John Deere 6068HF485, 4045, 4045HF485, 6068 OPERATOR’S MANUAL

PowerTech Plus

4045HF485 and

6068HF485

OEM Diesel Engines

OPERATOR’S MANUAL

PowerTech Plus 4045 and 6068

OEM Diesel Engines

OMRG36852 Issue 30Jun08 (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 3 / Stage IIIA 4.5 L and

1

6.8 L OEM emission-certified

engines:

Saran-built (France) Tier 3 Electronically Controlled
Engines:

• CD4045HF485 (HPCR Fuel System; 4-Valve Head)

• CD6068HF485 (HPCR Fuel System; 4-Valve Head)

Torreon-built (Mexico) Tier 3 Electronically Controlled
Engines:

• PE4045HF485 (HPCR Fuel System; 4-Valve Head)

• PE6068HF485 (HPCR Fuel System; 4-Valve Head)

IMPORTANT: Some information contained within

this manual refers to engines that
are capable of running on aviation
(jet) fuels. These engines are
specifically ordered and outfitted
with special hardened components
and fuel dosing element(s) that make
the engine capable of using these
fuels.

CAUTION: Engines NOT ordered and
outfitted with these special components are
NOT capable of using aviation (jet) fuels. If
you have any questions, please contact your
local servicing dealer.

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 3 and for European

Union as Stage IIIA.

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Introduction

IMPORTANT: This manual covers only the

PowerTech Plus Tier 3
emission-certified 4.5 and 6.8 L OEM
engines listed. These engines meet
Tier 3 / Stage IIIA emission
certification standards. (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. Engines which are Tier
2 / Stage II emission-certified are
covered in another manual,
OMRG33324.

NOTE: This manual covers engines provided to OEM

(Original Equipment Manufacturers). For
engines in Deere machines, refer to the
machine operator’s manual.

OURGP12,00000F1 –19–26JUN08–2/2

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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

Aprenda quie´n es su distribuidor y donde e´l 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 Plus 4.5/6.8 L Engines With Electronic Fuel Systems (Tier 3 / Stage IIIA
Emission Certified) (Four-Valve Cylinder Head “485” Models)

6068HF485 Engine (Electronic Fuel System With Denso High Pressure

RG13547 –UN–11NOV04

Common Rail)

6068HF485 Engine - Right Side View

RG13546 –UN–11NOV04

4045HF485 Engine - Right Side View

PowerTech is a trademark of Deere & Company

RG14361 –UN–14DEC05

OURGP11,0000067 –19–24JUN08–1/1

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Contents

Page

Record Keeping

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

Record Engine Serial Number ..............01-1

Engine Option Codes .....................01-2

Record High-Pressure Fuel Pump Model

Number..............................01-4

Record Engine Control Unit (ECU) Serial

Number..............................01-4

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

Fuels, Lubricants, and Coolant

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

Lubricity of Diesel Fuel....................10-2

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

Testing Diesel Fuel.......................10-3

Biodiesel Fuel...........................10-4

Aviation (Jet) Fuels.......................10-6

Minimizing the Effect of Cold Weather on

Diesel Engines ........................10-7

Diesel Engine Break-In Oil .................10-9

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

Diesel Engine Oil and Filter Service

Intervals ............................10-11

Engine Oil and Filter Service Intervals

(Jet Fuel Capable Engines Only) .........10-15

Mixing of Lubricants .....................10-16

OILSCAN and COOLSCAN ............10-16

Alternative and Synthetic Lubricants.........10-17

Lubricant Storage.......................10-17

Oil Filters .............................10-17

Diesel Engine Coolant ...................10-18

Drain Intervals for Diesel Engine Coolant ....10-19

Additional Information About Diesel

Engine Coolants and Supplemental Coolant

Additives............................10-20

Testing Diesel Engine Coolant .............10-21

Operating in Warm Temperature Climates ....10-22

Disposing of Coolant ....................10-22

Instrument Panels

Page

Using Diagnostic Gauge to Access Engine

Information ...........................15-4

Main Menu Navigation ....................15-5

Engine Configuration Data .................15-7

Accessing Stored Trouble Codes ............15-9

Accessing Active Trouble Codes ...........15-11

Engine Shutdown Codes .................15-13

Adjusting Backlighting....................15-14

Adjusting Contrast ......................15-16

Selecting Units Of Measurement ...........15-18

Setup 1-Up Display .....................15-21

Setup 4-Up Display .....................15-27

Engine Operation

Engine Break-In Service...................20-1

Starting the Engine.......................20-5

Restarting Engine After Emergency

Shutdown ............................20-8

Normal Engine Operation..................20-9

Warming Engine........................20-10

Cold Weather Operation..................20-11

Using a Booster Battery or Charger .........20-13

Avoid Excessive Engine Idling .............20-14

Changing Engine Speed..................20-15

Stopping The Engine ....................20-17

Auxiliary Gear Drive Limitations ............20-18

Generator Set (Standby) Applications........20-18

Lubrication and Maintenance

Observe Service Intervals..................25-1

Use Correct Fuels, Lubricants, and Coolant ....25-1

Lubrication and Maintenance Service

Interval Chart—Standard Industrial Engines . . 25-2
Lubrication and Maintenance Service

Interval Chart—Generator (Standby)

Applications ..........................25-4

Lubrication and Maintenance Service

Interval Chart—Jet Fuel Capable Engines....25-6

Lubrication & Maintenance/Daily

Daily Prestarting Checks ..................30-1

Continued on next pageInstrument Panels........................15-1

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2008

DEERE & COMPANY

Moline, Illinois

A John Deere ILLUSTRUCTIONManual

All rights reserved

Previous Editions

Copyright2005, 2005, 2006

i 070208

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Contents

Page Page

Lubrication & Maintenance 250 Hour (Jet Fuel Intermittent Fault Diagnostics (With

Electronic Controls).....................50-8Engine)/500 Hour/12 Month

Servicing Fire Extinguisher.................35-1 Displaying Diagnostic Gauge Software........50-8

Engine Troubleshooting ..................50-10Checking Engine Mounts ..................35-1

Servicing Battery ........................35-2 Precautions for Electrical System When

Steam Cleaning Engine ................50-17Changing Engine Oil and Replacing Filter .....35-4

Checking Crankcase Vent System ...........35-7 Engine Wiring Layout ....................50-18

Precautions For Welding .................50-19Checking Air Intake System ................35-8

Replacing Fuel Filter Elements (Diesel Fuel) . . . 35-9 Engine Wiring Diagram (Engines With

Full-Featured Instrument Panel) ..........50-20Replacing Fuel Filter and Dosing

Elements (Jet Fuel Capable Engines)......35-11 Engine Wiring Diagram (Engines With

Full-Featured Instrument Panel)Checking Belt Tensioner Spring Tension

and Belt Wear (Automatic Tensioner) ......35-14 (Continued)..........................50-22

Checking Engine Electrical Ground

Connections .........................35-16 Storage

Engine Storage Guidelines.................55-1Checking Cooling System.................35-16

Replenishing Supplemental Coolant Preparing Engine for Long Term Storage......55-2

Removing Engine from Long Term Storage ....55-3Additives (SCAs) Between Coolant

Changes ............................35-17

Testing Diesel Engine Coolant .............35-19 Specifications

General OEM Engine Specifications..........60-1Pressure Testing Cooling System...........35-20

Checking and Adjusting Engine Speeds......35-21 Engine Power Ratings And Fuel System

