John Deere 4045, 6068 OPERATOR’S MANUAL

OWERTECH



4.5 and 6.8 L

4045 and 6068

Tier 2 / Stage II

OEM Diesel Engines

OPERATOR’S MANUAL

OWERTECH

Stage II OEM Diesel Engines

4.5 and 6.8 L Tier 2 /

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.

Foreword

Introduction

THIS MANUAL CONTAINS INFORMATION to operate and service the following Tier 2 / Stage II emission-certified1engines:

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

• 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.

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)

Emission certified for United States as EPA Tier 2 and for European

Union as Stage II.

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.

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Introduction

IMPORTANT: This manual covers only

OWERTECH

 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

OWERTECH

Two exceptions: The 4045HF475 and 6068HF475 for generator

applications at 1500 rpm are still emission non-certified.

is a trademark of Deere & Company.

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.

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Introduction

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Engine Owner

Introduction

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’eˆtre 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 connaıˆtre. 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

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.

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

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Introduction

POWERTECH 4.5 L Engines With Electronic Fuel Systems (Tier 2 Emission Certified) (Two-Valve Cylinder Head Models)

4045 Engine (Stanadyne DE10 Injection Pump Shown)

OWERTECH

is a trademark of Deere & Company.

4045 Engine

RG11932 –UN–06NOV01

RG11931 –UN–06NOV01

OUOD002,0000162 –19–04AUG06–1/1

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Introduction

POWERTECH 6.8 L Engines With Electronic Fuel Systems (Tier 2 Emission Certified) (Two-Valve Cylinder Head Models)

6068 Engine (Bosch VP44 Injection Pump Shown)

OWERTECH

is a trademark of Deere & Company.

RG11933 –UN–24OCT01

6068 Engine

RG11934 –UN–24OCT01

OUOD002,0000163 –19–04AUG06–1/1

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Introduction

POWERTECH 4.5/6.8 L Engines With Electronic Fuel Systems (Tier 2 Emission Certified) (Four-Valve Cylinder Head “475” Models)

6068HF475 Engine Shown (Level 11 Electronic Fuel System With

Denso High Pressure Common Rail)

OWERTECH

is a trademark of Deere & Company.

RG12199 –UN–24MAY02

6068HF475 Shown

RG12200 –UN–24MAY02

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Page

Record Keeping

Engine Serial Number Plate ................01-1

Record Engine Serial Number ..............01-2

Engine Option Codes .....................01-3

Record Engine Control Unit (ECU) Serial

Number..............................01-5

Record Fuel Injection Pump Model Number ....01-5

Safety ................................05-1

Fuels, Lubricants, and Coolant

Diesel Fuel.............................10-1

Lubricity of Diesel Fuel....................10-1

Handling and Storing Diesel Fuel ............10-2

Testing Diesel Fuel.......................10-2

Bio-Diesel Fuel..........................10-3

Minimizing the Effect of Cold Weather on

Diesel Engines ........................10-4

Diesel Engine Break-In Oil .................10-5

Diesel Engine Oil ........................10-6

Diesel Engine Oil and Filter Service Intervals. . . 10-7

Mixing of Lubricants ......................10-9

Oil Filters .............................10-10

OILSCANand COOLSCAN .............10-10

Alternative and Synthetic Lubricants.........10-11

Lubricant Storage.......................10-11

Grease...............................10-12

Diesel Engine Coolant ...................10-13

Drain Intervals for Diesel Engine Coolant ....10-14

Supplemental Coolant Additives............10-15

Testing Diesel Engine Coolant .............10-15

Operating in Warm Temperature Climates ....10-16

Disposing of Coolant ....................10-16

Instrument Panel Identification

Instrument Panels - Identification ............15-1

Instrument Panel - Elect. Cont. Earlier Engines

Instrument Panel ........................16-1

Using Diagnostic Gauge to Access Engine

Information ...........................16-8

Page

Using Touch Switches to Display

Information ..........................16-10PowerTech Medallion.....................01-1

Changing Units of Measure (English or

Metric)..............................16-12

Viewing Engine Configuration Data .........16-14

Viewing Active Engine Service

Codes/Diagnostic Trouble Codes (DTCs) . . . 16-16 Viewing Stored Service

Codes/Diagnostic Trouble Codes

(DTCs) in the Engine ECU ..............16-17

Instrument Panel - Elect. Cont. Later Engines

Instrument Panels........................17-1

Using Diagnostic Gauge to Access Engine

Information ...........................17-4

Main Menu Navigation ....................17-5

Engine Configuration Data .................17-6

Accessing Stored Trouble Codes ............17-8

Accessing Active Trouble Codes ...........17-10

Engine Shutdown Codes .................17-12

Adjusting Backlighting....................17-13

Adjusting Contrast ......................17-15

Selecting Units Of Measurement ...........17-17

Setup 1-Up Display .....................17-20

Setup 4-Up Display .....................17-26

Instrument Panel - Mech. Cont. “270” Engines

Instrument Panel (Earlier 4.5 L “270”

