealer for troubleshooting. This is a read
only function.
1. Starting at the single or four engine parameter display,
press the "Menu" key.
Continued on next page
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PN=223
Troubleshooting
OURGP11,000012B –19–27JUL06–2/4
RG13234 –UN–22OCT03
Select Utilities
2. The main menu will be displayed. Use the "Arrow" key
to scroll through the menu until "Utilities" is highlighted.
OURGP11,000012B –19–27JUL06–3/4
RG13237 –UN–22OCT03
Select Utilities
3. Once "Utilities" is highlighted, press "Enter" to activate
the utilities function.
OURGP11,000012B –19–27JUL06–4/4
RG13236 –UN–13OCT03
Software Version
4. Scroll to the "Software Version". Press "Enter" to view
the software version. Press the menu button twice to
return to the main menu.
45-30
080706
PN=224
Storage
OURGP12,00000DF –19–27JUL06–1/1
Engine Storage Guidelines
1. John Deere engines can be stored outside for up to
three (3) months with no long term preparation IF
COVERED BY WATERPROOF COVERING. No
outside storage is recommended without a
waterproof covering.
2. John Deere engines can be stored in a standard
overseas shipping container for up to three (3)
months with no long term preparation.
3. John Deere engines can be stored inside for up to
six (6) months with no long term preparation.
4. John Deere engines expected to be stored more
than six (6) months MUST have long term storage
preparation. ( See PREPARING ENGINE FOR
LONG TERM STORAGE, later in this section.)
5. Long term storage includes the use of a stabilized
rust preventive oil to protect internal metal
components of the engine. This oil should be an
SAE 10 oil with 1-4 percent morpholine or
equivalent vapor corrosion inhibitor. These rust
preventive oils are available from area distributors.
50-1
080706
PN=225
Storage
OURGP11,000006C –19–27JUL06–1/2
Preparing Engine for Long Term Storage
The following storage preparations are used for long
term engine storage up to one year. After that, the
engine should be started, warmed up, and retreated
for an extended storage period.
IMPORTANT: Any time your engine will not be
used for over six (6) months, the
following recommendations for
storing it and removing it from
storage will help to minimize
corrosion and deterioration.
1. Change engine oil and replace filter. (See CHANGE
ENGINE OIL AND FILTER in Lubrication and
Maintenance/500 Hour Section.) Used oil will not
give adequate protection. Add one (1) ounce of rust
preventive oil to the engine crankcase for every
quart of oil. This rust preventive oil should be an
SAE 10 oil with 1-4 percent morpholine or
equivalent vapor corrosion inhibitor.
2. Service air cleaner. (See REPLACING AIR
CLEANER FILTER ELEMENTS in Service As
Required Section.)
3. Draining and flushing of cooling system is not
necessary if engine is to be stored only for several
months. However, for extended storage periods of a
year or longer, it is recommended that the cooling
system be drained, flushed, and refilled. Refill with
appropriate coolant. (See RECOMMENDED
ENGINE COOLANT in Fuels, Lubricants, and
Coolant Section and ADDING COOLANT in Service
As Required Section.)
4. Pour three (3) ounces of rust preventive oil into the
turbocharger intake. (It may be necessary to
temporarily install a short intake elbow on the
turbocharger inlet to receive the oil.)
5. Prepare a tank with a solution of diesel fuel and
rust preventive oil, at ten (10) ounces of rust
preventive oil per gallon of diesel fuel.
6. Remove existing lines/plugs as required, and run a
temporary line from the tank to the engine fuel
intake, and another temporary line from the fuel
return manifold to the tank, so rust preventive oil
solution is circulated through the injection system
during cranking.
7. Crank the engine several revolutions with starter
(do not allow the engine to start). This will allow
rust preventive oil solution to circulate.
8. Remove temporary lines installed in Step 6 above,
and replace any lines/plugs previously removed.
NOTE: One gallon of fuel/oil solution can be used to
treat 100 engines; two gallons to treat 200
engines, etc. The oil could then be replenished
by adding an additional five (5) ounces of rust
preventive oil per gallon of solution. However,
starting over with a new solution is
recommended to dispose of any water or other
impurities.
9. Loosen, or remove and store, fan/alternator
poly-vee belt.
10. Remove and clean batteries. Store them in a cool,
dry place and keep them fully charged.
11. Disengage the clutch for any driveline.
12. Clean the exterior of the engine with salt-free
water and touch up any scratched or chipped
painted surfaces with a good quality paint.
13. Coat all exposed (machined) metal surfaces with
grease or corrosion inhibitor if not feasible to paint.
14. Seal all openings on engine with plastic bags and
tape.
50-2
080706
PN=226
Continued on next page
Storage
OURGP11,000006C –19–27JUL06–2/2
15. Store the engine in a dry protected place. If
engine must be stored outside, cover it with a waterproof canvas or other suitable protective
material and use a strong waterproof tape.
RG,RG34710,5613 –19–27JUL06–1/1
Removing Engine from Long Term Storage
Refer to the appropriate section for detailed services
listed below or have your authorized servicing dealer
or engine distributor perform services that you may not
be familiar with.
1. Remove all protective coverings from engine.
Unseal all openings in engine and remove covering
from electrical systems.
2. Remove the batteries from storage. Install batteries
(fully charged) and connect the terminals.
3. Install fan/alternator poly-vee belt if removed.
4. Fill fuel tank.
5. Perform all appropriate prestarting checks. ( See
DAILY PRESTARTING CHECKS in Lubrication and
Maintenance/Daily Section.)
IMPORTANT: DO NOT operate starter more than
30 seconds at a time. Wait at least 2
minutes for starter to cool before
trying again.
6. Crank engine for 20 seconds with starter (do not
allow the engine to start). Wait 2 minutes and crank
engine an additional 20 seconds to assure bearing
surfaces are adequately lubricated.
7. Start engine and run at low idle and no load for
several minutes. Warm up carefully and check all
gauges before placing engine under load.
8. On the first day of operation after storage, check
overall engine for leaks and check all gauges for
correct operation.
50-3
080706
PN=227
Specifications
OURGP11,0000089 –19–27JUL06–1/2
General OEM Engine Specifications
ITEM 4045DF270 4045TF270 4045TF/HF275 4045HF475 6068TF/HF275 6068HF475
Number of Cylinders 4 4 4 4 6 6
Bore 106 mm 106 mm 106 mm 106 mm 106 mm 106 mm
(4.19 in.) (4.19 in.) (4.19 in.) (4.19 in.) (4.19 in.) (4.19 in.)
