PowerTech 4045D, 6068D, 4045T, 6068T Operator's Manual

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PowerTech™ 4.5 L and 6.8 L

*DCT*

*OMRG25204*

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 08OCT15 (ENGLISH)

*OMRG25204*

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.

Additional Proposition 65 Warnings can be found in this manual.

John Deere Power Systems

PRINTED IN U.S.A.

Instructions (INS)

content

Foreword

Introduction

ZE59858,000025E -19-25SEP15-1/1

This manual contains information to operate and service PowerTech 4.5 L & 6.8 L non-certified and Tier 1

emission 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.

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.

Emission certified for United States as EPA Tier 1 and

European Union as Stage 1.

Engine Owner

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 -19-20AUG15-1/1

John Deere Engine Owner:

It is important for you to register your new engine for factory warranty. Registering your engine will allow your Service Dealer to verify your warranty status should a repair be needed. The easiest way to register your engine is via the internet. To register your engine for warranty via the internet, please use the following URL:

http://www.johndeere.com/enginewarranty Your John Deere Engine Distributor or local John Deere Service Dealer will also be happy to provide this service. If you would like to view the John Deere Service Dealer network or locate your nearest Dealer, use the following URL: http://www.johndeere.com/dealer

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Identification View — 4.5 L Engines

4045D Engine

Introduction

RG7998 —UN—19JUN00

4045D Engine

RG7999 —UN—19JUN00

4045T Engine

RG7996 —UN—19JUN00

RG7997 —UN—19JUN00

4045T Engine

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Identification View — 6.8 L Engines

Introduction

6068D Engine

6068T Engine

RG8003 —UN—19JUN00

RG8001 —UN—19JUN00

RG8002 —UN—19JUN00

6068D Engine

RG8000 —UN—19JUN00

6068T Engine

RG,RG34710,5503 -19-20AUG15-1/1

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Introduction

Trademarks

AdBlue®

AMP® AMP is a trademark of Tyco Electronics

BIO-GREASE-GARD™ BIO-GREASE-GARD is a trademark of Deere & Company

Bio Hy-Gard™ Bio Hy-Gard is a trademark of Deere & Company

Bluetooth® Bluetooth is a trademark of Bluetooth SIG

Break-In Plus™

CINCH™ CINCH is a trademark of Cinch Inc.

COOL-GARD™ PLUS COOL-GARD is a trademark of Deere & Company

CoolScan™ CoolScan is a trademark of Deere & Company

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

Custom Performance™ Custom Performance is a trademark of Deere & Company

Deere™

DENSO® DENSO is a trademark of DENSO Corporation

DEUTSCH® DEUTSCH is a trademark of Deutsch Co.

DieselScan™ DieselScan is a trademark of Deere & Company

DuPont® DuPont is a trademark of E.I. DuPont de Nemours and Company

EXTREME-GARD™ EXTREME-GARD is a trademark of Deere & Company

FleetGard™ FleetGard is a trademark of Deere & Company

Fleetguard® Fleetguard is a trademark of Cummins Filtration

FlexBox™

Funk™

GREASE-GARD™ GREASE-GARD is a trademark of Deere & Company

Hy-Gard™ Hy-Gard is a trademark of Deere & Company

JDLink™

JDParts™

John Deere™

Loctite® Loctite is a trademark of Henkel Corporation

Metri-Pack® Metri-Pack is a trademark of Delphi Connection Systems

OILSCAN PLUS™ OILSCAN PLUS is a trademark of Deere & Company

Oilscan™ Oilscan is a trademark of Deere & Company

Permatex® Permatex is a trademark of Illinois Tool Works Inc.

Phoenix™

Plastigage® Plastigage is a trademark of Perfect Circle Corporation

Plus-50™ II

PowerSight™ PowerSight is a trademark of Deere & Company

PowerTech™

PowerTech™ E

PowerTech™ M

PowerTech™ Plus

PRECISION JOINT™ PRECISION JOINT is a trademark of Deere & Company

RemanSelect™ RemanSelect is a trademark of Deere & Company

Restore® Restore is a trademark of "Restore, Inc."

Scotch-Brite® Scotch-Brite is a trademark of 3M Co.

Scotch-Grip® Scotch-Grip is a trademark of 3M Co.

Service ADVISOR™ Service ADVISOR is a trademark of Deere & Company

SERVICEGARD™ SERVICEGARD is a trademark of Deere & Company

TACH-N-TIME™ TACH-N-TIME is a trademark of SPX Corp.

TeamMate™

TEFLON® TEFLON is a trademark of Du Pont Co.

TMIII™

AdBlue is a trademark of VDA, the German Association of the Automotive Industry.

Break-In Plus is a trademark of Deere & Company

Deere is a trademark of Deere & Company

FlexBox is a trademark of Deere & Company

Funk is a trademark of Deere & Company

JDLink is a trademark of Deere & Company

JDParts is a trademark of Deere & Company

John Deere is a trademark of Deere & Company

Phoenix is a trademark of Deere & Company

Plus-50 is a trademark of Deere & Company

PowerTech is a trademark of Deere & Company

TeamMate is a trademark of Deere & Company

TMIII is a trademark of Deere & Company

Continued on next page ZE59858,0000006 -19-13FEB14-1/2

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Introduction

Vari-Cool™ Vari-Cool is a trademark of Deere & Company

WEATHER PACK® WEATHER PACK is a trademark of Packard Electric

WINDOWS® WINDOWS is a trademark of Microsoft Corporation

ZE59858,0000006 -19-13FEB14-2/2

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Introduction

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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.......01-4

Safety

Understand Signal Words...................................05-1

Recognize Safety Information ............................05-1

Replace Safety Signs ......................................... 05-1

Follow Safety Instructions...................................05-2

California Proposition 65 Warning ......................05-2

Avoid Hot Exhaust ..............................................05-2

Work In Ventilated Area......................................05-2

Decommissioning: Proper Recycling

and Disposal of Fluids and Components .......05-3

Prevent Machine Runaway.................................05-3

Practice Safe Maintenance.................................05-4

Work in Clean Area ............................................05-4

Wear Protective Clothing ....................................05-5

Service Machines Safely .................................... 05-5

Use Proper Tools ................................................05-5

Support Machine Properly..................................05-6

Use Proper Lifting Equipment.............................05-6

Protect Against Noise.........................................05-6

Illuminate Work Area Safely ...............................05-7

Install All Guards ................................................05-7

Stay Clear of Rotating Drivelines........................05-7

Protect Against High Pressure Spray .................05-8

Service Cooling System Safely ..........................05-8

Remove Paint Before Welding or Heating..........05-8

Avoid High-Pressure Fluids ................................05-9

Avoid Heating Near Pressurized Fluid Lines ......05-9

Avoid Static Electricity Risk When Refueling....05-10

Handle Fuel Safely—Avoid Fires......................05-10

Prepare for Emergencies.................................. 05-11

Handle Starting Fluid Safely ............................. 05-11

Handling Batteries Safely ................................. 05-12

Prevent Acid Burns...........................................05-13

Prevent Battery Explosions ..............................05-13

Live With Safety................................................05-14

Fuels, Lubricants, and Coolant

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

Supplemental Diesel Fuel Additives ...................10-1

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

Page

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

BioDiesel Fuel ....................................................10-3

Testing Diesel Fuel ............................................. 10-4

Aviation (Jet) Fuels .............................................10-4

Burner Fuels ....................................................... 10-4

Fuel Filters..........................................................10-5

Minimizing the Effect of Cold Weather

on Diesel Engines ..........................................10-6

Diesel Engine Break-In Oil —

Non-Emissions Certified and Certified Tier 1, Tier 2, Tier 3, Stage

I, Stage II, and Stage III .................................10-7

Diesel Engine Oil — Non-Emissions

Certified and Certified Tier 1 and

Stage I............................................................10-8

Extended Diesel Engine Oil Service

Intervals — Non-Emissions Certified

and Certified Tier 1 and Stage I ..................... 10-9

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

Alternative and Synthetic Lubricants ..................10-9

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

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

Diesel Engine Coolant (engine with

wet sleeve cylinder liners) ............................ 10-11

Water Quality for Mixing with Coolant

Concentrate..................................................10-12

Operating in Warm Temperature Climates .......10-12

Testing Coolant Freeze Point ...........................10-13

Disposing of Coolant ........................................10-13

Engine Operating Guidelines

Instrument (Gauge) Panels ................................15-1

Instrument (Gauge) Panel (North America) ........15-2

VDO Instrument (Gauge) Panel

(Except North America)..................................15-3

Engine Break-In Service.....................................15-4

Auxiliary Gear Drive Limitations .........................15-6

Generator Set (Standby) Applications ................15-6

Starting the Engine.............................................15-6

Warming Engine ................................................. 15-8

Normal Engine Operation...................................15-8

Cold Weather Operation .....................................15-9

Changing Engine Speed...................................15-10

Avoid Excessive Engine Idling..........................15-10

Stopping the Engine ......................................... 15-11

Using a Booster Battery or Charger .................15-12

Original Instructions. 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.

Moline, Illinois

A John Deere ILLUSTRUCTION ™ Manual

Previous Editions

Continued on next page

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Contents

Page

Lubrication and Maintenance

Required Emission-Related Information.............20-1

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....................................................20-3

Lubrication & Maintenance — Daily

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

Lubrication & Maintenance — 250 Hours/6 Months

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

Changing Engine Oil and Replacing Filter..........30-1

Checking Engine Mounts....................................30-3

Servicing Battery ................................................30-3

Manual Belt Tensioner Adjustment .....................30-5

Manual Belt Tensioner Adjustment

Using Belt Tension Tool (Alternate Method For Engines Without

Auxiliary Drive) ...............................................30-6

Lubrication & Maintenance — 500 Hours/12 Months

Cleaning Crankcase Vent Tube..........................35-1

Checking Air Intake System ...............................35-1

Replacing Fuel Filter Element (Single Filter) ......35-2

Replacing Fuel Filter Elements (Dual Filters) .....35-3

Checking Belt Tensioner Spring

Tension and Belt Wear (Automatic

Tensioner) ......................................................35-4

Checking Engine Speeds ................................... 35-6

Checking Engine Electrical Ground

Connections ...................................................35-6

Checking Cooling System ..................................35-6

Replenishing Supplemental Coolant

Additives (SCAs) Between Coolant

Changes.........................................................35-7

Testing Diesel Engine Coolant............................35-8

Pressure Testing Cooling System.......................35-9

Lubrication & Maintenance — 2000 Hours/24 Months

Adjusting Variable Speed (Droop) on

Generator Set Engines...................................40-1

Checking Crankshaft Vibration Damper

(6-Cylinder Engine Only)................................40-3

Flushing and Refilling Cooling System ...............40-4

Testing Thermostats Opening Temperature .......40-6

Check and Adjust Valve Clearance ....................40-9

Page

Service as Required

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

Do Not Modify Fuel System ................................45-1

Adding Coolant ................................................... 45-2

Pre-Start Cleaning Guide ...................................45-3

Replacing Single Stage Air Cleaner ...................45-4

Replacing Axial Seal Air Cleaner Filter

Element ..........................................................45-5

Replacing Radial Seal Air Cleaner

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

Replacing Fan and Alternator Belts ....................45-7

Checking Fuses In Instrument Panels ................45-8

Checking Air Compressors.................................45-9

Bleeding the Fuel System...................................45-9

Troubleshooting

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

Engine Wiring Diagram Legend

(Standard Instrument Panel For

North America) ...............................................50-2

Wiring Diagram (Standard Instrument

Panel For North America) ..............................50-3

Engine Wiring Diagram—VDO

Instrument Panel (Except North America)......50-4

Engine Wiring Diagram Legend—VDO

Instrument Panel (Except North America)......50-5

Engine Troubleshooting......................................50-6

Storage

Engine Storage Guidelines.................................55-1

Preparing Engine for Long-Term Storage ...........55-1

Removing Engine from Long Term Storage ....... 55-2

Specifications

General OEM Engine Specifications —

4.5 L Engines .................................................60-1

General OEM Engine Specifications —

6.8 L Engines .................................................60-1

Engine Power Ratings And Fuel

Injection Pump Specifications — 4.5

L Engines ....................................................... 60-2

Engine Power Ratings And Fuel

Injection Pump Specifications — 6.8

L Engines ....................................................... 60-6

Engine Power Ratings And Fuel

Injection Pump Specifications ........................60-9

Engine Crankcase Oil Fill Quantities ................60-16

Unified Inch Bolt and Screw Torque Values......60-17

Metric Bolt and Screw Torque Values...............60-18

Lubrication and Maintenance Records

Using Lubrication and Maintenance Records .....65-1

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

250 Hour/6 Month Service..................................65-1

500 Hour/12 Month Service................................65-2

Continued on next page

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Page

2000 Hour/24 Month Service..............................65-2

Service as Required ........................................... 65-3

Warranty

John Deere Warranty in OEM Applications ........70-1

Emissions Control System Certification Label ....70-4

EPA Non-road Emissions Control

Warranty Statement—Compression Ignition ..70-5

CARB Non-road Emissions Control

Warranty Statement—Compression Ignition ..70-7

John Deere Service Literature Available

Technical Information..........................................75-1

Contents

iii

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Contents

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Record Keeping

POWERTECH® Medallion

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

OWERTECH®

RG11608 —UN—17OCT01RG11609 —UN—17OCT01

POWERTECH 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.

RG,RG34710,5505 -19-04JAN02-1/1

RG8007 —UN—15JAN99

13-Digit Engine Serial Number Plate

RG,RG34710,5506 -19-04JAN02-1/1

01-1

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Record Keeping

Record Engine Serial Number

Record all of the numbers and letters found on your engine serial number plate in the spaces provided below.

This information is very important for repair parts or warranty information.

Engine Serial Number (B)

Engine Model Number (C)

Coefficient of Absorption Value (D)

(Saran Engines Only)

RG7936 —UN—13NOV97

Dubuque Engine Serial Number Plate

RG7935 —UN—13NOV97

Saran Engine Serial Number Plate

01-2

RG9062 —UN—16MAR98

Torreon Engine Serial Number Plate

RG,RG34710,5507 -19-04JAN02-1/1

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Engine Option Codes

A—Engine Base Code

Record Keeping

RG10603A —UN—15JUN00

Engine Option Codes

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.

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.

NOTE: Your engine option code label may not contain

all option codes if an option has been added after the engine left the producing factory.

If option code label is lost or destroyed, consult your servicing dealer or engine distributor selling the engine for a replacement.

An additional option code label may also be delivered with the engine. Place this sticker or tag, for reference, either on this page or in the engine owner's warranty booklet under OPTION CODES title.

If an engine is ordered without a particular component, the last two digits of that functional group option code will be

Option Codes Description Option Codes Description

14 Flywheel Housing 48

15 Flywheel 49 Valve Actuating Mechanism

25 Fan 64 Exhaust Elbow

Rocker Arm Cover 45 Balancer Shafts

Oil Fill Inlet

Crankshaft Pulley

Fuel Injection Pump 50

Air Inlet 51

Air Cleaner

Oil Pan

Coolant Pump

Thermostat Cover

Thermostat 59

Fan Drive 60 Add-on Auxiliary Drive Pulley

Fan Belt 62 Alternator Mounting Bracket

Engine Coolant Heater

Radiator 66

Continued on next page OURGP11,0000005 -19-24JUN04-1/2

Cylinder Block With Liners and Camshaft

Crankshaft and Bearings

Connecting Rods and Pistons

Oil Pump

Cylinder Head With Valves

Auxiliary Gear Drive

Shipping Stand

Paint Option

Coolant Pump Inlet

Oil Cooler

Turbocharger

Coolant Temperature Switch

01-3

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Record Keeping

Option Codes Description Option Codes Description

33 Tachometer 76

41 Belt-Driven Front Auxiliary Drive 95

Exhaust Manifold

Crankcase Ventilator System

Starter Motor

Alternator 74

Instrument Panel

Fuel Filters 78

Front Plate 81

Fuel Transfer Pump

Thermostat Housing 87 Belt Tensioner

Oil Dipstick

Starting Aid

Timing Gear Cover With Gears

Electronic Tachometer Sensor

Crankshaft Rear Damper

Engine Serial Number Plate

Air Conditioning (Freon) Compressor

Air Restriction Indicator

Oil Pressure Switch

Air Compressor

Water Separator

Fan Pulley

Oil Filter

Special Equipment (Factory Installed)

Special Equipment (Field Installed)

Shipping

Service Only Items

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

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

OURGP11,0000005 -19-24JUN04-2/2

Manufacturer's No.

Serial No.

A—Serial Number Plate

RG8008A —UN—13JUN00

Record Injection Pump Serial Number

RG,RG34710,5511 -19-20MAY96-1/1

01-4

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Safety

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.

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.

TS187 —19—30SEP88

DX,SIGNAL -19-03MAR93-1/1

Replace Safety Signs

Replace missing or damaged safety signs. Use this operator’s manual for correct safety sign placement.

There can be additional safety information contained on parts and components sourced from suppliers that is not reproduced in this operator's manual.

T81389 —UN—28JUN13

DX,ALERT -19-29SEP98-1/1

TS201 —UN—15APR13

DX,SIGNS -19-18AUG09-1/1

05-1

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Safety

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.

There can be additional safety information contained on parts and components sourced from suppliers that is not reproduced in this operator's manual.

Learn how to operate the machine and how to use controls properly. Do not let anyone operate without instruction.

