OPERATOR'S MANUAL
POWERTECH® 4.5 L & 6.8 L Tier II OEM
Diesel Engines
OMRG33324 Issue 01APR03
(English)
-
POWERTECH 4.5 & 6.8 L
4045 and 6068 Tier II
OEM Diesel Engines
OPERATOR’S MANUAL
POWERTECH 4.5/6.8 L Tier II OEM
Diesel Engines
OMRG33324 Issue 01APR03 (ENGLISH)
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
If this product contains a gasoline engine:
WARNING
The engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth
defects or other reproductive harm.
The State of California requires the above two warnings.
John Deere Power Systems
LITHO IN U.S.A.
Introduction
Foreword
THIS MANUAL CONTAINS INFORMATION to operate
and service the following engines:
Saran-built (France) Tier II Mechanically Controlled
Engines:
• CD4045DF270
• CD4045TF270
Saran-built (France) Tier II Electronically Controlled
Engines:
•
•
•
•
•
•
CD4045TF275 (DE10 Fuel System)
CD4045HF275 (DE10 Fuel System)
CD4045HF475 (HPCR System; 4-Valve Head)
CD6068TF275 (DE10 Fuel System)
CD6068HF275 (DE10/VP44 Fuel System)
CD6068HF475 (HPCR System; 4-Valve Head)
Torreon-built (Mexico) Tier II Mechanically Controlled
Engines:
• PE4045DF270
• PE4045TF270
Torreon-built (Mexico) Tier II Electronically Controlled
Engines:
•
•
•
•
•
•
PE4045TF275 (DE10 Fuel System)
PE4045HF275 (DE10 Fuel System)
PE4045HF475 (HPCR System; 4-Valve Head)
PE6068TF275 (DE10 Fuel System)
PE6068HF275 (DE10/VP44 Fuel System)
PE6068HF475 (HPCR System; 4-Valve Head)
READ THIS MANUAL carefully to learn how to operate
and service your engine correctly. Failure to do so
could result in personal injury or equipment damage.
THIS MANUAL SHOULD BE CONSIDERED a
permanent part of your engine and should remain with
the engine when you sell it.
MEASUREMENTS IN THIS MANUAL are given in both
metric and customary U.S. unit equivalents. Use only
correct replacement parts and fasteners. Metric and
inch fasteners may require a specific metric or inch
wrench.
WRITE ENGINE SERIAL NUMBERS and option codes
in the spaces indicated in the Record Keeping Section.
Accurately record all the numbers. Your dealer also
needs these numbers when you order parts. File the
identification numbers in a secure place off the engine.
SETTING FUEL DELIVERY beyond published factory
specifications or otherwise overpowering will result in
loss of warranty protection for this engine.
CERTAIN ENGINE ACCESSORIES such as radiator,
air cleaner, and instruments are optional equipment on
John Deere OEM Engines. These accessories may be
provided by the equipment manufacturer instead of
John Deere. This operator’s manual applies only to the
engine and those options available through the John
Deere distribution network.
IMPORTANT: This manual covers only
POWERTECH Tier II emission certified
4.5 and 6.8 L OEM engines listed.
These engines meet Tier II emission
certification standards.1 (This is for
both the U.S. EPA and European
Union Council (EU) standards.)
Engines with mechanical controls
which are non-emission certified or
Tier I emission certified (U.S. and
EU) are covered in a separate
operators manual, OMRG25204.
NOTE: This manual covers engines provided to OEM
(Outside Equipment Manufacturers). For
engines in Deere machines, refer to the
machine operator’s manual.
1
Two exceptions: The 4045HF475 and 6068HF475 for generator
applications at 1500 rpm are still emission non-certified.
OMRGOEM,IFC –19–25FEB03–1/1
040103
PN=2
Introduction
Engine Owner
John Deere Engine Owner:
Impari a conoscere chi è e dove si trova. Alla Sua
prima occasione cerchi d’incontrarlo. Egli desidera farsi
conoscere e conoscere le Sue necessità.
Don’t wait until you need warranty or other service to
meet your local John Deere Engine Distributor or
Service Dealer.
Propietario De Equipo John Deere:
Learn who he is and where he is. At your first
convenience, go meet him. He’ll want to get to know
you and to learn what your needs might be.
No espere hasta necesitar servicio de garantı́a o de
otro tipo para conocer a su Distribuidor de Motores
John Deere o al Concesionario de Servicio.
Aux Utilisateurs De Moteurs John Deere:
Entérese de quién es, y dónde está situado. Cuando
tenga un momento, vaya a visitarlo. A él le gustará
conocerlo, y saber cuáles podrı́an ser sus
necesidades.
N’attendez pas d’être obligé d’avoir recours a votre
concessionnaire John Deere ou point de service le
plus proche pour vous adresser a lui.
John Deere MotorÄgare:
Renseignez-vous des que possible pour l’identifier et
le localiser. A la premiere occasion, prenez contact
avec lui et faites-vous connaı̂tre. Il sera lui aussi
heureux de faire votre connaissance et de vous
proposer ses services le moment venu.
An Den Besitzer Des John Deere Motors:
Warten Sie nicht auf einen evt. Reparaturfall um den
nächstgelegenen John Deere Händler kennen zu
lernen.
Vänta inte med att besöka Din John Deere
återförsäljare till dess att Du behöver service eller
garanti reparation.
Bekanta Dig med var han är och vem han är. Tag
första tillfälle att besöka honom. Han vill också träffa
Dig för att få veta vad Du behöver och hur han kan
hjälpa Dig.
Machen Sie sich bei ihm bekannt und nutzen Sie sein
“Service Angebot”.
Proprietario Del Motore John Deere:
Non aspetti fino a quando ha bisogno della garanzia o
di un altro tipo di assistenza per incontrarsi con il Suo
Concessionario che fornisce l’assistenza tecnica.
DPSG,OUOE003,2736 –19–11JAN99–1/1
040103
PN=3
Introduction
RG11931
RG11932
–UN–06NOV01
–UN–06NOV01
POWERTECH 4.5 L Engines With Electronic Fuel Systems (Tier II Emission Certified)
(Two-Valve Cylinder Head Models)
4045 Engine
4045 Engine (Stanadyne DE10 Injection Pump Shown)
POWERTECH is a trademark of Deere & Company
OUOD002,0000162 –19–25FEB03–1/1
040103
PN=4
Introduction
6068 Engine (Bosch VP44 Injection Pump Shown)
POWERTECH is a trademark of Deere & Company
–UN–24OCT01
RG11934
RG11933
–UN–24OCT01
POWERTECH 6.8 L Engines With Electronic Fuel Systems (Tier II Emission Certified)
(Two-Valve Cylinder Head Models)
6068 Engine
OUOD002,0000163 –19–25FEB03–1/1
040103
PN=5
Introduction
6068HF475 Engine Shown (Level 11 Electronic Fuel System With
Denso High Pressure Common Rail)
POWERTECH is a trademark of Deere & Company
RG12200
RG12199
–UN–24MAY02
–UN–24MAY02
POWERTECH 4.5/6.8 L Engines With Electronic Fuel Systems (Tier II Emission Certified)
(Four-Valve Cylinder Head Models)
6068HF475 Shown
OUOD005,000017F –19–25FEB03–1/1
040103
PN=6
Contents
Page
Record Keeping
PowerTech Medallion . . . . . . . . . . . . . . . . . . . . .
Engine Serial Number Plate . . . . . . . . . . . . . . . .
Record Engine Serial Number . . . . . . . . . . . . . .
Engine Option Codes . . . . . . . . . . . . . . . . . . . . .
Record Fuel Injection Pump Model Number . . . .
Page
Viewing Stored Service Codes (DTC) in
Engine ECU . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Break-In Service . . . . . . . . . . . . . . . . . .
Starting the Engine. . . . . . . . . . . . . . . . . . . . . .
Normal Engine Operation . . . . . . . . . . . . . . . . .
Warming Engine. . . . . . . . . . . . . . . . . . . . . . . .
Cold Weather Operation . . . . . . . . . . . . . . . . . .
Using a Booster Battery or Charger . . . . . . . . .
Avoid Excessive Engine Idling . . . . . . . . . . . . .
Changing Engine Speeds . . . . . . . . . . . . . . . .
Stopping The Engine . . . . . . . . . . . . . . . . . . . .
Auxiliary Gear Drive Limitations . . . . . . . . . . . .
Generator Set (Standby) Applications. . . . . . . .