Stroke 127 mm 127 mm 127 mm 127 mm 127 mm 127 mm
(5.0 in.) (5.0 in.) (5.0 in.) (5.0 in.) (5.0 in.) (5.0 in.)
Displacement 4.5 L 4.5 L 4.5 L 4.5 L 6.8 L 6.8 L
(276 cu in.) (276 cu in.) (276 cu in.) (276 cu in.) (414 cu in.) (414 cu in.)
Compression Ratio 17.6:1 17.0:1 17.0:1 17.0:1 17.0:1 17.0:1
Aspiration Natural Turbocharged Turbocharged Turbocharged Turbocharged Turbocharged
Engine Firing Order 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-5-3-6-2-4 1-5-3-6-2-4
Valves Per Cylinder 1 Intake 1 Intake 1 Intake 2 Intake 1 Intake 2 Intake
1 Exhaust 1 Exhaust 1 Exhaust 2 Exhaust 1 Exhaust 2 Exhaust
Valve Clearance (Cold)
Intake (Checking) 0.31-0.38 mm 0.31-0.38 mm 0.31-0.38 mm 0.31-0.38 mm 0.31-0.38 mm 0.31-0.38 mm
(0.012-0.015 in) (0.012-0.015 in) (0.012-0.015 in) (0.012-0.015 in) (0.012-0.015 in) (0.012-0.015 in)
Exhaust (Checking) 0.41-0.48 mm 0.41-0.48 mm 0.41-0.48 mm 0.41-0.48 mm 0.41-0.48 mm 0.41-0.48 mm
(0.016-0.019 in) (0.016-0.019 in) (0.016-0.019 in) (0.016-0.019 in) (0.016-0.019 in) (0.016-0.019 in)
Intake (Adjusting) 0.36 mm 0.36 mm 0.36 mm 0.36 mm 0.36 mm 0.36 mm
(0.014 in.) (0.014 in.) (0.014 in.) (0.014 in.) (0.014 in.) (0.014 in.)
Exhaust (Adjusting) 0.46 mm 0.46 mm 0.46 mm 0.46 mm 0.46 mm 0.46 mm
(0.018 in.) (0.018 in.) (0.018 in.) (0.018 in.) (0.018 in.) (0.018 in.)
Max. Crank Pressure 0.5 kPa 0.5 kPa 0.5 kPa 0.5 kPa 0.5 kPa 0.5 kPa
(2 H
2
O) (2 H
2
O) (2 H
2
O) (2 H
2
O) (2 H
2
O) (2 H
2
O)
Vibration Damper 1.50 mm 1.50 mm 1.50 mm 1.50 mm 1.50 mm 1.50 mm
Maximum Radial Runout (0.060 in.) (0.060 in.) (0.060 in.) (0.060 in.) (0.060 in.) (0.060 in.)
Battery Capacities (CCA)
12-Volt System 640 640 640 640 800 800
24-Volt System 570 570 570 570 570 570
Governor Regulation 7—10 % 7—10 % 7—10 % 7—10 % 7—10 % 7—10 %
(Industrial)
Governor Regulation 5 % 5 % 5% 5% 5 % 5%
(Generator)
Thermostat Start To 82°C82°C82°C82°C82°C82°C
Open Temperature (180°F) (180°F) (180°F) (180°F) (180°F) (180°F)
Thermostat Fully Open 94°C94°C94°C94°C94°C94°C
Temperature (202°F) (202°F) (202°F) (202°F) (202°F) (202°F)
Coolant Capacity 8.5 L 8.5 L 8.5 L 8.5 L 11.3 L 11.3 L
(9 qt) (9 qt) (9 qt) (9 qt) (12 qt) (12 qt)
Recommended Radiator 70 kPa 70 kPa 70 kPa 70 kPa 70 kPa 70 kPa
Pressure Cap (10 psi) (10 psi) (10 psi) (10 psi) (10 psi) (10 psi)
Crankcase Oil Fill See “Engine Crankcase Oil Fill Quantities” later in this section.
Capacity
55-1
080706
PN=228
Continued on next page
Specifications
OURGP11,0000089 –19–27JUL06–2/2
ITEM 4045DF270 4045TF270 4045TF/HF275 4045HF475 6068TF/HF275 6068HF475
Oil Pressure At Rated 345 ±103 kPa 345 ±103 kPa 345 ±103 kPa 345 ±103 kPa 345 ±103 kPa 345 ±103 kPa
Speed, Full Load 3.45 ±1.03 bar 3.45 ±1.03 bar 3.45 ±1.03 bar 3.45 ±1.03 bar 3.45 ±1.03 bar 3.45 ±1.03 bar
(50 ±15 psi) (50 ±15 psi) (50 ±15 psi) (50 ±15 psi) (50 ±15 psi) (50 ±15 psi)
Oil Pressure At Low Idle 103 kPa 103 kPa 103 kPa 103 kPa 103 kPa 103 kPa
(Minimum) (15 psi) (15 psi) (15 psi) (15 psi) (15 psi) (15 psi)
Length 860 mm 860 mm 860 mm 860 mm 1123 mm 1123 mm
(33.9 in.) (33.9 in.) (33.9 in.) (33.9 in.) (44.2 in.) (44.2 in.)
Width 612 mm 612 mm 612 mm 612 mm 623 mm 608 mm
(24.1 in.) (24.1 in.) (24.1 in.) (24.1 in.) (24.5 in.) (23.9 in.)
Height 856 mm 994 mm 994 mm 994 mm 1015 mm 1044 mm
(33.7 in.) (39.1 in.) (39.1 in.) (39.1 in.) (40.0 in.) (41.1 in.)