TS201 —UN—15APR13

Keep your machine in proper working condition. Unauthorized modifications to the machine may impair the function and/or safety and affect machine life.

California Proposition 65 Warning

Diesel engine exhaust, some of its constituents, along with certain machine components contain or emit chemicals known to the State of California to cause cancer and birth

Avoid Hot Exhaust

Servicing machine or attachments with engine running can result in serious personal injury. Avoid exposure and skin contact with hot exhaust gases and components.

Exhaust parts and streams become very hot during operation. Exhaust gases and components reach temperatures hot enough to burn people, ignite, or melt common materials.

If you do not understand any part of this manual and need assistance, contact your John Deere dealer.

DX,READ -19-16JUN09-1/1

defects or other reproductive harm. In addition, certain fluids contained in the machine and certain products of component wear contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

RG41061,000001F -19-12JAN10-1/1

RG17488 —UN—21AUG09

DX,EXHAUST -19-20AUG09-1/1

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.

05-2

TS220 —UN—15APR13

DX,AIR -19-17FEB99-1/1

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Decommissioning: Proper Recycling and Disposal of Fluids and Components

Safety and environmental stewardship measures must be taken into account when decommissioning a machine and/or component. These measures include the following:

Use appropriate tools and personal protective

•

equipment such as clothing, gloves, face shields or glasses, during the removal or handling of objects and materials. Follow instructions for specialized components.

•

Release stored energy by lowering suspended machine

•

elements, relaxing springs, disconnecting the battery or other electrical power, and releasing pressure in hydraulic components, accumulators, and other similar systems. Minimize exposure to components which may have

•

residue from agricultural chemicals, such as fertilizers and pesticides. Handle and dispose of these components appropriately. Carefully drain engines, fuel tanks, radiators, hydraulic

•

cylinders, reservoirs, and lines before recycling components. Use leak-proof containers when draining fluids. Do not use food or beverage containers. Do not pour waste fluids onto the ground, down a drain,

•

or into any water source. Observe all national, state, and local laws, regulations,

•

or ordinances governing the handling or disposal of waste fluids (example: oil, fuel, coolant, brake fluid);

Safety

filters; batteries; and, other substances or parts. Burning of flammable fluids or components in other than specially designed incinerators may be prohibited by law and could result in exposure to harmful fumes or ashes. Service and dispose of air conditioning systems

•

appropriately. Government regulations may require a certified service center to recover and recycle air conditioning refrigerants which could damage the atmosphere if allowed to escape. Evaluate recycling options for tires, metal, plastic,

•

glass, rubber, and electronic components which may be recyclable, in part or completely. Contact your local environmental or recycling center, or

•

your John Deere dealer for information on the proper way to recycle or dispose of waste.

TS1133 —UN—15APR13

DX,DRAIN -19-01JUN15-1/1

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.

TS177 —UN—11JAN89

DX,BYPAS1 -19-29SEP98-1/1

05-3

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Safety

Practice Safe Maintenance

Understand service procedure before doing work. Keep area clean and dry.

Never lubricate, service, or adjust machine while it is moving. Keep hands, feet , and clothing from power-driven parts. Disengage all power and operate controls to relieve pressure. Lower equipment to the ground. Stop the engine. Remove the key. Allow machine to cool.

Securely support any machine elements that must be raised for service work.

Keep all parts in good condition and properly installed. Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or debris.

On self-propelled equipment, disconnect battery ground cable (-) before making adjustments on electrical systems or welding on machine.

On towed implements, disconnect wiring harnesses from tractor before servicing electrical system components or welding on machine.

Work in 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.

TS218 —UN—23AUG88

DX,SERV -19-17FEB99-1/1

T6642EJ —UN—18OCT88

DX,CLEAN -19-04JUN90-1/1

05-4

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Wear Protective Clothing

Wear close fitting clothing and safety equipment appropriate to the job.

Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine.

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.

Safety

TS206 —UN—15APR13

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Use Proper Tools

Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards.

Use power tools only to loosen threaded parts and fasteners.

For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches.

Use only service parts meeting John Deere specifications.

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05-5

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PN=21

Support Machine Properly

Always lower the attachment or implement to the ground before you work on the machine. If the work requires that the machine or attachment be lifted, provide secure support for them. If left in a raised position, hydraulically supported devices can settle or leak down.

Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. Follow recommended procedures in this manual.

When implements or attachments are used with a machine, always follow safety precautions listed in the implement or attachment operator's manual.

Use Proper Lifting Equipment

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

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

Safety

TS229 —UN—23AUG88

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Protect Against Noise

Prolonged exposure to loud noise can cause impairment or loss of hearing.

Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.

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PN=22

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.

Install All Guards

Rotating cooling system fans, belts, pulleys, and drives can cause serious injury.

Keep all guards in place at all times during engine operation.

Wear close-fitting clothes. Stop the engine and be sure fans, belts, pulleys, and drives are stopped before making adjustments, connections, or cleaning near fans and their drive components.

Safety

TS223 —UN—23AUG88

DX,LIGHT -19-04JUN90-1/1

Stay Clear of Rotating Drivelines

Entanglement in rotating driveline can cause serious injury or death.

Keep all shields in place at all times. Make sure rotating shields turn freely.

Wear close-fitting clothing. Stop the engine and be sure that all rotating parts and drivelines are stopped before making adjustments, connections, or performing any type of service on engine or machine driven equipment.

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PN=23

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.

Service Cooling System Safely

Explosive release of fluids from pressurized cooling system can cause serious burns.

Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

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Remove Paint Before Welding or Heating

Avoid potentially toxic fumes and dust.

Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch.

Remove paint before heating:

Remove paint a minimum of 100 mm (4 in.) from area

•

to be affected by heating. If paint cannot be removed, wear an approved respirator before heating or welding. If you sand or grind paint, avoid breathing the dust.

•

Wear an approved respirator. If you use solvent or paint stripper, remove stripper with

•

soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

Do not use a chlorinated solvent in areas where welding will take place.

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

Dispose of paint and solvent properly.

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Avoid High-Pressure Fluids

Inspect hydraulic hoses periodically – at least once per year – for leakage, kinking, cuts, cracks, abrasion, blisters, corrosion, exposed wire braid or any other signs of wear or damage.

Replace worn or damaged hose assemblies immediately with John Deere approved replacement parts.

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

Avoid Heating Near Pressurized Fluid Lines

Safety

X9811 —UN—23AUG88

with this type of injury should reference a knowledgeable medical source. Such information is available in English from Deere & Company Medical Department in Moline, Illinois, U.S.A., by calling 1-800-822-8262 or +1 309-748-5636.

DX,FLUID -19-12OCT11-1/1

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.

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PN=25

Safety

Avoid Static Electricity Risk When Refueling

The removal of sulfur and other compounds in Ultra-Low Sulfur Diesel (ULSD) fuel decreases its conductivity and increases its ability to store a static charge.

Refineries may have treated the fuel with a static dissipating additive. However, there are many factors that can reduce the effectiveness of the additive over time.

Static charges can build up in ULSD fuel while it is flowing through fuel delivery systems. Static electricity discharge when combustible vapors are present could result in a fire or explosion.

Therefore, it is important to ensure that the entire system used to refuel your machine (fuel supply tank, transfer pump, transfer hose, nozzle, and others) is properly grounded and bonded. Consult with your fuel or fuel system supplier to ensure that the delivery system is in compliance with fueling standards for proper grounding and bonding practices.

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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.

Use only an approved fuel container for transporting flammable liquids.

Never fill fuel container in pickup truck with plastic bed liner. Always place fuel container on ground before refueling. Touch fuel container with fuel dispenser nozzle before removing can lid. Keep fuel dispenser nozzle in contact with fuel container inlet when filling.

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Do not store fuel container where there is an open flame, spark, or pilot light such as within a water heater or other appliance.

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PN=26

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.

Safety

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Do not incinerate or puncture a starting fluid container.

Do not use starting fluid on an engine equipped with glow plugs or an air intake heater.

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PN=27

Safety

Handling Batteries Safely

Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check battery electrolyte level.

Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.

Always remove grounded (-) battery clamp first and replace grounded clamp last.

Sulfuric acid in battery electrolyte is poisonous and strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.

Avoid hazards by:

Filling batteries in a well-ventilated area

•

Wearing eye protection and rubber gloves

•

Avoiding use of air pressure to clean batteries

•

Avoiding breathing fumes when electrolyte is added

•

Avoiding spilling or dripping electrolyte

•

Using correct battery booster or charger procedure.

•

If acid is spilled on skin or in eyes:

1. Flush skin with water.

2. Apply baking soda or lime to help neutralize the acid.

3. Flush eyes with water for 15—30 minutes. Get medical attention immediately.

TS204 —UN—15APR13TS203 —UN—23AUG88

If acid is swallowed:

1. Do not induce vomiting.

2. Drink large amounts of water or milk, but do not exceed 2 L (2 qt.).

3. Get medical attention immediately.

WARNING: Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.

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PN=28

Prevent Acid Burns

Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.

Avoid the hazard by:

1. Filling batteries in a well-ventilated area.

2. Wearing eye protection and rubber gloves.

3. Avoiding breathing fumes when electrolyte is added.

4. Avoiding spilling or dripping electrolyte.

5. Use proper jump start procedure.

If you spill acid on yourself:

1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize the acid.

3. Flush your eyes with water for 15—30 minutes. Get medical attention immediately.

If acid is swallowed:

1. Do not induce vomiting.

2. Drink large amounts of water or milk, but do not exceed 2 L (2 quarts).

3. Get medical attention immediately.

Safety

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).

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Live With Safety

Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields.

Safety

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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 fuel produced by hydrotreating animal fats and vegetable oils is basically identical to petroleum diesel fuel. 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 40 minimum. Cetane number greater than 47 is preferred, especially for temperatures below –20 °C (–4 °F) or elevations above 1675 m (5500 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

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

A maximum scar diameter of 0.45 mm is preferred.

Diesel fuel quality and 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 10 000 mg/kg (10 000 ppm).

Sulfur content for Interim Tier 4, Final Tier 4, Stage III B, and Stage IV Engines

Sulfur Content for Tier 3 and Stage III A Engines

Use of diesel fuel with sulfur content less than 1000

•

mg/kg (1000 ppm) is RECOMMENDED. Use of diesel fuel with sulfur content 1000—2000 mg/kg

•

(1000—2000 ppm) REDUCES the oil and filter change interval.

BEFORE using diesel fuel with sulfur content greater

•

than 2000 mg/kg (2000 ppm), contact your John Deere dealer.

Sulfur Content for Tier 2 and Stage II Engines

Use of diesel fuel with sulfur content less than 2000

•

mg/kg (2000 ppm) is RECOMMENDED. Use of diesel fuel with sulfur content 2000—5000 mg/kg

•

(2000—5000 ppm) REDUCES the oil and filter change interval. BEFORE using diesel fuel with sulfur content greater

•

than 5000 mg/kg (5000 ppm), contact your John Deere dealer.

Sulfur Content for Other Engines

Use of diesel fuel with sulfur content less than 5000

•

mg/kg (5000 ppm) is RECOMMENDED. Use of diesel fuel with sulfur content greater than 5000

•

mg/kg (5000 ppm) REDUCES the oil and filter change interval.

IMPORTANT: Do not mix used diesel engine oil or any

other type of lubricating oil with diesel fuel.

Improper fuel additive usage may cause damage on fuel injection equipment of diesel engines.

Use ONLY ultra low sulfur diesel (ULSD) fuel with a

•

maximum of 15 mg/kg (15 ppm) sulfur content.

Supplemental Diesel Fuel Additives

Diesel fuel can be the source of performance or other operational problems for many reasons. Some causes include poor lubricity, contaminants, low cetane number, and a variety of properties that cause fuel system deposits. These and others are referenced in other sections of this Operator's Manual.

To optimize engine performance and reliability, closely follow recommendations on fuel quality, storage, and handling, which are found elsewhere in this Operator's Manual.

10-1

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To further aid in maintaining performance and reliability of the engine's fuel system, John Deere has developed a family of fuel additive products for most global markets. The primary products include Fuel-Protect Diesel Fuel Conditioner (full feature conditioner in winter and summer formulas) and Fuel-Protect Keep Clean (fuel injector deposit removal and prevention). Availability of these and other products varies by market. See your local John Deere dealer for availability and additional information about fuel additives that might be right for your needs.

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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

0.52 mm as measured by ASTM D6079 or ISO 12156-1. A maximum scar diameter of 0.45 mm is preferred.

Handling and Storing Diesel Fuel

CAUTION: Reduce the risk of fire. 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.

If fuel of low or unknown lubricity is used, add John Deere Fuel-Protect Diesel Fuel Conditioner (or equivalent) at the specified concentration.

Lubricity of BioDiesel Fuel

Fuel lubricity can improve significantly with BioDiesel blends up to B20 (20% BioDiesel). Further increase in lubricity is limited for BioDiesel blends greater than B20.

DX,FUEL5 -19-07FEB14-1/1

When using BioDiesel 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 or John Deere dealer for recommendations.

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BioDiesel Fuel

Fuels, Lubricants, and Coolant

BioDiesel fuel is 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.

Before using fuel containing BioDiesel, review the BioDiesel Use Requirements and Recommendations in this Operator’s Manual.

Environmental laws and regulations can encourage or prohibit the use of biofuels. Operators should consult with appropriate governmental authorities prior to using biofuels.

All John Deere Engines with Exhaust Filter (Released 2011 and After)

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

BioDiesel concentrations above B20 can harm the engine’s emission control systems and should not be used. Risks include, but are not limited to, more frequent stationary regeneration, soot accumulation, and increased intervals for ash removal.

John Deere approved fuel conditioners, which contain detergent and dispersant additives, are required when using BioDiesel blends from B10—B20, and are recommended when using lower BioDiesel blends.

All John Deere Engines Excluding Exhaust Filter (Primarily Released Prior to 2012)

These John Deere engines can operate on BioDiesel blends above B20 (up to 100% BioDiesel). Operate at levels above B20 ONLY if the BioDiesel is permitted by law and meets the EN 14214 specification (primarily available in Europe). Engines operating on BioDiesel blends above B20 might not fully comply with or be permitted by all applicable emissions regulations. Expect up to a 12% reduction in power and an 18% reduction in fuel economy when using 100% BioDiesel.

BioDiesel Use Requirements and Recommendations

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

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.bq9000.org

BioDiesel contains residual ash. Ash levels exceeding the maximums allowed in either ASTM D6751 or EN14214 can result in more rapid ash loading and require more frequent cleaning of the Exhaust Filter (if present).

The fuel filter can require more frequent replacement, when using BioDiesel fuel, particularly if switching from diesel. Check engine oil level daily prior to starting engine. A rising oil level can indicate fuel dilution of the engine oil. BioDiesel blends up to B20 must be used within 90 days of the date of BioDiesel manufacture. BioDiesel blends above B20 must be used within 45 days from the date of BioDiesel manufacture.

When using BioDiesel blends up to B20, the following must be considered:

Cold-weather flow degradation

•

Stability and storage issues (moisture absorption,

•

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

•

(primarily an issue with older engines) Possible reduction of service life of engine components

•

Request a certificate of analysis from your fuel distributor to ensure that the fuel is compliant with the specifications provided in this Operator’s Manual.

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

The following must also be considered if using BioDiesel blends above B20:

Possible coking or blocked injector nozzles, resulting in

•

power loss and engine misfire if John Deere approved fuel conditioners are not used Possible crankcase oil dilution (requiring more frequent

•

oil changes) Possible lacquering or seizure of internal components

•

Possible formation of sludge and sediments

•

Possible thermal oxidation of fuel at elevated

•

temperatures Possible compatibility issues with other materials

•

(including copper, lead, zinc, tin, brass, and bronze) used in fuel handling equipment

Continued on next page DX,FUEL7 -19-15MAY13-1/2

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Fuels, Lubricants, and Coolant

Possible reduction in water separator efficiency

•

Possible damage to paint if exposed to BioDiesel

•

Possible corrosion of fuel injection equipment

•

Possible elastomeric seal and gasket material

•

degradation (primarily an issue with older engines) Possible high acid levels within fuel system

•

Because BioDiesel blends above B20 contain more

•

ash, using blends above B20 can result in more rapid

Testing Diesel Fuel

A fuel analysis program can help to monitor the quality of diesel fuel. The fuel analysis can provide critical data such as cetane number, fuel type, sulfur content, water content, appearance, suitability for cold weather

Aviation (Jet) Fuels

IMPORTANT: Not all fuels should be considered for

regular use. Some fuels that can be used in this engine are for emergency only and can cause premature engine and component wear if used long term. Unless your engine has been specifically designed for prolonged use of aviation fuel, the following fuels should be used for an emergency only fuel alternative.

Aviation (jet) fuels may be used with the following restrictions.

ash loading and require more frequent cleaning of the Exhaust Filter (if present)

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 -19-15MAY13-2/2

operations, bacteria, cloud point, acid number, particulate contamination, and whether the fuel meets specification.

Contact your John Deere dealer for more information on diesel fuel analysis.