Specifications .........................60-3

Lubrication & Maint./2000 Hour/24 Month

Checking Crankshaft Vibration Damper

(6-Cylinder Engine Only).................40-1

Engine Crankcase Oil Fill Quantities .........60-5

Unified Inch Bolt and Screw Torque Values ....60-6

Metric Bolt and Screw Torque Values.........60-7

Flushing and Refilling Cooling System ........40-2

Testing Thermostats Opening Temperature ....40-5

Checking and Adjusting Valve Clearance......40-9

Testing Glow Plugs for Continuity (If

Applicable) ..........................40-11

Lubrication and Maintenance Records

Using Lubrication and Maintenance Records . . . 65-1

Daily (Prestarting) Service .................65-1

250 Hour/12 Month Service (Jet Fuel

Capable Engines) ......................65-2

Service as Required

Additional Service Information ..............45-1

Do Not Modify Fuel System ................45-2

500 Hour/12 Month Service ................65-3

2000 Hour/24 Month Service ...............65-4

Service as Required......................65-5

Adding Coolant..........................45-3

Replacing Single Stage Air Cleaner ..........45-5

Replacing Axial Seal Air Cleaner Filter

Element .............................45-6

Replacing Radial Seal Air Cleaner Filter

Emission System Warranty

Emission Control System Certification Label....70-1

U.S. EPA Emmission Control Warranty

Statement ............................70-1

Element .............................45-8

Replacing Fan and Alternator Belts .........45-10

Checking Fuses ........................45-11

Checking Air Compressors................45-11

Bleeding Fuel System....................45-12

Troubleshooting

General Troubleshooting Information .........50-1

Instrument Panel Method for Retrieving

Diagnostic Trouble Codes................50-2

Displaying Of Diagnostic Trouble Codes

(DTCs) ..............................50-3

Listing of Diagnostic Trouble Codes (DTCs)....50-4

ii 070208

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Record Keeping

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

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

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. Use all 13 digits when providing
engine serial number.

Engine Serial Number (B)

__ __ __ __ __ __ __ __ __ __ __ __ __

Engine Model Number (C)

__ __ __ __ __ __ __ __ __ __ __

13-Digit Engine Serial Number Plate

RG13550 –UN–11NOV04

OURGP12,000007D –19–15SEP04–1/1

RG14627 –UN–13JAN06

Saran Factory Engine Serial Number Plate

NOTE: Engine serial numbers on the 7th digit indicates

the Emission Level 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

Torreon Factory Engine Serial Number Plate

RG13716 –UN–23JAN06

OURGP11,00000AB –19–21FEB06–1/1

01-1 070208

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Engine Option Codes

Record Keeping

RG13717 –UN–25JAN05

A—Engine Base Code (Shown

on Engine Option Code
Label

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.

Continued on next page

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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 51 Cylinder Head With Valves
12 Oil Fill Inlet 52 Auxiliary Gear Drive
13 Crankshaft Pulley/Damper 53 Fuel Heater
14 Flywheel Housing 54 Air Intake for Turbocharger
15
16
17
18
19
20
21 Thermostat Cover 63 Low Pressure Fuel Line
22 Thermostat 64 Exhaust Elbow
23
24
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
45 Balancer Shafts 89 Exhaust Gas Recirculating (EGR) System
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)
50 Oil Pump 99 Service Only Items

Flywheel 55 Shipping Stand
Fuel Injection Pump 56 Paint Option
Air Inlet 57 Coolant Pump Inlet
Air Cleaner 59 Oil Cooler
Oil Pan 60 Add-on Auxiliary Drive Pulley
Coolant Pump 62 Alternator Mounting Bracket

Fan Drive 65 Turbocharger
Fan Belt 66 Coolant Temperature Switch

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

OURGP12,000007F –19–15SEP04–2/2

01-3 070208

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Record Keeping

Record High-Pressure Fuel Pump Model Number

Record the high-pressure fuel pump model and serial
number 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

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 High-Pressure Fuel Pump Serial Number

RG13718 –UN–11NOV04

OURGP12,0000080 –19–15SEP04–1/1

RG13799 –UN–18NOV04

Record Engine Control Unit (ECU) Serial Number

OURGP12,00000AD –19–16NOV04–1/1

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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 070208

TS201 –UN–23AUG88

DX,READ –19–03MAR93–1/1

PN=13

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 –19–09JAN07–1/1

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 070208

TS202 –UN–23AUG88

DX,FIRE1 –19–03MAR93–1/1

PN=14

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.

TS227 –UN–23AUG88

DX,FLAME –19–29SEP98–1/1

05-3 070208

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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

TS228 –UN–23AUG88

OURGP12,00001DA –19–25FEB03–1/1

TS206 –UN–23AUG88

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.

DX,WEAR –19–10SEP90–1/1

TS207 –UN–23AUG88

DX,NOISE –19–03MAR93–1/1

05-4 070208

PN=16

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.

TS1132 –UN–26NOV90

DX,MSDS,NA –19–03MAR93–1/1

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.

Rotating Drivelines

TS1644 –UN–22AUG95

OUO1004,0000BD8 –19–15OCT07–1/1

05-5 070208

PN=17

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.

TS218 –UN–23AUG88

DX,SERV –19–17FEB99–1/1

TS220 –UN–23AUG88

DX,AIR –19–17FEB99–1/1

05-6 070208

PN=18

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.

X9811 –UN–23AUG88

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.

DX,FLUID –19–03MAR93–1/1

TS953 –UN–15MAY90

DX,TORCH –19–10DEC04–1/1

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

DX,WW,HPCR1 –19–07JAN03–1/1

TS1343 –UN–18MAR92

05-7 070208

PN=19

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.

TS220 –UN–23AUG88

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.

DX,PAINT –19–24JUL02–1/1

TS281 –UN–23AUG88

DX,RCAP –19–04JUN90–1/1

05-8 070208

PN=20

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

TS677 –UN–21SEP89

OUOD006,000009D –19–15MAY08–1/1

TS271 –UN–23AUG88

Hot Surface

OURGP12,0000135 –19–15OCT07–1/1

05-9 070208

PN=21

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.

TS220 –UN–23AUG88

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).

Work in Clean Area

Before starting a job:

• Clean work area and machine.

• Make sure you have all necessary tools to do your job.

• Have the right parts on hand.

• Read all instructions thoroughly; do not attempt

shortcuts.

DX,DUST –19–15MAR91–1/1

TS204 –UN–23AUG88

DX,SPARKS –19–03MAR93–1/1

DX,CLEAN –19–04JUN90–1/1

T6642EJ –UN–18OCT88

05-10 070208

PN=22

Safety

Illuminate Work Area Safely

Illuminate your work area adequately but safely. Use a
portable safety light for working inside or under the
machine. Make sure the bulb is enclosed by a wire cage.
The hot filament of an accidentally broken bulb can ignite
spilled fuel or oil.

DX,LIGHT –19–04JUN90–1/1

TS223 –UN–23AUG88

05-11 070208

PN=23

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.

Explosion

TS204 –UN–23AUG88

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 070208

Acid

TS203 –UN–23AUG88

DPSG,OUO1004,2758 –19–15OCT07–1/1

PN=24

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.

Use Proper Lifting Equipment

TS1343 –UN–18MAR92

DX,SPRAY –19–16APR92–1/1

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

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

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.

DX,LIFT –19–04JUN90–1/1

TS226 –UN–23AUG88

TS779 –UN–08NOV89

Use only service parts meeting John Deere specifications.

05-13 070208

DX,REPAIR –19–17FEB99–1/1

PN=25

Safety

Dispose of Waste Properly

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.

TS1133 –UN–26NOV90

DX,DRAIN –19–03MAR93–1/1

05-14 070208

PN=26

Diesel Fuel

Fuels, Lubricants, and Coolant

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. Renewable diesel is basically identical
to petroleum diesel fuel that is created by
Hydrotreating fats and oils. Renewable diesel that
meets EN 590 or ASTM D975 is acceptable for use at
all percentage mixture levels.

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) should be at least
5°C(9°F) below the expected lowest temperature or
Cloud Point below the expected lowest ambient
temperature.

Fuel lubricity should pass a 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 as shown in the table.

• BEFORE using diesel fuel with sulfur content greater
than 0.50% (5000 ppm), contact your John Deere
dealer.