Weight 387 kg 451 kg 451 kg 451 kg 587 kg 587 kg
(853 lb) (993 lb) (993 lb) (993 lb) (1290 lb) (1290 lb)
55-2
080706
PN=229
Specifications
OURGP11,000008A –19–27JUL06–1/3
Engine Power Ratings
1
And Fuel System
Specifications
2
Engine Fuel System Electronic Software System Power Rated Slow Idle Fast Idle
Model Option Codes Option Codes Voltage Rating @ Speed (rpm) (rpm)
Rated Speed (rpm)
kW (hp)
4045DF270 164J ................... .................................... 12V ......... 36 (48) ......... 2250 .......... 850 ................. 2450
(Mechanical 164K .................. .................................... 24V ......... 36 (48) ......... 2250 .......... 850 ................. 2450
Controls) 164N .................. .................................... 12V ......... 60 (80) ......... 2500 .......... 850 ................. 2700
164O ................ .................................... 24V ........ 60 (80) ......... 2500 .......... 850 ................. 2700
164L .................. .................................... 12V ......... 55 (74) ......... 2500 .......... 850 ................. 2700
164M ................. .................................... 24V ......... 55 (74) ......... 2500 .......... 850 ................. 2700
162Q .................. .................................... 12V ......... 50 (67) ......... 1800 .......... 1400 ............... 1870
164P .................. .................................... 12V ......... 50 (67) ......... 1800 .......... 1400 ............... 1870
164Q .................. .................................... 24V ......... 50 (67) ......... 1800 .......... 1400 ............... 1870
4045TF270 164V .................. .................................... 12V ......... 74 (99) ......... 2500 .......... 850 ................. 2700
(Mechanical 164W ................. .................................... 24V ......... 74 (99) ......... 2500 .......... 850 ................. 2700
Controls) 164T .................. .................................... 12V ......... 74 (99) 2200 .......... 850 ................. 2400
164U .................. .................................... 24V ......... 74 (99) ......... 2200 .......... 850 ................. 2400
163N, 164X ....... .................................... 12V ......... 74 (99) ......... 1800 .......... 1400 ............... 1870
164Y .................. .................................... 24V ......... 74 (99) ......... 1800 .......... 1400 ............... 1870
164R .................. .................................... 12V ......... 63 (84) ......... 2500 .......... 850 ................. 2700
164S .................. .................................... 24V ......... 63 (84) ......... 2500 .......... 850 ................. 2700
4045TF275 161K, 163H ....... 7288 ............................ 12V ......... 86 (115) ....... 2500 .......... 800 ................. 2700
161L, 163L ........ 7289 ............................ 24V ......... 86 (115) ....... 2500 .......... 800 ................. 2700
161K, 163H ....... 7290 ............................ 12V ......... 82 (110) ....... 2400 .......... 800 ................. 2600
161L, 163L ........ 7291 ............................ 24V ......... 82 (110) ....... 2400 .......... 800 ................. 2600
161K, 163H ....... 7292 ............................ 12V ......... 84 (112) ....... 1800 .......... 1150 ............... 1870
161L, 163L ........ 7293 ............................ 24V ......... 84 (112) ....... 1800 .......... 1150 ............... 1870
4045HF275 161F, 163G ....... 7262 ............................ 12V ......... 104 (140) ..... 2400 .......... 800 ................. 2600
161G, 163K ....... 7263 ............................ 24V ......... 104 (140) ..... 2400 .......... 800 ................. 2600
161F, 163G ....... 7264 ............................ 12V ......... 93 (125) ....... 2400 .......... 800 ................. 2600
161G, 163K ....... 7265 ............................ 24V ......... 93 (125) ....... 2400 .......... 800 ................. 2600
161F, 163G ....... 72BD ........................... 12V ......... 104 (140) ..... 2200 .......... 800 ................. 2400
161G, 163K ....... 72BE ........................... 24V ......... 104 (140) ..... 2200 .......... 800 ................. 2400
161F, 163G ....... 7266 ............................ 12V ......... 93 (125) ....... 2200 .......... 800 ................. 2400
161G, 163K ....... 7267 ............................ 24V ......... 93 (125) ....... 2200 .......... 800 ................. 2400
161F, 163G ....... 7268 ............................ 12V ......... 86 (115) ....... 2000 .......... 800 ................. 2100
161G, 163K ....... 7269 ............................ 24V ......... 86 (115) ....... 2000 .......... 800 ................. 2100
161F, 163G ....... 7270 ............................ 12V ......... 108 (145) ..... 1800 .......... 1150 ............... 1870
161G, 163K ....... 7271 ............................ 24V ......... 108 (145) ..... 1800 .......... 1150 ............... 1870
1
Power ratings are for bare engines without drag effect of cooling fan or
accessories like air compressors.
2
Engine speeds listed are preset to factory specification. Slow idle speed
may be reset depending upon specific vehicle application requirements.
Refer to your machine operator’s manual for engine speeds that are
different from those preset at the factory.
55-3
080706
PN=230
Continued on next page
Specifications
OURGP11,000008A –19–27JUL06–2/3
Engine Fuel System Electronic Software System Power Rated Slow Idle Fast Idle
Model Option Codes Option Codes Voltage Rating @ Speed (rpm) (rpm)
Rated Speed (rpm)
kW (hp)
4045HF275 161F, 163G ....... 7272 ............................ 12V ......... 117 (157) ..... 1800 .......... 1150 ............... 1870
161G, 163K ....... 7273 ............................ 24V ......... 117 (157) ..... 1800 .......... 1150 ............... 1870
161G, 163K ....... 72BB ........................... 24V ......... 93 (125) ....... 2400 .......... 800 ................. 2600
161F, 163G ....... .................................... 12V ......... 99 (133) ....... 1500 .......... 1400 ............... 1575
161G, 163K ....... .................................... 24V ......... 99 (133) ....... 1500 .......... 1400 ............... 1575
4045HF475 161V .................. 72AT ........................... 12V ......... 129 (173) ..... 2400 .......... 800 ................. 2600
(4-Valve 161V .................. 72AU ........................... 12V ......... 119 (160) ..... 2200 .......... 800 ................. 2400
Head) 161V .................. 72AV ........................... 12V ......... 143 (192) ..... 1800 .......... 1400 ............... 1870
161V .................. 72AW .......................... 12V ......... 120 (161) ..... 1500 .......... 1400 ............... 1560
6068TF275 161J, 163M ....... 72AA ........................... 24V ......... 123 (165) ..... 2400 ......... 800 ................. 2600
161H, 163F ....... 72AB ........................... 12V ......... 101 (135) ..... 2200 .......... 800 ................. 2400