DX,FUEL6 -19-14APR11-1/1

Type

Jet A Not Recommended.Lower viscosity and density than

Jet A-1 Not Recommended.Lower viscosity and density than

Jet B Not Recommended.Lower density and extremely

JP-4 Not Recommended.Lower density and extremely

JP-5 Not Recommended.Lower viscosity and density than

JP-7 Not Recommended.Lower viscosity and density than

JP-8 Not Recommended.Lower viscosity and density than

Comments

base No. 2-D diesel fuel. Power loss up to 10% can be expected.

base No. 2-D diesel fuel. Power loss up to 10% can be expected. May be used as an emergency fuel only, with the addition of John Deere PREMIUM DIESEL FUEL CONDITIONER (or equivalent) at the specified concentration.

low viscosity compared to base No. 2-D diesel fuel. Power loss up to 14% can be expected. May be used as an emergency fuel only, with the addition of John Deere PREMIUM DIESEL FUEL CONDITIONER (or equivalent) at the specified concentration.

base No. 2-D diesel fuel. Power loss up to 10% can be expected.

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Burner Fuels

Burner fuels, like kerosene, may be used with the following restrictions.

10-4

Type

No.2

No.1

Comments

Higher density and specific gravity than base No. 2-D diesel fuel. Power increase up to 3% can be expected.

Lower viscosity than base No. 2-D diesel fuel. Power loss up to 2% can be expected.

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Fuels, Lubricants, and Coolant

Fuel Filters

The importance of fuel filtration cannot be overemphasized with modern fuel systems. The combination of increasingly restrictive emission regulations and more efficient engines requires fuel system to operate at much higher pressures. Higher pressures can only be achieved using fuel injection components with very close tolerances. These close

manufacturing tolerances have significantly reduced capacities for debris and water.

John Deere brand fuel filters have been designed and produced specifically for John Deere engines.

To protect the engine from debris and water, always change engine fuel filters as specified in this manual.

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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 following information outlines steps that can minimize the effect that cold weather may have on starting and operation of your engine. See your John Deere dealer for additional information and local availability of cold-weather aids.

Use Winter Grade Fuel

When temperatures fall below 0 °C (32 °F), winter grade fuel (No. 1-D in North America) is best suited for cold-weather operation. Winter grade fuel has a lower cloud point and a lower pour point.

Cloud point is the temperature at which wax begins to form in the fuel. This wax causes fuel filters to plug. Pour point is the lowest temperature at which movement of the fuel is observed.

NOTE: On average, winter grade diesel fuel has a lower

Btu (heat content) rating. Using winter grade fuel may reduce power and fuel efficiency, but should not cause any other engine performance effects. Check the grade of fuel being used before troubleshooting for low-power complaints in cold-weather operation.

Air Intake Heater

An air intake heater is an available option for some engines to aid cold weather starting.

Ether

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

CAUTION: Ether is highly flammable. Do not

use ether when starting an engine equipped with glow plugs or an air intake heater.

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 in this section.)

Diesel Fuel Flow Additive

Use John Deere Fuel-Protect Diesel Fuel Conditioner (winter formula), which contains anti-gel chemistry, or equivalent fuel conditioner to treat non-winter grade fuel (No. 2-D in North America) during the cold-weather season. This generally extends operability to about 10 °C (18 °F) below the fuel cloud point. For operability at even lower temperatures, use winter grade fuel.

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.

BioDiesel

When operating with BioDiesel blends, wax formation can occur at warmer temperatures. Begin using John Deere Fuel-Protect Diesel Fuel Conditioner (winter formula) at 5 °C (41 °F) to treat BioDiesel fuels during the cold-weather season. Use B5 or lower blends at temperatures below 0 °C (32 °F). Use only winter grade petroleum diesel fuel at temperatures below -10 °C (14 °F).

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 -19-15MAY13-1/1

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Fuels, Lubricants, and Coolant

Diesel Engine Break-In Oil — Non-Emissions Certified and Certified Tier 1, Tier 2, Tier 3, Stage I, Stage II, and Stage III

New engines are filled at the factory with either John Deere Break-In™ or John Deere Break-In Plus™ Engine Oil. During the break-in period, add John Deere Break-In™ or Break-In Plus™ Engine Oil, respectively, 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.

If John Deere Break-In™ Engine Oil is used during the initial operation of a new or rebuilt engine, change the oil and filter at a maximum of 100 hours.

If John Deere Break-In Plus™ Engine Oil is used, change the oil and filter at a minimum of 100 hours and a maximum equal to the interval specified for John Deere Plus-50™ II or Plus-50™ oil.

After engine overhaul, fill the engine with either John Deere Break-In™ or Break-In Plus™ Engine Oil.

If John Deere Break-In™ or Break-In Plus™ Engine Oil is not available, use an SAE 10W-30 viscosity grade diesel engine oil meeting one of the following and change the oil and filter at a maximum of 100 hours of operation:

API Service Classification CE

•

API Service Classification CD

•

Break-In is a trademark of Deere & Company. Break-In Plus is a trademark of Deere & Company Plus-50 is a trademark of Deere & Company.

API Service Classification CC

•

ACEA Oil Sequence E2

•

ACEA Oil Sequence E1

•

IMPORTANT: Do not use Plus-50™ II, Plus-50™, or

engine oils meeting any of the following for the initial break-in of a new or rebuilt engine:

API CJ-4 ACEA E9

API CI-4 PLUS ACEA E7

API CI-4 ACEA E6

API CH-4 ACEA E5

API CG-4 ACEA E4

API CF-4 ACEA E3

API CF-2

API CF

These oils do not allow the engine to break in properly.

John Deere Break-In Plus™ Engine Oil can be used for all John Deere diesel engines at all emission certification levels.

After the break-in period, use John Deere Plus-50™ II, John Deere Plus-50™, or other diesel engine oil as recommended in this manual.

DX,ENOIL4 -19-15MAY13-1/1

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PN=37

Fuels, Lubricants, and Coolant

SAE 30

SAE 40

SAE 0W-40

50 C

40 C

30 C

20 C

10 C

0 C

-10 C

-20 C

-30 C

-40 C

122 F

50 F

32 F

14 F

-4 F

-22 F

-40 F

104 F

68 F

86 F

SAE 5W-30

SAE 10W-30

SAE 10W-40

SAE-15W-40

Diesel Engine Oil — Non-Emissions Certified and Certified Tier 1 and Stage I

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

John Deere Plus-50™ II oil is preferred.

John Deere Plus-50™ is also recommended.

Other oils may be used if they meet one or more of the following:

John Deere Torq-Gard™

•

API Service Category CJ-4

•

API Service Category CI-4 PLUS

•

API Service Category CI-4

•

API Service Category CH-4

•

API Service Category CG-4

•

API Service Category CF-4

•

ACEA Oil Sequence E9

•

ACEA Oil Sequence E7

•

ACEA Oil Sequence E6

•

ACEA Oil Sequence E5

•

ACEA Oil Sequence E4

•

ACEA Oil Sequence E3

•

ACEA Oil Sequence E2

•

If oils meeting API CG-4, API CF-4, or ACEA E2 are used, reduce the service interval by 50%.

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.

Plus-50 is a trademark of Deere & Company Torq-Gard is a trademark of Deere & Company

If diesel fuel with sulfur content greater than 5000 mg/kg (5000 ppm) is used, reduce the service interval by 50%.

DO NOT use diesel fuel with sulfur content greater than 10000 mg/kg (10000 ppm).

Oil Viscosities for Air Temperature Ranges

TS1687 —UN—18JUL07

DX,ENOIL -19-15JUN10-1/1

10-8

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PN=38

Fuels, Lubricants, and Coolant

Extended Diesel Engine Oil Service Intervals — Non-Emissions Certified and Certified Tier 1 and Stage I

When John Deere Plus-50™ II or John Deere Plus-50™ is used with the specified John Deere filter, the service interval for engine oil and filter changes may be increased by 50% but not to exceed a maximum of 500 hours.

Use oil analysis to evaluate the condition of the oil and to aid in selection of the proper oil and filter service interval. Contact your John Deere dealer for more information on engine oil analysis.

Change the oil and oil filter at least once every 12 months even if the hours of operation are fewer than the otherwise recommended service interval.

When ACEA E9, ACEA E7, ACEA E6, ACEA E5, or ACEA E4 oils are used with specified John Deere filter, use engine oil analysis to determine if the service interval for engine oil and filter changes may be increased by a maximum of 50% but not to exceed 500 hours.

If John Deere Plus-50™ II or John Deere Plus-50™, ACEA E9, ACEA E7, ACEA E6, ACEA E5, or ACEA E4

Plus-50 is a trademark of Deere & Company Torq-Gard is a trademark of Deere & Company

Mixing of Lubricants

oils are used with other than the specified John Deere filter, change the engine oil and filter at the normal service interval.

If John Deere Torq-Gard™, API CJ-4, API CI-4 PLUS, API CI-4, API CH-4, or ACEA E3 oils are used, change the engine oil and filter at the normal service interval.

If API CG-4, API CF-4, or ACEA E2 oils are used, change the engine oil and filter at 50% of the normal service interval.

IMPORTANT: To avoid engine damage:

Reduce oil and filter service intervals by 50%

•

when using BioDiesel blends greater than B20. Oil analysis may allow longer service intervals. Use only approved oil types.

•

DX,ENOIL6 -19-15JUN10-1/1

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.

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.

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

DX,LUBMIX -19-18MAR96-1/1

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 lubricants.

Re-refined base stock products may be used if the finished lubricant meets the performance requirements.

DX,ALTER -19-11APR11-1/1

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Lubricant Storage

Fuels, Lubricants, and Coolant

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

Use clean containers to handle all lubricants.

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.

Make certain that all containers are properly marked to identify their contents.

Properly dispose of all old containers and any residual lubricant they may contain.

DX,LUBST -19-11APR11-1/1

Use filters meeting John Deere performance specifications.

DX,FILT -19-18MAR96-1/1

10-10

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PN=40

Fuels, Lubricants, and Coolant

Diesel Engine Coolant (engine with wet sleeve cylinder liners)

Preferred Coolants

The following pre-mix engine coolants are preferred:

John Deere COOL-GARD™II

•

John Deere COOL-GARD II PG

•

COOL-GARD II pre-mix coolant is available in several concentrations with different freeze protection limits as shown in the following table.

COOL-GARD II pre-mix Freeze Protection Limit

COOL-GARD II 20/80 -9 °C (16 °F)

COOL-GARD II 30/70 -16 °C (3 °F)

COOL-GARD II 50/50 -37 °C (-34 °F)

COOL-GARD II 55/45 -45 °C (-49 °F)

COOL-GARD II PG 60/40 -49 °C (-56 °F)

COOL-GARD II 60/40 -52 °C (-62 °F)

Not all COOL-GARD II pre-mix products are available in all countries.

Use COOL-GARD II PG when a non-toxic coolant formulation is required.

Additional Recommended Coolants

The following engine coolant is also recommended:

John Deere COOL-GARD II Concentrate in a 40—60%

•

mixture of concentrate with quality water.

IMPORTANT: When mixing coolant concentrate with

water, do not use less than 40% or greater than 60% concentration of coolant. Less than 40% gives inadequate additives for corrosion protection. Greater than 60% can result in coolant gelation and cooling system problems.

Coolant concentrate meeting ASTM D6210

•

requirements in a 40—60% mixture of concentrate with quality water

If coolant meeting one of these specifications is unavailable, use a coolant concentrate or pre-mix coolant that has a minimum of the following chemical and physical properties:

Provides cylinder liner cavitation protection according to

•

either the John Deere Cavitation Test Method or a fleet study run at or above 60% load capacity Is formulated with a nitrite-free additive package

•

Protects the cooling system metals (cast iron, aluminum

•

alloys, and copper alloys such as brass) from corrosion

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.

Coolant Drain Intervals

Drain and flush the cooling system and refill with fresh coolant at the indicated interval, which varies with the coolant used.

When COOL-GARD II or COOL-GARD II PG is used, the drain interval is 6 years or 6000 hours of operation.

If a coolant other than COOL-GARD II or COOL-GARD II PG is used, reduce the drain interval to 2 years or 2000 hours of operation.

IMPORTANT: Do not use cooling system sealing

additives or antifreeze that contains sealing additives.

Other Coolants

Other ethylene glycol or propylene glycol base coolants may be used if they meet the following specification:

Pre-mix coolant meeting ASTM D6210 requirements

•

COOL-GARD is a trademark of Deere & Company

10-11

Do not mix ethylene glycol and propylene glycol base coolants.

Do not use coolants that contain nitrites.

DX,COOL3 -19-15MAY13-1/1

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PN=41

Fuels, Lubricants, and Coolant

Water Quality for Mixing with Coolant Concentrate

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

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

Chlorides <40 mg/L

Sulfates <100 mg/L

Total solids

Total dissolved I hardness

pH 5.5—9.0

<340 mg/L

<170 mg/L

IMPORTANT: Do not use bottled drinking water

because it often contains higher concentrations of total dissolved solids.

Operating in Warm Temperature Climates

John Deere engines are designed to operate using recommended engine coolants.

Always use a recommended 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.

Freeze Protection

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

Ethylene Glycol

40% -24 °C (-12 °F)

50% -37 °C (-34 °F)

60% -52 °C (-62 °F)

Propylene Glycol

40% -21 °C (-6 °F)

50% -33 °C (-27 °F)

60% -49 °C (-56 °F)

Freeze Protection Limit

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

DX,COOL19 -19-15MAY13-1/1

Foaming, hot surface aluminum and iron corrosion, scaling, and cavitation occur when water is used as the coolant, even when coolant conditioners are added.

Drain cooling system and refill with recommended engine coolant as soon as possible.

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Fuels, Lubricants, and Coolant

Testing Coolant Freeze Point

The use of a handheld coolant refractometer is the quickest, easiest, and most accurate method to determine coolant freeze point. This method is more accurate than a test strip or a float-type hydrometer which can produce poor results.

A coolant refractometer is available through your John Deere dealer under the SERVICEGARD™ tool program. Part number 75240 provides an economical solution to accurate freeze point determination in the field.

To use this tool:

1. Allow cooling system to cool to ambient temperatures.

2. Open radiator cap to expose coolant.

3. With the included dropper, collect a small coolant sample.

4. Open the lid of the refractometer, place one drop of coolant on the window and close the lid.

5. Look through the eyepiece and focus as necessary.

6. Record the listed freeze point for the type of coolant (ethylene glycol coolant or propylene glycol) being tested.

TS1732 —UN—04SEP13

SERVICEGARD™ Part Number 75240

SERVICEGARD is a trademark of Deere & Company

Disposing of Coolant

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

Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

Do not pour waste onto the ground, down a drain, or into any water source.

Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your John Deere engine distributor or servicing dealer.

TS1733 —UN—04SEP13

Image with a Drop of 50/50 Coolant Placed on the Refractometer Window

DX,COOL,TEST -19-13JUN13-1/1

TS1133 —UN—15APR13

Recycle Waste

RG,RG34710,7543 -19-09JAN07-1/1

10-13

100915

PN=43

Engine Operating Guidelines

Instrument (Gauge) Panels

All controls and gauges are optional equipment for John Deere OEM Engines. They may be provided by the equipment manufacturer instead of John Deere. The following information applies only to those controls and gauges provided by John Deere.

IMPORTANT: Any time an electric gauge or meter

does not register correctly, replace it with a new one. Do not attempt to repair it.

Two types of instrument panels are offered on 4.5 L and

6.8 L engines, as shown on this page. See following for complete information on each type of instrument panel.

RG11299 —UN—12SEP00

North American Instrument Panel

VDO Instrument Panel (Except North America)

DPSG,RG34710,107 -19-10JAN02-1/1

RG10606A —UN—19JUN00

15-1

100915

PN=44

Engine Operating Guidelines

Instrument (Gauge) Panel (North America)

IMPORTANT: Any time an electric gauge or meter

does not register correctly, replace it with a new one. Do not attempt to repair it.

Following is a brief description of the components on the instrument (gauge) panel:

A—Oil Pressure Gauge - This gauge indicates oil pressure. It also has an adjustable electrical contact which activates the safety switch when oil pressure goes below the pressure set point. This will automatically stop the engine.

B—Coolant Temperature Gauge - This gauge indicates coolant temperature. It also has an electrical contact which activates the safety switch when coolant temperature goes above the temperature set point. This will automatically stop the engine.

C—Key Switch - The key switch is used to start and stop the engine. A key is required to operate the switch so as to prevent unauthorized operation of the engine.

D—Tachometer - The tachometer indicates engine speed in hundreds of revolutions per minute (rpm).

E—Safety Switch (Reset Button) - The safety switch de-energizes the fuel shut-off solenoid or injection rack puller to stop the engine, if one or more conditions are met:

Low or no oil pressure

•

High coolant temperature

•

Low crankcase oil level (if equipped with engine oil level

•

switch) High crankcase oil level (if equipped with engine oil

•

level switch)

The reset button has to be held in when starting the engine. The button allows the safety switch to override the shut-down circuits until safe engine oil pressure is maintained. Once engine oil pressure is within specifications, the safety switch will latch and the reset button can be released.

F—Fuse Holder - Contains 14 amp fuse.

G—Ammeter - The ammeter indicates the rate of charge

(+) or discharge (—) of the battery. When the engine is first started, the ammeter will usually indicate a charge rate of approximately 30 amps. After a short period of operation, the ammeter needle will point slightly to the right of “0”, indicating the charging system is operating normally. A problem with the charging system is indicated if the ammeter needle points to the left of “0” during engine operation.

H—Hour Meter - The hour meter operates when the engine is operating, or when the reset button is manually

North American Instrument Panel

Hour Meter And Tachometer Codes

A—Oil Pressure Gauge B—Coolant Temperature

Gauge C—Key Switch D—Tachometer E—Reset (Safety) Switch

F— Fuse Holder (14 Amp Fuse) G—Ammeter H—Hourmeter I— Hand Throttle J— Tachometer Binary Code

held in while the key switch is in the ON position. The accumulated hours are displayed in hours and tenths of hours. On some panels, the hourmeter may be separate from the tachometer.