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,FUEL1 –19–05OCT07–1/1

10-1 070208

PN=27

Lubricity of Diesel Fuel

Fuels, Lubricants, and Coolant

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 maximum scar diameter of

0.45 mm as measured by ASTM D6079 or ISO
12156-1.

Handling and Storing Diesel Fuel

CAUTION: Handle fuel carefully. Do not fill
the fuel tank when engine is running.

If fuel of low or unknown lubricity is used, add John
Deere PREMIUM DIESEL FUEL CONDITIONER (or
equivalent) at the specified concentration.

Lubricity of Biodiesel Fuel

Significant improvement in lubricity can occur with
biodiesel blends up to B20. The gain in lubricity above
a 20% blend is limited.

DX,FUEL5 –19–05OCT07–1/1

When using bio-diesel fuel, the fuel filter may require
more frequent replacement due to premature plugging.

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.

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,FUEL4 –19–19DEC03–1/1

10-2 070208

PN=28

Fuels, Lubricants, and Coolant

Testing Diesel Fuel

DIESELSCAN is 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

DX,FUEL6 –19–14NOV05–1/1

10-3 070208

PN=29

Biodiesel Fuel

Fuels, Lubricants, and Coolant

Biodiesel is a fuel comprised of mono-alkyl esters of
long chain fatty acids derived from vegetable oils or
animal fats. Biodiesel blends are biodiesel mixed with
petroleum diesel fuel on a volume basis.

Biodiesel users in the U.S. are strongly encouraged to
purchase biodiesel blends from a BQ-9000 Certified
Marketer and sourced from a BQ-9000 Accredited
Producer (as certified by the National Biodiesel Board).
Certified Marketers and Accredited Producers can be
found at the following website: http://www.bq-9000.org.

While 5% blends are preferred (B5), biodiesel
concentrations up to a 20% blend (B20) in petroleum
diesel fuel can be used in all John Deere engines.
Biodiesel blends up to B20 can be used ONLY if the
biodiesel (100% biodiesel or B100) meets ASTM
D6751 (US), EN 14214 (EU), or equivalent
specification. Expect a 2% reduction in power and a
3% reduction in fuel economy when using B20.

John Deere approved fuel conditioners containing
detergent/dispersant additives are recommended when
using lower biodiesel blends, but are required when
using blends of B20 or greater.

John Deere engines can also operate on biodiesel
blends above B20 (up to 100% biodiesel) ONLY if the
biodiesel meets the EN 14214 specification (primarily
available in Europe). Engines operating on biodiesel
blends above B20 may not fully comply with all
applicable emissions regulations. Expect up to a 12%
reduction in power and an 18% reduction in fuel
economy when using 100% biodiesel. John Deere
approved fuel conditioners containing
detergent/dispersant additives are required.

The petroleum diesel portion of biodiesel blends must
meet the requirements of ASTM D975 (US) or EN 590
(EU) commercial standards.

Biodiesel blends up to B20 must be used within 90
days of the date of biodiesel manufacture. Biodiesel
blends from B21 to B100 must be used within 45 days
of the date of biodiesel manufacture.

Request a certificate of analysis from your fuel
distributor to ensure that the fuel is compliant with the
above specifications.

Consult your John Deere dealer for approved biodiesel
fuel conditioners to improve storage and performance
with biodiesel fuels.

When using biodiesel fuel, the engine oil level must be
checked daily. If oil becomes diluted with fuel, shorten
oil change intervals. Refer to Diesel Engine Oil and
Filter Service Intervals for more details regarding
biodiesel and engine oil change intervals.

The following must be considered when using
biodiesel blends up to B20:

• Cold weather flow degradation

• Stability and storage issues (moisture absorption,

oxidation, microbial growth)

• Possible filter restriction and plugging (usually a
problem when first switching to biodiesel on used
engines.)

• Possible fuel leakage through seals and hoses

• Possible reduction of service life of engine

components

The following must also be considered when using
biodiesel blends above B20.

• Possible coking and/or blocked injector nozzles,
resulting in power loss and engine misfire if John
Deere approved fuel conditioners containing
detergent/dispersant additives are not used

• Possible crankcase oil dilution, requiring more
frequent oil changes

• Possible corrosion of fuel injection equipment

• Possible lacquering and/or seizure of internal

components

• Possible formation of sludge and sediments

• Possible thermal oxidation of fuel at elevated

temperatures

• Possible elastomer seal and gasket material
degradation ( primarily an issue with older engines)

Continued on next page

DX,FUEL7 –19–04OCT07–1/2

10-4 070208

PN=30

Fuels, Lubricants, and Coolant

• Possible compatibility issues with other materials
(including copper, lead, zinc, tin, brass, and bronze)
used in fuel systems and fuel handling equipment

• Possible reduction in water separator efficiency

• Potential high acid levels within fuel system

• Possible damage to paint if exposed to biodiesel

IMPORTANT: Raw pressed vegetable oils are NOT

acceptable for use as fuel in any
concentration in John Deere
engines. Their use could cause
engine failure.

DX,FUEL7 –19–04OCT07–2/2

10-5 070208

PN=31

Fuels, Lubricants, and Coolant

Aviation (Jet) Fuels

Aviation (jet) fuels may be used in jet fuel capable
engines with the following restrictions.

Type Comments

Jet A Lower viscosity and density than base No. 2-D diesel

Jet A-1 Lower viscosity and density than base No. 2-D diesel

Jet B Not Recommended.Lower density and extremely

JP-4 Not Recommended.Lower density and extremely

JP-5 Lower viscosity and density than base No. 2-D diesel

JP-7 Lower viscosity and density than base No. 2-D diesel

JP-8 Lower viscosity and density than base No. 2-D diesel

fuel. Power loss up to 10% can be expected.

fuel. Power loss up to 10% can be expected.

low viscosity compared to base No. 2-D diesel fuel.
Power loss up to 14% can be expected.

low viscosity compared to base No. 2-D diesel fuel.
Power loss up to 12% can be expected.

fuel. Power loss up to 9% can be expected.

fuel. Power loss up to 10% can be expected.

fuel. Power loss up to 10% can be expected.

AS60879,00000E1 –19–30JUN08–1/1

10-6 070208

PN=32

Fuels, Lubricants, and Coolant

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 Blend Diesel Fuel

When temperatures fall below -10°C (14°F), winter
blend diesel fuel is best suited for cold weather
operation. Winter blend diesel 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 lowest temperature at which
movement of the fuel is observed.

NOTE: On an average, winter blend diesel fuel has a

lower BTU (heat content) rating. Using winter
blend diesel 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.

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 on the
expected air temperature range between oil changes
and a 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 formula) which contains anti-gel chemistry, or
equivalent to treat Grade No.2-D fuel during the cold
weather season. This generally extends operability
about 10°C (18°F) below its Cloud Point. For
operability at temperatures further below, winter grade
fuel (a blend of No.2-D and No.1-D, or straight No.1-D
fuel) is best suited for cold weather operation.

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.

Air Intake Heater

An air intake heater is an available option to aid cold
weather staring.

Ether

An ether port on the intake is available to aid cold
weather starting.

CAUTION: Do not use ether when (1) starting
with an engine equipped with glow plugs or
(2) when starting with an air intake heater.

CAUTION: Do not use ether when starting
with an air intake heater.

Biodiesel

When running with BIODIESEL blends wax formation
can generate at warmer temperatures. Begin to use
John Deere Premium Biodiesel Conditioner (winter) at
5°C (40°F) to treat biodiesel fuels during the cold
weather season. Below 0°C (32°F) John Deere
requires the use of B5 or lower blends. Below -10°C
(14°F) John Deere requires the use of winter blend
diesel fuel.

Continued on next page

DX,FUEL10 –19–04OCT07–1/2

10-7 070208

PN=33

Fuels, Lubricants, and Coolant

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.