01-1
01-1
01-2
01-3
01-5
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-1
Fuels, Lubricants, and Coolant
Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Lubricity of Diesel Fuel . . . . . . . . . . . . . . . . . . . . 10-2
Filling Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Diesel Fuel Storage . . . . . . . . . . . . . . . . . . . . . . 10-3
Dieselscan Fuel Analysis . . . . . . . . . . . . . . . . . . 10-3
Bio-Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Handling And Storing Bio-Diesel Fuel. . . . . . . . . 10-5
Minimizing the Effect of Cold Weather on
Diesel Engines . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Diesel Engine Break-In Oil . . . . . . . . . . . . . . . . . 10-8
Diesel Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . 10-9
Mixing of Lubricants . . . . . . . . . . . . . . . . . . . . . 10-10
OILSCAN and COOLSCAN . . . . . . . . . . . . 10-10
Alternative and Synthetic Lubricants. . . . . . . . . 10-11
Lubricant Storage . . . . . . . . . . . . . . . . . . . . . . . 10-11
Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
Diesel Engine Coolant . . . . . . . . . . . . . . . . . . . 10-13
Diesel Engine Coolants, Supplemental
Additive Information . . . . . . . . . . . . . . . . . . . 10-14
Testing Diesel Engine Coolant . . . . . . . . . . . . . 10-15
Supplemental Coolant Additives . . . . . . . . . . . . 10-16
Operating in Warm Temperature Climates . . . . 10-17
Disposing of Coolant . . . . . . . . . . . . . . . . . . . . 10-17
15-16
15-17
15-20
15-22
15-23
15-24
15-26
15-27
15-28
15-30
15-31
15-31
Engine Operation- 4.5L “270” Engines
Instrument (Gauge) Panel . . . . . . . . . . . . . . . . . 16-1
Normal Engine Operation . . . . . . . . . . . . . . . . . . 16-3
Break-In Service. . . . . . . . . . . . . . . . . . . . . . . . . 16-4
Auxiliary Gear Drive Limitations . . . . . . . . . . . . . 16-5
Generator Set (Standby) Power Units. . . . . . . . . 16-6
Starting The Engine . . . . . . . . . . . . . . . . . . . . . . 16-6
Cold Weather Starting . . . . . . . . . . . . . . . . . . . . 16-7
Warming Engine. . . . . . . . . . . . . . . . . . . . . . . . . 16-9
Avoid Excessive Engine Idling . . . . . . . . . . . . . 16-10
Stopping the Engine . . . . . . . . . . . . . . . . . . . . . 16-11
Using a Booster Battery or Charger . . . . . . . . . 16-12
Lubrication and Maintenance
Observe Service Intervals. . . . . . . . . . . . . . . . . .
Use Correct Fuels, Lubricants, and Coolant . . . .
Lubrication and Maintenance Service
Interval Chart—Standard Industrial Engines . .
Lubrication and Maintenance Service
Interval Chart—Generator (Standby)
Applications . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Operation- Except 4.5L “270” Engines
Electronic Instrument (Gauge) Panel . . . . . . . . . 15-1
Using Diagnostic Gauge To Access Engine
Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-7
Using Touch Switches To Display Information . . 15-9
Changing Units of Measure (English or
Metric). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-11
Viewing Engine Configuration Data . . . . . . . . . 15-13
Viewing Active Engine Service Codes (DTC) . . 15-15
20-1
20-1
20-2
20-4
Lubrication & Maintenance/Daily
Daily Prestarting Checks . . . . . . . . . . . . . . . . . . 25-1
Lubrication & Maintenance/500 Hour/12 Month
Servicing Fire Extinguisher . . . . . . . . . . . . . . . . . 30-1
Continued on next page
All information, illustrations and specifications in this manual are based on
the latest information available at the time of publication. The right is
reserved to make changes at any time without notice.
COPYRIGHT  2003
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION Manual
Previous Editions
Copyright  2001, 2002
i
040103
PN=1
Contents
Page
Page
Checking Engine Mounts . . . . . . . . . . . . . . . . . . 30-1
Servicing Battery . . . . . . . . . . . . . . . . . . . . . . . . 30-2
Manual Belt Tensioner Adjustment . . . . . . . . . . . 30-4
Manual Belt Tensioner Adjustment Using
Belt Tension Tool (Alternate Method
For Engines Without Auxiliary Drive). . . . . . . . 30-5
Changing Engine Oil and Replacing Filter . . . . . 30-7
Cleaning Crankcase Vent Tube . . . . . . . . . . . . . 30-9
Checking Air Intake System . . . . . . . . . . . . . . . 30-10
Replacing Fuel Filter Elements . . . . . . . . . . . . . 30-11
Checking Belt Tensioner Spring Tension
and Belt Wear (Automatic Tensioner) . . . . . . 30-13
Checking Engine Electrical Ground
Connections . . . . . . . . . . . . . . . . . . . . . . . . . 30-15
Checking Cooling System. . . . . . . . . . . . . . . . . 30-15
Replenishing Supplemental Coolant
Additives (SCAs) Between Coolant
Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16
Testing Diesel Engine Coolant . . . . . . . . . . . . . 30-18
Pressure Testing Cooling System. . . . . . . . . . . 30-19
Checking and Adjusting Engine Speeds . . . . . . 30-20
Bleed the Fuel System (Engines with
Electronic Fuel Systems and Stanadyne DE10
Pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-14
Bleed the Fuel System (Engines with
Electronic Fuel Systems and Denso High
Pressure Common Rail) (4045HF475,
6068HF475) . . . . . . . . . . . . . . . . . . . . . . . . . 40-17
Bleed the Fuel System (4045DF270,
4045TF270) . . . . . . . . . . . . . . . . . . . . . . . . . 40-19
Troubleshooting
General Troubleshooting Information . . . . . . . . . 45-1
Precautions For Welding On Engines
Equipped With Electronic Engine Control Unit
(ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-2
Engine Wiring Layout (Electronic Fuel
System With Stanadyne DE10 Injection
Pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-3
Engine Wiring Layout (Electronic Fuel
System With Bosch VP44 Injection Pump) . . . 45-4
Engine Wiring Layout (Electronic Fuel
System With Denso High Pressure Common
Rail)(4045HF475,6068HF475). . . . . . . . . . . . . 45-5
Engine Wiring Diagram (Electronic
Instrument Panel) . . . . . . . . . . . . . . . . . . . . . . 45-6
Engine Wiring Diagram (Engines With
Electronic Instrument Panel) . . . . . . . . . . . . . . 45-7
Engine Troubleshooting . . . . . . . . . . . . . . . . . . . 45-8
Blink Code Method for Retrieving
Diagnostic Trouble Codes (All Except
Early VP44 Pump Engines). . . . . . . . . . . . . . 45-16
Blink Code Method for Retrieving
Diagnostic Trouble Codes (Early VP44
Pump Engines Only) . . . . . . . . . . . . . . . . . . . 45-18
Instrument Panel Method for Retrieving
Diagnostic Trouble Codes . . . . . . . . . . . . . . . 45-20
Displaying Of Diagnostic Trouble Codes
(DTCs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-21
Listing of Diagnostic Trouble Codes (DTCs)
(Engines With Electronic Fuel
Systems And Stanadyne DE10 Pump) . . . . . 45-22
Listing of Diagnostic Trouble Codes (DTCs)
(Engines With Electronic Fuel
Systems And Bosch VP44 Pump). . . . . . . . . 45-24
Listing of Diagnostic Trouble Codes (DTCs)
(Engines With Electronic Fuel
Systems And Denso High Pressure Common
Rail) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-26
Error Codes Displayed (With Diagnostic
Gauge on Electronic Panels). . . . . . . . . . . . . 45-28
Lubrication & Maint./2000 Hour/24 Month
Adjusting Variable Speed (Droop) — 4.5
L “270” Generator Set Engines Only . . . . . . . . 35-1
Checking Crankshaft Vibration Damper
(6-Cylinder Engine Only). . . . . . . . . . . . . . . . . 35-2
Flushing and Refilling Cooling System . . . . . . . . 35-3
Testing Thermostats Opening Temperature . . . . 35-6
Check and Adjust Valve Clearance (All
Engines Except 4045HF475 And
6068HF475) . . . . . . . . . . . . . . . . . . . . . . . . . . 35-9
Check and Adjust Valve Clearance
(4045HF475 And 6068HF475 Engines). . . . . 35-12
Test Glow Plugs for Continuity
(4045HF475 And 6068HF475 Engines). . . . . 35-15
Service as Required
Additional Service Information . . . . . . . . . . . . . . 40-1
Do Not Modify Fuel System . . . . . . . . . . . . . . . . 40-2
Adding Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . 40-3
Replacing Single Stage Air Cleaner . . . . . . . . . . 40-5
Replacing Axial Seal Air Cleaner Filter
Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-6
Replacing Radial Seal Air Cleaner Filter
Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-8
Replacing Fan and Alternator Belts . . . . . . . . . 40-10
Checking Fuses . . . . . . . . . . . . . . . . . . . . . . . . 40-11
Checking Air Compressors . . . . . . . . . . . . . . . . 40-11
Bleeding the Fuel System (Engines With
Electronic Fuel Systems And Bosch VP44
Pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-12
Continued on next page
ii
040103
PN=2
Contents
Page
Intermittent Fault Diagnostics (With
Electronic Controls). . . . . . . . . . . . . . . . . . . . 45-29
Storage
Engine Storage Guidelines . . . . . . . . . . . . . . . . . 50-1
Preparing Engine for Long Term Storage . . . . . . 50-2
Removing Engine from Long Term Storage . . . . 50-3
Specifications
General OEM Engine Specifications. . . . . . . . . .
Engine Power Ratings And Fuel System
Specifications . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Crankcase Oil Fill Quantities . . . . . . . . .
Unified Inch Bolt and Cap Screw Torque
Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Metric Bolt and Cap Screw Torque Values . . . . .
Lubrication and Maintenance Records
Using Lubrication and Maintenance Records . . .
Daily (Prestarting) Service . . . . . . . . . . . . . . . . .
500 Hour/12 Month Service . . . . . . . . . . . . . . . .
2000 Hour/24 Month Service . . . . . . . . . . . . . . .
Service as Required . . . . . . . . . . . . . . . . . . . . . .
55-1
55-3
55-6
55-7
55-8
60-1
60-1
60-2
60-3
60-4
Emission System Warranty
U.S. EPA Emmission Control Warranty
Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65-1
Emission Control System Certification Label. . . . 65-2
iii
040103
PN=3
Contents
iv
040103
PN=4
Record Keeping
POWERTECH Medallion
A medallion is located on the rocker arm cover which
identifies each engine as a John Deere POWERTECH
engine.
RG11609
–UN–17OCT01
RG11608
–UN–17OCT01
NOTE: Four-valve head engines also have “16V” or ”24V”
printed on their medallions. The 4045HF475 has
“16V” to denote 16 valves total while 6068HF475
has “24V” to denote 24 valves total.
POWERTECH is a trademark of Deere & Company.