I—Hand Throttle - The hand throttle is used to manually control engine speed. If the hand throttle is electronic (as shown), turn the knob clockwise or counterclockwise to change engine speed. If the hand throttle is mechanical (not shown), turning the handle, either clockwise or counterclockwise, will lock the throttle position. Turn the handle half way between the two lock positions to unlock the throttle.

Continued on next page DPSG,RG34710,108 -19-08JAN02-1/2

RG11299B —UN—17AUG00

RG10607 —UN—19OCT99

15-2

100915

PN=45

Engine Operating Guidelines

J—Tachometer Binary Code - The tachometer is calibrated to the number of flywheel gear teeth read. The dip switch to set the binary code is located in back of

VDO Instrument (Gauge) Panel (Except North America)

IMPORTANT: Any time an electric gauge or meter

does not register correctly, replace it with a new one. Do not attempt to repair it.

Following is a brief description of the components on the instrument (gauge) panel:

A—Oil Pressure Gauge - The oil pressure gauge indicates engine oil pressure.

B—Coolant Temperature Gauge - The coolant temperature gauge indicates coolant temperature.

C—Tachometer - The tachometer indicates engine speed in hundreds of revolutions per minute (rpm).

tachometer and must be set at “10110011” to operate at 30 pulses per revolution.

DPSG,RG34710,108 -19-08JAN02-2/2

VDO Instrument Panel

A—Oil Pressure Gauge B—Coolant Temperature

Gauge C—Tachometer D—Engine Control Light E—Preheater Light F— Fuel Level Light

G—Battery Light H—Oil Pressure Light I— Coolant Temperature Light J— Key/Start Switch K—Hour Meter

RG10606B —UN—20OCT99

The engine control system consists of the following:

D—Engine Control Light - The engine control light illuminates after the engine has started and oil pressure is up to specification. The light indicates that the engine protection circuitry is activated.

E—Preheater Light - The preheater light illuminates when the key is turned to the bulb test position (position I). It should go off after approximately five seconds. When the key switch is held in position II, the engine preheater is energized and the preheater light illuminates.

F—Fuel Level Light - The fuel level light illuminates when the key is turned to the bulb test position (position I). It should go off after approximately five seconds. After the engine is running, if the engine runs out of fuel, the light will illuminate and protection circuitry will stop the engine. The fuel level light will remain on indicating the engine was stopped due to the fuel tank being empty.

G—Battery Light - The battery light illuminates when the key is turned to the bulb test position (position I). It should go off after approximately five seconds. After the engine is running, if the alternator stops charging, the light will illuminate and protection circuitry will stop the engine. The battery light will remain on indicating the engine was stopped due to the alternator not charging.

H—Oil Pressure Light - The oil pressure light illuminates when the key switch is turned to the bulb test position

(position I). The light will remain on until the engine is started and the specified oil pressure is reached. If oil pressure is lost during engine operation, the light will illuminate and protection circuitry will stop the engine. The oil pressure light will remain on, indicating that the engine was stopped due to a low oil pressure condition.

I—Coolant Temperature Light - The coolant temperature light illuminates when the key is turned to the bulb test position (position I). It should go off after approximately five seconds. After the engine is running, if the engine overheats, the light will illuminate and protection circuitry will stop the engine. The coolant temperature light will remain on indicating the engine was stopped due to the engine overheating.

Other components on the instrument panel:

J—Key/Start Switch - The four-position key start switch controls the electrical system.

K—Hour Meter - The hour meter is an integral part of the tachometer. It shows the accumulated hours of engine service. The hour meter operates when the engine is running and accumulated hours are displayed in hours and tenths of hours.

DPSG,RG34710,109 -19-08JAN02-1/1

15-3

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PN=46

Engine Operating Guidelines

Engine Break-In Service

The engine is ready for normal operation. However, extra care during the first 250 hours of operation will result in more satisfactory long-term engine performance and life. DO NOT exceed 250 hours of operation with break-in oil.

1. This engine is factory-filled with John Deere ENGINE BREAK-IN OIL. 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 250 hour period, a longer break-in period may be required. In these situations, an additional 250 hour break-in period is recommended using a new change of John Deere ENGINE BREAK-IN OIL and a new John Deere oil filter.

RG8009 —UN—06JAN99

Check Engine Oil

OURGP12,0000076 -19-09SEP04-1/4

IMPORTANT: DO NOT add makeup oil until the oil

level is BELOW the ADD mark on dipstick. John Deere ENGINE BREAK-IN OIL (TY22041) should be used to make up any oil consumed during the break-in period.

3. Check engine oil level more frequently during engine break-in period. If oil must be added during this period, John Deere ENGINE BREAK-IN OIL is preferred. See ENGINE BREAK-IN OIL, in Fuels, Lubricants, and Coolant Section.

IMPORTANT: DO NOT use PLUS-50® Engine Oil

during the break-in period of a new engine or engine that has had a major overhaul. PLUS-50® oil will not allow a new or overhauled engine to properly wear during this break-in period.

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.

PLUS-50 is a trademark of Deere & Company.

At normal operating temperature of 115°C (240°F) sump.

RG8028A —UN—15JAN99

Crosshatch Pattern On Oil Dipstick

A—Crosshatch Pattern On Oil

Dipstick

Engine

—Oil Pressure at

Full Load Rated Speed...... 345 ± 103 kPa (3.45 ± 1.03 bar) (50 ± 15 psi)

Minimum Oil Pressure at

Rated Speed.........................................................275 (2.75 bar) (40 psi)

Minimum Oil Pressure at

850 rpm ........................................................ 105 kPa (1.05 bar) (15 psi)

Coolant Temperature

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

Continued on next page OURGP12,0000076 -19-09SEP04-2/4

Specification

15-4

100915

PN=47

Engine Operating Guidelines

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 250 hours (maximum), change engine oil and replace engine oil filter. (See CHANGING ENGINE OIL AND REPLACING OIL FILTER in Lubrication and Maintenance/250 Hour/6 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 air temperature is below -10°C (14°F), use an engine block heater.

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. Check poly-vee belt for proper alignment and seating in pulley grooves.

A—Coolant Temperature

Gauge

RG7961B —UN—22JAN99

Changing Oil And Oil Filter Before First 250 Hours

OURGP12,0000076 -19-09SEP04-3/4

15-5

RG11299F —UN—17AUG00

North American (1999— ) Instrument Panel Shown

OURGP12,0000076 -19-09SEP04-4/4

100915

PN=48

Engine Operating Guidelines

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

RG7634A —UN—22JAN99

Auxiliary Gear Drive

RG,RG34710,5555 -19-27JUL06-1/1

Generator Set (Standby) Applications

To assure that your engine will deliver efficient standby operation when needed, start engine and run at rated

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.

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

3. Disengage clutch (if equipped) controlling any engine drivelines.

speed (with 50%—70% load) for 30 minutes every 2 weeks. DO NOT allow engine to run extended period of time with no load.

RG,RG34710,5556 -19-27JUL06-1/1

TS220 —UN—15APR13

Use Proper Ventilation

NOTE: Electronically controlled governor applications

may be equipped with a rotary speed potentiometer on the throttle (A) on the instrument panel.

Continued on next page RG,RG34710,5557 -19-07JAN02-1/2

15-6

100915

PN=49

Engine Operating Guidelines

4. On mechanical governor (7-10% regulation) engines,

pull hand throttle (A) 1/3 of the way out. Turn the handle in either direction to lock it in place.

5. If equipped, depress and hold reset button (B) while

starting.

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.

6. Turn the key switch (C) clockwise to crank the engine.

When the engine starts, release the key 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.

7. After the engine starts, continue to hold the reset

button in until the oil pressure gauge (D) reads at least 105 kPa (1.05 bar) (15 psi). The safety controls will not allow the engine to run at a lower oil pressure unless the reset button is held in.

RG11299X —UN—18OCT01

North American Standard Instrument Panel (1999— ) Shown

RG11610 —UN—17OCT01

VDO Standard Instrument Panel (Except North America)

IMPORTANT: Should the engine die when operating

under load, immediately disengage PTO clutch and restart the engine. Overheating of turbocharger parts may occur when oil flow is stopped.

8. Check all gauges for normal engine operation. If

operation is not normal, stop the engine and determine the cause.

A—Hand Throttle B—Reset Button

C—Key Start Switch D—Oil Pressure Gauge

RG,RG34710,5557 -19-07JAN02-2/2

15-7

100915

PN=50

Engine Operating Guidelines

Warming Engine

IMPORTANT: To assure proper lubrication, operate

engine at or below 1200 rpm with no load for 1–2 minutes. Extend this period 2–4 minutes when operating at temperatures below freezing.

Engines used in generator set applications where the governor is locked at a specified speed may not have a slow idle function. Operate these engines at high idle for 1 to 2 minutes before applying the load. This procedure does not apply to standby generator sets where the engine is loaded immediately upon reaching rated speed.

1. Check oil pressure gauge (A) as soon as engine starts. If gauge needle does not rise above minimum oil pressure specification of 105 kPa (1.05 bar) (15.0 psi) within 5 seconds, stop the engine and determine the cause. Normal engine oil pressure is 345 kPa (3.45 bar) (50 psi) at rated full load speed (1800–2500 rpm) with oil at normal operating temperature of 115°C (240°F).

NOTE: On certain engines, the oil pressure and

coolant temperature gauges are replaced by indicator warning lights. The lights must be "OFF" when engine is running.

2. Watch coolant temperature gauge (B). Do not place engine under full load until it is properly warmed up. The normal engine coolant temperature range is 82°—94°C (180°—202°F).

RG11612 —UN—17OCT01

Standard North American Instrument Panel

RG10613 —UN—21OCT99

Standard VDO Instrument Panel (Except North America)

A—Oil Pressure Gauge B—Coolant Temperature

Gauge

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.

Normal Engine Operation

Observe engine coolant temperature and engine oil pressure. Temperatures and pressures will vary between engines and with changing operating conditions, temperatures, and loads.

Normal engine coolant operating temperature range is 82°—94°C (180°—202°F). If coolant temperature rises above 112°C (234°F), reduce load on engine. Unless temperature drops quickly, stop engine and determine cause before resuming operation.

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

RG,RG34710,5560 -19-08JAN02-1/1

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

•

RG,RG34710,5552 -19-20MAY96-1/1

15-8

100915

PN=51

Engine Operating Guidelines

Cold Weather Operation

CAUTION: Ether injector starting fluid is highly

flammable. DO NOT use starting fluid on engines equipped with air intake heaters.

DO NOT use starting fluid near fire, sparks, or flames. DO NOT incinerate or puncture a starting fluid container.

Engines may be equipped with intake air heaters, coolant heaters, or ether injectors as a cold weather starting aid.

Starting aids are required below 32°F (0°C). 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.

Other cold weather starting aids are required at temperatures below -22°F (-30°C) or at altitudes above 1500 m (5000 ft).

TS1356 —UN—18MAR92

Handle Starting Fluid with Care

1. Follow steps 1—4 as listed under , then proceed as follows according to the instrument (gauge) panel on your engine.

2. Switch on the air intake heater for 30 seconds or activate ether injector by following suppliers instructions.

3. Follow remaining steps 5—8 as listed under earlier in this section.

Additional information on cold weather operation is available from your authorized servicing dealer.

RG11521 —19—10JAN01

Cold Weather Starting Guidelines

RG,RG34710,5050 -19-08JAN02-1/1

15-9

100915

PN=52

Engine Operating Guidelines

Changing Engine Speed

To increase engine speed, turn throttle handle (A), if equipped, to the horizontal position and pull out until desired engine speed is obtained. Turn the handle in either direction to lock throttle position. The handle is pushed inward to decrease engine speed.

NOTE: On engines without handle, use throttle lever

to control engine speed.

A—Throttle Handle

RG11299I —UN—11SEP00

North American Standard Instrument Panel Shown

RG,RG34710,5561 -19-07JAN02-1/1

Avoid Excessive Engine Idling

Prolonged idling may cause the engine coolant temperature to fall below its normal range. This, in turn, causes crankcase oil dilution, due to incomplete fuel combustion, and permits formation of gummy deposits on valves, pistons, and piston rings. It also promotes rapid accumulation of engine sludge and unburned fuel in the exhaust system.

Once an engine is warmed to normal operating temperatures, engine should be idled at slow idle speed.

Slow idle speed for this engine is 850 rpm at factory. If an engine will be idling for more than 5 minutes, stop and restart later.

NOTE: Generator set applications where the governor

is locked at a specified speed may not have a slow idle function. These engines will idle at no load governed speed (high idle).

RG,RG34710,5562 -19-27JUL06-1/1

15-10

100915

PN=53

Engine Operating Guidelines

Stopping the Engine

1. Disengage clutch (if equipped) controlling engine drivelines.

2. Move the throttle (A) to slow idle on standard (mechanical) governor engines.

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.

For engines in generator set applications, where the governor 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.

3. Turn key switch (B) to "OFF" position to stop the engine. Remove ignition key.

IMPORTANT: Make sure that exhaust stack cap (rain

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

RG11299J —UN—11SEP00

North American Standard Instrument Panel Shown

A—Throttle

B—Key Switch

RG10616 —UN—16JUN00

Exhaust Stack Rain Cap

RG,RG34710,5563 -19-07JAN02-1/1

15-11

100915

PN=54

Engine Operating Guidelines

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.

TS204 —UN—15APR13

Exploding Battery

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).

6. Start the engine. Disconnect jumper cables immediately after engine starts. Disconnect NEGATIVE (–) cable first.

24-Volt System

A—12-Volt Machine Battery

(ies)

B—12-Volt Booster Battery

(ies)

RG4698 —UN—14DEC88

C—Booster Cable D—Cable to Starting Motor

RG,RG34710,5564 -19-27JUL06-1/1

15-12

100915

PN=55

Lubrication and Maintenance

Required Emission-Related Information

Service Provider

A qualified repair shop or person of the owner's choosing may maintain, replace, or repair emission control devices and systems with original or equivalent replacement parts. However, warranty, recall, and all other services paid for by John Deere must be performed at an authorized John Deere service center.

DX,EMISSIONS,REQINFO -19-12JUN15-1/1

Observe Service Intervals

Using hour meter (A) as guide, perform all services at the hourly intervals indicated on following pages. At each scheduled maintenance interval, perform all previous maintenance operations in addition to the ones specified. Keep a record of hourly intervals and services performed using charts provided in Lubrication and Maintenance Records Section.

IMPORTANT: Recommended service intervals are for

normal operating conditions. Service MORE OFTEN if engine is operated under adverse conditions. Neglecting maintenance can result in failures or permanent damage to the engine.

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.

RG11299A —UN—17AUG00

North American Instrument Panel Hour Meter Shown

DPSG,OUOE003,20 -19-07JAN02-1/1

TS100 —UN—23AUG88

DPSG,OUOE003,20 -19-09OCT07-1/1

20-1

100915

PN=56

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

Item Daily

Check Engine Oil and Coolant Level

Check Fuel Filter(s)/Water Separator Bowl

Check Air Cleaner Dust Unloader Valve & Indicator

Perform Visual Walkaround Inspection

Service Fire Extinguisher

Change Engine Oil And Replace Oil Filter

Check Engine Mounts

Service Battery

Check Manual Belt Tensioner and Belt Wear

•

6 Month

•

Clean Crankcase Vent Tube

Check Air Intake Hoses, Connections, & System

Replace Single or Dual Fuel Filter Elements

Check Automatic Belt Tensioner and Belt Wear

Check Engine Speeds

Check Engine Electrical Ground Connection

Coolant Solution Analysis-Add SCAs as required

Pressure Test Cooling System

Check Cooling System

Test Thermostats

250 Hour/

Flush Cooling System

Check Crankshaft Vibration Damper (6.8 L Engines)

Check and Adjust Engine Valve Clearance

Add Coolant

Replace Air Cleaner Elements

Replace Poly-Vee Belt

Check Fuses

Check Air Compressor (If Equipped)

Bleed Fuel System

Replace primary air cleaner element when restriction indicator shows a vacuum of 625 mm (25 in.) H2O.

Change the oil for the first time after 100 hours maximum of break-in operation. For subsequent oil and

filter intervals, see recommendations in section 10.

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.

Replace crankshaft damper every 4500 hours or 60 months, whichever occurs first.

500 Hour/ 12 Month

•

2000 Hour/

24 Month As Required

•

OURGP11,0000006 -19-20AUG15-1/1

•

20-2

100915

PN=57

Lubrication and Maintenance

Lubrication and Maintenance Service Interval Chart—Generator (Standby) Applications

below to titles in Lubrication and Maintenance Sections for procedures.

