PowerTec OMRG25204 User Manual
PowerTech
4.5 L and 6.8 L
Non-Certified and
Tier 1 Certified
OEM Diesel Engines
OPERATOR’S MANUAL
PowerTech 4.5 L and 6.8 L
Non-Certified and Tier 1 Certified
OEM Diesel Engines
OMRG25204 Issue 02Nov06 (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 4.5 L & 6.8 L non-certified and
Tier 11emission certified OEM engines built at
Dubuque Iowa (T0), Saran France (CD) and Torreon
Mexico (PE) from 1996 on. These engines have
mechanically-controlled fuel systems.
SARAN BUILT NON-CERTIFIED ENGINES
• CD4045DF120
• CD4045TF120
• CD4045TF220
• CD4045HF120
• CD6068TF120
• CD6068TF220
• CD6068HF120
TORREON BUILT NON-CERTIFIED ENGINES
• PE4045TF120
• PE4045TF220
• PE4045HF120
• PE6068TF120
• PE6068TF220
• PE6068HF120
DUBUQUE BUILT NON-CERTIFIED ENGINES
• T04045DF120
• T04045TF120
• T04045TF220
• T04045HF120
SARAN BUILT TIER 1 CERTIFIED ENGINES
• CD4045DF150
• CD4045DF151
• CD4045DF152
• CD4045DF153
• CD4045DF154
• CD4045DF157
• CD4045DF158
• CD4045TF150
• CD4045TF152
• CD4045TF154
• CD4045TF155
• CD4045TF157
• CD4045TF158
• CD4045TF161
• CD4045TF162
• CD4045TF250
• CD4045TF251
• CD4045TF252
• CD4045TF253
• CD4045TF257
• CD4045TF258
• CD4045HF150
• CD4045HF152
• CD4045HF157
• CD4045HF158
• CD4045HF252
• CD6068DF150
• CD6068TF150
• CD6068TF151
• CD6068TF152
• CD6068TF157
• CD6068TF158
• CD6068TF159
• CD6068TF250
• CD6068TF251
• CD6068TF257
• CD6068TF258
• CD6068HF150
• CD6068HF157
• CD6068HF158
• CD6068HF250
• CD6068HF252
• CD6068HF254
• CD6068HF258
TORREON BUILT TIER 1 CERTIFIED ENGINES
• PE4045DF150
• PE4045TF150
1
Emission certified for United States as EPA Tier 1 and European
Union as Stage 1.
OURGP11,0000004 –19–27OCT06–1/2
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Introduction
• PE4045TF151
• PE4045HF150
• PE4045HF252
• PE6068DF150
• PE6068TF150
• PE6068TF151
• PE6068TF250
• PE6068HF150
• PE6068HF250
DUBUQUE BUILT TIER 1 CERTIFIED ENGINES
• T04045DF150
• T04045DF151
• T04045DF152
• T04045DF153
• T04045TF150
• T04045TF151
• T04045TF152
• T04045TF250
• T04045TF251
• T04045HF120
• T04045HF150
• T06068DF150
• T06068TF150
• T06068TF151
• T06068TF250
• T06068HF150
• T06068HF250
NOTE: Before 2005, all Non-certified and Tier 1
Certified Saran built engines used the following
serial number sequences:
•
(CDxxxxD500000) - (CDxxxxD799999)
•
(CDxxxxT500000) - (CDxxxxT799999)
•
(CDxxxxH500000) - (CDxxxxH799999)
Since 2005, non-certified engines have the
seventh digit of the serial number as “B” while
Tier 1 certified engines have the seventh digit
as “C”.
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.
RIGHT-HAND AND LEFT-HAND sides are determined
by standing at the drive or flywheel end (rear) of the
engine and facing toward the front of the engine.
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.
NOTE: This operators manual covers only engines
provided to OEM (Outside Equipment
Manufacturers). For engines in Deere
machines, refer to the machine operators
manual.
OURGP11,0000004 –19–27OCT06–2/2
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Engine Owner
Introduction
John Deere Engine Owner:
Don’t wait until you need warranty or other service to
meet your local John Deere Engine Distributor or
Service Dealer. To register your engine for warranty
via the Internet, use the following URL:
http://www.johndeere.com/enginewarranty
Learn who your dealer is and where he is. At your first
convenience, go meet him. He’ll want to get to know
you and to learn what your needs might be.