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,FUEL10 –19–04OCT07–2/2

10-8 070208

PN=34

Fuels, Lubricants, and Coolant

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.

Operate the engine under various conditions, particularly
heavy loads with minimal idling, to help seat engine
components properly.

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 CJ-4 ACEA E7
API CI-4 PLUS ACEA E6
API CI-4 ACEA E5
API CH-4 ACEA E4
API CG-4 ACEA E3
API CF-4
API CF-2
API CF

These oils will not allow the engine to
break-in properly.

PLUS-50 is a trademark of Deere & Company.

BK34394,0000149 –19–24JUN08–1/1

10-9 070208

PN=35

Fuels, Lubricants, and Coolant

Diesel Engine Oil

Use oil viscosity based on the expected air temperature
range during the period between oil changes.

John Deere PLUS-50 oil is preferred.

Oils meeting one of the following specifications are also
recommended:

• ACEA Oil Sequence E7

• ACEA Oil Sequence E6

Extended service intervals may apply when John Deere
PLUS-50, ACEA E7, or ACEA E6 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 CJ-4

• API Service Category CI-4 PLUS

• API Service Category CI-4

• ACEA Oil Sequence E5

• ACEA Oil Sequence E4

SAE 15W-40

SAE 10W-40

SAE 10W-30

o

50 C

o

40 C

o

30 C

o

20 C

o

10 C

o

0 C

o

-10 C

o

-20 C

o

-30 C

o

-40 C

o

122 F

o

104 F

o

86 F

o

68 F

o

50 F

o

32 F

o

14 F

o

-4 F

o

-22 F

o

-40 F

SAE 0W-40

Oil Viscosities for Air Temperature Ranges

SAE 5W-30

TS1691 –UN–18JUL07

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

DX,ENOIL11 –19–26JUL07–1/1

10-10 070208

PN=36

Fuels, Lubricants, and Coolant

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

0.10% (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 as shown in the table.

• 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 1.00% (10 000 ppm).

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
or ACEA E6

• Perform engine oil analysis to determine the actual
extended service life of ACEA E7 and ACEA E6 oils

• Use of an approved John Deere oil filter

• Use of diesel fuel with sulfur content less than

0.50% (5000 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 4045 or 6068 (4.5 L or

6.8 L) chart.

2. Locate your engine oil pan option code (19__) on

engine label.

IMPORTANT: If using BIODIESEL blends greater

than B20, shorten oil change interval
to half the recommended service
interval or monitor engine oil using
OILSCAN to ensure that fuel dilution
does not exceed 5%.

Oil types (premium or standard) in the tables include:

• “Premium Oils” include John Deere PLUS-50,
ACEA E7, or ACEA E6 oils.

• “Standard Oils” include John Deere TORQ-GARD
SUPREME, API CJ-4, API CI-4 PLUS, API CI-4,
ACEA E5, or ACEA E4 oils.
Use of lower specification oils in Tier 3 engines may
result in premature engine failure.

3. In the chart column under your oil pan code, select
wheather you use premium oil (PLUS-50 or
equivalvent) 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 300 hours of operation).

PLUS-50 is a trademark of Deere & Company
TORQ-GARD SUPREME is a trademark of Deere & Company

Continued on next page

OURGP11,0000054 –19–26JUN08–1/4

10-11 070208

PN=37

Fuels, Lubricants, and Coolant

4045 (4.5 L) Engine Oil and Filter Service Intervals in Hours of Operation

Oil Pan Option Codes

Power Rating Fuel Sulfur Content

kW (hp) Std Prem Std Prem Std Prem Std Prem

111 (149) Less Than 0.10% (1000 ppm) 250 375 250 500 250 500 250 500

0.10% - 0.20% (1000 - 2000 ppm) 200 300 200 300 250 500 250 500

0.20% - 0.50% (2000 - 5000 ppm) 150 250 150 250 200 300 200 300

115 (154) Less Than 0.10% (1000 ppm) 250 375 250 500 250 500 250 500

0.10% - 0.20% (1000 - 2000 ppm) 200 300 200 300 200 300 250 500

0.20% - 0.50% (2000 - 5000 ppm) 150 250 150 250 150 250 200 300

129 (173) Less Than 0.10% (1000 ppm) *

0.10% - 0.20% (1000 - 2000 ppm) * * 200 300 200 300 250 500

0.20% - 0.50% (2000 - 5000 ppm) * * 150 250 150 250 200 300

147 (197) Less Than 0.10% (1000 ppm) * * 250 375 250 375 250 500

0.10% - 0.20% (1000 - 2000 ppm) * * 200 300 200 300 250 500

0.20% - 0.50% (2000 - 5000 ppm) * * 150 250 150 250 200 300

Use of premium oil also requires use of an approved John Deere oil filter.

a

If considering fuel with sulfur content of 0.50% - 1.00% (5000 ppm - 10,000 ppm), contact your John Deere Dealer (dealer to reference

DTAC solution).

b

Asterisks indicate: Not available in this engine power level with oil pan options above.

a

1903, 19BB 19AE, 19BC 1923, 19BA 1976, 19AZ

Interval Interval Interval Interval

Oil Oil Oil Oil Oil Oil Oil Oil

b

* 250 375 250 500 250 500

b

bb

bb

bb

bb

bb

Continued on next page

OURGP11,0000054 –19–26JUN08–2/4

10-12 070208

PN=38

Fuels, Lubricants, and Coolant

6068 (6.8 L) Engine Oil and Filter Service Intervals in Hours of Operation

Oil Pan Option Codes

Power Fuel Sulfur Content
Rating 1909, 19AS,

kW (hp) Std Prem Std Prem Std Prem Std Prem Std Prem Std Prem

134-140 Less Than 0.10% (1000 ppm) 250 500 250 500 250 500 250 500 250 500 250 500
(180-188)

0.10% - 0.20% (1000 - 2000 ppm) 250 500 250 500 250 500 250 500 250 500 250 500

0.20% - 0.50% (2000 - 5000 ppm) 200 300 200 300 200 300 200 300 250 500 250 500

144 (193) Less Than 0.10% (1000 ppm) 250 500 250 500 250 500 250 500 250 500 250 500

0.10% - 0.20% (1000 - 2000 ppm) 200 300 250 500 250 500 250 500 250 500 250 500

0.20% - 0.50% (2000 - 5000 ppm) 150 250 200 300 200 300 200 300 250 500 250 500

149 (200) Less Than 0.10% (1000 ppm) 250 500 250 500 250 500 250 500 250 500 250 500

0.10% - 0.20% (1000 - 2000 ppm) 200 300 200 300 250 500 250 500 250 500 250 500

0.20% - 0.50% (2000 - 5000 ppm) 150 250 150 250 200 300 200 300 250 500 250 500

155-162 Less Than 0.10% (1000 ppm) 250 500 250 500 250 500 250 500 250 500 250 500
(208-217)

0.10% - 0.20% (1000 - 2000 ppm) 200 300 200 300 250 500 250 500 250 500 250 500

0.20% - 0.50% (2000 - 5000 ppm) 150 250 150 250 200 300 200 300 200 300 200 300

168-173 Less Than 0.10% (1000 ppm) 250 375 250 500 250 500 250 500 250 500 250 500
(225-232)

0.10% - 0.20% (1000 - 2000 ppm) 200 300 200 300 250 500 250 500 250 500 250 500

0.20% - 0.50% (2000 - 5000 ppm) 150 250 150 250 200 300 200 300 200 300 200 300

175 (235) Less Than 0.10% (1000 ppm) 250 375 250 375 250 500 250 500 250 500 250 500

0.10% - 0.20% (1000 - 2000 ppm) 200 300 200 300 250 500 250 500 250 500 250 500

0.20% - 0.50% (2000 - 5000 ppm) 150 250 150 250 200 300 200 300 200 300 200 300

181-198 Less Than 0.10% (1000 ppm) 250 375 250 375 250 500 250 500 250 500 250 500
(243-266)