161J, 163M ....... 72AC ........................... 24V ......... 101 (135) ..... 2200 .......... 800 ................. 2400
161H, 163F ....... 72AD ........................... 12V ......... 112 (150) ..... 2200 .......... 800 ................. 2400
161J, 163M ....... 72AE ........................... 24V ......... 112 (150) ..... 2200 .......... 800 ................. 2400
161H, 163F ....... 72AF ........................... 12V ......... 104 (140) ..... 2000 .......... 800 ................. 2100
161J, 163M ....... 72AG .......................... 24V ......... 104 (140) ..... 2000 .......... 800 ................. 2100
161H, 163F ....... 72AH ........................... 12V ......... 123 (165) ..... 1800 .......... 1150 ............... 1870
161J, 163M ....... 72AJ ........................... 24V ......... 123 (165) ..... 1800 .......... 1150 ............... 1870
161H, 163F ....... 7294 ............................ 12V ......... 116 (155) ..... 2500 .......... 800 ................. 2700
161J, 163M ....... 7295 ............................ 24V ......... 116 (155) ..... 2500 .......... 800 ................. 2700
161H, 163F ....... 7296 ............................ 12V ......... 127 (170) ..... 2500 ......... 800 ................. 2700
161J, 163M ....... 7297 ............................ 24V ......... 127 (170) ..... 2500 .......... 800 ................. 2700
161H, 163F ....... 7298 ............................ 12V ......... 123 (165) ..... 2400 .......... 800 ................. 2600
161H, 163F ....... .................................... 12V ......... 105 (141) ..... 1500 .......... 1400 ............... 1575
161H, 163F ....... .................................... 24V ......... 105 (141) ..... 1500 .......... 1400 ............... 1575
6068HF275 16YS .................. 7201, 7222, 7230 ....... 12V ......... 168 (225) ..... 2400 .......... 850 ................. 2600
16YT .................. 7202, 7223, 7231 ....... 24V ......... 168 (225) ..... 2400 .......... 850 ................. 2600
16YS .................. 7203, 7224, 7232 ....... 12V ......... 149 (200) ..... 2400 .......... 800 ................. 2600
16YT .................. 7204 ............................ 24V ......... 149 (200) ..... 2400 .......... 850 ................. 2600
16YS .................. 7228, 7236 ................. 12V ......... 149 (200) ..... 2200 .......... ....................... 2400
16YT .................. 7297, 7237 ................. 24V ......... 149 (200) ..... 2200 .......... ....................... 2400
16YS .................. 7205, 7226, 7234 ....... 12V ......... 138 (185) ..... 2400 .......... 850 ................. 2600
16YT .................. 7206, 7227, 7235 ....... 24V ......... 138 (185) ..... 2400 .......... 850 ................. 2600
16YS .................. 7207 ............................ 12V ......... 149 (200) ..... 2200 .......... 800 ................. 2400
16YT .................. 7208, 7402, 7411 ....... 24V ......... 149 (200) ..... 2200 .......... 800 ................. 2400
16YS .................. 7274 ............................ 12V ......... 187 (250) ..... 2400 .......... 850 ................. 2600
16YT .................. 7275 ............................ 24V ......... 187 (250) ..... 2400 .......... 850 ................. 2600
16YS .................. 7276 ............................ 12V ......... 168 (225) ..... 2200 .......... 800 ................. 2400
16YT .................. 7277 ............................ 24V ......... 168 (225) ..... 2200 .......... 800 ................. 2400
16YS .................. 7278 ............................ 12V ......... 157 (210) ..... 2000 .......... 800 ................. 2100
16YT .................. 7279 ............................ 24V ......... 157 (210) ..... 2000 .......... 800 ................. 2100
161N, 163E ....... 7280 ............................ 12V ......... 129 (173) ..... 2000 .......... 800 ................. 2100
161Q, 163J ........ 7281 ............................ 24V ......... 129 (173) ..... 2000 .......... 800 ................. 2100
161N, 163E ....... 7282 ............................ 12V ......... 164 (220) ..... 1800 .......... 1150 ............... 1870
161Q, 163J ........ 7283 ............................ 24V ......... 164 (220) ..... 1800 .......... 1150 ............... 1870
16YS .................. 7284 ............................ 12V ......... 187 (250) ..... 1800 .......... 1150 ............... 1870
16YT .................. 7285 ............................ 24V ......... 187 (250) ..... 1800 .......... 1150 ............... 1870
16YS, 162B ....... 7286 ............................ 12V ......... 210 (282) ..... 1800 .......... 1150 ............... 1870
55-4
080706
PN=231
Continued on next page
Specifications
OURGP11,000008A –19–27JUL06–3/3
Engine Fuel System Electronic Software System Power Rated Slow Idle Fast Idle
Model Option Codes Option Codes Voltage Rating @ Speed (rpm) (rpm)
Rated Speed (rpm)
kW (hp)
6068HF275 16YT, 162C ....... 7287 ............................ 24V ......... 210 (282) ..... 1800 .......... 1150 ............... 1870
16YS .................. .................................... 12V ......... 138 (185) ..... 1500 .......... 1400 ............... 1560
16YT .................. .................................... 24V ......... 138 (185) ..... 1500 .......... 1400 ............... 1560
16YS .................. .................................... 12V ......... 175 (235) ..... 1500 .......... 1400 ............... 1560
16YT .................. .................................... 24V ......... 175 (235) ..... 1500 .......... 1400 ............... 1560
6068HF475 161U .................. 72AP ........................... 12V ......... 205 (275) ..... 2400 .......... 800 ................. 2600
4-Valve 165B .................. 72CQ .......................... 24V ......... 205 (275) ..... 2400 .......... 800 ................. 2600
Head) 161U .................. 72AQ .......................... 12V ......... 187 (250) ..... 2200 .......... 800 ................. 2400
165B .................. 72CR .......................... 24V ......... 187 (250) ..... 2200 .......... 800 ................. 2400
161U .................. 72AR ........................... 12V ......... 234 (314) ..... 1800 .......... 1400 ............... 1870
165B .................. 72CS ........................... 24V ......... 234 (314) ..... 1800 .......... 1400 ............... 1870
161U .................. 72AS ........................... 12V ......... 207 (278) ..... 1500 .......... 1400 ............... 1560
165B .................. 72CT ........................... 24V ......... 207 (278) ..... 1500 .......... 1400 ............... 1560
55-5
080706
PN=232
Specifications
OURGP11,000008B –19–27JUL06–1/1
Engine Crankcase Oil Fill Quantities
To determine the option code for the oil fill quantity of
your engine, refer to the engine option code label
affixed to the rocker arm cover. The first two digits of
the code (19) identify the oil pan option group. The last
two digits of each code identify the specific oil pan on
your engine.