Aux Utilisateurs De Moteurs John Deere:
N’attendez pas d’eˆtre oblige´d’avoir recours a`votre
concessionnaire John Deere ou au point de service le
plus proche pour vous adresser a`lui. Pour enregistrer
votre moteur pour la garantie via Internet, utilisez
l’adresse suivante:
http://www.johndeere.com/enginewarranty
Renseignez-vous de`s que possible pour l’identifier et
le localiser. A la premie`re occasion, prenez contact
avec lui et faites-vous connaıˆtre. Il sera lui aussi
heureux de faire votre connaissance et de vous
proposer ses services le moment venu.
An Den Besitzer Des John Deere Motors:
Warten Sie nicht auf einen evt. Reparaturfall, um den
na¨chstgelegenen John Deere Ha¨ndler kennen zu
lernen. Zur Registrierung Ihres Motors fu¨r die Garantie
dient folgende Internet-Adresse:
http://www.johndeere.com/enginewarranty
distributore dei motori John Deere o del
concessionario che fornisce l’assistenza tecnica. Per
registrare via Internet la garanzia del suo motore, si
collegi al seguente sito URL:
http://www.johndeere.com/enginewarranty
Lo identifichi e si informi sulla sua ubicazione. Alla
prima occasione utile lo contatti. Egli desidera fare la
sua conoscenza e capire quali potrebbero essere le
sue necessita`.
Propietario De Equipo John Deere:
No espere hasta necesitar servicio de garantı´aode
otro tipo para conocer a su Distribuidor de Motores
John Deere o al Concesionario de Servicio. Registre
su motor para la garantı´a en la siguiente direccio´nde
internet: http://www.johndeere.com/enginewarranty
Ente´rese de quie´nes,ydo´nde esta´situado. Cuando
tenga un momento, vaya a visitarlo. A e´l le gustara
´
conocerlo, y saber cua´les podrı´an ser sus
necesidades.
Till a¨gare av John Deere motorer:
Ta reda pa˚vem din a˚terfo¨rsa¨ljare a¨r och beso¨k honom
sa˚snart tillfa¨lle ges. Va¨nta inte tills det a¨r dags fo¨r
service eller eventuellt garantiarbete. Din motor
garantiregistrerar Du via Internet pa
˚
http://www.johndeere.com/enginewarranty
Din a˚terfo¨rsa¨ljare vill mycket ga¨rna tra¨ffa dig fo¨r att la¨ra
ka¨nna dina behov och hur ba¨st han kan hja¨lpa dig.
Machen Sie sich bei ihm bekannt und nutzen Sie sein
“Service Angebot”.
Proprietario del motore John Deere:
Non aspetti fino al momento di far valere la garanzia o
di chiedere assistenza per fare la conoscenza del
OURGP11,0000251 –19–11OCT06–1/1
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Introduction
POWERTECH4.5 L Engines With Mechanical Controls (Tier 1 Emission Certified)
4045D Engine
4045T Engine
4045D Engine
RG7998 –UN–19JUN00
RG7999 –UN–19JUN00
RG7997 –UN–19JUN00
4045T Engine
RG7996 –UN–19JUN00
P
OWERTECH
is a trademark of Deere & Company
RG,RG34710,5501 –19–04JAN02–1/1
110306
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Introduction
POWERTECH6.8 L Engines With Mechanical Controls (Tier 1 Emission Certified)
6068D Engine
6068T Engine
RG8003 –UN–19JUN00
RG8001 –UN–19JUN00
6068D Engine
RG8002 –UN–19JUN00
RG8000 –UN–19JUN00
6068T Engine
P
OWERTECH
is a trademark of Deere & Company
RG,RG34710,5503 –19–04JAN02–1/1
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Contents
Page Page
Record Keeping
PowerTech Medallion.....................01-1
Engine Serial Number Plate ................01-1
Record Engine Serial Number ..............01-2
Engine Option Codes .....................01-3
Record Fuel Injection Pump Model Number ....01-5
Safety ................................05-1
Fuels, Lubricants, and Coolant
Diesel Fuel.............................10-1
Lubricity of Diesel Fuel....................10-1
Handling and Storing Diesel Fuel ............10-2
Testing Diesel Fuel.......................10-2
Bio-Diesel Fuel..........................10-3
Aviation (Jet) Fuels.......................10-4
Burner Fuels............................10-4
Minimizing the Effect of Cold Weather on
Diesel Engines ........................10-5
Diesel Engine Break-In Oil .................10-6
Diesel Engine Oil ........................10-7
Extended Diesel Engine Oil Service Intervals. . . 10-8
Mixing of Lubricants ......................10-8
OILSCANand COOLSCAN ..............10-9