Engines) .............................18-1

Instrument Panel (Later 4.5 L “270” Engines). . . 18-3

Engine Operation - Except 4.5L “270” Engines

Engine Break-In Service...................19-1

Starting the Engine.......................19-4

Normal Engine Operation..................19-7

Warming Engine.........................19-8

Cold Weather Operation...................19-9

Using a Booster Battery or Charger .........19-11

Avoid Excessive Engine Idling .............19-12

Changing Engine Speed..................19-13

Stopping The Engine ....................19-16

Continued on next page

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.

DEERE & COMPANY

Moline, Illinois

A John Deere ILLUSTRUCTIONManual

Previous Editions

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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

Normal Engine Operation..................20-1

Break-In Service.........................20-2

Auxiliary Gear Drive Limitations .............20-3

Generator Set (Standby) Power Units.........20-4

Starting The Engine ......................20-4

Cold Weather Starting ....................20-6

Warming Engine.........................20-8

Avoid Excessive Engine Idling ..............20-9

Testing Thermostats Opening Temperature ....35-6

Check and Adjust Valve Clearance (All

Engines Except 4045HF475 And

6068HF475) ..........................35-9

Check and Adjust Valve Clearance

(4045HF475 And 6068HF475 Engines).....35-12

Test Glow Plugs for Continuity

(4045HF475 And 6068HF475 Engines).....35-15

Stopping the Engine.....................20-10

Using a Booster Battery or Charger .........20-11

Service as Required

Additional Service Information ..............40-1

Do Not Modify Fuel System ................40-2Lubrication and Maintenance

Observe Service Intervals..................21-1

Use Correct Fuels, Lubricants, and Coolant ....21-1

Lubrication and Maintenance Service

Interval Chart—Standard Industrial Engines . . 21-2

Lubrication and Maintenance Service

Interval Chart—Generator (Standby)

Applications ..........................21-4

Lubrication & Maintenance/Daily

Daily Prestarting Checks ..................25-1

Lubrication & Maintenance/500 Hour/12 Month

Servicing Fire Extinguisher.................30-1

Checking Engine Mounts ..................30-1

Servicing Battery ........................30-2

Manual Belt Tensioner Adjustment...........30-4

Manual Belt Tensioner Adjustment Using

Belt Tension Tool (Alternate Method

For Engines Without Auxiliary Drive)........30-5

Changing Engine Oil and Replacing Filter .....30-7

Checking Crankcase Vent System ...........30-9

Checking Air Intake System ...............30-11

Adding Coolant..........................40-3

Replacing Single Stage Air Cleaner ..........40-5

Replacing Axial Seal Air Cleaner Filter

Element .............................40-6

Replacing Radial Seal Air Cleaner Filter

Element .............................40-8

Replacing Fan and Alternator Belts .........40-10

Checking Fuses ........................40-11

Checking Air Compressors................40-11

Bleeding the Fuel System (Engines With

Electronic Fuel Systems And Bosch VP44

Pump)..............................40-12

Bleed the Fuel System (Engines with

Electronic Fuel Systems and Stanadyne DE10

Pump)..............................40-14

Bleed the Fuel System (Engines with

Electronic Fuel Systems and Denso High

Pressure Common Rail) (4045HF475,

6068HF475) .........................40-17

Bleed the Fuel System (4045DF270,

4045TF270) .........................40-19

Replacing Fuel Filter Elements.............30-12

Checking Belt Tensioner Spring Tension

and Belt Wear (Automatic Tensioner) ......30-14

Checking Engine Electrical Ground

Connections .........................30-16

Checking Cooling System.................30-16

Replenishing Supplemental Coolant

Additives (SCAs) Between Coolant

Changes ............................30-17

Testing Diesel Engine Coolant .............30-19

Pressure Testing Cooling System...........30-20

Checking and Adjusting Engine Speeds......30-21

Troubleshooting

General Troubleshooting Information .........45-1

Precautions For Welding On Engines

Equipped With Electronic Engine Control Unit

(ECU) ...............................45-2

Precautions for Electrical System When

Steam Cleaning Engine .................45-2

Engine Wiring Layout (Electronic Fuel

System With Stanadyne DE10 Injection

Pump)...............................45-3

Engine Wiring Layout (Electronic Fuel

System With Bosch VP44 Injection Pump) . . . 45-4Lubrication & Maint./2000 Hour/24 Month