The following table lists engine crankcase oil fill
quantities:
Engine Model Oil Pan Option Crankcase Oil
Code(s) Capacity L (qt)
4045DF270 1901 8.5 (9.0)
1902 8.5 (9.0)
1903 12.0 (12.7)
1904 13.0 (13.7)
1923 15.0 (15.8)
4045TF270 1903 12.0 (12.7)
1904 13.0 (13.7)
1923 15.0 (15.8)
4045TF275 1902 12.0 (12.7)
1903 12.5 (13.2)
1904 13.5 (14.3)
1923 15.0 (15.8)
4045HF275 1904 13.5 (14.3)
1923 15.0 (15.8)
1976 20.5 (21.6)
4045HF475 1923 15.0 (15.8)
1976 20.5 (21.6)
6068TF275 1907 19.5 (20.6)
1908 19.0 (20.1)
1909 19.0 (20.1)
1924 24.2 (25.6)
1944 20.0 (21.1)
1956 18.0 (19.0)
1961 31.5 (33.3)
19AC 27.0 (28.5)
6068HF275 1907 19.5 (20.6)
1908 19.0 (20.1)
1909 19.0 (20.1)
1924 24.2 (25.6)
1961 31.5 (33.3)
19AC 27.0 (28.5)
6068HF475 1924 23.7 (25.0)
1961 31.5 (33.3)
19AC 27.0 (28.5)
NOTE: Crankcase oil capacity may vary slightly from
amount shown. ALWAYS fill crankcase to
within crosshatch on dipstick. DO NOT overfill.
55-6
080706
PN=233
Specifications
TORQ1 –19–24APR03–1/1
Unified Inch Bolt and Screw Torque Values
TS1671 –UN–01MAY03
Bolt or SAE Grade 1 SAE Grade 2
a
SAE Grade 5, 5.1 or 5.2 SAE Grade 8 or 8.2
Screw Lubricated
b
Dry
c
Lubricated
b
Dry
c
Lubricated
b
Dry
c
Lubricated
b
Dry
c
Size N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in
1/4 3.7 33 4.7 42 6 53 7.5 66 9.5 84 12 106 13.5 120 17 150
N•m lb-ft N•m lb-ft
5/16 7.7 68 9.8 86 12 106 15.5 137 19.5 172 25 221 28 20.5 35 26
N•m lb-ft N•m lb-ft
3/8 13.5 120 17.5 155 22 194 27 240 35 26 44 32.5 49 36 63 46
N•m lb-ft N•m lb-ft N•m lb-ft
7/16 22 194 28 20.5 35 26 44 32.5 56 41 70 52 80 59 100 74
N•m lb-ft
1/2 34 25 42 31 53 39 67 49 85 63 110 80 120 88 155 115
9/16 48 35.5 60 45 76 56 95 70 125 92 155 115 175 130 220 165
5/8 67 49 85 63 105 77 135 100 170 125 215 160 240 175 305 225
3/4 120 88 150 110 190 140 240 175 300 220 380 280 425 315 540 400
7/8 190 140 240 175 190 140 240 175 490 360 615 455 690 510 870 640
1 285 210 360 265 285 210 360 265 730 540 920 680 1030 760 1300 960
1-1/8 400 300 510 375 400 300 510 375 910 670 1150 850 1450 1075 1850 1350
1-1/4 570 420 725 535 570 420 725 535 1280 945 1630 1200 2050 1500 2600 1920
1-3/8 750 550 950 700 750 550 950 700 1700 1250 2140 1580 2700 2000 3400 2500
1-1/2 990 730 1250 930 990 730 1250 930 2250 1650 2850 2100 3600 2650 4550 3350
Torque values listed are for general use only, based on the strength of the Replace fasteners with the same or higher grade. If higher
bolt or screw. DO NOT use these values if a different torque value or grade fasteners are used, tighten these to the strength of the
tightening procedure is given for a specific application. For plastic insert or original. Make sure fastener threads are clean and that you
crimped steel type lock nuts, for stainless steel fasteners, or for nuts on properly start thread engagement. When possible, lubricate
U-bolts, see the tightening instructions for the specific application. Shear plain or zinc plated fasteners other than lock nuts, wheel bolts
bolts are designed to fail under predetermined loads. Always replace shear or wheel nuts, unless different instructions are given for the
bolts with identical grade. specific application.
a
Grade 2 applies for hex cap screws (not hex bolts) up to 6. in (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long,
and for all other types of bolts and screws of any length.
b
“Lubricated? means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or 7/8 in. and larger fasteners with
JDM F13C zinc flake coating.
c
“Dry? means plain or zinc plated without any lubrication, or 1/4 to 3/4 in. fasteners with JDM F13B zinc flake coating.
55-7
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Specifications
DX,TORQ2 –19–24APR03–1/1
Metric Bolt and Screw Torque Values
4.84.8 8.8 9.8 10.9 12.9 12.9
12.9
12.9
10.9
9.8
8.8
4.8
TS1670 –UN–01MAY03
Bolt or Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9
Screw Lubricated
a
Dry
b
Lubricated
a
Dry
b
Lubricated
a
Dry
b
Lubricated
a
Dry
b
Size N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in
M6 4.7 42 6 53 8.9 79 11.3 100 13 115 16.5 146 15.5 137 19.5 172
N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft
M8 11.5 102 14.5 128 22 194 27.5 243 32 23.5 40 29.5 37 27.5 47 35
N•m lb-ft N•m lb-ft N•m lb-ft
M10 23 204 29 21 43 32 55 40 63 46 80 59 75 55 95 70
N•m lb-ft
M12 40 29.5 50 37 75 55 95 70 110 80 140 105 130 95 165 120
M14 63 46 80 59 120 88 150 110 175 130 220 165 205 150 260 190
M16 100 74 125 92 190 140 240 175 275 200 350 255 320 235 400 300
M18 135 100 170 125 265 195 330 245 375 275 475 350 440 325 560 410
M20 190 140 245 180 375 275 475 350 530 390 675 500 625 460 790 580
M22 265 195 330 245 510 375 650 480 725 535 920 680 850 625 1080 800
M24 330 245 425 315 650 480 820 600 920 680 1150 850 1080 800 1350 1000
M27 490 360 625 460 950 700 1200 885 1350 1000 1700 1250 1580 1160 2000 1475
M30 660 490 850 625 1290 950 1630 1200 1850 1350 2300 1700 2140 1580 2700 2000
M33 900 665 1150 850 1750 1300 2200 1625 2500 1850 3150 2325 2900 2150 3700 2730
M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2770 4750 3500
Torque values listed are for general use only, based on the strength Shear bolts are designed to fail under predetermined loads. Always
of the bolt or screw. DO NOT use these values if a different torque replace shear bolts with identical property class. Replace fasteners
value or tightening procedure is given for a specific application. For with the same or higher property class. If higher property class
stainless steel fasteners or for nuts on U-bolts, see the tightening fasteners are used, tighten these to the strength of the original. Make
instructions for the specific application. Tighten plastic insert or sure fastener threads are clean and that you properly start thread
crimped steel type lock nuts by turning the nut to the dry torque engagement. When possible, lubricate plain or zinc plated fasteners
shown in the chart, unless different instructions are given for the other than lock nuts, wheel bolts or wheel nuts, unless different
specific application. instructions are given for the specific application.