RG,RG34710,5505 –19–27FEB03–1/1
Engine Serial Number Plate
“CD” = Saran, France
“PE” = Torreon, Mexico
“T0” = Dubuque, Iowa
“J0” = Rosario, Argentina
RG8007
•
•
•
•
–UN–15JAN99
Each engine has a 13-digit John Deere engine serial
number. The first two digits identify the factory that
produced the engine:
The engine’s serial number plate (A) is located on the
right-hand side of cylinder block behind the fuel filter.
13-Digit Engine Serial Number Plate
A—Serial Number Plate
RG,RG34710,5506 –19–10NOV01–1/1
01-1
040103
PN=9
Record Keeping
Record Engine Serial Number
–UN–07NOV01
Record all of the numbers and letters found on your
engine serial number plate in the spaces provided below.
RG11949
This information is very important for repair parts or
warranty information.
Engine Serial Number (B)
Saran Engine Serial Number Plate
Engine Model Number (C)
RG11948
–UN–06NOV01
Coefficient of Absorption Value (D)
(Saran Engines Only)
Torreon Engine Serial Number Plate
RG,RG34710,5507 –19–10NOV01–1/1
01-2
040103
PN=10
Record Keeping
RG11946
–UN–06NOV01
Engine Option Codes
A—Engine Base Code
In addition to the serial number plate, OEM engines
have an engine option code label affixed to the rocker
arm cover. These codes indicate which of the engine
options were installed on your engine at the factory.
When in need of parts or service, furnish your
authorized servicing dealer or engine distributor with
these numbers.
The engine option code label includes an engine base
code (A). This base code must also be recorded along
with the option codes.
The first two digits of each code identify a specific
group, such as alternators. The last two digits of each
code identify one specific option provided on your
engine, such as a 12-volt, 55-amp alternator.
NOTE: These option codes are based on the latest
information available at the time of publication.
The right is reserved to make changes at any
time without notice.
If an engine is ordered without a particular component,
the last two digits of that functional group option code
will be 99, 00, or XX. The list on the next page shows
only the first two digits of the code numbers. For future
reference such as ordering repair parts, it is important
to have these code numbers available. To ensure this
availability, enter the third and fourth digits shown on
your engine option code label in the spaces provided
on the following page.
Continued on next page
01-3
RG,RG34710,5508 –19–05MAR03–1/2
040103
PN=11
Record Keeping
NOTE: Your engine option code label may not contain
all option codes if an option has been added
after the engine left the producing factory.
An additional option code label may also be
delivered with the engine. Place this sticker or
tag, for reference, either on this page or in the
engine owner’s warranty booklet under
OPTION CODES title.
If option code label is lost or destroyed,
consult your servicing dealer or engine
distributor selling the engine for a replacement.
Option Codes
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
35
36
37
39
40
41
43
44
46
47
48
49
Description
Rocker Arm Cover
Oil Fill Inlet
Crankshaft Pulley/Damper
Flywheel Housing
Flywheel
Fuel Injection Pump
Air Inlet
Air Cleaner
Oil Pan
Coolant Pump
Thermostat Cover
Thermostat
Fan Drive
Fan Belt
Fan
Engine Coolant Heater
Radiator
Exhaust Manifold
Crankcase Ventilator System
Starter Motor
Alternator
Instrument Panel
Tachometer
Fuel Filters
Front Plate
Fuel Transfer Pump
Thermostat Housing
Oil Dipstick
Belt-Driven Front Auxiliary Drive
Starting Aid
Timing Gear Cover With Gears
Cylinder Block With Liners and Camshaft
Crankshaft and Bearings
Connecting Rods and Pistons
Valve Actuating Mechanism
Option Codes
50
51
52
53
55
56
57
59
60
62
63
64
65
66
67
68
69
71
72
74
75
76
77
78
79
81
83
84
86
87
88
95
96
97
98
99
Description
Oil Pump
Cylinder Head With Valves
Auxiliary Gear Drive
Fuel Heater
Shipping Stand
Paint Option
Coolant Pump Inlet
Oil Cooler
Add-on Auxiliary Drive Pulley
Alternator Mounting Bracket
Low Pressure Fuel Line
Exhaust Elbow
Turbocharger
Coolant Temperature Switch
Electronic Sensors (Base Engine)
Crankshaft Rear Damper
Engine Serial Number Plate
Engine Oil Bypass Filter
ECU Electronic Software Option
Air Conditioning (Freon) Compressor
Air Restriction Indicator
Pressure Switches and Sensors
Timing Gear Cover
Air Compressor
Engine Certification
Primary Fuel Filter And Water Separator
Electronic Software (Vehicle Option)
Electrical Wiring Harness
Fan Pulley
Belt Tensioner
Oil Filter
Special Equipment (Factory Installed)
Engine Installation Kit
Special Equipment (Field Installed)
Shipping (Engine Hanger Straps)
Service Only Items
Engine Base Code (See “A” on previous page.)
RG,RG34710,5508 –19–05MAR03–2/2
01-4
040103
PN=12
Record Keeping
Record Fuel Injection Pump Model Number
Record the fuel injection pump model and serial
information found on the serial number plate (A).
Model No.
RPM
–UN–06NOV01
Manufacturer’s No.
Serial No.
RG11943
A—Serial Number Plate
Record Injection Pump Serial Number
RG,RG34710,5511 –19–10NOV01–1/1
01-5
040103
PN=13
Safety
Recognize Safety Information
–UN–07DEC88
This is a safety-alert symbol. When you see this symbol
on your machine or in this manual, be alert to the
potential for personal injury.
T81389
Follow recommended precautions and safe operating
practices.
Safety-alert symbol
DX,ALERT –19–29SEP98–1/1
Understand Signal Words
A signal word—DANGER, WARNING, or CAUTION—is
used with the safety-alert symbol. DANGER identifies the
most serious hazards.
TS187
–19–30SEP88
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.
Signal Words
DX,SIGNAL –19–03MAR93–1/1
05-1
040103
PN=14
Safety
Follow Safety Instructions
–UN–23AUG88
Carefully read all safety messages in this manual and on
your machine safety signs. Keep safety signs in good
condition. Replace missing or damaged safety signs. Be
sure new equipment components and repair parts include
the current safety signs. Replacement safety signs are
available from your John Deere dealer.
TS201
Learn how to operate the machine and how to use
controls properly. Do not let anyone operate without
instruction.
Safety Messages
Keep your machine in proper working condition.
Unauthorized modifications to the machine may impair the
function and/or safety and affect machine life.
If you do not understand any part of this manual and need
assistance, contact your John Deere dealer.
DX,READ –19–03MAR93–1/1
Replace Safety Signs
TS201
–UN–23AUG88
Replace missing or damaged safety signs. See the
machine operator’s manual for correct safety sign
placement.
DX,SIGNS1 –19–04JUN90–1/1
05-2
040103
PN=15
Safety
Prevent Bypass Starting
Avoid possible injury or death from engine runaway.
–UN–28FEB89
Do not start engine by shorting across starter terminal.
Engine will start with PTO engaged if normal circuitry is
bypassed.
RG5419
Start engine only from operator’s station with PTO
disengaged or in neutral.
Prevent Bypass Starting
RG,RG34710,7508 –19–30JUN97–1/1
Handle Fuel Safely—Avoid Fires
Handle fuel with care: it is highly flammable. Do not refuel
the machine while smoking or when near open flame or
sparks.
–UN–23AUG88
Always stop engine before refueling machine. Fill fuel tank
outdoors.
TS202
Prevent fires by keeping machine clean of accumulated
trash, grease, and debris. Always clean up spilled fuel.
Avoid Fires
DX,FIRE1 –19–03MAR93–1/1
05-3
040103
PN=16
Safety
Prepare for Emergencies
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
TS291
–UN–23AUG88
Keep emergency numbers for doctors, ambulance service,
hospital, and fire department near your telephone.
First Aid Kit
DX,FIRE2 –19–03MAR93–1/1
Handle Starting Fluid Safely
Starting fluid is highly flammable.
–UN–18MAR92
Keep all sparks and flame away when using it. Keep
starting fluid away from batteries and cables.
TS1356
To prevent accidental discharge when storing the
pressurized can, keep the cap on the container, and store
in a cool, protected location.
Do not incinerate or puncture a starting fluid container.
Store Safely
DX,FIRE3 –19–16APR92–1/1
05-4
040103
PN=17
Safety
Handle Fluids Safely—Avoid Fires
When you work around fuel, do not smoke or work near
heaters or other fire hazards.
–UN–23AUG88
Store flammable fluids away from fire hazards. Do not
incinerate or puncture pressurized containers.
Make sure machine is clean of trash, grease, and debris.
TS227
Do not store oily rags; they can ignite and burn
spontaneously.
Avoid Fires
DX,FLAME –19–29SEP98–1/1
Service Engines Safely
–UN–23AUG88
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.
TS228
Remove rings and other jewelry to prevent electrical
shorts and entanglement in moving parts.
Moving Parts
OURGP12,00001DA –19–25FEB03–1/1
05-5
040103
PN=18
Safety
Wear Protective Clothing
Wear close fitting clothing and safety equipment
appropriate to the job.
–UN–23AUG88
Prolonged exposure to loud noise can cause impairment
or loss of hearing.
Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones
while operating machine.
TS206
Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.
Protective Clothing
DX,WEAR –19–10SEP90–1/1
Protect Against Noise
Prolonged exposure to loud noise can cause impairment
or loss of hearing.
TS207
–UN–23AUG88
Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.
Noise Exposure
DX,NOISE –19–03MAR93–1/1
05-6
040103
PN=19
Safety
Handle Chemical Products Safely
–UN–26NOV90
Direct exposure to hazardous chemicals can cause
serious injury. Potentially hazardous chemicals used with
John Deere equipment include such items as lubricants,
coolants, paints, and adhesives.