Adjusting Variable Speed (Droop) — 4.5

L “270” Generator Set Engines Only........35-1

Continued on next page

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Contents

Page Page

Engine Wiring Layout (Electronic Fuel Lubrication and Maintenance Records

System With Denso High Pressure Common

Rail)(4045HF475,6068HF475).............45-5

Engine Wiring Diagram (With Earlier

Electronic Instrument Panel) ..............45-6

Engine Wiring Diagram (Engines With

Using Lubrication and Maintenance Records . . . 60-1

Daily (Prestarting) Service .................60-1

500 Hour/12 Month Service ................60-2

2000 Hour/24 Month Service ...............60-3

Service as Required......................60-4

Electronic Instrument Panel) ..............45-7

Engine Wiring Diagram (With Later

Full-Featured Electronic Instrument Panel) . . . 45-8 Engine Wiring Diagram (With Later

Full-Featured Electronic Instrument Panel)—

Emission System Warranty

U.S. EPA Emmission Control Warranty

Statement ............................65-1

Emission Control System Certification Label....65-2

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

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Contents

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Record Keeping

POWERTECH Medallion

A medallion is located on the rocker arm cover which identifies each engine as a John Deere P 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.

OWERTECH



RG11608 –UN–17OCT01RG11609 –UN–17OCT01

OWERTECH

is a trademark of Deere & Company.

Engine 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.

A—Serial Number Plate

01-1

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RG8007 –UN–15JAN99

13-Digit Engine Serial Number Plate

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Record Keeping

Record Engine Serial Number

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:

Saran Engine Serial Number Plate

RG11949 –UN–07NOV01

RG11948 –UN–06NOV01

Torreon Engine Serial Number Plate

•

“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

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01-2

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Record Keeping

Engine Option Codes

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.

RG11946 –UN–06NOV01

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.

Continued on next page

01-3

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Record Keeping

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.

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

If option code label is lost or destroyed,

OPTION CODES title. consult your servicing dealer or engine distributor selling the engine for a replacement.

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

01-4

Engine Base Code (See “A” on previous page.)

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Record Keeping

Record Engine Control Unit (ECU) Serial Number

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.

A—Serial Number Label

Record Fuel Injection Pump Model Number

Record the fuel injection pump model and serial information found on the serial number plate (A).

Model No. RPM

Manufacturer’s No.

Serial No.

A—Serial Number Plate

Record Engine Control Unit (ECU) Serial Number

RG13799 –UN–18NOV04

OURGP12,00000AD –19–27JUL06–1/1

RG11943 –UN–06NOV01

Record Injection Pump Serial Number

01-5

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Safety

Recognize Safety Information

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.

Understand Signal Words

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.

Follow Safety Instructions

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.

DX,ALERT –19–29SEP98–1/1

T81389 –UN–07DEC88

TS187 –19–30SEP88

DX,SIGNAL –19–03MAR93–1/1

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

TS201 –UN–23AUG88

DX,READ –19–03MAR93–1/1

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Replace Safety Signs

Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement.

Safety

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,SIGNS1 –19–04JUN90–1/1

TS201 –UN–23AUG88

RG5419 –UN–28FEB89

Prevent Bypass Starting

RG,RG34710,7508 –19–27JUL06–1/1

Handle Fuel Safely—Avoid Fires

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

TS202 –UN–23AUG88

DX,FIRE1 –19–03MAR93–1/1

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Safety

Prepare for Emergencies

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.

Handle Starting Fluid Safely

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,FIRE2 –19–03MAR93–1/1

TS291 –UN–23AUG88

TS1356 –UN–18MAR92

DX,FIRE3 –19–16APR92–1/1

Handle Fluids Safely—Avoid Fires

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.

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Safety

Service Engines Safely

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.

Wear Protective Clothing

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.

Moving Parts

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Protect Against Noise

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.

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Safety

Handle Chemical Products Safely

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.)

Stay Clear of 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.

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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.

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Rotating Drivelines

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Safety

Practice Safe Maintenance

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.

Work In Ventilated Area

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

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Safety

Avoid High-Pressure Fluids

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.

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Avoid Heating Near Pressurized Fluid Lines

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.

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.

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Only technicians familiar with this type of system can perform repairs. (See your John Deere dealer.)

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Safety

Remove Paint Before Welding or Heating

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.

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Do all work in an area that is well ventilated to carry toxic fumes and dust away.

Dispose of paint and solvent properly.

Service Cooling System Safely

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.

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Safety

Install Fan Guards

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.

Avoid Hot Parts

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).

Rotating Fan

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Hot Surface

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Safety

Avoid Harmful Asbestos Dust

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.

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Prevent Battery Explosions

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).

Use Proper Lifting Equipment

Lifting heavy components incorrectly can cause severe injury or machine damage.

Follow recommended procedure for removal and installation of components in the manual.

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Safety

Use Proper Tools

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.

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Handling Batteries Safely

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.

Safety

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.

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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.

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Safety

Protect Against High Pressure Spray

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.

Dispose of Waste Properly

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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.

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