0.10% - 0.20% (1000 - 2000 ppm) 200 300 200 300 200 300 250 500 250 500 250 500

0.20% - 0.50% (2000 - 5000 ppm) 150 250 150 250 150 250 200 300 200 300 200 300

205 (275) Less Than 0.10% (1000 ppm) *

0.10% - 0.20% (1000 - 2000 ppm) * * 200 300 200 300 200 300 250 500 250 500

0.20% - 0.50% (2000 - 5000 ppm) * * 150 250 150 250 150 250 200 300 200 300

Use of premium oil also requires use of an approved John Deere oil filter.

a

If considering fuel with sulfur content of 0.50% - 1.00% (5000 ppm - 10,000 ppm), contact your John Deere Dealer (dealer to reference

DTAC solution).

b

Asterisks indicate: Not available in this engine power level with oil pan options above.

a

1907, 1908, 19AQ 1924 19AC, 19AV 1961 19AU

19AT

Interval Interval Interval Interval Interval Interval

Oil Oil Oil Oil Oil Oil Oil Oil Oil Oil Oil Oil

b

* 250 375 250 500 250 500 250 500 250 500

b

bb

bb

Continued on next page

OURGP11,0000054 –19–26JUN08–3/4

10-13 070208

PN=39

Fuels, Lubricants, and Coolant

6068 (6.8 L) Engine Oil and Filter Service Intervals in Hours of Operation, Continued

Oil Pan Option Codes

Power Fuel Sulfur Content
Rating 1909, 19AS,

kW (hp) Std Prem Std Prem Std Prem Std Prem Std Prem Std Prem

212-235 Less Than 0.10% (1000 ppm) *
(284-315)

0.10% - 0.20% (1000 - 2000 ppm) ****200300200300250500250500

0.20% - 0.50% (2000 - 5000 ppm) ****150250150250200300200300

Use of premium oil also requires use of an approved John Deere oil filter.

a

If considering fuel with sulfur content of 0.50% - 1.00% (5000 ppm - 10,000 ppm), contact your John Deere Dealer (dealer to reference

DTAC solution).

b

Asterisks indicate: Not available in this engine power level with oil pan options above.

a

1907, 1908, 19AQ 1924 19AC, 19AV 1961 19AU

19AT

Interval Interval Interval Interval Interval Interval

Oil Oil Oil Oil Oil Oil Oil Oil Oil Oil Oil Oil

b

b

b

*

*

bbbb

bbbb

b

*

250 375 250 500 250 500 250 500

OURGP11,0000054 –19–26JUN08–4/4

10-14 070208

PN=40

Fuels, Lubricants, and Coolant

Engine Oil and Filter Service Intervals (Jet Fuel Capable Engines Only)

The oil and filter service interval information in the
following chart should be used as a guideline. 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 fuel.

4045 (4.5 L) Engine Oil and Filter Service Intervals in Hours of Operation

Oil Pan Option Code Dosing Element

Power Rating Fuel Sulfur Content

kW (hp) Std Oil Prem Oil Std Oil Prem Oil
129 (173) Aviation (Jet) Fuels 250 250 250 250

Diesel Fuel - Less Than 0.10% (1000 ppm) 250 500 250 250
Diesel Fuel - 0.10% - 0.20% (1000 - 2000 ppm) 250 500 250 250
Diesel Fuel - 0.20% - 0.50% (2000 - 5000 ppm) 200 300 250 250

Use of premium oil also requires use of an approved John Deere oil filter.

a

When using jet fuels, the service interval recommendation is to change all filters and dosing element every 250 hr.

a

1976 8196

Interval Interval

Option Code

6068 (6.8 L) Engine Oil and Filter Service Intervals in Hours of Operation

Oil Pan Option Code Dosing Element

Power Rating Fuel Sulfur Content

kW (hp) Std Oil Prem Oil Std Oil Prem Oil
129 (173) Aviation (Jet) Fuels 250 250 250 250

Diesel Fuel - Less Than 0.10% (1000 ppm) 250 500 250 250
Diesel Fuel - 0.10% - 0.20% (1000 - 2000 ppm) 250 500 250 250
Diesel Fuel - 0.20% - 0.50% (2000 - 5000 ppm) 200 300 250 250

Use of premium oil also requires use of an approved John Deere oil filter.

a

When using jet fuels, the service interval recommendation is to change all filters and dosing element every 250 hr.

a

1946 81AE

Interval Interval

Option Code

AS60879,00000DF –19–26JUN08–1/1

10-15 070208

PN=41

Mixing of Lubricants

Fuels, Lubricants, and Coolant

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.

OILSCAN and COOLSCAN

OILSCAN and COOLSCAN are 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
OILSCAN and COOLSCAN kits.

Consult your John Deere dealer to obtain specific
information and recommendations.

DX,LUBMIX –19–18MAR96–1/1

T6828AB –UN–15JUN89T6829AB –UN–18OCT88

OILSCAN is a trademark of Deere & Company.
COOLSCAN is a trademark of Deere & Company.

DX,OILSCAN –19–02DEC02–1/1

10-16 070208

PN=42

Fuels, Lubricants, and Coolant

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.

Lubricant Storage

Your equipment can operate at top efficiency only
when clean lubricants are used.

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,ALTER –19–15JUN00–1/1

Make certain that all containers are properly marked to

identify their contents.
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.

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.

Properly dispose of all old containers and any residual

lubricant they may contain.

DX,LUBST –19–18MAR96–1/1

DX,FILT –19–18MAR96–1/1

10-17 070208

PN=43

Diesel Engine Coolant

Fuels, Lubricants, and 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-GARD Prediluted 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:

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:

• 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

COOL-GARD is a trademark of Deere & Company

• 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

Continued on next page

DX,COOL3 –19–27OCT05–1/2

10-18 070208

PN=44

Fuels, Lubricants, and Coolant

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.

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.

IMPORTANT: Do not mix ethylene glycol and

propylene glycol base coolants.

DX,COOL3 –19–27OCT05–2/2

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

When John Deere COOL-GARD is used, the drain
interval may be extended to 5 years or 5000 hours of

COOL-GARD is a trademark of Deere & Company

If COOL-GARD is not used, the drain interval is
reduced to 2 years or 2000 hours of operation.

DX,COOL11 –19–19DEC03–1/1

10-19 070208

PN=45

Fuels, Lubricants, and Coolant

Additional Information About Diesel Engine Coolants and Supplemental Coolant Additives

Engine coolants are a combination of three chemical
components: ethylene glycol or propylene glycol
antifreeze, inhibiting coolant additives, and quality
water.

Coolant specifications

Some products, including John Deere COOL-GARD
Prediluted Coolant, are fully formulated coolants that
contain all three components in their correct
concentrations. Do not add an initial charge of
supplemental coolant additives to these fully
formulated products.

Coolants meeting ASTM D6210 do not require an
initial charge of supplemental coolant additives.

Some coolant concentrates, including John Deere
COOL-GARD Coolant Concentrate, contain both glycol
antifreeze and inhibiting coolant additives. Mix these
products with quality water, but do not add an initial
charge of supplemental coolant additives.

Coolants meeting ASTM D4985 require an initial
charge of supplemental coolant additives.

Replenish coolant additives

simple mixture of ethylene glycol or propylene glycol
and water will not give adequate protection.

Use of supplemental coolant additives reduces
corrosion, erosion, and pitting. These chemicals
reduce the number of vapor bubbles in the coolant and
help form a protective film on cylinder liner surfaces.
This film acts as a barrier against the harmful effects
of collapsing vapor bubbles.

Avoid automotive-type coolants

Never use automotive-type coolants (such as those
meeting ASTM D3306). These coolants do not contain
the correct additives to protect heavy-duty diesel
engines. They often contain a high concentration of
silicates and may damage the engine or cooling
system.