Check the MSDS before you start any job using a
hazardous chemical. That way you will know exactly what
the risks are and how to do the job safely. Then follow
procedures and recommended equipment.
TS1132
A Material Safety Data Sheet (MSDS) provides specific
details on chemical products: physical and health hazards,
safety procedures, and emergency response techniques.
Material Safety Data Sheet
(See your John Deere dealer for MSDS’s on chemical
products used with John Deere equipment.)
DX,MSDS,NA –19–03MAR93–1/1
Stay Clear of Rotating Drivelines
Entanglement in rotating driveline can cause serious injury
or death.
–UN–22AUG95
Keep tractor master shield and driveline shields in place
at all times. Make sure rotating shields turn freely.
TS1644
Wear close fitting clothing. Stop the engine and be sure
PTO driveline is stopped before making adjustments,
connections, or cleaning out PTO driven equipment.
Rotating Drivelines
DX,PTO –19–12SEP95–1/1
05-7
040103
PN=20
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.
–UN–23AUG88
On self-propelled equipment, disconnect battery ground
cable (-) before making adjustments on electrical systems
or welding on machine.
TS218
On towed implements, disconnect wiring harnesses from
tractor before servicing electrical system components or
welding on machine.
Keep Area Clean
DX,SERV –19–17FEB99–1/1
Work In Ventilated Area
–UN–23AUG88
Engine exhaust fumes can cause sickness or death. If it is
necessary to run an engine in an enclosed area, remove
the exhaust fumes from the area with an exhaust pipe
extension.
TS220
If you do not have an exhaust pipe extension, open the
doors and get outside air into the area
Engine exhaust fumes
DX,AIR –19–17FEB99–1/1
05-8
040103
PN=21
Safety
Avoid High-Pressure Fluids
Escaping fluid under pressure can penetrate the skin
causing serious injury.
–UN–23AUG88
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.
If an accident occurs, see a doctor immediately. Any fluid
injected into the skin must be surgically removed within a
few hours or gangrene may result. Doctors unfamiliar with
this type of injury should reference a knowledgeable
medical source. Such information is available from Deere
& Company Medical Department in Moline, Illinois, U.S.A.
X9811
Search for leaks with a piece of cardboard. Protect hands
and body from high pressure fluids.
High-Pressure Fluids
DX,FLUID –19–03MAR93–1/1
Avoid Heating Near Pressurized Fluid Lines
TS953
–UN–15MAY90
Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to
yourself and bystanders. Do not heat by welding,
soldering, or using a torch near pressurized fluid lines or
other flammable materials. Pressurized lines can be
accidentally cut when heat goes beyond the immediate
flame area.
Flammable Spray
DX,TORCH –19–03MAR93–1/1
05-9
040103
PN=22
Safety
Do Not Open High-Pressure Fuel System
–UN–18MAR92
High-pressure fluid remaining in fuel lines can cause
serious injury. Do not disconnect or attempt repair of fuel
lines, sensors, or any other components between the
high-pressure fuel pump and nozzles on engines with
High Pressure Common Rail (HPCR) fuel system.
TS1343
Only technicians familiar with this type of system can
perform repairs. (See your John Deere dealer.)
High-Pressure Fuel Lines
DX,WW,HPCR1 –19–07JAN03–1/1
Remove Paint Before Welding or Heating
Avoid potentially toxic fumes and dust.
–UN–23AUG88
Hazardous fumes can be generated when paint is heated
by welding, soldering, or using a torch.
• 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.
TS220
Remove paint before heating:
Toxic Fumes
Do not use a chlorinated solvent in areas where welding
will take place.
Do all work in an area that is well ventilated to carry toxic
fumes and dust away.
Dispose of paint and solvent properly.
DX,PAINT –19–24JUL02–1/1
05-10
040103
PN=23
Safety
Service Cooling System Safely
Explosive release of fluids from pressurized cooling
system can cause serious burns.
TS281
–UN–23AUG88
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.
Cooling System
DX,RCAP –19–04JUN90–1/1
Install Fan Guards
Rotating cooling system fans can cause serious injury.
TS677
–UN–21SEP89
Keep fan guards in place at all times during engine
operation. Wear close fitting clothes. Stop the engine and
be sure fan is stopped before making adjustments or
connections, or cleaning near the front of the engine.
Rotating Fan
OUOD006,000009D –19–04DEC02–1/1
05-11
040103
PN=24
Safety
Avoid Hot Parts
TS271
External dry exhaust parts become very hot during
operation. Turbochargers may reach temperatures as high
as 500°C (932°F) under full load, and naturally aspired
exhaust manifolds may reach 600°C (1112°F) under full
load. This may ignite paper, cloth or wooden materials.
Parts on engines that have been at full load and reduced
to no load idle will maintain approximately 150°C (302°F).
–UN–23AUG88
Avoid skin contact with exhaust manifolds, turbochargers
and mufflers. Keep flammable materials clear of the
turbocharger.
Hot Surface
OUOD006,000009E –19–04DEC02–1/1
Avoid Harmful Asbestos Dust
Avoid breathing dust that may be generated when
handling components containing asbestos fibers. Inhaled
asbestos fibers may cause lung cancer.
TS220
–UN–23AUG88
Components in products that may contain asbestos fibers
are brake pads, brake band and lining assemblies, clutch
plates, and some gaskets. The asbestos used in these
components is usually found in a resin or sealed in some
way. Normal handling is not hazardous as long as
airborne dust containing asbestos is not generated.
Asbestos Dust
Avoid creating dust. Never use compressed air for
cleaning. Avoid brushing or grinding material containing
asbestos. When servicing, wear an approved respirator. A
special vacuum cleaner is recommended to clean
asbestos. If not available, apply a mist of oil or water on
the material containing asbestos.
Keep bystanders away from the area.
DX,DUST –19–15MAR91–1/1
05-12
040103
PN=25
Safety
Prevent Battery Explosions
Keep sparks, lighted matches, and open flame away from
the top of battery. Battery gas can explode.
–UN–23AUG88
Never check battery charge by placing a metal object
across the posts. Use a volt-meter or hydrometer.
TS204
Do not charge a frozen battery; it may explode. Warm
battery to 16°C (60°F).
Battery Explosions
DX,SPARKS –19–03MAR93–1/1
05-13
040103
PN=26
Safety
Handling Batteries Safely
–UN–23AUG88
CAUTION: Battery gas can explode. Keep
sparks and flames away from batteries. Use a
flashlight to check battery electrolyte level.
TS204
Never check battery charge by placing a metal
object across the posts. Use a voltmeter or
hydrometer.
Always remove grounded (—) battery clamp
first and replace it last.
Explosion
CAUTION: Sulfuric acid in battery electrolyte is
poisonous. It is strong enough to burn skin, eat
holes in clothing, and cause blindness if
splashed into eyes.
Avoid the hazard by:
1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is
added.
4. Avoiding spilling or dripping electrolyte.
5. Using proper jump start procedure.
If you spill acid on yourself:
–UN–23AUG88
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.
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.
TS203
If acid is swallowed:
Acid
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.
DPSG,OUO1004,2758 –19–11MAY00–1/1
05-14
040103
PN=27
Safety
Protect Against High Pressure Spray
TS1343
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.
–UN–18MAR92
Spray from high pressure nozzles can penetrate the skin
and cause serious injury. Keep spray from contacting
hands or body.
High Pressure Spray
DX,SPRAY –19–16APR92–1/1
Dispose of Waste Properly
–UN–26NOV90
Improperly disposing of waste can threaten the
environment and ecology. Potentially harmful waste used
with John Deere equipment include such items as oil, fuel,
coolant, brake fluid, filters, and batteries.
Do not pour waste onto the ground, down a drain, or into
any water source.
TS1133
Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.
Recycle Waste
Air conditioning refrigerants escaping into the air can
damage the Earth’s atmosphere. Government regulations
may require a certified air conditioning service center to
recover and recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of waste
from your local environmental or recycling center, or from
your John Deere dealer.
DX,DRAIN –19–03MAR93–1/1
05-15
040103
PN=28
Fuels, Lubricants, and Coolant
Diesel Fuel
Consult your local fuel distributor for properties of the
diesel fuel available in your area.
In general, diesel fuels are blended to satisfy the low
temperature requirements of the geographical area in
which they are marketed.
Diesel fuels specified to EN 590 or ASTM D975 are
recommended.
Required fuel properties
In all cases, the fuel must meet the following
properties:
Cetane number of 45 minimum. Cetane number
greater than 50 is preferred, especially for
temperatures below -20°C (-4°F) or elevations above
1500 m (5000 ft).
Cold Filter Plugging Point (CFPP) below the
expected low temperature OR Cloud Point at least
5°C (9°F) below the expected low temperature.
Fuel lubricity should pass a minimum load level of
3100 grams as measured by ASTM D6078 or,
maximum scar diameter of 0.45 mm as measured by
ASTM D6079.
Sulfur content:
• Diesel fuel quality and fuel sulfur content must
comply with all existing regulations for the area in
which the engine operates.
• Sulfur content less than 0.05% (500 ppm) is
preferred.
• If diesel fuel with sulfur content greater than 0.05%
(500 ppm) is used, crankcase oil service intervals
may be affected. (See recommendation for Diesel
Engine Oil.)
• DO NOT use diesel fuel with sulfur content greater
than 1.0%.
IMPORTANT: DO NOT mix used engine oil or any
other type of lubricating oil with
diesel fuel.
OUOD002,0000171 –19–18DEC01–1/1
10-1
040103
PN=29
Fuels, Lubricants, and Coolant
Lubricity of Diesel Fuel
Diesel fuel must have adequate lubricity to ensure
proper operation and durability of fuel injection system
components.