NOTE: Use service intervals listed below for generator

(standby) applications. Match service items

Lubrication and Maintenance Service Intervals

Item

Operate Engine at Rated Speed and 50%–70% Load a Minimum

Weeks

•

of 30 Minutes

Every 2

Check Engine Oil and Coolant Level

Check Fuel Filter(s)/Water Separator Bowl

Check Air Cleaner Dust Unloader Valve & Indicator

Perform Visual Walkaround Inspection

•

Service Fire Extinguisher

Change Engine Oil and Replace Oil Filter

Check Engine Mounts

Service Battery

Clean Crankcase Vent Tube

Check Air Intake Hoses, Connections, & System

Replace Single or Dual Fuel Filter Elements

Check Belt Tensioner and Belt Wear

Check Engine Speeds

Check Engine Electrical Ground Connection

Coolant Solution Analysis-Add SCAs as required

Pressure Test Cooling System

Check Cooling System

Test Thermostats

Flush Cooling System

Check Variable Speed (Droop) (Gen-Sets)

Check Crankshaft Vibration Damper (6.8 L Engines)

Check and Adjust Engine Valve Clearance

Add Coolant

Replace Air Cleaner Elements

Replace Poly-Vee Belt

Check Fuses

Check Air Compressor (If Equipped)

Bleed Fuel System

Replace primary air cleaner element when restriction indicator shows a vacuum of 625 mm (25 in.) H2O.

Change the oil for the first time after 100 hours maximum of break-in operation. For subsequent oil and

filter intervals, see recommendations in section 10.

Replace crankshaft damper every 4500 hours or 60 months, whichever occurs first.

250 Hours or

12 Months

•

500 Hours or

12 Months

•

2000 Hours

or 24 Months As Required

•

OURGP11,0000007 -19-20AUG15-1/1

•

20-3

100915

PN=58

Lubrication & Maintenance — Daily

Daily Prestarting Checks

Do the following BEFORE STARTING THE ENGINE for the first time each day:

IMPORTANT: DO NOT add makeup oil until the oil

level is BELOW the add mark.

A—Left Side Oil Filler Cap B—Right Side Oil Filler Cap

C—Cover Oil Filler Cap D—Crosshatch On Dipstick

RG8009A —UN—16JUN00

Left Side Oil Filler Cap

RG8054A —UN—16JUN00

Right Side Oil Filler Cap

RG8028B —UN—15JAN99

Continued on next page OURGP12,0000048 -19-13OCT06-1/4

Rocker Arm Cover Filler Cap

Crosshatch on Dipstick

25-1

RG8025B —UN—16JUN00

100915

PN=59

Lubrication & Maintenance — Daily

1. Check engine oil level on dipstick. Add as required, using seasonal viscosity grade oil. (See DIESEL ENGINE OIL in Fuels, Lubricants, and Coolant Section for oil specifications.)

Depending on application, oil may be added at left (A) or right (B) side oil filler cap and rocker arm cover filler cap (C) locations.

IMPORTANT: DO NOT fill above the top mark on

the dipstick. Oil levels anywhere within crosshatch (D) are considered in the acceptable operating range.

CAUTION: Explosive release of fluids from

pressurized cooling system can cause serious burns.

Only remove filler cap when engine is cold or when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

2. Check the coolant level when engine is cold. Coolant level should be at bottom of filler neck. Fill radiator (A) with proper coolant solution if level is low. (See ADDING COOLANT in Service As Required Section.) Check overall cooling system for leaks.

TS281 —UN—15APR13

High-Pressure Fluids

NOTE: Refer to your vehicle's operator's manual

for recommendations for non-John Deere supplied accessories.

RG4675 —UN—14DEC88

Fill Radiator

A—Fill Radiator

Continued on next page OURGP12,0000048 -19-13OCT06-2/4

25-2

100915

PN=60

Lubrication & Maintenance — Daily

3. Check the single or dual fuel filters for water or debris. If filter is fitted with a see-through water separator bowl, drain as needed based on a daily visual inspection.

IMPORTANT: Drain water into a suitable container

and dispose of properly.

a. Loosen drain plugs (B) at bottom of each fuel filter

or bowl, if equipped, two or three turns.

b. Loosen air bleed plugs (A) two full turns on fuel filter

mountings and drain water from bottom until fuel starts to drain out.

c. When fuel starts to drain out, tighten drain plugs

securely.

After draining water from the fuel filter, the filter must be primed by bleeding all air from the fuel system.

a. Operate primer lever of the fuel supply pump (C)

until fuel flow is free from air bubbles.

b. Tighten bleed plugs securely, and continue

operating hand primer until pumping action is not felt. Primer lever is spring-loaded, and will return to normal position.

If the fuel system needs further bleeding of air, see BLEEDING FUEL SYSTEM in Service As Required Section, later in this manual.

RG13542 —UN—20JUL04

Drain Fuel Filters (Dual Filters Shown)

RG7317A —UN—16JUN00

Priming At Fuel Supply Pump

A—Air Bleed Plugs B—Drain Plugs

C—Fuel Supply Pump Primer

Lever

Continued on next page OURGP12,0000048 -19-13OCT06-3/4

25-3

100915

PN=61

Lubrication & Maintenance — Daily

4. If the air cleaner has an automatic dust unloader valve (A), squeeze the unloader valve on air cleaner assembly to clear away any dust buildup.

If equipped with air intake restriction indicator gauge (B), check gauge to determine if air cleaner needs to be serviced.

IMPORTANT: Maximum air intake restriction is 6.25

kPa (0.06 bar) (1.0 psi) (25 in. H

O). A clogged air cleaner element will cause excessive intake restriction and a reduced air supply to the engine.

5. Make a thorough inspection of the engine compartment. Look for oil or coolant leaks, worn fan and accessory drive belts, loose connections and trash build-up. Remove trash buildup and have repairs made as needed if leaks are found.

NOTE: Wipe all fittings, caps, and plugs before

performing any maintenance to reduce the chance of system contamination.

Inspect:

Radiator for leaks and trash build-up.

•

Air intake system hoses and connections for cracks

•

and loose clamps. Fan, alternator, and accessory drive belts for cracks,

•

breaks or other damage.

Dust Unloader Valve and Indicator Gauge

A—Dust Unloader Valve B—Air Restriction Indicator

Water pump for coolant leaks.

•

NOTE: It is normal for a small amount of leakage to

occur as the engine cools down and parts contract. Excessive coolant leakage may indicate the need to replace the water pump seal. Contact your engine distributor or servicing dealer for repairs.

OURGP12,0000048 -19-13OCT06-4/4

RG7332A —UN—22JAN99

25-4

100915

PN=62

Lubrication & Maintenance — 250 Hours/6 Months

Servicing Fire Extinguisher

A fire extinguisher (A) is available from your authorized servicing dealer or engine distributor.

Read and follow the instructions which are packaged with it. The extinguisher should be inspected at least every 250 hours of engine operation or once a month. Once extinguisher is operated, no matter how long, it must be recharged. Keep record of inspections on the tag which comes with the extinguisher instruction booklet.

A—Fire Extinguisher

Changing Engine Oil and Replacing Filter

NOTE: Change engine oil and oil filter for the first

time after 100 hours maximum of operation, then every 250 hours thereafter.

If John Deere PLUS-50® or ACEA E4 or E5 engine oil and a John Deere oil filter are used, the oil and filter change interval may be extended by 50 percent.

OILSCAN® or OILSCAN PLUS®is a John Deere sampling program to help you monitor machine performance and identify potential problems before they cause serious damage. OILSCAN® and OILSCAN PLUS®kits are available from your John Deere engine distributor or servicing dealer. Oil samples should be taken prior to the oil change. Refer to instructions provided with kit.

To change engine oil and oil filter:

1. Run engine approximately 5 minutes to warm up oil. Shut engine off.

2. Remove oil pan drain plug (arrow).

RW4918 —UN—15DEC88

Fire Extinguisher

RG,RG34710,5567 -19-20MAY96-1/1

RG11616 —UN—24OCT01

Oil Filter

3. Drain crankcase oil from engine while warm.

NOTE: Drain plug location may vary, depending

on the application.

A—Oil Filter Element

PLUS-50 is a trademark of Deere & Company. OILSCAN is a trademark of Deere & Company. OILSCAN PLUS is a trademark of Deere & Company.

Oil Pan Drain Plug

Continued on next page OURGP12,0000078 -19-31OCT06-1/3

30-1

RG4881 —UN—29NOV88

100915

PN=63

Lubrication & Maintenance — 250 Hours/6 Months

4. Turn filter element (A) counterclockwise using a suitable filter wrench to remove. Discard oil filter element.

NOTE: Depending on engine application, oil filter may

be located on either side of the engine.

5. Remove oil filter packing and clean filter mounting pad.

IMPORTANT: Filtration of oils is critical to

proper lubrication. Always change filter regularly. Use filter meeting John Deere performance specifications.

6. Oil new packing and install new filter element. Hand tighten element according to values printed on filter element. If values are not provided, tighten element approximately 3/4 — 1-1/4 turn after packing contacts filter housing. DO NOT overtighten filter element.

7. Install oil pan drain plug with O-ring or copper washer. If copper washer is used, install with raised center against plug. If O-ring or washer is damaged, replace it.

8. Tighten drain plug to specifications.

RG7961A —UN—22JAN99

Removing Oil Filter Element

A—Oil Filter Element

Specification

Oil Pan Drain Plug With Copper

Washer—Torque............................................................. 70 N·m (52 lb ft)

Oil Pan Drain Plug With

O-Ring—Torque............................................................. 50 N·m (37 lb ft)

OURGP12,0000078 -19-31OCT06-2/3

9. Fill engine crankcase with correct John Deere engine oil through rocker arm cover opening (B) or either side oil filler (C) depending on engine application. (See DIESEL ENGINE OIL in Fuels, Lubricants, and Coolant Section for determining correct engine oil.)

To determine the correct oil fill quantity for your engine, see ENGINE CRANKCASE OIL FILL QUANTITIES in the Specifications Section of this manual.

IMPORTANT: Immediately after completing any

oil change, crank engine for 30 seconds without permitting engine to start. This will help insure adequate lubrication to engine components before engine starts.

NOTE: Crankcase oil capacity may vary slightly. ALWAYS

fill crankcase to full mark or within crosshatch on dipstick, whichever is present. DO NOT overfill.

10. Start engine and run to check for possible leaks.

11. Stop engine and check oil level after 10 minutes. Oil level reading should be within crosshatch of dipstick.

B—Rocker Arm Cover Oil Filler C—Side Oil Filler

RG8025A —UN—19JUN00

Rocker Arm Cover Oil Filler

RG8054B —UN—19JUN00

Side Oil Filler

OURGP12,0000078 -19-31OCT06-3/3

30-2

100915

PN=64

Lubrication & Maintenance — 250 Hours/6 Months

Checking Engine Mounts

Engine mounting is the responsibility of the vehicle or generator manufacturer. Follow manufacturer's guidelines for mounting specifications.

IMPORTANT: Use only Grade SAE 8 or higher grade

of hardware for engine mounting.

Servicing Battery

CAUTION: Battery gas can explode. Keep sparks

and flames away from batteries. Use a flashlight to check battery electrolyte level.

Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.

Always remove grounded NEGATIVE (–) battery clamp first and replace it last.

WARNING: Battery posts, terminals, and related

accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.

1. On regular batteries, check electrolyte level. Fill each cell to bottom of filler neck with distilled water.

NOTE: Low-maintenance or maintenance-free batteries

should require little additional service. However, electrolyte level can be checked by cutting the center section of decal on dash-line, and removing cell plugs. If necessary, add clean, soft water to bring level to bottom of filler neck.

2. Keep batteries clean by wiping them with a damp cloth. Keep all connections clean and tight. Remove

1. Check the engine mounting bracket, vibration isolators, and mounting bolts on support frame and engine block for tightness. Tighten as necessary.

2. Inspect overall condition of vibration isolators, if equipped. Replace isolators if rubber has deteriorated or mounts have collapsed, as necessary.

DPSG,RG34710,111 -19-07JAN02-1/1

TS204 —UN—15APR13

Exploding Battery

any corrosion, and wash terminals with a solution of 1 part baking soda and 4 parts water. Tighten all connections securely.

NOTE: Coat battery terminals and connectors

with a mixture of petroleum jelly and baking soda to retard corrosion.

3. Keep battery fully charged, especially during cold weather. If a battery charger is used, turn charger off before connecting charger to battery(ies). Attach POSITIVE (+) battery charger lead to POSITIVE (+) battery post. Then attach NEGATIVE (–) battery charger lead to a good ground.

Continued on next page RG,RG34710,5568 -19-27JUL06-1/2

30-3

100915

PN=65

Lubrication & Maintenance — 250 Hours/6 Months

CAUTION: Sulfuric acid in battery electrolyte is

poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.

Avoid the hazard by:

1. Filling batteries in a well-ventilated area.

2. Wearing eye protection and rubber gloves.

3. Avoiding breathing fumes when electrolyte is added.

4. Avoiding spilling or dripping electrolyte.

5. Use proper jump start procedure.

If you spill acid on yourself:

1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize the acid.

3. Flush your eyes with water for 10–15 minutes. Get medical attention immediately.

If acid is swallowed:

1. Drink large amounts of water or milk.

2. Then drink milk of magnesia, beaten eggs, or vegetable oil.

3. Get medical attention immediately.

In freezing weather, run engine at least 30 minutes to assure thorough mixing after adding water to battery.

If necessary to replace battery(ies), replacements must meet or exceed the following recommended capacities at

-18°C (0°F):

Specification

12 Volt Standard Duty Starter—Cold Cranking

Amps.................................................................................................. 640

12 Volt Heavy Duty Starter—Cold Cranking

Amps.................................................................................................. 800

TS203 —UN—23AUG88

Sulfuric Acid

24 Volt Standard Duty Starter—Cold Cranking

Amps.................................................................................................. 570

RG,RG34710,5568 -19-27JUL06-2/2

30-4

100915

PN=66

Lubrication & Maintenance — 250 Hours/6 Months

Manual Belt Tensioner Adjustment

NOTE: Two types of manual tensioners shown.

NOTE: Inspect belts for cracks, fraying, or stretched-out

areas. Replace if necessary.

As a reference check, twist belt in the middle of a 254—305 mm (10—12 in.) span with two fingers. A properly tensioned belt will turn 75—85 degrees. If belt turns more, it needs to be tightened. If belt turns less, it needs to be loosened.

NOTE: If timing gear cover or alternator bracket interfere

with installation/centering of belt tension gauge (A), install gauge with face toward engine.

1. Install JDG1341 Belt Tension Gauge (A) on belt, halfway between pulleys as shown. (JDG1341 Belt Tension Gauge available from local John Deere Dealer or Distributor.)

2. Loosen cap screws (B) and (C).

3. Slide alternator or tensioner bracket (D) in slot by hand to remove all excess slack in belt.

IMPORTANT: Do not pry against alternator rear frame.

4. Stretch belt by prying outward on alternator front frame or tensioner bracket. Observing tension gauge, stretch the belt until specified tension is achieved.

Specification

New Belt—Tension................................ 470—650 N (105—145 lb-force)

Used Belt—Tension................................. 400—580 N (90—130 lb-force)

5. Tighten cap screws (B) and (C).

NOTE: After ten minutes run-in, new belts are considered

used. Belt tension must then be rechecked per used belt specifications.

Check Belt Tension

Adjust Belt Tension

A—Belt Tension Gauge B—Cap Screw

C—Cap Screw D—Tensioner Bracket

6. Run engine for ten minutes and immediately re-check belt tension per used belt specification above.

7. Reset belt tension as necessary.

OURGP11,0000008 -19-24JUN04-1/1

RG10556 —UN—21DEC99

RG10557 —UN—21DEC99

30-5

100915

PN=67

Lubrication & Maintenance — 250 Hours/6 Months

Manual Belt Tensioner Adjustment Using Belt Tension Tool (Alternate Method For Engines Without Auxiliary Drive)

NOTE: The JDG1520 Belt Tension Tool may not be

compatible with all alternators. In that case, use the preceding method for belt tensioning.

NOTE: Inspect belts for cracks, fraying, or stretched-out

areas. Replace if necessary.

1. Loosen upper (A) and lower (B) alternator bracket cap screws. Lower cap screw must remain tight enough to prevent excessive alternator play but allow alternator to pivot by hand.

2. Insert JDG1520 Belt Tension Tool (C) behind belt (D) and over alternator mounting screw.

A—Upper Alternator Bracket

Cap Screw

B—Lower Alternator Bracket

Cap Screw

C—JDG1520 Belt Tension Tool D—Belt

RG11812 —UN—31OCT01

Alternator Bracket and Cap Screws

RG11813 —UN—31OCT01

Belt Tension Tool

Continued on next page OURGP11,0000009 -19-24JUN04-1/2

30-6

100915

PN=68

Lubrication & Maintenance — 250 Hours/6 Months

3. Place torque wrench (C) on belt tensioning tool (B) at 90° to tool. Pivot alternator (A) until desired torque is achieved according to specification using the following table.

Specification

New Belt—Tension................................ 470—650 N (105—145 lb-force)

Used Belt—Tension................................. 400—580 N (90—130 lb-force)

JDG1520 Belt Tensioning Tool Torque Table

Desired Belt Tension

N (lb-force)

445 (100) 108 (90)

489 (110) 115 (85)

534 (120) 122 (90)

623 (140) 135 (100)

Applied Torque On Tool

N·m (lb-ft)

4. While holding tension with torque wrench (B), scribe a reference mark (D) on alternator in line with notch (E) on upper alternator bracket.

5. Continue to hold tension with torque wrench and tighten upper alternator bracket cap screw.

6. Check position of reference mark to see if alternator moved while tightening. If alternator moved, loosen upper alternator bracket cap screw and repeat the tension adjustment procedure.