Water quality

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.
All water used in the cooling system should meet the
following minimum specifications for quality:

The concentration of coolant additives is gradually
depleted during engine operation. Periodic
replenishment of inhibitors is required, even when
John Deere COOL-GARD or another fully formulated
coolant is used. Follow the recommendations in this
manual for the use of supplemental coolant additives.

Why use supplemental coolant additives?

Operating without proper coolant additives will result in
increased corrosion, cylinder liner erosion and pitting,
and other damage to the engine and cooling system. A

COOL-GARD is a trademark of Deere & Company

Chlorides <40 mg/L
Sulfates <100 mg/L
Total dissolved solids <340 mg/L
Total hardness <170 mg/L
pH 5.5 to 9.0

Freeze protection

The relative concentrations of glycol and water in the
engine coolant determine its freeze protection limit.

Continued on next page

DX,COOL7 –19–19DEC03–1/2

10-20 070208

PN=46

Fuels, Lubricants, and Coolant

Ethylene Glycol Freeze Protection Limit

40% -24°C (-12°F)
50% -37°C (-34°F)
60% -52°C (-62°F)

Propylene Glycol Freeze Protection Limit

40% -21°C (-6°F)
50% -33°C (-27°F)
60% -49°C (-56°F)

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.

DO NOT use a coolant-water mixture greater than
60% ethylene glycol or 60% propylene glycol.

DX,COOL7 –19–19DEC03–2/2

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 and COOLSCAN PLUS

Coolant test strips

Coolant test strips are available from your John Deere
dealer. These test strips provide a simple, effective

COOLSCAN is a trademark of Deere & Company
COOLSCAN PLUS is a trademark of Deere & Company

For a more thorough evaluation of your coolant,
perform a COOLSCAN or COOLSCAN PLUS analysis,
where available. See your John Deere dealer for
information.

DX,COOL9 –19–19DEC03–1/1

10-21 070208

PN=47

Fuels, Lubricants, and Coolant

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.

Disposing of Coolant

Improperly disposing of engine coolant can threaten the
environment and ecology.

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.

DX,COOL6 –19–18MAR96–1/1

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.

Recycle Waste

TS1133 –UN–26NOV90

RG,RG34710,7543 –19–09JAN07–1/1

10-22 070208

PN=48

Instrument Panels

Instrument Panels

Basic Instrument Panel

RG13276 –UN–28OCT03

Full-Featured 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

RG13277 –UN–22OCT03

Tier 3 John Deere PowerTech Plus 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.

PowerTech is a trademark of Deere & Company

NOTE: Section 20 following covers operation of

engine with these controls.

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.

Continued on next page

OURGP12,0000081 –19–17JUN08–1/3

15-1 070208

PN=49

Instrument Panels

Instrument Panels (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 20.

Continued on next page

OURGP12,0000081 –19–17JUN08–2/3

15-2 070208

PN=50

Instrument Panels

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)

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 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)

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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Instrument Panels

Using Diagnostic Gauge to Access Engine Information

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

• Exhaust gas temperature

• Fuel 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

Diagnostic Gauge

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A—Diagnostic Gauge
B—Menu Key
C—Arrow Keys
D—Enter Key
E—Red “STOP ENGINE” Indicator Light
F—Amber “WARNING” Indicator Light

Continued on next page

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Instrument Panels

NOTE: Engine parameters which can be accessed will

vary with the engine application. Diagnostic gauge
can be programmed for readouts in one of the
following languages; English, French, German,
Italian, Spanish and Portuguese. Contact your
engine distributor or dealer.

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.

Main Menu Navigation

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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.

2. The first seven items of the "Main Menu" will be

displayed.

Menu Key

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Continued on next page

Menu Display

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Instrument Panels

3. Pressing the "Arrow" keys will scroll through the menu

selections.

4. Pressing the right arrow key will scroll down to reveal

the last items of "Main Menu" screen, highlighting the

next item down.

Main Menu Items

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Last Items On Main Menu

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.

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Use Arrow Buttons To Scroll / Quadrant Display

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Instrument Panels

Engine Configuration Data

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.

Menu Key

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2. The main menu will be displayed. Use the "Arrow" keys

to scroll through the menu until "Engine Config" is

highlighted.

3. Once "Engine Config" menu item has been highlighted,

press the "Enter" key to view the engine configuration

data.

Select Engine Configuration

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Continued on next page

Enter Key

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Instrument Panels

4. Use the "Arrow" keys to scroll through the engine

configuration data.

5. Press the "Menu" key to return to the main menu.

6. Press the "Menu" key to exit the main menu and return

to the engine parameter display.

Use Arrow Keys To Scroll

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Return To Main Menu

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Exit Main Menu

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Instrument Panels

Accessing Stored Trouble Codes

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.

Menu Key

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2. The main menu will be displayed. Use the "Arrow" keys

to scroll through the menu until "Stored Codes" is

highlighted.

Select Stored Codes

Continued on next page

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3. Once the "Stored Codes" menu item has been

highlighted press the "Enter" key to view the stored

codes.

Instrument Panels

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.

Enter Key

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Use Arrow Keys To Scroll

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5. Press the "Menu" key to return to the main menu.

Return To Main Menu

Continued on next page

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Instrument Panels

6. Press the "Menu" key to exit the main menu and return

to the engine parameter display.

Accessing Active Trouble Codes

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.

Exit Main Menu

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Normal Operation

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.

15-11 070208

Active Trouble Codes Displayed

Continued on next page

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Instrument Panels

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.

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.

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.

Use Arrow Keys To Scroll

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Hide Trouble Codes

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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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Continued on next page

Active Trouble Code Icon

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Enter Key

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Instrument Panels

7. The single or four parameter screen will display the

warning icon until the trouble code condition is

corrected.

Engine Shutdown Codes

1. During normal operation the single or four parameter

screen will be displayed.

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.

Active Trouble Code Condition

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Normal Operation

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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.

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.

15-13 070208

Shutdown Message

Hide Trouble Code

Continued on next page

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Instrument Panels

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.

5. Pressing the "Enter" key once again will hide the

trouble code and return the screen to the single or four

parameter display.

Flashing Shutdown Icon

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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.

Adjusting Backlighting

1. Turn the key switch to the ON position. Starting at the

single or four engine parameter display, press the

"Menu" key.

Redisplay Trouble Code

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Shutdown Icon

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Continued on next page

Menu Key

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Instrument Panels

2. The main menu will be displayed. Use the "Arrow" keys

to scroll through the menu until "Adjust Backlight" is

highlighted.

3. Once the "Adjust Backlight" menu item has been

highlighted, press the "Enter" key to activate the

"Adjust Backlight" function.

4. Use the "Arrow" keys to select the desired backlight

intensity.

Select Adjust Backlight

Press Enter Key

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Continued on next page

Adjust Backlight Intensity

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Instrument Panels

5. Press the "Menu" key to return to the main menu.

6. Press the "Menu" key to exit the main menu and return

to the engine parameter display.

Return To Main Menu

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Exit Main Menu

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Adjusting Contrast

1. Turn the key switch to the ON position. Starting at the

single or four engine parameter display press the

"Menu" key.

15-16 070208

Continued on next page

Menu Key

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Instrument Panels

2. The main menu will be displayed. Use the "Arrow" keys

to scroll through the menu until "Adjust Contrast" is

highlighted.

3. Once the "Adjust Contrast" menu item has been

highlighted, press the "Enter" key to activate the

"Adjust Contrast" function.

Select Adjust Contrast

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Press Enter Key

4. Use the "Arrow" keys to select the desired contrast

intensity.

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Continued on next page

Adjust Contrast Intensity

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Instrument Panels

5. Press the "Menu" key to return to the main menu.

6. Press the "Menu" key to exit the main menu and return

to the engine parameter display.

Return To Main Menu

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Exit Main Menu

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Selecting Units Of Measurement

1. Turn the key switch to the ON position. Starting at the

single or four engine parameter display, press the

"Menu" key.