Use of low lubricity diesel fuels may also cause
accelerated wear, injection nozzle erosion or corrosion,
engine speed instability, hard starting, low power, and
engine smoke.
Diesel fuels for highway use in the United States and
Canada require sulfur content less than 0.05% (500
ppm).
Fuel lubricity should pass a minimum load level of
3100 gram as measured by the ASTM D6078 or
maximum scar diameter of 0.45 mm as measured by
ASTM D6079.
Diesel fuel in the European Union requires sulfur
content less than 0.05% (500 ppm).
ASTM D975 and EN 590 specifications do not require
fuels to pass a fuel lubricity test.
Experience shows that some low sulfur diesel fuels
may have inadequate lubricity and their use may
reduce performance in fuel injection systems due to
inadequate lubrication of injection pump components.
The lower concentration of aromatic compounds in
these fuels also adversely affects injection pump seals
and may result in leaks.
If fuel of low or unknown lubricity is used, add John
Deere PREMIUM DIESEL FUEL CONDITIONER (or
equivalent) at the specified concentration.
OUOD002,0000179 –19–18DEC01–1/1
Filling Fuel Tank
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.
TS202
DO NOT smoke while filling fuel tank or
servicing fuel system.
–UN–23AUG88
CAUTION: Handle fuel carefully. Do not fill the
fuel tank when engine is running.
Fill fuel tank at the end of each day’s operation to prevent
condensation in tank. As moist air cools, condensation
may form and freeze during cold weather.
RG,RG34710,7527 –19–30JUN97–1/1
10-2
040103
PN=30
Fuels, Lubricants, and Coolant
Diesel Fuel Storage
Store diesel fuel in plastic, aluminum, and steel
containers specially coated for diesel fuel storage.
CAUTION: Handle fuel carefully. Do not fill
the fuel tank when engine is running.
Avoid storing fuel over long periods of time. If fuel is
stored for more than a month prior to use, or there is a
slow turnover in fuel tank or supply tank, add a fuel
conditioner such as John Deere PREMIUM DIESEL
FUEL CONDITIONER or equivalent to stabilize the fuel
and prevent water condensation. John Deere
PREMIUM DIESEL FUEL CONDITIONER is available
in winter and summer formulas. Fuel conditioner also
reduces fuel gelling and controls wax separation during
cold weather.
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.
IMPORTANT: DO NOT store diesel fuel in
galvanized containers. Diesel fuel
stored in galvanized containers
reacts with zinc coating on container
to form zinc flakes. If fuel contains
water, a zinc gel will also form. The
gel and flakes will quickly plug fuel
filters, damage injection nozzles and
injection pump.
IMPORTANT: The fuel tank is vented through the
filler cap. If a new filler cap is
required, always replace with an
original vented cap.
DO NOT use brass-coated containers
for fuel storage. Brass is an alloy of
copper and zinc.
RG,RG34710,7526 –19–18DEC01–1/1
Dieselscan Fuel Analysis
DIESELSCAN is a John Deere fuel sampling program to
help you monitor the quality of your fuel source. It verifies
fuel type, cleanliness, water content, suitability for cold
weather operation, and if fuel is within ASTM
specifications. Check with your John Deere dealer for
availability of DIESELSCAN kits.
DIESELSCAN is a trademark of Deere & Company
DX,FUEL6 –19–06DEC00–1/1
10-3
040103
PN=31
Fuels, Lubricants, and Coolant
Bio-Diesel Fuel
Consult your local fuel distributor for properties of the
bio-diesel fuel available in your area.
Bio-diesel fuels may be used ONLY if the bio-diesel
fuel properties meet the latest edition of ASTM D6751,
DIN 51606 or equivalent specification.
It has been found that bio-diesel fuels may improve
lubricity in concentrations up to a 5% blend in
petroleum diesel fuel.
When using a blend of bio-diesel fuel, the engine oil
level must be checked daily when the air temperature
is -10°C (14°F) or lower. If the oil becomes diluted with
fuel, shorten oil change intervals accordingly.
IMPORTANT: Raw pressed vegetable oils are NOT
acceptable for use for fuel in any
concentration in John Deere
engines.
These oils do not burn completely,
and will cause engine failure by
leaving deposits on injectors and in
the combustion chamber.
A major environmental benefit of bio-diesel fuel is its
ability to biodegrade. This makes proper storage and
handling of bio-diesel fuel especially important. Areas
of concern include:
• Quality of new fuel
• Water content of the fuel
• Problems due to aging of the fuel
Potential problems resulting from deficiencies in the
above areas when using bio-diesel fuel in
concentrations above 5% may lead to the following
symptoms:
•
•
•
•
•
•
•
•
Power loss and deterioration of performance
Fuel leakage
Corrosion of fuel injection equipment
Coked and/or blocked injector nozzles, resulting in
engine misfire
Filter plugging
Lacquering and/or seizure of internal components
Sludge and sediments
Reduced service life of engine components
RG41183,0000046 –19–18DEC01–1/1
10-4
040103
PN=32
Fuels, Lubricants, and Coolant
Handling And Storing Bio-Diesel Fuel
CAUTION: Handle fuel carefully. Do not fill
the fuel tank when engine is running.
DO NOT smoke while you fill the fuel tank or
service the fuel system.
Fill the fuel tank at the end of each day’s operation to
prevent water condensation and freezing during cold
weather.
Keep all storage tanks as full as practicable to
minimize condensation.
Ensure that all fuel tank caps and covers are installed
properly to prevent moisture from entering.
Fuel filter may require more frequent replacement due
to premature plugging.
Check engine oil level daily prior to starting engine. A
rising oil level may indicate fuel dilution of the engine
oil.
IMPORTANT: The fuel tank is vented through the
filler cap. If a new filler cap is
required, always replace it with an
original vented cap.
When fuel is stored for an extended period or if there
is a slow turnover of fuel, add a fuel conditioner to
stabilize the fuel and prevent water condensation.
Contact your fuel supplier for recommendations.
Monitor water content of the fuel regularly.
OUOD002,0000176 –19–18DEC01–1/1
10-5
040103
PN=33
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.
IMPORTANT: Do NOT use ether when starting with
air intake heaters.
However, for effective starting and cold weather
operation, a little extra care is necessary. The
information below outlines steps that can minimize the
effect that cold weather may have on starting and
operation of your engine. See your authorized
engine distributor or servicing dealer for additional
information and local availability of cold weather aids.
Fuel Heaters
Two options are available with fuel heaters: one
location is at the inlet port of the primary fuel filter,
while the other location is at the inlet port of the final
fuel filter.
Coolant Heaters
Use Grade No. 1-D Fuel
When temperatures fall below 5°C (40°F), Grade No.
1-D fuel is best suited for cold weather operation.
Grade No. 1-D fuel has a lower cloud point and a
lower pour point.
Cloud point is the temperature at which wax will begin
to form in the fuel and this wax causes fuel filters to
plug. Pour point is the temperature at which fuel
begins to thicken and becomes more resistant to flow
through fuel pumps and lines.
NOTE: On an average, Grade No. 1-D fuel has a
lower BTU (heat content) rating than Grade
No. 2-D fuel. When using Grade No. 1-D fuel
you may notice a drop in power and fuel
efficiency, but should not experience any other
engine performance effects. Check the grade
of fuel being used before troubleshooting for
low power complaints in cold weather
operation.
Engine block heaters (coolant) are an available option
to aid cold weather starting.
Glow Plugs
Glow plugs are used to aid cold weather starting on
engines equipped with the 4 valve cylinder head (475
suffix).
IMPORTANT: Do NOT use ether when starting with
glow plugs.
Seasonal Viscosity Oil and Proper Coolant
Concentration
Use seasonal grade viscosity engine oil based on
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 later in this
section).
Air Intake Heaters
This option is available on suffix “275” engines. Air
intake heaters are located on the cylinder head.
Continued on next page
10-6
RG,RG34710,7529 –19–25FEB03–1/2
040103
PN=34
Fuels, Lubricants, and Coolant
Diesel Fuel Flow Additive
IMPORTANT: Treat fuel when outside temperature
drops below 0°C (32°F). For best
results, use with untreated fuel.
Follow all recommended instructions
on label.
Use John Deere Premium Diesel Fuel Conditioner
(Winter) or equivalent to treat fuel during the cold
weather season. This winter formulation is a
combination diesel fuel conditioner and anti-gel
additive.
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.
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 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 engine
distributor or servicing dealer.
RG,RG34710,7529 –19–25FEB03–2/2
10-7
040103
PN=35
Fuels, Lubricants, and Coolant
Diesel Engine Break-In Oil
New engines are filled at the factory with John Deere
ENGINE BREAK-IN OIL (SAE 10W-30). During the
break-in period, add John Deere ENGINE BREAK-IN
OIL as needed to maintain the specified oil level.
(Order TY22041.)
Change the oil and filter after the first 100 hours of
operation of a new or rebuilt engine.
After the break-in period, use John Deere PLUS-50
or other diesel engine oil as recommended in this
manual.
IMPORTANT: Do NOT use PLUS-50 oil or engine
oils meeting any of the following
during the first 100 hours of
operation of a new or rebuilt engine:
•
•
•
•
•
•
After engine overhaul, fill the engine with John Deere
ENGINE BREAK-IN OIL.
If John Deere ENGINE BREAK-IN OIL is not available,
use a diesel engine oil of the correct viscosity (SAE
10W-30) which meets one of the following during the
first 100 hours of operation:
API CI-4
ACEA E5
API CH-4
ACEA E4
API CG-4
ACEA E3
These oils will not allow the engine
to break-in properly.
• API Service Classification CC
• API Service Classification CD
• ACEA Specification E1
If CC, CD, or E1 oils are not available, then use
preferably CE or E2 types of oil.