a
“Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or M20 and larger fasteners with
JDM F13C zinc flake coating.
b
“Dry” means plain or zinc plated without any lubrication, or M6 to M18 fasteners with JDM F13B zinc flake coating.
55-8
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Lubrication and Maintenance Records
RG,RG34710,5620 –19–27JUL06–1/1
Using Lubrication and Maintenance Records
Refer to specific Lubrication and Maintenance Section
for detailed service procedures.
1. Keep a record of the number of hours you operate
your engine by regular observation of hour meter.
2. Check your record regularly to learn when your
engine needs service.
3. DO ALL the services within an interval section.
Write the number of hours (from your service
records) and the date in the spaces provided. For a
complete listing of all items to be performed and the
service intervals required, refer to the
quick-reference chart near the front of the
Lubrication and Maintenance Section.
IMPORTANT: The service recommendations
covered in this manual are for the
accessories that are provided by
John Deere. Follow manufacturer’s
service recommendations for
servicing engine driven equipment
not supplied by Deere.
RG,RG34710,5621 –19–27JUL06–1/1
Daily (Prestarting) Service
•Check engine oil level.
•Check coolant level.
•Check fuel filters/water bowls.
•Check air cleaner dust unloader valve and air restriction
indicator, if equipped.
•Perform visual walkaround inspection.
60-1
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Lubrication and Maintenance Records
OURGP11,000008D –19–27JUL06–1/1
500 Hour/12 Month Service
•Service fire extinguisher.
•Check engine mounts.
•Service battery.
•Check manual belt tensioner and belt wear.
•Change engine oil and filter.
1
•Check crankcase vent system.
•Check air intake hoses, connections, and system.
•Replace fuel filter element.
•Check automatic belt tensioner and belt wear.
•Check engine electrical ground connection.
•Check cooling system.
•Coolant solution analysis – add SCAs as needed.
•Pressure test cooling system.
•Check engine speeds.
Hours
Date
Hours
Date
Hours
Date
Hours
Date
Hours
Date
Hours
Date
Hours
Date
Hours
Date
1
If other than John Deere PLUS 50
or ACEA E7, ACEA E6, ACEA
E5 or ACEA E4 engine oil and the specified filter are used, the
service interval for engine oil and filter is reduced (see DIESEL
ENGINE OIL AND FILTER INTERVALS chart).
60-2
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Lubrication and Maintenance Records
RG,RG34710,5625 –19–27JUL06–1/1
2000 Hour/24 Month Service
•Check crankshaft vibration damper (6-cylinder only).
•Flush and refill cooling system.
1
•Test thermostats.
•Check and adjust valve clearance.
•Test glow plugs (4045HF475, 6068HF475)
Hours
Date
Hours
Date
Hours
Date
Hours
Date
Hours
Date
Hours
Date
Hours
Date
Hours
Date
1
If John Deere COOL-GARD is used, the flushing interval may be
extended to 3000 hours, or 36 months. If John Deere COOL-GARD
is used and the coolant is tested annually AND additives are
replenished as needed by adding a supplemental coolant additive,
the flushing interval may be extended to 5000 hours or 60 months,
whichever occurs first.
60-3
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Lubrication and Maintenance Records
RG,RG34710,5627 –19–27JUL06–1/1
Service as Required
•Add coolant
•Service air cleaner.
•Replace poly-vee belts.
•Check fuses
•Check air compressor (if equipped)
•Bleed fuel system
Hours
Date
Hours
Date
Hours
Date
Hours
Date
Hours
Date
Hours
Date
Hours
Date
Hours
Date
60-4
080706
PN=239
Emission System Warranty
RG,RG34710,7629 –19–27JUL06–1/1
U.S. EPA Emissions Control Warranty Statement
Emissions control-related parts and components are
warranted by John Deere for five years or 3000 hours
of operation, whichever occurs first. John Deere further
warrants that the engine covered by this warranty was
designed, built, and equipped so as to conform at the
time of sale with all U.S. emissions standards at the
time of manufacture, and that it is free of defects in
materials and workmanship which would cause it not
to meet these standards within the period of five years
or 3000 hours of operation, whichever occurs first.
Warranties stated in this manual refer only to
emissions-related parts and components of your
engine. The complete engine warranty, less
emissions-related parts and components, is provided
separately as the “John Deere New Off-Highway
Engine Warranty”.
65-1
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Emission System Warranty
DPSG,RG41165,133 –19–27JUL06–1/1
Emissions Control System Certification Label
RG11947 –UN–06NOV01
Emissions Label
CAUTION: Statutes providing severe
penalties for tampering with emissions
controls may apply to the user or dealer.
The emissions warranty described below applies only
to those engines marketed by John Deere that have
been certified by the United States Environmental
Protection Agency (EPA) and/or California Air
Resources Board (CARB); and used in the United
States and Canada in non-road mobile (self-propelled
or portable/transportable
1
) equipment. The presence of
an emissions label like the one shown signifies that the
engine has been certified with the EPA and/or CARB.
The EPA and CARB warranties only apply to new
engines having the certification label affixed to the
engine and sold as stated above in the geographic
areas. The presence of an EU number in the third line
of the label signifies that the engine has been certified
with the European Union countries per Directive
97/68/EC. The emissions warranty does not apply to
the EU countries.