Alternative and Synthetic Lubricants..........10-9
Lubricant Storage.......................10-10
Oil Filters .............................10-10
Grease...............................10-11
Diesel Engine Coolant ...................10-12
Drain Intervals for Diesel Engine Coolant ....10-13
Additional Information About Diesel
Engine Coolants and Supplemental Coolant
Additives............................10-14
Supplemental Coolant Additives............10-15
Additional Information About Diesel
Engine Coolants and Supplemental Coolant
Additives............................10-16
Testing Diesel Engine Coolant .............10-17
Operating in Warm Temperature Climates ....10-18
Disposing of Coolant ....................10-18
Engine Operating Guidelines
Instrument (Gauge) Panels.................15-1
Instrument (Gauge) Panel (North America).....15-2
VDO Instrument (Gauge) Panel (Except
North America) ........................15-4
Engine Break-In Service...................15-6
Auxiliary Gear Drive Limitations .............15-9
Generator Set (Standby) Applications.........15-9
Starting the Engine......................15-10
Warming Engine........................15-12
Normal Engine Operation.................15-13
Cold Weather Operation..................15-14
Changing Engine Speed..................15-15
Avoid Excessive Engine Idling .............15-15
Stopping the Engine.....................15-16
Using a Booster Battery or Charger .........15-17
Lubrication and Maintenance
Observe Service Intervals..................20-1
Use Correct Fuels, Lubricants, and Coolant ....20-1
Lubrication and Maintenance Service
Interval Chart—Standard Industrial Engines . . 20-2
Lubrication and Maintenance Service
Interval Chart—Generator (Standby)
Applications ..........................20-4
Lubrication & Maintenance/Daily
Daily Prestarting Checks ..................25-1
Lubrication & Maintenance/250 Hour/6 Month
Servicing Fire Extinguisher.................30-1
Changing Engine Oil and Replacing Filter .....30-2
Checking Engine Mounts ..................30-4
Servicing Battery ........................30-5
Manual Belt Tensioner Adjustment...........30-7
Manual Belt Tensioner Adjustment Using
Belt Tension Tool (Alternate Method
For Engines Without Auxiliary Drive)........30-8
Lubrication & Maintenance/500 Hour/12 Month
Cleaning Crankcase Vent Tube .............35-1
Checking Air Intake System ................35-2
Replacing Fuel Filter Element (Single Filter)....35-3
Continued on next page
All information, illustrations and specifications in this manual are based on
the latest information available at the time of publication. The right is
reserved to make changes at any time without notice.
COPYRIGHT2006
DEERE & COMPANY
Moline, Illinois
A John Deere ILLUSTRUCTIONManual
All rights reserved
Previous Editions
Copyright1996, 2000, 2002, 2004
i
110306
PN=1
Contents
Page Page
Replacing Fuel Filter Elements (Dual Filters) . . . 35-5 Specifications
General OEM Engine Specifications—4.5 LChecking Belt Tensioner Spring Tension
and Belt Wear (Automatic Tensioner) .......35-6 Engines..............................60-1
General OEM Engine Specifications—6.8 LChecking Engine Speeds ..................35-9
Checking Engine Electrical Ground Engines..............................60-2
Engine Power Ratings And Fuel InjectionConnections ..........................35-9
Checking Cooling System.................35-10 Pump Specifications ....................60-3
Engine Crankcase Oil Fill Quantities ........60-11Replenishing Supplemental Coolant
Additives (SCAs) Between Coolant Unified Inch Bolt and Screw Torque Values . . . 60-15
Metric Bolt and Screw Torque Values........60-16Changes ............................35-11
Testing Diesel Engine Coolant .............35-12
Pressure Testing Cooling System...........35-13 Lubrication and Maintenance Records
Using Lubrication and Maintenance Records . . . 65-1
Lubrication & Maint./2000 Hour/24 Month
Adjusting Variable Speed (Droop) on
Generator Set Engines ..................40-1
Checking Crankshaft Vibration Damper
(6-Cylinder Engine Only).................40-3
Daily (Prestarting) Service .................65-1