PLUS-50 is a trademark of Deere & Company.
OUOD002,0000178 –19–05MAR03–1/1
10-8
040103
PN=36
Fuels, Lubricants, and Coolant
Use preferably multi-viscosity oils based on the
expected air temperature range during the period between
oil changes.
30˚C
86˚F
20˚C
68˚F
10˚C
50˚F
0˚C
32˚F
If PLUS-50 or ACEA-E4/E5 oil are not available, John
Deere TORQ-GARD SUPREME may be used, as well
as other oils meeting one or more of the following:
-10˚C
14˚F
-20˚C
-4˚F
• API Service Classification CI-4
• API Service Classification CH-4
• ACEA Specification E3
-30˚C
-22˚F
-40˚C
-40˚F
NOTE: If other than PLUS-50 or ACEA-E4/E5 oil and
the specified John Deere filter are used, the
service interval for the engine oil and filter is
reduced to 250 hours maximum.
TS1668A
NOTE: When John Deere PLUS-50 or ACEA-E4/E5 oil
and the specified John Deere filter are used, the
service interval for the engine oil and filter is 500
hours maximum.
SAE 0W-40
104˚F
SAE 10W-40
40˚C
John Deere PLUS-50 is the preferred diesel engine
oil. ACEA Specification E4 and E5 are also
recommended.
SAE 5W-30
122˚F
SAE 15W-40
50˚C
–UN–14DEC01
Diesel Engine Oil
Diesel Engine Oil
Multi-viscosity diesel engine oils are preferred.
Diesel fuel quality and sulfur content must comply with all
existing emissions regulations for the area in which the
engine operates.
If diesel fuel with sulfur content greater than 0.05% (500
ppm) is used, reduce the oil and filter change interval by
100 hours.
If diesel fuel with sulfur content greater than 0.5% (5000
ppm) is used, reduce the service interval by 50%.
Diesel fuel with sulfur content greater than 1.0% (10,000
ppm) is not recommended.
PLUS-50 is a trademark of Deere & Company.
TORQ-GARD SUPREME is a trademark of Deere & Company
OURGP12,00001DC –19–26FEB03–1/1
10-9
040103
PN=37
Fuels, Lubricants, and Coolant
Mixing of Lubricants
In general, avoid mixing different brands or types of oil.
Oil manufacturers blend additives in their oils to meet
certain specifications and performance requirements.
Consult your John Deere engine distributor or servicing
dealer to obtain specific information and
recommendations.
Mixing different oils can interfere with the proper
functioning of these additives and degrade lubricant
performance.
DX,LUBMIX –19–18MAR96–1/1
OILSCAN and COOLSCAN
–UN–15JUN89
OILSCAN, OILSCAN PLUS, COOLSCAN and
COOLSCAN PLUS are John Deere sampling programs
to help you monitor machine performance and identify
potential problems before they cause serious damage.
T6828AB
Oil and coolant samples should be taken from each
system prior to its recommended change interval.
Check with your John Deere engine distributor or
servicing dealer for the availability of OILSCAN,
OILSCAN PLUS, COOLSCAN and COOLSCAN
PLUS kits.
T6829AB
–UN–18OCT88
Sampling Programs
OILSCAN is a trademark of Deere & Company.
COOLSCAN is a trademark of Deere & Company.
OILSCAN PLUS is a trademark of Deere & Company.
COOLSCAN PLUS is a trademark of Deere & Company.
Recommended Change Interval
OUOD002,0000173 –19–25FEB03–1/1
10-10
040103
PN=38
Fuels, Lubricants, and Coolant
Alternative and Synthetic Lubricants
Conditions in certain geographical areas may require
lubricant recommendations different from those printed in
this manual.
Some John Deere brand coolants and lubricants may not
be available in your location.
Consult your John Deere dealer to obtain information and
recommendations.
Synthetic lubricants may be used if they meet the
performance requirements as shown in this manual.
The temperature limits and service intervals shown in this
manual apply to both conventional and synthetic oils.
Re-refined base stock products may be used if the
finished lubricant meets the performance requirements.
DX,ALTER –19–15JUN00–1/1
Lubricant Storage
Your equipment can operate at top efficiency only
when clean lubricants are used.
Make certain that all containers are properly marked to
identify their contents.
Use clean containers to handle all lubricants.
Properly dispose of all old containers and any residual
lubricant they may contain.
Whenever possible, store lubricants and containers in
an area protected from dust, moisture, and other
contamination. Store containers on their side to avoid
water and dirt accumulation.
DX,LUBST –19–18MAR96–1/1
10-11
040103
PN=39
Fuels, Lubricants, and Coolant
Grease
Use grease based on NLGI consistency numbers and the
expected air temperature range during the service interval.
The following greases are preferred:
• John Deere SD POLYUREA GREASE
The following greases are also recommended:
John
John
John
John
Deere
Deere
Deere
Deere
HD MOLY GREASE
HD LITHIUM COMPLEX GREASE
HD WATER RESISTANT GREASE
GREASE-GARD
–UN–30JUN99
•
•
•
•
Other greases may be used if they meet the following:
TS1667
• NLGI Performance Classification GC-LB
IMPORTANT: Some types of grease thickener are not
compatible with others. Consult your
grease supplier before mixing different
types of grease.
DX,GREA1 –19–24JAN00–1/1
10-12
040103
PN=40
Fuels, Lubricants, and Coolant
Diesel Engine Coolant
The engine cooling system is filled to provide
year-round protection against corrosion and cylinder
liner pitting, and winter freeze protection to -37°C
(-34°F).
The following engine coolant is preferred for service:
• John Deere COOL-GARD Prediluted Coolant
The following engine coolant is also recommended:
• John Deere COOL-GARD Coolant Concentrate in a
40 to 60% mixture of concentrate with quality water.
Other low silicate ethylene glycol base coolants for
heavy-duty engines may be used if they meet one of
the following specifications:
• ASTM D5345 (prediluted coolant)
• ASTM D4985 (coolant concentrate) in a 40 to 60%
mixture of concentrate with quality water
protection at lower temperatures is required, consult
your John Deere dealer for recommendations.
Water quality is important to the performance of the
cooling system. Distilled, deionized, or demineralized
water is recommended for mixing with ethylene glycol
base engine coolant concentrate.
IMPORTANT: Do not use cooling system sealing
additives or antifreeze that contains
sealing additives.
Coolant Drain Intervals
Drain the factory fill engine coolant, flush the cooling
system, and refill with new coolant after the first 3
years or 3000 hours of operation. Subsequent drain
intervals are determined by the coolant used for
service. At each interval, drain the coolant, flush the
cooling system, and refill with new coolant.
Coolants meeting these specifications require use of
supplemental coolant additives, formulated for
heavy-duty diesel engines, for protection against
corrosion and cylinder liner erosion and pitting.
When John Deere COOL-GARD is used, the drain
interval may be extended to 5 years or 5000 hours of
operation, provided that the coolant is tested annually
AND additives are replenished, as needed, by adding
a supplemental coolant additive.
A 50% mixture of ethylene glycol engine coolant in
water provides freeze protection to -37°C (-34°F). If
If COOL-GARD is not used, the drain interval is
reduced to 2 years or 2000 hours of operation.
DX,COOL3 –19–05FEB99–1/1
10-13
040103
PN=41
Fuels, Lubricants, and Coolant
Diesel Engine Coolants, Supplemental Additive Information
Engine coolants are a combination of three chemical
components: ethylene glycol (antifreeze), inhibiting
coolant additives, and quality water.
help form a protective film on cylinder liner surfaces.
This film acts as a barrier against the harmful effects
of collapsing vapor bubbles.
Coolant Specifications
Avoid Automotive-Type Coolants
Some products, including John Deere John Deere
COOL-GARD Prediluted Coolant, are fully formulated
coolants that contain all three components in their
correct concentrations. Do not add an initial charge of
supplemental coolant additives to these fully
formulated products.
Never use automotive-type coolants (such as those
meeting ASTM D3306 or ASTM D4656). These
coolants do not contain the correct additives to protect
heavy-duty diesel engines. They often contain a high
concentration of silicates and may damage the engine
or cooling system.
Some coolant concentrates, including John Deere
COOL-GARD Coolant Concentrate, contain both
ethylene glycol antifreeze and inhibiting coolant
additives. Mix these products and quality water, but do
not add an initial charge of supplemental coolant
additives.
Water Quality
Coolants meeting ASTM D5345 (prediluted coolant) or
ASTM D4985 (coolant concentrate) require an initial
charge of supplemental coolant additives.
Water quality is important to the performance of the
cooling system. Distilled, deionized, or demineralized
water is recommended for mixing with ethylene glycol
base engine coolant concentrate. All water used in the
cooling system should meet the following minimum
specifications for quality:
Replenish Coolant Additives
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. Follow the
recommendations in this manual for the use of
supplemental coolant additives.
Chlorides
<40 mg/L
Sulfates
<100 mg/L
Total Dissolved Solids
<340 mg/L
Total Hardness
<170 mg/L
pH
5.5 to 9.0
Freeze Protection
The relative concentrations of ethylene glycol and
water in the engine coolant determine its freeze
protection limit.
Why Use Supplemental Coolant Additives?
Operating without proper coolant additives will result in
increased corrosion, cylinder liner erosion and pitting,
and other damage to the engine and cooling system. A
simple mixture of ethylene glycol and water will not
give adequate protection.
Use of supplemental coolant additives reduces
corrosion, erosion, and pitting. These chemicals
reduce the number of vapor bubbles in the coolant and
Ethylene Glycol
Freeze Protection Limit
40%
-24°C (-12°F)
50%
-37°C (-34°F)
60%
-52°C (-62°F)
DO NOT use a coolant-water mixture greater than
60% ethylene glycol.