RG11814 —UN—31OCT01

Belt Tension Tool and Torque Wrench

7. Remove belt tension tool and tighten lower alternator bracket cap screw.

A—Alternator B—Belt Tensioning Tool C—Torque Wrench

D—Reference Mark E—Alternator Upper Bracket

Notch

RG11815 —UN—31OCT01

Scribe Reference Mark

OURGP11,0000009 -19-24JUN04-2/2

30-7

100915

PN=69

Lubrication & Maintenance — 500 Hours/12 Months

Cleaning Crankcase Vent Tube

If you operate the engine in dusty conditions, clean the tube at shorter intervals.

1. Remove and clean crankcase vent tube (A).

2. Install the vent tube. Be sure the O-ring fits correctly in the rocker arm cover for elbow adapter. Tighten hose clamp securely.

A—Crankcase Vent Tube

Checking Air Intake System

IMPORTANT: The air intake system must not leak.

Any leak, no matter how small, may result in internal engine damage due to abrasive dirt and dust entering the intake system.

1. Inspect all intake hoses (piping) for cracks. Replace as necessary.

RG8017A —UN—19JUN00

Crankcase Vent Tube

RG,RG34710,5574 -19-08JAN02-1/1

2. Check clamps (A) on piping which connect the air cleaner, engine and, if present, turbocharger. Tighten clamps as necessary. This will help prevent dirt from entering the air intake system through loose connections causing internal engine damage.

3. If engine has a rubber dust unloader valve (B), inspect the valve on bottom of air cleaner for cracks or plugging. Replace as necessary.

IMPORTANT: ALWAYS REPLACE primary air

cleaner element when air restriction indicator shows a vacuum of 625 mm (25 in.) H

is torn, or visibly dirty.

4. Test air restriction indicator (C) for proper operation. Replace indicator as necessary.

IMPORTANT: If not equipped with air restriction

indicator, replace air cleaner elements at 500 Hours or 12 Months, whichever occurs first.

Unloader Valve and Air Restriction Indicator

A—Clamps B—Dust Unloader Valve

RG4689 —UN—20DEC88

Check Clamps

RG7332B —UN—22JAN99

C—Air Restriction Indicator

RG,RG34710,5575 -19-07JAN02-1/1

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Lubrication & Maintenance — 500 Hours/12 Months

Replacing Fuel Filter Element (Single Filter)

CAUTION: Escaping fluid under pressure can

penetrate the skin causing serious injury. Relieve pressure before disconnecting fuel or other lines. Tighten all connections before applying pressure. Keep hands and body away from pinholes and nozzles which eject fluids under high pressure. Use a piece of cardboard or paper to search for leaks. Do not use your hand.

If any fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result. Doctors unfamiliar with this type of injury may call the Deere & Company Medical Department in Moline, Illinois, or other knowledgeable medical source.

1. Close fuel shut-off valve, if equipped.

2. Thoroughly clean fuel filter assembly and surrounding area.

3. Loosen drain plug (C) and drain fuel into a suitable container.

X9811 —UN—23AUG88

High-Pressure Fluids

NOTE: Lifting up on retaining ring as it is rotated helps

to get it past raised locators.

4. Firmly grasp the retaining ring (A) and rotate it clockwise 1/4 turn (when viewed from top). Remove ring with filter element (B).

5. Inspect filter mounting base for cleanliness. Clean as required.

NOTE: Raised locators on fuel filter canister must

be indexed properly with slots in mounting base for correct installation.

6. Install new filter element onto mounting base. Be sure element is properly indexed and firmly seated on base. It may be necessary to rotate filter for correct alignment.

7. Align keys on filter element with slots in filter base.

8. Install retaining ring onto mounting base making certain dust seal is in place on filter base. Hand tighten

Fuel Filter

A—Retaining Ring B—Filter Element

C—Drain Plug D—Bleed Plug

ring (about 1/3 turn) until it “snaps” into the detent. DO NOT overtighten retaining ring.

NOTE: The proper installation is indicated when a "click"

is heard and a release of the retaining ring is felt.

A plug is provided with the new element for plugging the used element.

9. Open fuel shut-off valve and bleed the fuel system. (See BLEEDING FUEL SYSTEM in Service As Required Section.) Tighten bleed plug (D).

OURGP11,000000A -19-24JUN04-1/1

RG7721 —UN—15JAN99

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Replacing Fuel Filter Elements (Dual Filters)

CAUTION: Escaping fluid under pressure can

1. Close fuel shut-off valve, if equipped.

2. Thoroughly clean fuel filter assemblies and surrounding area.

NOTE: Perform the following steps on each fuel filter.

X9811 —UN—23AUG88

High-Pressure Fluids

3. Loosen drain plug (C) and drain fuel into a suitable container.

NOTE: Lifting up on retaining ring as it is rotated helps

to get it past raised locators.

4. Firmly grasp the retaining ring (A) and rotate it clockwise 1/4 turn (when viewed from top). Remove ring with filter element (B).

5. Inspect filter mounting base for cleanliness. Clean as required.

6. On primary filter with water separator, remove filter element from water separator bowl. Drain and clean separator bowl. Dry with compressed air. Install water separator bowl onto new element. Tighten securely.

NOTE: Raised locators on fuel filter canister must

be indexed properly with slots in mounting base for correct installation.

7. Install new filter element onto mounting base. Be sure element is properly indexed and firmly seated on base. It may be necessary to rotate filter for correct alignment.

8. Align keys on filter element with slots in filter base.

Dual Fuel Filters (Final Filter at Left, Primary Filter with Bowl at Right)

A—Retaining Ring B—Filter Element

C—Drain Plug D—Bleed Plug

9. Install retaining ring onto mounting base making certain dust seal is in place on filter base. Hand tighten ring (about 1/3 turn) until it “snaps” into the detent. DO NOT overtighten retaining ring.

NOTE: The proper installation is indicated when a "click"

is heard and a release of the retaining ring is felt.

A plug is provided with the new element for plugging the used element.

10. Open fuel shut-off valve and bleed the fuel system. (See BLEEDING FUEL SYSTEM in Service As Required Section.) Tighten bleed plug (D).

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Checking Belt Tensioner Spring Tension and Belt Wear (Automatic Tensioner)

Belt drive systems equipped with automatic (spring) belt tensioners cannot be adjusted or repaired. The automatic belt tensioner is designed to maintain proper belt tension over the life of the belt. If tensioner spring tension is not within specification, replace tensioner assembly.

Checking Belt Wear

The belt tensioner is designed to operate within the limit of arm movement provided by the cast stops (A and B) when correct belt length and geometry is used.

Visually inspect cast stops (A and B) on belt tensioner assembly.

If the tensioner stop on swing arm (A) is hitting the fixed stop (B), check mounting brackets (alternator, belt tensioner, idler pulley, etc.) and the belt length. Replace belt as needed (see REPLACING FAN AND ALTERNATOR BELTS in Service As Required Section).

RG8098 —UN—18NOV97

Cast Stops

A—Cast Stops B—Cast Stop

Continued on next page OURGP12,000004A -19-28JUL04-1/2

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Lubrication & Maintenance — 500 Hours/12 Months

Checking Tensioner Spring Tension

A belt tension gauge will not give an accurate measure of the belt tension when automatic spring tensioner is used. Measure tensioner spring tension using a torque wrench and procedure outlined below:

NOTE: Later engines have a 12.7 mm (1/2 in.) square

drive hole in tensioner, so no socket drive is required.

1. Release tension on belt using a breaker bar and socket (if required) on tension arm. Remove belt from pulleys.

2. Release tension on tension arm and remove breaker bar.

3. Put a mark (A) on swing arm of tensioner as shown.

4. Measure 21 mm (0.83 in.) from (A) and put a mark (B) on tensioner mounting base.

5. Install torque wrench (C) so that it is aligned with center of pulley and tensioner. Rotate the swing arm with the torque wrench until marks (A and B) are aligned.

6. Record torque wrench measurement and compare with specification below. Replace tensioner assembly as required.

Specification

Spring Tension—Torque.......................................18-22 N·m (13-16 lb-ft)

RG7977 —UN—14NOV97

Marks on Tensioner

RG12054 —UN—08JAN02

Align Marks

NOTE: Threads on earlier belt tensioner roller cap

screw are LEFT-HAND threads.

A—Mark On Swing Arm B—Mark On Tensioner

Mounting Base

C—Torque Wrench

RG12065 —UN—28JAN02

Align Torque Wrench With Pulley And Tensioner

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Checking Engine Speeds

Observe tachometer (A) reading on the instrument panel to verify engine speeds while running engine. (Refer to Specifications section later in this manual for engine speed specifications.) If engine speeds need adjustment, contact your engine dealer or distributor.

A—Tachometer

RG11299A —UN—17AUG00

Check Engine Speed On Tachometer

OURGP11,000000B -19-24JUN04-1/1

Checking Engine Electrical Ground Connections

Keep all engine ground connections clean and tight to prevent electrical arcing which can damage electronic components.

Checking Cooling System

CAUTION: Explosive release of fluids from

pressurized cooling system can cause serious burns.

Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

IMPORTANT: Air must be expelled from cooling

system when system is refilled. Loosen temperature sending unit fitting at rear of cylinder head or plug in thermostat housing to allow air to escape when filling system. Retighten fitting or plug when all the air has been expelled.

1. Visually check entire cooling system for leaks. Tighten all clamps securely.

OUOD002,0000169 -19-08OCT01-1/1

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High-Pressure Fluids

2. Thoroughly inspect all cooling system hoses for hard, flimsy, or cracked condition. Replace hoses if any of the above conditions are found.

RG,RG34710,5580 -19-20MAY96-1/1

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Replenishing Supplemental Coolant Additives (SCAs) Between Coolant Changes

Radiator Coolant Check

IMPORTANT: Do not add supplemental coolant

additives when the cooling system is drained and refilled with John Deere COOL-GARD®

NOTE: If system is to be filled with coolant that does not

contain SCAs, the coolant must be precharged. Determine the total system capacity and premix with 3% John Deere Coolant Conditioner.

Through time and use, the concentration of coolant additives is gradually depleted during engine operation. Periodic replenishment of inhibitors is required, even when John Deere COOL-GARD® is used. The cooling system must be recharged with additional supplemental coolant additives available in the form of liquid coolant conditioner.

Maintaining the correct coolant conditioner concentration (SCAs) and freeze point is essential in your cooling system to protect against rust, liner pitting and corrosion, and freeze-ups due to incorrect coolant dilution.

John Deere LIQUID COOLANT CONDITIONER is recommended as a supplemental coolant additive in John Deere engines.

DO NOT mix one brand of SCA with a different brand.

Test the coolant solution every 500 hours or 12 months of operation using either John Deere coolant test strips or a COOLSCAN® analysis. If a COOLSCAN® analysis is not

COOL-GARD is a registered trademark of Deere & Company COOLSCAN is a registered trademark of Deere & Company

RG6261 —UN—08DEC97

JT07298 Coolant/Battery Tester

available, recharge the system per instructions printed on label of John Deere Liquid Coolant Conditioner.

IMPORTANT: ALWAYS maintain coolant at correct

level and concentration. DO NOT operate engine without coolant even for a few minutes.

If frequent coolant makeup is required, the glycol concentration should be checked with JTO7298 Coolant/Battery Tester to ensure that the desired freeze point is maintained. Follow manufacturer's instructions provided with Coolant/Battery Tester.

Add the manufacturer's recommended concentration of supplemental coolant additive. DO NOT add more than the recommended amount.

The use of non-recommended supplemental coolant additives may result in additive drop-out and gelation of the coolant.

If other coolants are used, consult the coolant supplier and follow the manufacturer's recommendation for use of supplemental coolant additives.

See DIESEL ENGINE COOLANTS AND SUPPLEMENTAL ADDITIVE INFORMATION for proper mixing of coolant ingredients before adding to the cooling system.

DPSG,OUOD002,1921 -19-07JAN02-1/1

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Testing Diesel Engine Coolant

Maintaining adequate concentrations of glycol and inhibiting additives in the coolant is critical to protect the engine and cooling system against freezing, corrosion, and cylinder liner erosion and pitting.

Test the coolant solution at intervals of 12 months or less and whenever excessive coolant is lost through leaks or overheating.

Coolant Test Strips

Coolant test strips are available from your John Deere dealer. These test strips provide a simple, effective method to check the freeze point and additive levels of your engine coolant.

When Using John Deere COOL-GARD II

John Deere COOL-GARD II Premix™ , COOL-GARD II PG Premix and COOL-GARD II Concentrate are maintenance free coolants for up to six years or 6000 hours of operation, provided that the cooling system is topped off using only John Deere COOL-GARD II Premix or COOL-GARD II PG premix. Test the coolant condition annually with coolant test strips designed for use with John Deere COOL-GARD II coolants. If the test strip chart indicates that additive is required, add John Deere COOL-GARD II Coolant Extender as directed.

COOL-GARD is a trademark of Deere & Company

Add only the recommended concentration of John Deere COOL-GARD II Coolant Extender. DO NOT add more than the recommended amount.

When Using Nitrite-Containing Coolants

Compare the test strip results to the supplemental coolant additive (SCA) chart to determine the amount of inhibiting additives in your coolant and whether more John Deere Liquid Coolant Conditioner should be added.

Add only the recommended concentration of John Deere Liquid Coolant Conditioner. DO NOT add more than the recommended amount.

Coolant Analysis

For a more thorough evaluation of your coolant, perform a coolant analysis. The coolant analysis can provide critical data such as freezing point, antifreeze level, pH, alkalinity, nitrite content (cavitation control additive), molybdate content (rust inhibitor additive), silicate content, corrosion metals, and visual assessment.

Contact your John Deere dealer for more information on coolant analysis.

DX,COOL9 -19-11APR11-1/1

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Pressure Testing Cooling System

Test Radiator Cap

RG6557 —UN—20JAN93

RG6558 —UN—20JAN93

Test Cooling System

CAUTION: Explosive release of fluids from

pressurized cooling system can cause serious burns.

Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

Test Radiator Cap

1. Remove radiator cap and attach to D05104ST Tester as shown.

2. Pressurize cap to specification listed. Gauge should hold pressure for 10 seconds within the normal range if cap is acceptable.

If gauge does not hold pressure, replace radiator cap.

Specification

Radiator Cap Holding Pressure (Not Opening For 10

Seconds)—Pressure..........................70 kPa (0.7 bar) (10 psi) minimum

3. Remove the cap from gauge, turn it 180°, and retest cap. This will verify that the first measurement was accurate.

Test Cooling System

NOTE: Engine should be warmed up to test

overall cooling system.

1. Allow engine to cool, then carefully remove radiator cap.

2. Fill radiator with coolant to the normal operating level.

IMPORTANT: DO NOT apply excessive pressure

to cooling system, doing so may damage radiator and hoses.

3. Connect gauge and adapter to radiator filler neck. Pressurize cooling system to specification listed for radiator cap.

4. With pressure applied, check all cooling system hose connections, radiator, and overall engine for leaks.

If leakage is detected, correct as necessary and pressure test system again.

If no leakage is detected, but the gauge indicated a drop in pressure, coolant may be leaking internally within the system or at the block-to-head gasket. Have your engine distributor or servicing dealer correct this problem immediately.

RG,RG34710,5586 -19-07JAN02-1/1

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Adjusting Variable Speed (Droop) on Generator Set Engines

Stanadyne Mechanical Injection Pumps Only

1. Warm engine to normal operating temperature.

2. When necessary, disconnect throttle linkage or cable.

3. Adjust slow idle (C) and adjust fast idle (B) speed when necessary.

4. Run engine at fast idle, then apply load until reaching rated speed.

5. Check power. Adjust with the screw (A) if needed.

6. Remove load from engine.

7. Again check and adjust fast idle if screw (A) has been turned.

8. Repeat procedure until both the engine power and the fast idle speed are correct.

RG12066 —UN—29JAN02

Droop Adjustment Screw

9. Reinstall throttle linkage if previously removed.

A—Adjustment Screw B—Fast Idle Adjustment

Continued on next page RG,RG34710,5583 -19-28JAN02-1/2

C—Slow Idle Adjustment

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DENSO In-Line Injection Pumps Only

1. Check for specified no-load (frequency). If governor regulation is within 5–7% range, no adjustment is necessary.

2. If governor regulation is above 7% or below 5%, stop engine and remove cap nuts from adjusting screws before making adjustments.

3. Remove droop adjusting screw access plug (B, shown removed) from top of governor housing.

4. Back out slow idle (adjusting) screw (D) and bumper screw. Pull back on throttle lever (F, toward rear of governor housing) by hand until the droop adjusting screw (C) inside housing can be adjusted through the access plug hole.

5. Screw the droop screw in (clockwise), counting the turns until screw bottoms out. Then, return screw to original setting.

NOTE: A noticeable click will occur at each 1/4 turn of

droop adjusting screw. One click clockwise will increase no-load speed approximately 10 rpm, counterclockwise will reduce speed by 10 rpm.

6. Screw in the droop screw (clockwise) no more than 1/2 turn (two clicks) at a time to reduce governor droop. Turn counterclockwise no more than two clicks at a time to increase governor droop (to reduce governor sensitivity).

7. Replace access plug in top of governor housing. Start engine, apply full (100%) load, and readjust high idle adjusting screw until 1500 rpm is obtained at the specified power.

8. Screw in idle (bumper) spring until engine speed increases 5–10 rpm.

9. Repeat steps 4 through 7 until governor regulation is within the 5–7% range.

DENSO In-Line Injection Pump

A—Fast Idle (Stop) Screw B—Droop Adjusting Screw

Access Plug Location C—Droop Adjusting Screw D—Slow Idle (Adjusting) Screw

E—Idle (Bumper) Spring F— Throttle Lever G—Mechanical Shutoff Lever

Delphi (Lucas) Injection Pumps Only

See your authorized Delphi (Lucas) Repair Station for speed droop adjustment. This service requires that an internal pump adjustment be made.