250 Hour/6 Month Service .................65-2
500 Hour/12 Month Service ................65-3
2000 Hour/24 Month Service ...............65-4
Service as Required......................65-5
Flushing and Refilling Cooling System ........40-4
Testing Thermostats Opening Temperature ....40-7
Check and Adjust Valve Clearance .........40-10
Emission System Warranty
U.S. EPA Emissions Control Warranty
Statement ............................70-1
Service as Required
Emissions Control System Certification Label. . . 70-1
Additional Service Information ..............45-1
Do Not Modify Fuel System ................45-1
Adding Coolant..........................45-2
Replacing Single Stage Air Cleaner ..........45-3
Replacing Axial Seal Air Cleaner Filter
Element .............................45-4
Replacing Radial Seal Air Cleaner Filter
Element .............................45-6
Replacing Fan and Alternator Belts ..........45-8
Checking Fuses In Instrument Panels ........45-9
Checking Air Compressors................45-10
Bleeding the Fuel System.................45-11
Troubleshooting
General Troubleshooting Information .........50-1
Engine Wiring Diagram Legend
(Standard Instrument Panel For North
America) .............................50-3
Wiring Diagram (Standard Instrument
Panel For North America) ................50-4
Engine Wiring Diagram—VDO
Instrument Panel (Except North America) ....50-5
Engine Wiring Diagram Legend—VDO
Instrument Panel (Except North America) ....50-6
Engine Troubleshooting ...................50-7
Storage
Engine Storage Guidelines.................55-1
Preparing Engine for Long Term Storage......55-2
Removing Engine from Long Term Storage ....55-3
ii
110306
PN=2
POWERTECHMedallion
Record Keeping
A medallion is located on the rocker arm cover which
identifies each engine as a John Deere P
OWERTECH
engine.
RG11608 –UN–17OCT01RG11609 –UN–17OCT01
P
OWERTECH
is a trademark of Deere & Company.
Engine Serial Number Plate
Each engine has a 13-digit John Deere engine serial
number. The first two digits identify the factory that
produced the engine:
• “T0” indicates the engine was built in Dubuque, Iowa
• “CD” indicates the engine was built in Saran, France
• “PE” indicates the engine was built in Torreon, Mexico
• “J0” indicates the engine was built in Rosario, Argentina
Your engine’s serial number plate (A) is located on the
right-hand side of cylinder block behind the fuel filter.
01-1
RG,RG34710,5505 –19–04JAN02–1/1
RG8007 –UN–15JAN99
13-Digit Engine Serial Number Plate
RG,RG34710,5506 –19–04JAN02–1/1
110306
PN=9
Record Keeping
Record Engine Serial Number
Record all of the numbers and letters found on your
engine serial number plate in the spaces provided below.
This information is very important for repair parts or
warranty information.
Engine Serial Number (B)
Engine Model Number (C)
Coefficient of Absorption Value (D)
(Saran Engines Only)
Dubuque Engine Serial Number Plate
RG7936 –UN–13NOV97
Saran Engine Serial Number Plate
Torreon Engine Serial Number Plate
RG,RG34710,5507 –19–04JAN02–1/1
RG7935 –UN–13NOV97
RG9062 –UN–16MAR98
01-2
110306
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Engine Option Codes
Record Keeping
Engine Option Codes
A—Engine Base Code
In addition to the serial number plate, OEM engines
have an engine option code label affixed to the rocker
arm cover. These codes indicate which of the engine
options were installed on your engine at the factory.
When in need of parts or service, furnish your
authorized servicing dealer or engine distributor with
these numbers.
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.
RG10603A –UN–15JUN00
If an engine is ordered without a particular component,
the last two digits of that functional group option code
will be 99, 00, or XX. The list on the next page shows
only the first two digits of the code numbers. For future
reference such as ordering repair parts, it is important
to have these code numbers available. To ensure this
availability, enter the third and fourth digits shown on
your engine option code label in the spaces provided
on the following page.