DX,COOL7 –19–24JAN00–1/1
10-14
040103
PN=42
Fuels, Lubricants, and Coolant
Testing Diesel Engine Coolant
–UN–22SEP99
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.
Coolant Test Strips
RG7297
Test the coolant solution at intervals of 12 month 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.
RG7397
–UN–05DEC97
Compare the results to the supplemental coolant additive
(SCA) chart to determine the amount of inhibiting
additives in your coolant and whether more John Deere
COOLANT CONDITIONER should be added.
COOLSCAN and COOLSCAN PLUS
For a more thorough evaluation of your coolant, perform a
COOLSCAN or COOLSCAN PLUS analysis. See your
John Deere dealer for information.
COOLSCAN is a trademark of Deere & Company
COOLSCAN PLUS is a trademark of Deere & Company.
CoolScan Bellows
OUOD002,0000174 –19–18DEC01–1/1
10-15
040103
PN=43
Fuels, Lubricants, and Coolant
Supplemental Coolant Additives
The concentration of coolant additives is gradually
depleted during engine operation. For all recommended
coolants, replenish additives between drain intervals by
adding a supplemental coolant additive every 12 months
or as determined necessary by coolant testing.
John Deere COOLANT CONDITIONER is recommended
as a supplemental coolant additive in John Deere
engines.
IMPORTANT: Only use coolant additive to replenish
the coolant. Do not use additive when
the entire system is drained and refilled
with John Deere COOL-GARD.
If other coolants are used, consult the coolant supplier
and follow the manufacturer’s recommendation for use of
supplemental coolant additives.
The use of non-recommended supplemental coolant
additives may result in additive drop-out and gelation of
the coolant.
Add the manufacturer’s recommended concentration of
supplemental coolant additive. DO NOT add more than
the recommended amount.
OUOD006,0000019 –19–11JUN02–1/1
10-16
040103
PN=44
Fuels, Lubricants, and Coolant
Operating in Warm Temperature Climates
John Deere engines are designed to operate using glycol
base engine coolants.
Always use a recommended glycol base engine coolant,
even when operating in geographical areas where freeze
protection is not required.
IMPORTANT: Water may be used as coolant in
emergency situations only.
Foaming, hot surface aluminum and
iron corrosion, scaling, and cavitation
will occur when water is used as the
coolant, even when coolant
conditioners are added.
Drain cooling system and refill with
recommended glycol base engine
coolant as soon as possible.
DX,COOL6 –19–18MAR96–1/1
Disposing of Coolant
Do not pour waste onto the ground, down a drain, or into
any water source.
TS1133
Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.
–UN–26NOV90
Improperly disposing of engine coolant can threaten the
environment and ecology.
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.
RG,RG34710,7543 –19–30JUN97–1/1
10-17
040103
PN=45
Engine Operation- Except 4.5L “270” Engines
Electronic Instrument (Gauge) Panel
The electronic instrument panel is linked to the John
Deere engine control unit (ECU). This allows the operator
to monitor engine performance as well as to diagnose any
troubles during engine operation.
IMPORTANT: Any time an electric gauge or meter
does not register correctly, replace with
a new one. Do not attempt to repair it.
All gauges are plug-in type.
Following is a brief description of the gauges and controls
on the John Deere electronic instrument panel.
NOTE: The instrument panel for your engine may vary
from the one shown, depending on the options
selected.
RG9547
–UN–14AUG00
A—Engine Oil Pressure Gauge
B—Amber “WARNING” Indicator
C—Red “STOP ENGINE” Indicator
D—Diagnostic Gauge/Hour Meter
E—Touch Switch
F—Touch Switch
G—Audible Alarm (Optional)
H—Audible Alarm Override Switch (Optional)
I—Throttle Control (Optional)
J—Dimmer Control (Optional)
K—Engine Preheater Indicator (Optional)
L—Key Start Switch
M—Override Shutdown Rocker Switch
N—High-Low Speed Select Rocker Switch
O—Bump Speed Enable Rocker Switch (Optional)
P—Speed Select Rocker Switch
Q—Fuse Holder (5-Amp Fuse)
R—Tachometer (Optional)
S—Power Meter (Percent Load) (Optional)
T—Voltmeter (Optional)
U—Engine Coolant Temperature Gauge (Optional)
Electronic Instrument Panel
DPSG,OUOD002,1571 –19–23NOV01–1/1
15-1
040103
PN=46
Engine Operation- Except 4.5L “270” Engines
Electronic Instrument (Gauge) Panel
Engine Oil Pressure Gauge
Touch Switches
The engine oil pressure gauge (A) indicates engine oil
pressure in pounds per square inch (psi). It is
connected to an audible alarm (G) to warn the
operator if oil pressure drops below the preset safe
operating pressure set for the engine.
The touch switches are used to change the display on
the window of the diagnostic gauge to access engine
performance data. Pressing the DOWN switch (E) or
UP switch (F) scrolls through various engine
parameters and diagnostic fault codes.
Amber “Warning” Indicator
Audible Alarm (Optional)
The amber “WARNING” indicator (B) signals an
abnormal condition such as low oil pressure, high
coolant temperature, low battery voltage, etc. Use the
Service Code menu of the diagnostic gauge (D) to
identify the trouble.
The audible alarm (G) sounds whenever a low oil
pressure or high coolant temperature condition exists.
Red “Stop Engine” Indicator
The red “STOP ENGINE” indicator (C) signals operator
to stop engine immediately or as soon as safely
possible. A condition exists that could cause damage
to engine.
Audible Alarm Override Switch (Optional)
The audible alarm override switch (H) can be pressed
to silence the alarm for approximately 2-1/2 minutes.
Throttle Control (Optional)
The throttle control (I) is used to control engine speed.
This control is available as part of the panel only on
engines with analog throttle.
Diagnostic Gauge/Hour Meter
Dimmer Control (Optional)
The diagnostic gauge (D) displays diagnostic trouble
codes (DTCs) as they occur. Other information on the
engine can be accessed using the touch switches (E
and F). The hour meter shows the operating hours of
the engine. Normally, the gauge will alternately flash
from the displayed parameters to the message
“SvrcCode”. (See following in this section for operating
the diagnostic gauge switches to access engine
information. Also see TROUBLESHOOTING section
for a list of diagnostic trouble codes (DTCs) and
corresponding engine problems.)
The dimmer control (J) is used to control illumination of
the instrument panel gauges.
Engine Preheater Indicator (Optional)
The engine preheater indicator (K) lights up while the
engine is being preheated for cold weather starting.
When the engine is warmed up, the light goes off,
indicating the engine can now be started.
DPSG,OUOD002,1572 –19–25MAR03–1/1
15-2
040103
PN=47
Engine Operation- Except 4.5L “270” Engines
Electronic Instrument (Gauge) Panel
Key Start Switch
The three-position key switch (L) controls the engine
electrical system. When the key switch is turned clockwise
to “START”, the engine will crank. When the engine starts,
the key is released and returns to the “ON” (Run) position.
Override Shutdown Rocker Switch
NOTE: This switch may be present, but not active,
depending on panel options originally selected.
Pressing the upper half of the override shutdown switch
(M) will override an engine shutdown signal. The switch
must be pressed within 30 seconds to prevent undesired
shutdown of engine. The switch can be overridden for 30
seconds at a time to move the vehicle to a safe location.
NOTE: Holding the switch continuously “ON” will not reset
the 30 second timer.
High-Low Speed Select Rocker Switch
The high-low speed select switch (N) is used to set the
engine at operating speeds of slow (turtle) or fast (rabbit).
Factory preset idle speeds can then be adjusted using the
Bump Enable Switch (O) with the Speed Select Switch
(P). See “Changing Engine Speeds” later in this section.
Bump Speed Enable Rocker Switch (Optional)
RG9547
–UN–14AUG00
The bump speed enable switch (O) has a center position
which locks the speed select switch (P) to prevent
accidental changes in operating speed. To unlock the
speed select switch, press and hold either the upper or
lower half of the speed enable switch (O).
Electronic Instrument Panel
DPSG,OUOD002,1573 –19–25MAR03–1/1
15-3
040103
PN=48
Engine Operation- Except 4.5L “270” Engines
Electronic Instrument (Gauge) Panel
Speed Select Rocker Switch
The speed select switch (P) is used to bump engine
speed up (+) or down (-) in small increments during
operation. This switch must be used with the bump
speed enable switch (O) in the unlocked position (top
or bottom half of button depressed).
How To Select Preset Operating Speeds (Bump
Speeds)
First select slow or fast speed option by pressing
speed select switch (N) to “turtle” (slow) or “rabbit”
(fast). Then you can press either the upper or lower
portion of the bump enable switch (O) to unlock the
high or low speed setting. The bump enable must be
held down as the speed select rocker (P) is used to
change the high or low speed setting by pressing (+)
to increase speed or (-) to decrease speed.
Once the slow idle speed has been set, the bump
enable rocker must be pressed and released three
times within two seconds to commit the operating
speed to memory. If not done, the engine’s new speed
will only be effective until the key switch is shut off.
Then the high or low operating speed will revert back
to the previous setting. The fast idle speed cannot be
locked to a new speed in memory. It will revert to the
factory preset speed.
Fuse Holder
The fuse holder (Q) contains a 5-amp fuse for power
to the instrument panel.
Tachometer (Optional)
The tachometer (R) indicates engine speed in
hundreds of revolutions per minute (rpm).
Power (Percent Load) Meter (Optional)
The power meter (S) shows percent of available power
being used by the engine.
The voltmeter (T) indicates system battery voltage.
The amber “WARNING” light (B) will illuminate when
battery voltage is too low for proper operation of the
fuel injection system.