15-18 070208

Continued on next page

Menu Key

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Instrument Panels

2. The main menu will be displayed. Use the "Arrow" keys

to scroll through the menu until "Select Units" is

highlighted.

3. Once the "Select Units" menu item has been

highlighted press the "Enter" key to access the "Select

Units" function.

Select Units

Press Enter Key

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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.

Select Desired Units

Continued on next page

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Instrument Panels

5. Press the "Enter" key to select the highlighted units.

6. Press the "Menu" key to return to the main menu.

Press Enter Key to Select

Return To Main Menu

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7. Press the "Menu" key to return to the engine

parameter display.

Press Menu Key

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Instrument Panels

Setup 1-Up Display

1. Turn the key switch to the ON position. Starting at the

single engine parameter display, press the "Menu" key.

2. Use the "Arrow" keys to scroll through the menu until

"Setup 1-Up Display" is highlighted.

Menu Key

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Setup 1-Up Display

3. Once "Setup 1-Up Display" menu item has been

highlighted press the "Enter" key to access the "Setup

1-Up Display" function.

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Continued on next page

Press Enter Key

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Instrument Panels

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.

1-Up Display Options

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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

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Select Defaults

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Instrument Panels

6. Press the "Enter" key to activate the "Use Defaults"

function.

7. The display parameters are reset to the factory

defaults, then the display will return to the "Setup 1-Up

Display" menu.

Defaults Selected

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Restored To Defaults

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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.

Select Custom Setup

Continued on next page

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9. Press the "Enter" key to display a list of engine

parameters.

Instrument Panels

10. Use the "Arrow" keys to scroll to and highlight a

selected parameter (parameter with a number to right
of it).

Engine Parameters

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Select Parameters

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11. Press the "Enter" key to deselect the selected

parameter, removing it from the list of parameters
being displayed on the 1-Up Display.

Deselect Parameters

Continued on next page

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Instrument Panels

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).

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.

Select Desired Parameters

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Select Parameters For Display

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.

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Automatic Scan Off

Continued on next page

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16. Press the "Enter" key to toggle the "Automatic Scan"

function on.

17. Press the "Enter" key again to toggle the "Automatic

Scan" function off.

Automatic Scan On

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Automatic Scan Off

Continued on next page

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18. Once the "Use Defaults", "Custom Setup" and

"Automatic Scan" functions have been set, press the
"Menu" key to return to the main menu.

Instrument Panels

19. Press the "Menu" key to exit the main menu and

return to the engine parameter display.

Menu Key

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Exit Main Menu

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Setup 4-Up Display

1. Turn the key switch to the ON position. From the single

or four engine parameter display, press the "Menu"

key.

15-27 070208

Continued on next page

Menu Key

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Instrument Panels

2. The main menu will be displayed. Use the "Arrow" keys

to scroll through the menu until "Setup 4-Up Display" is

highlighted.

3. Once the "Setup 4-Up Display" menu item has been

highlighted, press the "Enter" key to activate the "Setup

4-Up Display" menu.

Select Setup 4-Up Display

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Press Enter Key

Continued on next page

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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.

Instrument Panels

RG13244 –UN–02OCT03

Select Factory Defaults

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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.

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.

Restored To Defaults

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Continued on next page

Custom Setup

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Instrument Panels

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.

8. Press the "Enter" key and a list of engine parameters

will be displayed.

Select Parameters

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List Of Engine Parameters

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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".

Select Desired Engine Parameter

Continued on next page

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10. Press the "Enter" key to change the selected

parameter in the quadrant to the new parameter.

Instrument Panels

11. Use the "Menu" keys to return to the "4-Up Custom

Setup" screen.

12. The selected quadrant has now changed to the new

selected parameter.

Enter Selected Parameter

Return To 4-Up Custom Setup

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Continued on next page

4-Up Display

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Instrument Panels

13. Repeat the parameter selection process until all

spaces are as desired.

14. Press the "Menu" key to return to the main menu.

15. Press the "Menu" key to exit the main menu and

return to the engine parameter display.

Return To Main Menu

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Select Remaining Parameters

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Engine Operation

Engine Break-In Service

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 DIESEL

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 DIESEL ENGINE

BREAK-IN OIL and a new John Deere oil filter.

Continued on next page

Check Engine Oil

RG13719 –UN–11NOV04

OURGP11,0000055 –19–07DEC05–1/4

20-1 070208

PN=81

Engine Operation

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 DIESEL ENGINE BREAK-IN OIL is

preferred. See DIESEL ENGINE BREAK-IN OIL, in

Fuels, Lubricants, and Coolant Section for other oils

allowed.

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

RG8028A –UN–15JAN99

Crosshatch Pattern On Dipstick

A—Crosshatch Pattern On Dipstick

These oils will not allow the engine to
break-in properly.

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.

Continued on next page

OURGP11,0000055 –19–07DEC05–2/4

20-2 070208

PN=82

Engine Operation

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 the normal 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 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).

If air temperature is below -10°C (14°F), use an
engine block heater.

Engine Oil Filter

RG13721 –UN–11NOV04

A—Engine Oil Filter

Continued on next page

OURGP11,0000055 –19–07DEC05–3/4

20-3 070208

PN=83

Engine Operation

6. Watch coolant temperature gauge (A) 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.

7. Watch oil pressure gauge (B) for pressure within

specification.

1

Engine

—Oil Pressure at Full
Load Rated Speed With Oil
Warmed to 115°C (240°F) 345 ± 103 kPa (3.45 ± 1.03 bar)

Minimum Oil Pressure at Slow

Idle 105 kPa (1.05 bar) (15 psi)..................................................................

Coolant Temperature Range 82°–94°C (180°–202°F)................................

Specification

.....................

(50 ± 15 psi)

8. Check poly-vee belt for proper alignment and seating

in pulley grooves.

1

Engine oil pressure at rated speed can be as low as 241 kPa (2.41 bar)
(35 psi) and as high as 586 kPa (5.86 bar) (85 psi). This not detrimental
to the engine.

Watch Coolant Temperature and Oil Pressure on Panel

RG13720 –UN–11NOV04

A—Engine Coolant Temperature Gauge
B—Oil Pressure Gauge

OURGP11,0000055 –19–07DEC05–4/4

20-4 070208

PN=84

Engine Operation

Starting the Engine

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.

Use Proper Ventilation

TS220 –UN–23AUG88

2. Open the fuel supply shut-off valve, if equipped.

3. Disengage clutch (if equipped) controlling any engine

drivelines.

Continued on next page

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20-5 070208

PN=85

Engine Operation

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.

Analog Throttle Control and Speed Select Switch

RG13722 –UN–11NOV04

A—Analog Throttle Control (Optional)
B—Speed Select Rocker Switch

Continued on next page

OURGP12,0000086 –19–22SEP04–2/3

20-6 070208

PN=86

Engine Operation

5. Turn the key start switch (A) clockwise to the “ON”

position. Wait until the Engine Preheater Indicator light
turns off, then turn the key start switch clockwise
“START” position to crank the engine. (In cold weather,
preheater indicator light remains on longer while
engine is warmed. See COLD WEATHER
OPERATION later in this section.) 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. (See “Changing Engine Speeds” later in this
section).

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.)

Start And Idle Engine Controls On Instrument Panel

RG13723 –UN–11NOV04

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)

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20-7 070208

PN=87

Engine Operation

Restarting Engine After Emergency Shutdown

In the event of an emergency engine shutdown, the
following procedures are required to restart the engine.

1. Correct the condition causing the emergency

shutdown.

2. Perform initial restarting procedures, as required. See

STARTING THE ENGINE, steps 1 through 4, earlier in
this section.

NOTE: For ALL emergency shutdowns, the controller

must be reset before the engine can be restarted.
Recycle the key switch to reset the controller.