Continued on next page
01-3
OURGP11,0000005 –19–24JUN04–1/2
110306
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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 45 Balancer Shafts
12 Oil Fill Inlet 46 Cylinder Block With Liners and Camshaft
13 Crankshaft Pulley 47 Crankshaft and Bearings
14 Flywheel Housing 48 Connecting Rods and Pistons
15 Flywheel 49 Valve Actuating Mechanism
16 Fuel Injection Pump 50 Oil Pump
17 Air Inlet 51 Cylinder Head With Valves
18 Air Cleaner 52 Auxiliary Gear Drive
19 Oil Pan 55 Shipping Stand
20 Coolant Pump 56 Paint Option
21 Thermostat Cover 57 Coolant Pump Inlet
22 Thermostat 59 Oil Cooler
23 Fan Drive 60 Add-on Auxiliary Drive Pulley
24 Fan Belt 62 Alternator Mounting Bracket
25 Fan 64 Exhaust Elbow
26 Engine Coolant Heater 65 Turbocharger
27 Radiator 66 Coolant Temperature Switch
28 Exhaust Manifold 67 Electronic Tachometer Sensor
29 Crankcase Ventilator System 68 Crankshaft Rear Damper
30 Starter Motor 69 Engine Serial Number Plate
31 Alternator 74 Air Conditioning (Freon) Compressor
32 Instrument Panel 75 Air Restriction Indicator
33 Tachometer 76 Oil Pressure Switch
35 Fuel Filters 78 Air Compressor
36 Front Plate 81 Water Separator
37 Fuel Transfer Pump 86 Fan Pulley
39 Thermostat Housing 87 Belt Tensioner
40 Oil Dipstick 88 Oil Filter
41 Belt-Driven Front Auxiliary Drive 95 Special Equipment (Factory Installed)
43 Starting Aid 97 Special Equipment (Field Installed)
44 Timing Gear Cover With Gears 98 Shipping
99 Service Only Items
01-4
Engine Base Code (See “A” on previous page.)
OURGP11,0000005 –19–24JUN04–2/2
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Record Keeping
Record Fuel Injection Pump Model Number
Record the fuel injection pump model and serial
information found on the serial number plate (A).
Model No. RPM
Manufacturer’s No.
Serial No.
A—Serial Number Plate
Record Injection Pump Serial Number
RG8008A –UN–13JUN00
RG,RG34710,5511 –19–20MAY96–1/1
01-5
110306
PN=13
Safety
Recognize Safety Information
This is a safety-alert symbol. When you see this symbol
on your machine or in this manual, be alert to the
potential for personal injury.
Follow recommended precautions and safe operating
practices.
Understand Signal Words
A signal word—DANGER, WARNING, or CAUTION—is
used with the safety-alert symbol. DANGER identifies the
most serious hazards.
DANGER or WARNING safety signs are located near
specific hazards. General precautions are listed on
CAUTION safety signs. CAUTION also calls attention to
safety messages in this manual.
Follow Safety Instructions
Carefully read all safety messages in this manual and on
your machine safety signs. Keep safety signs in good
condition. Replace missing or damaged safety signs. Be
sure new equipment components and repair parts include
the current safety signs. Replacement safety signs are
available from your John Deere dealer.
DX,ALERT –19–29SEP98–1/1
T81389 –UN–07DEC88
TS187 –19–30SEP88
DX,SIGNAL –19–03MAR93–1/1
Learn how to operate the machine and how to use
controls properly. Do not let anyone operate without
instruction.
Keep your machine in proper working condition.
Unauthorized modifications to the machine may impair the
function and/or safety and affect machine life.
If you do not understand any part of this manual and need
assistance, contact your John Deere dealer.
05-1
TS201 –UN–23AUG88
DX,READ –19–03MAR93–1/1
110306
PN=14
Replace Safety Signs
Replace missing or damaged safety signs. See the
machine operator’s manual for correct safety sign
placement.
Safety
Prevent Machine Runaway
Avoid possible injury or death from machinery runaway.
Do not start engine by shorting across starter terminals.
Machine will start in gear if normal circuitry is bypassed.
NEVER start engine while standing on ground. Start
engine only from operator’s seat, with transmission in
neutral or park.
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.
DX,SIGNS1 –19–04JUN90–1/1
TS201 –UN–23AUG88
TS177 –UN–11JAN89
DX,BYPAS1 –19–29SEP98–1/1
Prevent fires by keeping machine clean of accumulated
trash, grease, and debris. Always clean up spilled fuel.
05-2
TS202 –UN–23AUG88
DX,FIRE1 –19–03MAR93–1/1
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Safety
Prepare for Emergencies
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service,
hospital, and fire department near your telephone.
Handle Starting Fluid Safely
Starting fluid is highly flammable.
Keep all sparks and flame away when using it. Keep
starting fluid away from batteries and cables.
To prevent accidental discharge when storing the
pressurized can, keep the cap on the container, and store
in a cool, protected location.