RG5752 —UN—03NOV97

10. Replace all cap nuts onto adjusting screws and tighten lock nuts securely.

40-2

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Checking Crankshaft Vibration Damper (6-Cylinder Engine Only)

1. Remove belts (shown removed).

2. Grasp vibration damper with both hands and attempt to turn it in both directions. If rotation is felt, damper is defective and should be replaced.

IMPORTANT: The vibration damper assembly is not

repairable and should be replaced every 4500 hours or 60 months, whichever occurs first.

3. Check vibration damper radial runout by positioning a dial indicator (A) so probe contacts damper outer diameter.

4. With engine at operating temperature, rotate crankshaft using either JDE83 or JD81-1 Flywheel Turning Tool.

5. Note dial indicator reading. If runout exceeds specifications given below, replace vibration damper.

Specification

Vibration Damper—Maximum

Radial Runout............................................................ 1.50 mm (0.060 in.)

RG8018 —UN—15JAN99

Grasp Vibration Damper

RG7508 —UN—23NOV97

Check Runout

RG,RG34710,5585 -19-16JAN02-1/1

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Flushing and Refilling Cooling System

CAUTION: Explosive release of fluids from

pressurized cooling system can cause serious burns.

Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

NOTE: When John Deere COOL-GARD is used, the

drain interval is 3000 hours or 36 months. The drain interval may be extended to 5000 hours or 60 months of operation, provided that the

coolant is tested annually AND additives are replenished, as needed, by adding a supplemental coolant additive (SCA).

If COOL-GARD is not used, the flushing interval is 2000 hours or 24 months of operation.

Drain old coolant, flush the entire cooling system, test thermostats, and fill with recommended clean coolant per the following procedure.

1. Pressure test entire cooling system and pressure cap if not previously done. (See PRESSURE TESTING COOLING SYSTEM, in the Lubrication and Maintenance/500 Hour/12 Month Section.)

2. Slowly open the engine cooling system filler cap or radiator cap (A) to relieve pressure and allow coolant to drain faster.

TS281 —UN—15APR13

High-Pressure Fluids

RG12833 —UN—13FEB03

Radiator Cap

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Lubrication & Maintenance — 2000 Hours/24 Months

3. Open engine block drain valve (A) on left side of engine. Drain all coolant from engine block.

NOTE: These engines use several different oil filter

adapters. Use either drain plug (B) or (C) to drain coolant, whichever is more accessible for the oil filter adapter on your engine.

4. Open radiator drain valve. Drain all coolant from radiator.

5. Remove thermostats at this time, if not previously done. Install cover (without thermostats) using old gasket and tighten cap screws to 47 N·m (35 lb-ft).

6. Test thermostat opening temperature. (See Inspecting Thermostats And Testing Opening Temperature in Service As Required Section.)

7. Close all drain valves after coolant has drained.

CAUTION: Do not run engine longer than

10 minutes. Doing so may cause engine to overheat which may cause burns when radiator water is draining.

8. Fill the cooling system with clean water. Run the engine about 10 minutes to stir up possible rust or sediment.

9. Stop engine, pull off lower radiator hose and remove radiator cap. Immediately drain the water from system before rust and sediment settle.

10. After draining water, close drain valves. Reinstall radiator cap and radiator hose and clamp. Fill the cooling system with clean water and a heavy duty cooling system cleaner such as Fleetguard® RESTORE™ and RESTORE PLUS™. Follow manufacturer's directions on label.

11. After cleaning the cooling system, drain cleaner and fill with water to flush the system. Run the engine about 10 minutes, remove radiator cap and pull off lower radiator hose to drain out flushing water.

12. Close all drain valves on engine and radiator. Reinstall radiator hose and tighten clamps securely. Install thermostats using a new gasket. (See TESTING THERMOSTATS OPENING TEMPERATURE later in this section.)

IMPORTANT: Air must be expelled from cooling

system when system is refilled. Loosen

Fleetguard is a trademark of Cummins Engine Company, Inc. RESTORE is a trademark of Fleetguard. RESTORE PLUS is a trademark of Fleetguard.

Engine Block Drain Valve

A—Engine Block Drain Valve B—Engine Block Drain Plug

C—Engine Block Drain Plug

temperature sending unit fitting at rear of cylinder head or plug in thermostat housing to allow air to escape when filling system. Retighten fitting or plug after filling cooling system.

NOTE: Coolant capacity may vary depending

on application.

13. Add coolant to radiator until coolant touches bottom of filler neck. (See specification for capacity.) Install radiator cap.

Specification

4.5 L Engine— Coolant

Capacity..................................................................................8.5 L (9 qt)

6.8 L Engine—Coolant

Capacity.............................................................................. 11.3 L (12 qt)

14. Run engine until it reaches operating temperature. This mixes the solution uniformly and circulates it through the entire system. The normal engine coolant temperature range is 82°—94°C (180° — 202°F).

15. After running engine, check coolant level and entire cooling system for leaks.

16. Inspect the fan belt for wear and check belt tension. (See Checking Belt Tensioner Spring Tension and Belt Wear in Lubrication and Maintenance 500 Hour/12 Month section.

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Testing Thermostats Opening Temperature

To Remove Thermostat(s)

NOTE: On some engines, the coolant manifold/thermostat

housing is an integral part of the cylinder head.

CAUTION: Explosive release of fluids from

pressurized cooling system can cause serious burns. DO NOT drain coolant until it has cooled below operating temperature. Always loosen radiator pressure cap or drain valve slowly to relieve pressure.

1. Visually inspect area around thermostat housing for leaks.

2. Remove radiator pressure cap and partially drain cooling system.

3. Remove thermostat cover-to-water pump tube (A) and seal.

A—Cover-To-Coolant Pump

Tube

TS281 —UN—15APR13

High Pressure Fluids

4. Remove thermostat cover (B) with gasket.

5. Remove thermostat(s)

6. Remove and discard all gasket material. Clean gasket surfaces.

7. Clean and check cover for cracks or damage.

B—Thermostat Cover

RG8115A —UN—15JAN98

Thermostat Cover-to-Water Pump Tube

DPSG,RG34710,112 -19-07JAN02-1/5

RG7921A —UN—13NOV97

Thermostat Cover

Continued on next page DPSG,RG34710,112 -19-07JAN02-2/5

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Testing Thermostats Opening Temperature

1. Remove thermostat(s).

2. Visually inspect thermostat(s) for corrosion or damage. If dual thermostats, replace as a matched set as necessary.

CAUTION: DO NOT allow thermostat or

thermometer to rest against the side or bottom of container when heating water. Either may rupture if overheated.

3. Suspend thermostat and a thermometer in a container of water.

4. Stir the water as it heats. Observe opening action of thermostat and compare temperatures with the specification given in chart below.

NOTE: Due to varying tolerances of different suppliers,

initial opening and full open temperatures may vary slightly from specified temperatures.

THERMOSTAT TEST SPECIFICATIONS

Rating

71°C (160°F) 69—72°C (156—162°F) 84°C (182°F)

77°C (170°F) 74—78°C (166—172°F) 89°C (192°F)

82°C (180°F) 80—84°C (175—182°F) 94°C (202°F)

89°C (192°F) 86—90°C (187—194°F) 101°C (214°F)

90°C (195°F) 89—93°C (192—199°F) 103°C (218°F)

92°C (197°F) 89—93°C (193—200°F) 105°C (221°F)

96°C (205°F) 94—97°C (201—207°F) 100°C (213°F)

99°C (210°F) 96—100°C (205—212°F) 111°C (232°F)

Initial Opening (Range) Full Open

(Nominal)

RG5971 —UN—23NOV97

Testing Thermostat Opening Temperature

5. Remove thermostat and observe its closing action as it cools. In ambient air the thermostat should close completely. Closing action should be smooth and slow.

6. Replace any defective thermostat. On a dual thermostat engine, replace both thermostats.

Continued on next page DPSG,RG34710,112 -19-07JAN02-3/5

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Lubrication & Maintenance — 2000 Hours/24 Months

To Install Thermostats

IMPORTANT: Install manifold gasket so that smaller

(round) holes are at lower left and upper right corners of manifold (matching studs A).

1. Clean all gasket material from thermostat cover and housing mounting surfaces.

2. Using guide studs (A) to keep gasket in place, install a new gasket on cylinder head.

3. Install thermostat(s) with jiggle wire facing up in the 12 o'clock position.

4. Using a screwdriver to hold thermostat(s) in place, install thermostat(s) and water manifold/thermostat cover.

5. Tighten cover cap screws to 70 N·m (52 lb-ft).

6. Lubricate new O-ring with PT507 Multi-Purpose Grease. Install seal (B) in thermostat cover.

A—Guide Studs B—Seal

7. Install coolant manifold/thermostat cover-to-coolant pump tube (C). Tighten clamps.

8. If not already done, fill cooling system and check for leaks.

IMPORTANT: Air must be expelled from cooling

system when filling. Loosen temperature sending unit fitting at rear of cylinder head or plug in thermostat housing to allow air to escape when filling system. Tighten fitting or plug when all air has been expelled.

C—Cover-To-Coolant Pump

Tube

RG7614A —UN—06NOV97

Installing Thermostat Cover

RG7921B —UN—13NOV97

Thermostat Cover Seal

DPSG,RG34710,112 -19-07JAN02-4/5

RG8115B —UN—15JAN98

Cover-To-Coolant Pump Tube

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PN=86

Lubrication & Maintenance — 2000 Hours/24 Months

Check and Adjust Valve Clearance

CAUTION: To prevent accidental starting of engine

while performing valve adjustments, always disconnect NEGATIVE (—) battery terminal.

IMPORTANT: Valve clearance MUST BE checked

and adjusted with engine COLD.

1. Remove rocker arm cover and crankcase ventilator tube.

IMPORTANT: Visually inspect contact surfaces of

valve tips and rocker arm wear pads. Check all parts for excessive wear, breakage, or cracks. Replace parts that show visible damage.

Rocker arms that exhibit excessive valve clearance should be inspected more thoroughly to identify damaged parts.

2. Remove plastic plugs or cover plate from engine timing/rotation hole (A) and timing pin hole (B).

NOTE: Some engines are equipped with flywheel

housings which do not allow use of an engine flywheel rotation tool. These engines may be rotated from front nose of engine, using JDG966 Crankshaft Front/Rear Rotation Adapter.

3. Using JDE83 or JD81-1 Flywheel Turning Tool, rotate engine flywheel in running direction (clockwise viewed from front) until No. 1 cylinder is at TDC compression stroke. Insert JDG1571 or JDE81-4 Timing Pin in flywheel.

Flywheel Housing Timing Holes

A—Timing/Rotation Hole

B—Timing Pin Hole

4. With engine lock-pinned at TDC of No. 1 piston's compression stroke, check valve clearance to following specifications. (Use sequence for 4-cylinder or 6-cylinder engines as outlined on next page.)

Specification

Intake Valve Clearance For Checking (Rocker Arm-to-Valve Tip) (Engine

Cold)—Clearance.............................................................0.31—0.38 mm

(0.012—0.015 in.) Exhaust Valve Clearance For Checking (Rocker Arm-to-Valve Tip) (Engine

Cold)—Clearance.............................................................0.41—0.48 mm

(0.016—0.019 in.)

RG7408 —UN—06AUG96

If No.1 cylinder rocker arms are loose, the engine is at No. 1 TDC compression.

If No. 1 cylinder rocker arms are not loose, rotate engine one full revolution (360°) to No. 1 TDC compression.

Continued on next page DPSG,RG41165,137 -19-16JAN02-1/4

40-9

100915

PN=87

Lubrication & Maintenance — 2000 Hours/24 Months

5. If valves need adjusting, use the appropriate valve clearance adjustment procedure on the next page and adjust to specifications below. Loosen the jam nut (A) on rocker arm adjusting screw. Turn adjusting screw until feeler gauge slips with a slight drag. Hold the adjusting screw from turning with screwdriver and tighten jam nut to specifications. Recheck clearance again after tightening jam nut. Readjust clearance as necessary.

Specification

Intake Valve Clearance For Adjusting (Rocker Arm-to-Valve Tip) (Engine

Cold)—Clearance...................................................... 0.36 mm (0.014 in.)

Exhaust Valve Clearance For Adjusting (Rocker Arm-to-Valve Tip) (Engine

Cold)—Clearance...................................................... 0.46 mm (0.018 in.)

Rocker Arm Adjusting

Screw Jam Nut—Torque................................................. 27 N·m (20 lb-ft)

6. Replace rocker arm cover and crankcase ventilator tube.

RG7409 —UN—06AUG96

Adjusting Valves

A—Adjusting Screw Jam Nut

DPSG,RG41165,137 -19-16JAN02-2/4

4-Cylinder Engine:

NOTE: Firing order is 1-3-4-2.

1. Using JDE81-4 Timing Pin, lock No. 1 piston at TDC compression stroke (B).

2. Adjust valve clearance on No. 1 and 3 exhaust valves and No. 1 and 2 intake valves.

3. Turn crankshaft 360°. Lock No. 4 piston at TDC compression stroke (C).

4. Adjust valve clearance on No. 2 and 4 exhaust valves and No. 3 and 4 intake valves.

A—Front of Engine B—No. 1 Piston TDC

Compression

C—No. 4 Piston TDC

Compression

E—Exhaust Valve I— Intake Valve

RG4776 —UN—31OCT97

4-Cylinder Engine Valve Adjustment

Continued on next page DPSG,RG41165,137 -19-16JAN02-3/4

40-10

100915

PN=88

Lubrication & Maintenance — 2000 Hours/24 Months

6-Cylinder Engine:

NOTE: Firing order is 1-5-3-6-2-4.

1. Lock No. 1 piston at TDC compression stroke (B).

2. Adjust valve clearance on No. 1, 3 and 5 exhaust valves and No. 1, 2, and 4 intake valves.

3. Turn crankshaft 360°. Lock No. 6 piston at TDC compression stroke (C).

4. Adjust valve clearance on No. 2, 4 and 6 exhaust valves and No. 3, 5, and 6 intake valves.

A—Front of Engine B—No. 1 Piston TDC

Compression

C—No. 6 Piston TDC

Compression

E—Exhaust Valve I— Intake Valve

RG4777 —UN—31OCT97

6-Cylinder Engine Valve Adjustment

DPSG,RG41165,137 -19-16JAN02-4/4

40-11

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PN=89

Service as Required

Additional Service Information

This is not a detailed service manual. If you want more detailed service information, use the form in the back of this manual to order a component technical manual.

Do Not Modify Fuel System

IMPORTANT: Modification or alteration of the injection

pump (arrow), the injection pump timing, or the fuel injectors in ways not recommended by the manufacturer will terminate the warranty obligation to the purchaser.

In addition, tampering with fuel system which alters emission-related equipment on engines may result in fines or other penalties, per EPA regulations or other local emission laws.

Do not attempt to service injection pump or fuel injectors yourself. Special training and special tools are required. (See your authorized servicing dealer or engine distributor.)

RG4624 —UN—15DEC88

Component Technical Manual

RG,RG34710,5591 -19-20MAY96-1/1

RG8022A —UN—19JUN00

Fuel Injection Pump

Never steam clean or pour cold water on an injection pump while it is still warm. To do so may cause seizure of pump parts.

OURGP12,000004D -19-03AUG04-1/1

45-1

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PN=90

Adding Coolant

CAUTION: Explosive release of fluids from

pressurized cooling system can cause serious burns.

Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

Service as Required

IMPORTANT: Never pour cold liquid into a hot

engine, as it may crack cylinder head or block. DO NOT operate engine without coolant for even a few minutes.

John Deere TY15161 Cooling System Sealer may be added to the radiator to stop leaks. DO NOT use any other stop-leak additives in the system.

Air must be expelled from cooling system when coolant is added.

1. Loosen temperature sending unit fitting at rear of cylinder head or plug in side of thermostat housing to allow air to escape when filling system.

IMPORTANT: When adding coolant to the system,

use the appropriate coolant solution. ( See ENGINE COOLANT SPECIFICATIONS in Fuels, Lubricants, and Coolant Section for mixing of coolant ingredients before adding to cooling system.)

Do not overfill cooling system. A pressurized system needs space for heat expansion without overflowing at top of radiator.

2. Remove radiator cap (A) and fill until coolant level touches bottom of radiator filler neck.

3. Tighten plugs and fittings when air has been expelled from system.

TS281 —UN—15APR13

High-Pressure Fluids

RG12833 —UN—13FEB03

Radiator Filler Cap

A—Radiator Filler Cap

4. Run engine until it reaches operating temperature.

45-2

OURGP12,0000049 -19-22JUL04-1/1

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PN=91

Service as Required

Pre-Start Cleaning Guide

IMPORTANT: Before cleaning machine, allow ample

time for hot surfaces to cool.

IMPORTANT: Do not direct high-pressure spray from

hose output directly at or close to electrical connections and sensors.

Rigorous cleaning as needed is recommended. Clean more frequently during heavy machine use, and when weather conditions are dry.

Check enclosed areas daily. Clean the engine and

•

other enclosed areas of equipment to remove debris and any buildup of oil and grease. Keep the engine and engine compartment free of combustible material. Check for debris buildup daily on and around intake

•

systems, exhaust systems, and intercooler piping systems. Verify that there are no holes or leaks in intake or exhaust systems. Do not allow debris to build up near hot exhaust components. Verify that hot exhaust components are cleaned as often as environmental conditions require. Inspect cooling system daily to determine whether

•

cooling system needs cleaning. Visible buildup of residue that blocks airflow may degrade machine performance and requires more frequent cleaning depending on environmental conditions.