NOTE: The hp/kW rating on the engine emissions
certification label specifies the gross engine
hp/kW, which is flywheel power without fan. In
most applications this will not be the same
rating as the advertised vehicle hp/kW rating.
1
Equipment moved at least once every 12 months.
65-2
080706
PN=241
John Deere Service Literature Available
DX,SERVLIT –19–31JUL03–1/2
Technical Information
TS189 –UN–17JAN89TS191 –UN–02DEC88TS224 –UN–17JAN89
TS1663 –UN–10OCT97
Technical information can be purchased from John Deere.
Some of this information is available in electronic media,
such as CD-ROM disks, and in printed form. There are
many ways to order. Contact your John Deere dealer. Call
1-800-522-7448 to order using a credit card. Search
online from http://www.JohnDeere.com. Please have
available the model number, serial number, and name of
the product.
Available information includes:
•PARTS CATALOGS list service parts available for your
machine with exploded view illustrations to help you
identify the correct parts. It is also useful in assembling
and disassembling.
•OPERATOR’S MANUALS providing safety, operating,
maintenance, and service information. These manuals
and safety signs on your machine may also be available
in other languages.
•OPERATOR’S VIDEO TAPES showing highlights of
safety, operating, maintenance, and service information.
These tapes may be available in multiple languages
and formats.
•TECHNICAL MANUALS outlining service information for
your machine. Included are specifications, illustrated
assembly and disassembly procedures, hydraulic oil
flow diagrams, and wiring diagrams. Some products
have separate manuals for repair and diagnostic
information. Some components, such as engines, are
available in separate component technical manuals
•FUNDAMENTAL MANUALS detailing basic information
regardless of manufacturer:
– Agricultural Primer series covers technology in
farming and ranching, featuring subjects like
computers, the Internet, and precision farming.
– Farm Business Management series examines
“real-world” problems and offers practical solutions in
the areas of marketing, financing, equipment
selection, and compliance.
– Fundamentals of Services manuals show you how to
repair and maintain off-road equipment.
70-1
080706
PN=242
Continued on next page
John Deere Service Literature Available
DX,SERVLIT –19–31JUL03–2/2
– Fundamentals of Machine Operation manuals explain
machine capacities and adjustments, how to improve
machine performance, and how to eliminate
unnecessary field operations.
70-2
080706
PN=243
John Deere Service Literature Available
70-3
080706
PN=244
Index
Page Page
A
Cold weather aids.......................35-15
Except 4045DF,TF270 ..................19-9
Acid burns .............................30-2 4045DF,TF270 ........................20-6
Adjust Compressor, air ........................40-11
Valves, all except 475 engines ............35-9 Configuration data, viewing - earlier engines . . 16-14
Valves, 475 engines ...................35-12 Configuration data, viewing - later engines .....17-6
Air cleaner Coolant
Air intake restriction indicator .............25-1 Adding ..............................40-3
Dust unloader valve ....................25-1 Diesel engine ........................10-13
Replace single stage element .............40-5 Disposing ...........................10-16
Air compressor .........................40-11 Replenishing supplemental additives.......30-17
Air intake system, check..................30-11 Supplemental additives .................10-15
Alternator belts .........................40-10 Testing ........................10-15, 30-19
Auxiliary gear drive, limitations .........19-17, 20-3 Warm temperature climates .............10-16
Cooling system
Adding coolant ........................40-3
Check ..............................30-16
B
Flush................................35-3
Batteries Pressure test.........................30-20
Charge/Boost ...................19-11, 20-11 Pressure test radiator cap...............30-20
Service ..............................30-2 Refill ................................35-3
Battery acid burns .......................30-2 Crankcase vent system, check ..............30-9
Battery explosion ........................30-2 Crankshaft vibration damper................35-2
Belt tensioner
Manual tensioner, adjust .................30-4
Manual tensioner, adjust with tool..........30-5
Belt tensioner, automatic .................30-14
D
Belts, fan and alternator
Replacing ...........................40-10 Damper, checking........................35-2
Bleeding fuel system Diagnostic gauge
DE10 pump..........................40-14 Software version - later engines ..........45-29
High Pressure Common Rail.............40-17 Diagnostic Procedure ....................45-20
VP44 pump..........................40-12 Diagnostic procedure
4045DF/TF270 .......................40-19 Using diagnostic gauge - earlier engines ....16-8
Blink codes Using diagnostic gauge - later engines ......17-4
Bosch VP44 pump ....................45-24
High Pressure Common Rail.............45-26 Diagnostic trouble codes
Reading DTCs .......................45-18 Blink codes ..........................45-18
Break-in engine oil .......................10-5 Diagnostic trouble codes (DTCs)
Break-in, engine Active engine service codes, viewing - earlier
Except 4045DF,TF270 ..................19-1 engines ...........................16-16
4045DF,TF270 ........................20-2 Active engine service codes, viewing - later
engines ...........................17-10
Electronic systems and Bosch VP44.......45-24
Diagnostic Trouble Codes (DTCs)
C
Electronic systems and Denso High Pressure
Common Rail.......................45-26
Chart, service interval.................21-2, 21-4 Diagnostic trouble codes (DTCs)
Check and adjust Electronic systems and Stanadyne DE10 . . . 45-22
Valves, all except 475 engines ............35-9 Diagnostic trouble codes (DTC’s)
Valves, 475 engines ...................35-12
Check engine electrical ground.............30-16 Instrument panel ......................45-20
Index-1
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PN=1
Index
Page Page
Diagnostic trouble codes (DTCs) With Denso High Pressure Common Rail ....45-5
With Stanadyne DE10 pump..............45-3Stored service codes, viewing - earlier
engines ...........................16-17 Error Codes ...........................45-28
Stored service codes, viewing - later
engines ............................17-8
Diesel fuel .........................10-1, 10-3
F
DTCs (Diagnostic Trouble Codes)
View active service codes - earlier Fan belts .............................40-10
engines ...........................16-16 Filter, replace
View active service codes - later engines . . . 17-10 Fuel ...............................30-12
View stored service codes - earlier Oil..................................30-7
engines ...........................16-17 Fire extinguisher, service ..................30-1
View stored service codes - later engines....17-8 Fuel
Diesel ...........................10-1, 10-3
Handling and storing ....................10-2
Lubricity .............................10-1
E
Fuel filter
Checking.............................25-1
Emissions Draining water.........................25-1
EPA Statement ........................65-1 Replace ............................30-12