Do not incinerate or puncture a starting fluid container.
DX,FIRE2 –19–03MAR93–1/1
TS291 –UN–23AUG88
TS1356 –UN–18MAR92
DX,FIRE3 –19–16APR92–1/1
Handle Fluids Safely—Avoid Fires
When you work around fuel, do not smoke or work near
heaters or other fire hazards.
Store flammable fluids away from fire hazards. Do not
incinerate or puncture pressurized containers.
Make sure machine is clean of trash, grease, and debris.
Do not store oily rags; they can ignite and burn
spontaneously.
05-3
TS227 –UN–23AUG88
DX,FLAME –19–29SEP98–1/1
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Safety
Service Machines 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.
DX,LOOSE –19–04JUN90–1/1
TS228 –UN–23AUG88
TS206 –UN–23AUG88
DX,WEAR –19–10SEP90–1/1
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.
05-4
DX,NOISE –19–03MAR93–1/1
TS207 –UN–23AUG88
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Safety
Handle Chemical Products Safely
Direct exposure to hazardous chemicals can cause
serious injury. Potentially hazardous chemicals used with
John Deere equipment include such items as lubricants,
coolants, paints, and adhesives.
A Material Safety Data Sheet (MSDS) provides specific
details on chemical products: physical and health hazards,
safety procedures, and emergency response techniques.
Check the MSDS before you start any job using a
hazardous chemical. That way you will know exactly what
the risks are and how to do the job safely. Then follow
procedures and recommended equipment.
(See your John Deere dealer for MSDS’s on chemical
products used with John Deere equipment.)
Stay Clear of Rotating Drivelines
Entanglement in rotating driveline can cause serious injury
or death.
Keep master shield and driveline shields in place at all
times. Make sure rotating shields turn freely.
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.
05-5
Rotating Drivelines
TS1644 –UN–22AUG95
OUO1004,0000BD8 –19–11OCT06–1/1
110306
PN=18
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
110306
PN=19
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.
DX,FLUID –19–03MAR93–1/1
TS953 –UN–15MAY90
DX,TORCH –19–10DEC04–1/1
05-7
110306
PN=20
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
110306
PN=21
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 may reach temperatures as high
as 500°C (932°F) under full load, and naturally aspired
exhaust manifolds may reach 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 –19–11OCT06–1/1
TS271 –UN–23AUG88
Hot Surface
05-9
OUOD006,000009E –19–04DEC02–1/1
110306
PN=22
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).
DX,DUST –19–15MAR91–1/1
TS204 –UN–23AUG88
DX,SPARKS –19–03MAR93–1/1
05-10
110306
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.
05-11
Acid
TS203 –UN–23AUG88
DPSG,OUO1004,2758 –19–11OCT06–1/1
110306
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.
05-12
DX,REPAIR –19–17FEB99–1/1
110306
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
05-13
110306
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.
Required fuel properties
In all cases, the fuel shall meet the following
properties:
Cetane number of 45 minimum. Cetane number
greater than 50 is preferred, especially for
temperatures below -20°C (-4°F) or elevations above
1500 m (5000 ft).
Cold Filter Plugging Point (CFPP) below the
expected low temperature OR Cloud Point at least
5°C(9°F) below the expected low temperature.
Fuel lubricity should pass a minimum level of 3100
grams as measured by ASTM D6078 or maximum
scar diameter of 0.45 mm as measured by ASTM
D6079 or ISO 12156-1.
Sulfur content:
• Diesel fuel quality and fuel sulfur content must
comply with all existing emissions regulations for the
area in which the engine operates.
• Use of diesel fuel with sulfur content less than
0.10% (1000 ppm) is STRONGLY recommended.
• Use of diesel fuel with sulfur content 0.10% (1000
ppm to 0.50% (5000 ppm) may result in REDUCED
oil and filter change intervals.
• BEFORE using diesel fuel with sulfur content greater
than 0.50% (5000 ppm), contact your John Deere
dealer.
• DO NOT use diesel fuel with sulfur content greater
than 1.0%.
IMPORTANT: Do not mix used diesel engine oil or
any other type of lubricating oil with
diesel fuel.
IMPORTANT: Improper fuel additive usage may
cause damage on fuel injection
equipment of diesel engines.
Lubricity of Diesel Fuel
Most diesel fuels manufactured in the United States,
Canada, and the European Union have adequate
lubricity to ensure proper operation and durability of
fuel injection system components. However, diesel
fuels manufactured in some areas of the world may
lack the necessary lubricity.