3. Recycle the key start switch (A) as follows:

a. Turn key switch OFF.
b. Wait 15 seconds.

Restarting the Engine

RG13738 –UN–11NOV04

A—Key Start Switch

c. Turn key switch clockwise to crank the engine.

4. Perform final restarting procedures, as required. See

STARTING THE ENGINE, steps 6 and 7, earlier in this
section.

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PN=88

Normal Engine Operation

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.

Normal engine oil pressure at slow idle should be at
least 105 kPa (15 psi) and should rise to at least 172
kPa (1.72 bar) (25 psi) at rated speed. Engine oil
pressure at rated speed can be as low as 241 kPa
(2.41 bar) (35 psi) and high as 586 kPa (5.86 bar) (85
psi). This not detrimental to the engine.

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

NOTE: These engines meet emission standards with

an exhaust gas recirculation system and a
variable geometry turbocharger. A revving
sound may be heard for an instant after
starting, as the variable geometry turbocharger
recycles. This is normal.

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PN=89

Engine Operation

Warming Engine

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). Then engine idle drops to
normal.

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.

Oil Pressure and Coolant Temperature Gauges On Panel

RG13724 –UN–11NOV04

A—Engine Oil Pressure Gauge
B—Engine Coolant Temperature Gauge

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 psi)
within 5 seconds, stop the engine and determine the
cause. Normal engine oil pressure should be 345 kPa
± 103 (3.45 ± 1.03 bar) (50 ± 15 psi) at rated full load
speed (1800–2400 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.

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20-10 070208

PN=90

Cold Weather Operation

CAUTION: DO NOT use starting fluid on
engines equipped with 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.

Engine Operation

Engines may be equipped with a block heater, air intake
heater, coolant heater or fuel heater as cold weather
starting aids. The PowerTech Plus engines may be
equipped with glow plugs as an automatic cold weather
starting aid (see steps 1-4 following).

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.

If air temperature is below -10°C (14°F), use an engine
block heater.

Other cold weather starting aids are required at
temperatures below -25°C (-13°F) or at altitudes above
1500 m (5000 ft). (See “Using a Booster Battery or
Charger” later in this section.)

Handle Starting Fluid with Care

TS1356 –UN–18MAR92

RG13804 –19–24NOV04

Cold Weather Starting Guidelines

Continued on next page

OURGP11,0000058 –19–17JUN08–1/2

20-11 070208

PN=91

Engine Operation

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.

NOTE: Glow plugs operate automatically through the

ECU. The Engine Preheater Indicator light (B) on
these engines, 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 glow plugs. Operating time
depends on temperature. Do not crank engine
until light turns off.

2. Turn key start switch (A) ON to activate glow plugs, but

DO NOT crank engine until Engine Preheater Indicator
light (B) turns off.

3. Follow remaining steps 5—7 as listed earlier in

“Starting Engine” section.
Additional information on cold weather operation is

available from your authorized servicing dealer.

Activating Glow Plugs (if applicable) with Key Start Switch

RG13864 –UN–28JAN05

A—Key Start Switch

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20-12 070208

PN=92

Engine Operation

Using a Booster Battery or Charger

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.

Exploding Battery

TS204 –UN–23AUG88

RG4678 –UN–14DEC88

12-Volt System

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).

24-Volt System

RG4698 –UN–14DEC88

A—12-Volt Machine Battery (ies)
B—12-Volt Booster Battery (ies)
C—Booster Cable
D—Cable to Starting Motor

Continued on next page

RG,RG34710,5564 –19–27JUL06–1/2

20-13 070208

PN=93

Engine Operation

6. Start the engine. Disconnect jumper cables

immediately after engine starts. Disconnect NEGATIVE
(–) cable first.

Avoid Excessive Engine Idling

RG,RG34710,5564 –19–27JUL06–2/2

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 800 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).

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20-14 070208

PN=94

Engine Operation

Changing Engine Speed

Changing from slow to fast speed using Adjustable
High-Low Speed Select Rocker Switch (A)

Engine panels 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).

• 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 (-).

Changing Engine Speed with Full-Featured Panel

RG13725 –UN–11NOV04

A—High-Low Speed Select Rocker Switch
B—Bump Speed Enable Rocker Switch
C—Speed Select Rocker Switch
D—Analog Throttle Control (Optional)

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 throttle
(D)

NOTE: Pushing in on analog throttle will immediately take

engine to slow idle speed.

1. Set High-Low Speed Select Rocker Switch (A) to low
speed “turtle” position.

Continued on next page

OURGP12,000008A –19–22SEP04–1/3

20-15 070208

PN=95

Engine Operation

2. Turn analog throttle (D) 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.

Changing engine speeds on 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.

OURGP12,000008A –19–22SEP04–2/3

RG13289 –UN–30OCT03

Changing Engine Speed With Basic Panel

E—High-Low Speed Select Rocker Switch

The settings will not be stored, so above steps must be
repeated for each speed change.

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20-16 070208

PN=96

Engine Operation

Stopping The Engine

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.

3. Set either High-Low Speed Select Rocker Switch (A) or
Analog Throttle (B) 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.

4. 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.

5. Turn key switch (C) to “OFF” position to stop the
engine. Remove ignition key.

IMPORTANT: Make sure that exhaust stack rain cap

(D) is installed when engine is not
running. This will prevent water and dirt
from entering engine.

Stopping the Engine

RG13726 –UN–11NOV04

RG13727 –UN–11NOV04

Exhaust Stack Rain Cap

A—High-Low Speed Select Rocker Switch
B—Analog Throttle (Optional)
C—Key Switch
D—Exhaust Stack Rain Cap

OURGP12,000008B –19–22SEP04–1/1

20-17 070208

PN=97

Engine Operation

Auxiliary Gear Drive Limitations

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

A—Auxiliary Gear Drive

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.

Auxiliary Gear Drive

RG7634A –UN–22JAN99

RG,RG34710,5555 –19–27JUL06–1/1

RG,RG34710,5556 –19–27JUL06–1/1

20-18 070208

PN=98

Lubrication and Maintenance

Observe Service Intervals

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. Perform
maintenance at interval which occurs
first, for example, either at 500 hours of
operation or every 12 months. Service
MORE OFTEN if engine is operated
under adverse conditions. Neglecting
maintenance can result in failures or
permanent damage to the engine.

Hour Meter On Instrument Panel

RG13728 –UN–11NOV04

A—Hour Meter

Use Correct Fuels, Lubricants, and Coolant

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.

OURGP11,0000059 –19–07DEC05–1/1

TS100 –UN–23AUG88

John Deere Parts Network

DPSG,OUOE003,20 –19–27JUL06–1/1

25-1 070208

PN=99

Lubrication and Maintenance

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 Hours of 2000 Hours of

Operation/or Operation/or

Item Daily Months Months As Required

Check Engine Oil and Coolant Level •
Check Fuel Filter/Water Bowl •
Check Air Cleaner Dust Unloader Valve & Restriction Indicator •

a

Gauge
Visual Walk Around Inspection •
Service Fire Extinguisher •
Check Engine Mounts •
Service Battery •
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)
Flush and Refill Cooling System

e

d

Test Thermostats •
Check and Adjust Engine Valve Clearance •
Test Glow Plugs •
Add Coolant •
Replace Air Cleaner Elements •

a

Replace primary air cleaner element when restriction indicator shows a vacuum of 625 mm (25 in.) H2O. If not equipped with indicator,

replace air cleaner elements at 500 hours or 12 months, whichever occurs first.

b

During engine break-in, change the oil and filter for the first time after 100 hours of operation (maximum).

c

Service intervals depend on sulfur content of the diesel fuel, oil pan capacity, and the oil and filter used. (See DIESEL ENGINE OIL AND

FILTER SERVICE INTERVALS, in Fuels, Lubricants, and Coolant Section.)

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.

Every 12 Every 24

•

•

•

Continued on next page

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25-2 070208

PN=100