Engine Fuel injection pump model number...........01-5
Adjust speed.........................30-21 Fuel system
Break-in, except 4045DF,TF270 ...........19-1 Bleeding (DE10 pump) .................40-14
Break-in, 4045DF,TF270.................20-2 Bleeding (High Pressure Common Rail) ....40-17
Changing speed ......................19-13 Bleeding (VP44 pump) .................40-12
Check electrical ground.................30-16 Bleeding (4045DF/TF270)...............40-19
Idling...........................19-12, 20-9 Fuses, checking ........................40-11
Operation, except 4045DF,TF270 ..........19-7
Operation, 4045DF,TF270................20-1
Option codes..........................01-3
Serial number .........................01-1
G
Starting, except 4045DF,TF270 engine......19-4
Starting, 4045DF,TF270 engine ...........20-4 Gauges
Stopping, except 4045DF,TF270..........19-16 Except 4045DF,TF270 ..................19-8
Stopping, 4045DF,TF270 ...............20-10 4045DF,TF270 ........................20-8
Troubleshooting ......................45-10 Generator (Standby) Applications............21-4
Warming, except 4045DF,TF270...........19-8 Glow plugs
Warming, 4045DF,TF270 ................20-8 Test, 475 engines .....................35-15
Engine Control Unit (ECU) serial number ......01-5 Grease
Engine coolant Extreme pressure and multipurpose .......10-12
Disposing of .........................10-16
Engine mounts, check ....................30-1
Engine oil
I
Break-In .............................10-5
Change..............................30-7
Service Intervals .......................10-7 Idling engine.......................19-12, 20-9
Instrument panelsEngine speed
Changing ...........................19-13 Adjust backlighting - later engines.........17-13
Adjust contrast - later engines............17-15Engine wiring diagram
W/electronic instrument panel .............45-6 Changing units of measure - earlier
engines ...........................16-12Engine wiring layout
With Bosch VP44 pump .................45-4 Changing units of measure - later engines . . 17-17
Index-2
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PN=2
Index
Page Page
Component function - earlier engines .......16-1 Filler locations.........................25-1
Oil filter, change .........................30-7Component function - later engines.........17-1
identification ..........................15-1 Oil filters..............................10-10
Operating engineMain menu navigation - later engines .......17-5
Setup 1-up display - later engines.........17-20 Break-in, except 4045DF,TF270 ...........19-1
Break-in, 4045DF,TF270.................20-2Setup 4-up display - later engines.........17-26
Shutdown codes - later engines ..........17-12 Cold weather, except 4045DF,TF270 .......19-9
Cold weather, 4045DF,TF270 .............20-6Touch switches - earlier engines..........16-10
Using diagnostic gauge - earlier engines ....16-8 Normal operation, except 4045DF,TF270 ....19-7
Normal operation, 4045DF,TF270 ..........20-1Using diagnostic gauge - later engines ......17-4
Viewing active service codes - earlier Option codes ...........................01-3
engines ...........................16-16
Viewing active service codes - later
engines ...........................17-10
P
Viewing configuration data - earlier
engines ...........................16-14 Poly-vee belts
Viewing configuration data - later engines....17-6 Replace ............................40-10
Viewing stored service codes - earlier Power ratings ...........................55-3
engines ...........................16-17 Precautions for welding on engines equipped
Viewing stored service codes - later w/ECU ..............................45-2
engines ............................17-8
Intermittent fault diagnostics ...............45-29
R
L
Radiator cap testing .....................30-20
Recordkeeping
Listing of DTCs..............45-22, 45-24, 45-26 Engine Control Unit (ECU) serial number ....01-5
Lubricant Engine option codes ....................01-3
Mixing ...............................10-9 Engine serial number ...................01-1
Storage.............................10-11 Injection pump model number.............01-5
Lubrication and Maintenance
Service Interval Chart ...............21-2, 21-4
Lubricity of diesel fuel.....................10-1
S
Serial number
M
Engine ..............................01-1
Engine Control Unit (ECU) ...............01-5
Maintenance interval chart Fuel injection pump.....................01-5
Generator (Standby) applications ..........21-4 Service
Standard industrial applications............21-2 Battery ..............................30-2
Manual belt tensioner .....................30-4 Fire extinguisher .......................30-1
Manual belt tensioner - using belt tension tool . . 30-5 Intervals .........................21-2, 21-4
Mixing lubricants.........................10-9 Service intervals
Engine oil and filter .....................10-7
General information.....................21-1
O
Specifications
Battery capabilities .....................30-2
Belt tensioner ........................30-14Oil
Dipstick..............................25-1 Damper..............................35-2
Engine crankcase oil fill .................55-6Fill quantity ...........................55-6
Index-3
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PN=3
Index
Page Page
Fuel injection pump and power ratings ......55-3
W
General OEM .........................55-1
Standby power units.................19-17, 20-4 Warming engine, except 4045DF,TF270 ......19-8
Warming engine, 4045DF,TF270 ............20-8Starting engine, except 4045DF,TF270
engine...............................19-4 Warranty
Emission System ......................65-2Starting engine, 4045DF,TF270 engine .......20-4
Stopping engine, except 4045DF,TF270......19-16 Wiring diagrams, engine
Engines w/electronic instrument panel ......45-6Stopping engine, 4045DF,TF270 ...........20-10
Storage Wiring harness
With Bosch VP44 pump .................45-4Guidelines............................50-1
Long term ............................50-2 With Denso High Pressure Common Rail ....45-5
With Stanadyne DE10 pump..............45-3Removing from ........................50-3
Storing fuel.............................10-2
Storing lubricants .......................10-11
Supplemental coolant additives
Replenishing .........................30-17
T
Tensioner, belt
Automatic ...........................30-14
Manual ..............................30-4
Thermostat
Install ...............................35-6
Remove .............................35-6
Test opening temperature ................35-6
Touch switches - earlier engines ...........16-10
Trouble codes
Electronic systems and Bosch VP44.......45-24
Electronic systems and Denso High Pressure
Common Rail.......................45-26
Electronic systems and Stanadyne DE10 . . . 45-22
Troubleshooting
General, engine ......................45-10
U
Units of measure, changing - earlier engines . . 16-12
Units of measure, changing - later engines . . . 17-17
V
Valves
Clearance, check and adjust
All except 475 engines ................35-9
475 engines........................35-12
Vibration damper ........................35-2
Index-4
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