IMPORTANT: Make sure the diesel fuel used in
your machine demonstrates good
lubricity characteristics.
DX,FUEL1 –19–17NOV05–1/1
Fuel lubricity should pass a minimum load level of
3100 grams as measured by ASTM D6078 or a
maximum scar diameter of 0.45 mm as measured by
ASTM D6079 or ISO 12156-1.
If fuel of low or unknown lubricity is used, add John
Deere PREMIUM DIESEL FUEL CONDITIONER (or
equivalent) at the specified concentration.
DX,FUEL5 –19–27OCT05–1/1
10-1
110306
PN=27
Handling and Storing Diesel Fuel
Fuels, Lubricants, and Coolant
CAUTION: Handle fuel carefully. Do not fill
the fuel tank when engine is running.
DO NOT smoke while you fill the fuel tank or
service the fuel system.
Fill the fuel tank at the end of each day’s operation to
prevent water condensation and freezing during cold
weather.
Keep all storage tanks as full as practicable to
minimize condensation.
Ensure that all fuel tank caps and covers are installed
properly to prevent moisture from entering.
Monitor water content of the fuel regularly.
When using bio-diesel fuel, the fuel filter may require
more frequent replacement due to premature plugging.
Check engine oil level daily prior to starting engine. A
rising oil level may indicate fuel dilution of the engine
oil.
IMPORTANT: The fuel tank is vented through the
filler cap. If a new filler cap is
required, always replace it with an
original vented cap.
When fuel is stored for an extended period or if there
is a slow turnover of fuel, add a fuel conditioner to
stabilize the fuel and prevent water condensation.
Contact your fuel supplier for recommendations.
DX,FUEL4 –19–19DEC03–1/1
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
10-2
110306
PN=28
Bio-Diesel Fuel
Fuels, Lubricants, and Coolant
Consult your local fuel distributor for properties of the
bio-diesel fuel available in your area.
Bio-diesel fuels may be used ONLY if the bio-diesel
fuel properties meet the latest edition of ASTM D6751,
EN 14214, or equivalent specification.
It is recommended to purchase bio-diesel fuel blended
with B100 from a BQ-9000 Accredited Producer or a
BQ-9000 Certified Marketer as recommended by the
National Bio-diesel Board.
The maximum allowable bio-diesel concentration is a
5% blend (also known as B5) in petroleum diesel fuel.
It has been found that bio-diesel fuels may improve
lubricity in concentrations up to this 5% blend.
When using a blend of bio-diesel fuel, the engine oil
level must be checked daily when the air temperature
is –10°C (14°F) or lower. If oil becomes diluted with
fuel, shorten oil change intervals accordingly.
IMPORTANT: Raw pressed vegetable oils are NOT
acceptable for use as fuel in any
concentration in John Deere
engines.
leaving deposits on injectors and in
the combustion chamber.
A major environmental benefit of bio-diesel fuel is its
ability to biodegrade. This makes proper storage and
handling of bio-diesel fuel especially important. Areas
of concern include:
• Quality of new fuel
• Water content of the fuel
• Problems due to aging of the fuel
Potential problems resulting from deficiencies in the
above areas when using bio-diesel fuel in
concentrations above 5% may lead to the following
symptoms:
• Power loss and deterioration of performance
• Fuel leakage
• Corrosion of fuel injection equipment
• Coked and/or blocked injector nozzles, resulting in
engine misfire
• Filter plugging
• Lacquering and/or seizure of internal components
• Sludge and sediments
• Reduced service life of engine components
These oils do not burn completely,
and will cause engine failure by
Consult your fuel supplier for additives to improve
storage and performance of bio-diesel fuels.
DX,FUEL7 –19–14NOV05–1/1
10-3
110306
PN=29
Fuels, Lubricants, and Coolant
Aviation (Jet) Fuels
Aviation (jet) fuels may be used 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.
Burner Fuels
Burner fuels, like kerosene, may be used with the
following restrictions.
Type Comments
No.2 Higher density and specific gravity than base No. 2-D
diesel fuel. Power increase up to 3% can be
expected.
No.1 Lower viscosity than base No. 2-D diesel fuel. Power
loss up to 2% can be expected.
10-4
OURGP12,000003F –19–07JUL04–1/1
OURGP12,0000040 –19–07JUL04–1/1
110306
PN=30
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