Inspect difficult to observe areas daily as conditions

•

may require additional cleaning care to remove debris. Check for oil and fuel leaks daily. Replace or repair any

•

sources of leaks, including gaskets, seals, breather tubes, fittings, and fluid lines.

Maintenance and Service Reminders

Keep surfaces free of grease and oil.

•

Clean up after hydraulic and other fluid leaks.

•

Fuel Lines — Check for leaks, cracks, and kinks that

•

require service before use. Fuel Pumps — Check fittings, especially compression

•

ring couplings, for cracks and leaks. Fuel Injectors — Check pressure and return lines for

•

signs of leaks. When servicing fuel filter or draining water separator,

•

avoid fuel spills. Immediately clean up any fuel spill. Handle transmission and power steering fluids with

•

care. Immediately clean up any spills, especially around fill points. Check for transmission case venting system seepage,

•

transmission case leakage, power steering cylinder leakage, or power steering line leakage. Check for loose electrical connectors, damaged wiring,

•

corrosion, and poor connections.

ZE59858,0000009 -19-20MAY13-1/1

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PN=92

Service as Required

Replacing Single Stage Air Cleaner

IMPORTANT: ALWAYS REPLACE air cleaner when air

restriction indicator shows a vacuum of 625 mm (25 in.) H

NOTE: This procedure applies to John Deere single stage

air cleaner kits. Refer to manufacturers' instructions for servicing air cleaners not supplied by John Deere.

1. If equipped, loosen body clamp.

O, is torn, or visibly dirty.

2. Loosen clamp around outlet neck (A).

3. Remove air cleaner.

4. Install new filter so that overlap (B) of air cleaner outlet neck and engine intake pipe is to specification below.

Specification

Air Cleaner Neck to

Engine Intake—Overlap.................................................... 38 mm (1.5 in)

5. Tighten neck clamp (A) to specification below.

Specification

Air Cleaner Neck

Clamp—Torque........................................................... 6.8 N·m (60 lb-in.)

IMPORTANT: Do NOT overtighten body clamp.

Overtightening may cause crushing of air cleaner body. Tighten body clamp only until snug.

6. If equipped, tighten body clamp until snug.

IMPORTANT: Whenever the air cleaner has been

serviced or removed, ALWAYS fully depress the air restriction indicator reset button (if equipped) to assure accurate readings.

RG11319A —UN—06SEP00

Single Stage Air Filter

RG11320 —UN—07SEP00

Installation of Single Stage Air Cleaner

A—Outlet Neck Clamp B—Filter to Engine Overlap

7. If equipped, fully depress air restriction indicator reset button and release to reset indicator.

RG,RG34710,5594 -19-07JAN02-1/1

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PN=93

Service as Required

Replacing Axial Seal Air Cleaner Filter Element

IMPORTANT: ALWAYS REPLACE primary air

cleaner element when air restriction indicator shows a vacuum of 625 mm (25 in.) H is torn, or visibly dirty.

NOTE: This procedure applies to John Deere 2-stage

axial seal air cleaner kits. Refer to manufacturers' instructions for servicing air cleaners not supplied by John Deere.

1. Remove wing nut and remove canister cover shown in small illustration inset.

2. Remove wing nut (A) and remove primary element (B) from canister.

3. Thoroughly clean all dirt from inside canister.

NOTE: Some engines may have a dust unloader valve

IMPORTANT: Remove secondary (safety) element (E)

ONLY for replacement. DO NOT attempt to clean, wash, or reuse secondary element. Replacement of secondary element is usually necessary ONLY when primary element has a hole in it.

RG4686 —UN—20DEC88

Wing Nut and Primary Element

RG4687 —UN—20DEC88

Dust Unloader Valve

4. To replace secondary element, remove retaining nut (D) and secondary element (E). Immediately replace secondary element with new element to prevent dust from entering air intake system.

5. Install new primary element and tighten wing nut securely. Install cover assembly and tighten retaining wing nut securely.

IMPORTANT: Whenever the air cleaner has been

serviced or had cover removed, ALWAYS fully depress the air restriction indicator reset button (if equipped) to assure accurate readings.

6. If equipped, fully depress air restriction indicator reset button and release to reset indicator.

Retaining Nut and Secondary Element

A—Wing Nut B—Primary Element C—Dust Unloader Valve

RG11068 —UN—26JUN00

D—Retaining Nut E—Secondary Element

RG41165,000008A -19-12NOV01-1/1

45-5

100915

PN=94

Service as Required

Replacing Radial Seal Air Cleaner Filter Element

IMPORTANT: ALWAYS REPLACE primary air

cleaner element when air restriction indicator shows a vacuum of 625 mm (25 in.) H is torn, or visibly dirty.

NOTE: This procedure applies to John Deere 2-stage

radial seal air cleaner kits. Refer to manufacturers' instructions for servicing air cleaners not supplied by John Deere.

1. Unlatch and remove dust cap/cover (A) of air cleaner.

2. Move end of filter (B) back and forth gently to break seal.

3. Pull filter (B) off outlet tube and out of housing.

4. Thoroughly clean all dirt from inside housing and from outlet bore.

IMPORTANT: Remove secondary (safety) element (C)

ONLY for replacement. DO NOT attempt to clean, wash, or reuse secondary element. Replacement of secondary element is usually necessary ONLY when primary element has a hole in it.

5. To replace secondary element (C), pull filter element out gently. Immediately replace secondary element with new element to prevent dust from entering air intake system.

RG11321A —UN—08SEP00

Dust Cap/Cover

RG11322A —UN—08SEP00

Primary Filter Element

6. Install new primary filter element. Apply pressure by hand at outer rim of filter.

IMPORTANT: Do NOT use latches on cover to force

filter into air cleaner. Using cover to force filter will damage cleaner housing.

7. Close housing with dust unloader valve aimed down and latch latches.

IMPORTANT: Whenever the air cleaner has been

serviced or cover has been removed, ALWAYS fully depress the air restriction indicator reset button (if equipped) to assure accurate readings.

8. If equipped, fully depress air restriction indicator reset button and release to reset indicator.

Secondary Filter Element

A—Dust Cap/Cover B—Primary Filter Element

RG11327A —UN—08SEP00

C—Secondary Filter Element

RG41165,000008B -19-07OCT10-1/1

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100915

PN=95

Service as Required

Replacing Fan and Alternator Belts

Refer to CHECKING BELT TENSIONER SPRING TENSION AND BELT WEAR in Lubrication and Maintenance/250 Hour/6 Month Section for additional information on the belt tensioner.

1. Inspect belts for cracks, fraying, or stretched out areas. Replace if necessary.

2. To replace belt with automatic tensioner, release tension on belt using a breaker bar and socket (if required) on tension arm.

To replace belt with manual tensioner, release tension at belt tensioner (See MANUAL BELT TENSIONER ADJUSTMENT in Lubrication and Maintenance/250 Hour/6 Month Section.)

3. Remove poly-vee belt from pulleys and discard belt.

4. Install new belt, making sure belt is correctly seated in all pulley grooves. Refer to belt routing at right for your application.

5. Apply tension to belt with tensioner. Remove socket.

6. Start engine and check belt alignment.

*Measured from crank centerline to fan drive center.

A—Alternator CSP—Crankshaft Pulley FC—Freon (A/C) Compressor FD—Fan Drive

I— Idler Pulley T— Tensioner CP—Coolant Pump

RG11950 —UN—07NOV01

290 mm (11.4 in.) Fan Height and Lower*

RG11951 —UN—07NOV01

338 mm (13.3 in.) Fan Height and Higher Without Freon Compressor*

45-7

RG11952 —UN—07NOV01

402 mm (15.8 in.) Fan Height With Freon Compressor*

OURGP12,000004C -19-29JUL04-1/1

100915

PN=96

Service as Required

Checking Fuses In Instrument Panels

The following instructions apply to engines equipped with John Deere instrument panels.

1. On Engines With The North American Standard Instrument Panel ( —1998), check the fuse (A) between the ammeter (B) and key switch (C) located on back side of instrument panel. If defective, replace with an equivalent 25-amp fuse.

Also check the fuse (D) mounted on the bottom of the magnetic safety switch. If defective, install an equivalent 14-amp fuse.

2. On later (1999— ) North American Standard Instrument Panels, check the fuse in fuse holder (E) on front face of instrument panel. Replace as necessary with an equivalent 14-amp fuse.

3. For VDO Instrument Panels, the fuse is located on the electronic control card inside the panel's rear access cover. Remove cover and check fuse (F). If defective, replace with a 10-amp fuse. There is a spare fuse (G) available on the card in the “SPARE” terminal.

NOTE: For main electrical system fuses, see

engine wiring diagrams later in this manual in Troubleshooting Section.

A—25 Amp Fuse B—Ammeter C—Key Switch D—14 Amp Fuse

E—Fuse Holder F— 10 Amp Fuse G—Spare Fuse

RG4493 —UN—14DEC88

North American ( —1998) Standard Instrument Panel Shown

RG4496A —UN—01JUN01

North American ( —1998) Standard Instrument Panel Shown

45-8

RG11937 —UN—17OCT01

North American (1999— ) Instrument Panel Shown

RG12067 —UN—29JAN02

VDO Instrument Panel

RG,RG34710,5601 -19-07JAN02-1/1

100915

PN=97

Service as Required

Checking Air Compressor (If Equipped)

Air compressors are offered as options with John Deere OEM engines to provide compressed air to operate air-powered devices like vehicle air brakes.

Air compressors are engine-driven piston types. They are either air cooled or cooled with engine coolant. The compressors are lubricated with engine oil. The compressor runs continuously as gear or spline driven by the auxiliary drive of the engine but has “loaded” and “unloaded” operating modes. This is controlled by the vehicle's air system (refer to vehicle technical manual for complete air system checks and services).

See your John Deere engine distributor or servicing dealer for diagnostic and troubleshooting information. If diagnosis leads to an internal fault in the compressor, replace the complete compressor as a new or remanufactured unit.

Bleeding the Fuel System

CAUTION: Escaping fluid under pressure can

If ANY fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result. Doctors unfamiliar with this type of injury may call the Deere & Company Medical Department in Moline, Illinois, or other knowledgeable medical source.

Bleed the fuel system anytime the fuel system has been opened up. This includes:

After fuel filter changes.

•

After injection pump or nozzle replacement.

•

Anytime fuel lines have been disconnected.

•

Air Compressor (Optional)

OURGP12,00001E0 -19-26FEB03-1/1

High-Pressure Fluids

After engine has run out of fuel.

•

IMPORTANT: DO NOT pressurize fuel tank to push

fuel through system, as the pressure can damage fuel injection pump seals

IMPORTANT: Do not operate the engine at high speeds

or full loads just before bleeding the fuel system as this may cause fuel injection pump failure.

Continued on next page OURGP11,000000D -19-18OCT06-1/7

RG12836 —UN—27FEB03

X9811 —UN—23AUG88

45-9

100915

PN=98

Service as Required

1. Loosen the air bleed vent screws (A) two full turns by hand on fuel filter base. (One screw with single filter option.)

A—Air Bleed Vent Screws

2. Operate supply pump primer lever (B) until fuel flow is free from air bubbles.

3. Tighten bleed plug securely, continue operating hand primer until pumping action is not felt. Push hand primer inward (toward engine) as far as it will go.

Air Bleed Vent Screws (Final Filter at Left, Primary Filter

with Separator Bowl at Right)

OURGP11,000000D -19-18OCT06-2/7

RG13544 —UN—29JUL04

4. Start engine and check for leaks.

If engine will not start, it may be necessary to bleed air from fuel system at fuel injection pump or injection nozzles as explained next.

B—Fuel Supply Pump Primer

Lever

At Fuel Injection Pump

On Stanadyne rotary pumps:

1. Slightly loosen fuel return line connector (A) at fuel injection pump.

2. Operate fuel supply pump primer lever until fuel, without air bubbles, flows from fuel return line connection.

3. Tighten return line connector to 27 N·m (20 lb-ft).

4. Primer lever is spring-loaded and will return to normal position.

A—Fuel Return Line Connector

RG8013A —UN—15JAN99

Fuel Supply Pump Primer Lever

OURGP11,000000D -19-18OCT06-3/7

RG6264 —UN—03NOV97

Stanadyne Rotary Fuel Injection Pump

Continued on next page OURGP11,000000D -19-18OCT06-4/7

45-10

100915

PN=99

Service as Required

On Lucas rotary pumps:

1. Loosen bleed screw (B) on pump cover.

NOTE: On Models DP200/201/203 Injection Pumps,

bleed screw is located on top of cover near the fuel return line.

2. Operate fuel supply pump primer lever or turn ignition switch to “ON”.

3. Wait until fuel flow is free of air bubbles. Tighten bleed screw.

4. Primer lever is spring loaded and will return to normal position.

RG7948 —UN—13NOV97

Lucas Rotary Fuel Injection Pumps

CAUTION: NEVER loosen screw (C) securing

pump head, otherwise pump damage may occur.

On DENSO and Motorpal in-line pumps:

1. On DENSO pump shown, unscrew hand primer on fuel supply pump until it can be pulled by hand.

2. Open fuel filter port plug.

3. Operate the hand primer until a smooth flow of fuel, free of bubbles, comes out of the filter plug hole.

4. Simultaneously stroke the hand primer down and close the filter port plug. This prevents air from entering the system. Tighten plug securely. DO NOT overtighten.

IMPORTANT: Be sure hand primer is all the way

down in barrel before tightening to prevent internal thread damage.

5. On DENSO pump shown, lock hand primer in position.

At Fuel Injection Nozzles

B—Bleed Screw C—Screw

OURGP11,000000D -19-18OCT06-5/7

RG8069 —UN—23NOV97

DENSO Fuel Injection Pump Shown

OURGP11,000000D -19-18OCT06-6/7

1. Move the engine speed control lever to half throttle position. On engines equipped with electronic fuel shut-off solenoid, energize solenoid.

2. Using two open-end wrenches, loosen fuel line connection at injection nozzle as shown.

3. Crank engine over with starter motor, (but do not start engine), until fuel free from bubbles flows out of loosened connection.

4. Retighten connection to 27 N·m (20 lb-ft).

5. Repeat procedure for remaining injection nozzles (if necessary) until all air has been removed from fuel system.

45-11

RG7725 —UN—08JAN97

Fuel Line Connection

If engine still will not start, see your authorized servicing dealer or engine distributor.

OURGP11,000000D -19-18OCT06-7/7

100915

PN=100

PowerTech 4045D, 6068D, 4045T, 6068T Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

Record Keeping

Engine Serial Number Plate

Record Fuel Injection Pump Model Number

Safety

Understand Signal Words

Recognize Safety Information

Replace Safety Signs

California Proposition 65 Warning

Avoid Hot Exhaust

Work In Ventilated Area

Prevent Machine Runaway

Work in Clean Area

Service Machines Safely

Use Proper Tools

Use Proper Lifting Equipment

Protect Against Noise

Install All Guards

Stay Clear of Rotating Drivelines

Service Cooling System Safely

Remove Paint Before Welding or Heating

Avoid Heating Near Pressurized Fluid Lines

Handle Fuel Safely—Avoid Fires

Handle Starting Fluid Safely

Prevent Battery Explosions

Diesel Fuel

Fuels, Lubricants, and Coolant

Supplemental Diesel Fuel Additives

Handling and Storing Diesel Fuel

Testing Diesel Fuel

Aviation (Jet) Fuels

Burner Fuels

Mixing of Lubricants

Alternative and Synthetic Lubricants

Oil Filters

Operating in Warm Temperature Climates

Disposing of Coolant

Engine Operating Guidelines

Instrument (Gauge) Panels

VDO Instrument (Gauge) Panel (Except North America)

Engine Break-In Service

Generator Set (Standby) Applications

Starting the Engine

Warming Engine

Normal Engine Operation

Avoid Excessive Engine Idling

Lubrication and Maintenance

Required Emission-Related Information

Observe Service Intervals

Use Correct Fuels, Lubricants, and Coolant

Lubrication & Maintenance — Daily

Daily Prestarting Checks

Lubrication & Maintenance — 250 Hours/6 Months

Servicing Fire Extinguisher

Changing Engine Oil and Replacing Filter

Servicing Battery

Manual Belt Tensioner Adjustment Using Belt Tension Tool (Alternate Method For Engines Without Auxiliary Drive)

Lubrication & Maintenance — 500 Hours/12 Months

Cleaning Crankcase Vent Tube

Checking Air Intake System

Replacing Fuel Filter Element (Single Filter)

Replacing Fuel Filter Elements (Dual Filters)

Checking Belt Tensioner Spring Tension and Belt Wear (Automatic Tensioner)

Checking Engine Electrical Ground Connections

Checking Cooling System

Lubrication & Maintenance — 2000 Hours/24 Months

Adjusting Variable Speed (Droop) on Generator Set Engines

Checking Crankshaft Vibration Damper (6-Cylinder Engine Only)

Testing Thermostats Opening Temperature

Service as Required

Additional Service Information

Do Not Modify Fuel System

Pre-Start Cleaning Guide

Replacing Axial Seal Air Cleaner Filter Element

Replacing Radial Seal Air Cleaner Filter Element

Replacing Fan and Alternator Belts