Engine Coolant Temperature Gauge (Optional)
The coolant temperature gauge (U) indicates engine
coolant temperature in degrees Centigrade or
Fahrenheit. It is connected to an audible alarm (G) to
warn the operator if coolant temperature rises above
the preset safe operating temperature.
Cruise Control (Optional)
Engine ECU’s are available with and without the
Cruise Control function. The Cruise Control is an
Off-Road type that maintains a constant engine RPM
under varying load conditions. (By contrast,
automotive-type cruise control maintains a constant
road speed.)
The Cruise Cancel/Resume function is a one-button
Cancel then Resume control. The first time contact is
made with Cruise Control active, the Cruise Control
will disengage and the engine speed will drop to idle. If
the contact is made again within one minute and with
the engine speed above 1300 RPM, the Cruise Control
will “Resume”. This feature allows the placement of the
Cancel/Resume button in a convenient location in the
vehicle cab and does not require the use of the normal
Cruise controls for momentary interruptions in cruise
operation.
The Cancel/Resume function is intended for
applications like ag tractors and sprayers that turn
around at the end of each row in a field. This allows
the operator to use the throttle and/or brake to turn the
vehicle around. When ready to resume field
operations, the operator brings the engine speed
above 1300 RPM and activates the Cancel/Resume
function again to resume cruise speed. An internal
timer gives the operator one minute to complete the
turn around maneuver.
Voltmeter (Optional)
Continued on next page
15-4
AG,OUOD002,1620 –19–12NOV01–1/2
040103
PN=49
Engine Operation- Except 4.5L “270” Engines
The Cruise Control has the normal functions of:
•
•
•
•
Cruise Control power “ON” or “OFF”
“Set” or “Bump Up” Engine Speed
“Resume” or “Bump Down” Engine Speed
Vehicle brake or clutch pedal to disengage Cruise
Control.
The “Bump Up” and “Bump Down” speed controls
allow the operator to change the set speed. Small
engine speed changes can be made by “bumping” the
control switch. Holding the “Bump Up” or “Bump Down”
switch will result in greater engine RPM changes until
the engine reaches either full speed or idle. The Cruise
Control cannot operate beyond the normal min-max
engine speeds.
On 12-volt ECU’s, the engine speed can be set from
two different locations. The primary location would
normally be in the cab of the vehicle and is used to set
a constant engine speed while the vehicle is being
driven. The secondary cruise control is normally used
in a location that provides for engine PTO speed
control and is used with the engine in “neutral” or out
of gear. Both locations can have the normal “cruise”
functions.
See Specifications section under Fuel Systems
Specifications for the 1600 option code group which
matches your code to find rated speeds and idle
speeds for your engine.
NOTE: The Bump Throttle feature cannot be used
while operating cruise control.
AG,OUOD002,1620 –19–12NOV01–2/2
15-5
040103
PN=50
Engine Operation- Except 4.5L “270” Engines
15-6
040103
PN=51
Engine Operation- Except 4.5L “270” Engines
Using Diagnostic Gauge To Access Engine
Information
RG10031
–UN–28OCT99
The diagnostic gauge (A) allows the operator to view
many readouts of engine functions and diagnostic trouble
codes (DTCs). The gauge is linked to the electronic
control system and its sensors. This allows the operator to
monitor engine functions and to troubleshoot the engine
systems when needed.
Press the two touch switches (B) to view the various
engine functions in sequence. The displays can be
selected as either customary english or metric units.
Diagnostic Gauge
A—Diagnostic Gauge
B—Touch Switches
C—Amber and Red Lights
The following menu of engine parameters can be
displayed on the diagnostic gauge window:
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Engine hours
Engine rpm
System voltage
Percent engine load at the current rpm
Coolant temperature
Oil pressure
Fuel economy
Throttle position
Current fuel consumption
Active service (diagnostic) codes
Stored service (diagnostic) codes from the engine
Set the units for display
View the engine configuration parameters
Accelerator pedal position
Percentage load at current speed
Actual engine percent torque
Engine speed
Trip distance
Total vehicle distance
Engine hours
Trip fuel
Total fuel used
Coolant temperature
Fuel temperature
Engine oil temperature
Engine intercooler temperature
Fuel deliver pressure
Engine oil level
Engine oil pressure
Continued on next page
15-7
DPSG,OUOD007,2840 –19–12NOV01–1/2
040103
PN=52
Engine Operation- Except 4.5L “270” Engines
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Coolant pressure
Coolant level
Wheel base vehicle speed
Fuel rate
Instant fuel economy check
Average fuel economy
Barometric pressure
Air inlet temperature
Boost pressure
Intake manifold temperature
Air filter differential pressure
Exhaust gas temperature
Electrical potential (voltage)
Battery potential (voltage), switched
Transmission oil pressure (optional)
Transmission oil temperature (optional)
Estimated percent fan speed
NOTE: Engine parameters which can be accessed will
vary with the engine application.
The diagnostic gauge includes a two-line by
eight-character backlit Liquid Crystal Display (LCD). The
top line displays the data label, i.e. “EngHrs” and the
bottom line displays the matching unit information, i.e.
“1200 Hrs”. The diagnostic gauge uses two touch
switches (UP and DOWN) for scrolling through the engine
parameter list and viewing the menu list. Two lights (C)
(amber and red) are used to signal active trouble
messages received by the diagnostic gauge.
DPSG,OUOD007,2840 –19–12NOV01–2/2
15-8
040103
PN=53
Engine Operation- Except 4.5L “270” Engines
RG9947
–19–09DEC99
Using Touch Switches To Display Information
Using Touch Switches
Continued on next page
15-9
DPSG,OUOD007,2841 –19–21OCT99–1/2
040103
PN=54
Engine Operation- Except 4.5L “270” Engines
The touch switches on the diagnostic gauge allow
quick and easy navigation through the menu to find the
information needed. The diagram on the previous page
is a typical Main Menu of Engine Parameters. The
Main Menu has 14 entries; the first 10 are engine data
parameters, and the last four are sub-menu entry
points. The following two rules are used for accessing
the various items on the menus:
1. To scroll through the parameter list, press either
the UP or DOWN touch switches.
2. To select or exit a sub-menu, simultaneously
press the UP and DOWN switches.
To read any of the engine parameters, press either UP
or DOWN switches (as shown on diagram) until the
top line of the display shows the desired information.
Selecting Sub-Menus
Press either the UP or DOWN switches until the top
line of the display shows the label of the desired
sub-menu. Then press BOTH the UP and DOWN
switches at the same time. This action will select the
sub-menu and the next screen on the display will list
the Sub-Menu items. This is also the way to access
Diagnostic Trouble Codes (DTCs).
Selecting Engine Data Parameters
DPSG,OUOD007,2841 –19–21OCT99–2/2
15-10
040103
PN=55
Engine Operation- Except 4.5L “270” Engines
RG10018
–19–28OCT99
Changing Units Of Measure (English Or Metric)
Changing Units Of Measure
The diagnostic gauge can display engine data in either
English or Metric units. To toggle between these, the
Units Sub-Menu, must be selected.
To select the Units Sub-Menu, press the UP or DOWN
switches until the top line of the display reads “UNITS”.
Then press BOTH the UP and DOWN switches at the
same time to select the Units Sub-Menu. The above
diagram shows the steps for selecting the desired units
of measure. Two options are available:
1. Press both the switches to retain the current units
designation.
2. Press either UP or DOWN switch to toggle the units
selection, then press both switches to select the
desired unit of measure.
DPSG,OUOD007,2842 –19–21OCT99–1/1
15-11
040103
PN=56
Engine Operation- Except 4.5L “270” Engines
15-12
040103
PN=57
Engine Operation- Except 4.5L “270” Engines
RG10019
–19–28OCT99
Viewing Engine Configuration Data
Viewing Engine Configuration Data
Continued on next page
15-13
DPSG,OUOD002,1927 –19–19DEC00–1/2
040103
PN=58
Engine Operation- Except 4.5L “270” Engines
The diagnostic gauge can display the engine
configuration data stored in the Engine Control Unit
(ECU). To select the Engine Configuration Sub-Menu
(see diagram on previous page), press the UP or
DOWN switches until the top line of the display reads
“E-Config”. Then press BOTH the UP and DOWN
switches at the same time to select the Engine
Configuration Sub-Menu . The diagnostic gauge will
display the engine configuration data as shown in the
diagram.
DPSG,OUOD002,1927 –19–19DEC00–2/2
15-14
040103
PN=59
Engine Operation- Except 4.5L “270” Engines
RG11510
–19–31OCT00
Viewing Active Engine Service Codes or Diagnostic Trouble Codes (DTCs)
Viewing Active Service Codes (DTCs)
The diagnostic gauge continuously monitors all
messages broadcast over the Control Area Network
(CAN) and displays all Active Service Codes (DTCs) at
the time the message is broadcast. The word
“SrvcCode” is displayed on the second line. The
display will cycle every 5 seconds between the
currently displayed parameter and the “SrvcCode”
message until the active trouble code clears. To view
the active codes, select the Service Code Sub-Menu
by pressing the UP or DOWN switches until the top
line of the display reads “SrvcCode”. Then press
BOTH the UP and DOWN switches at the same time
to select the Service (DTC) Code Sub-Menu. The
diagnostic gauge has the ability to display all Active
Service Codes received. The diagram above titled
Service Codes Sub-Menu shows the process for
selecting Active Service Codes and their values.
NOTE: For a list of Service Codes or Diagnostic
Trouble Codes (DTCs) and their causes, refer
to TROUBLESHOOTING Section 45, later in
this manual. An alternate method of accessing
trouble codes for engines without the
diagnostic gauge is the blink code method.
See Section 45.
DPSG,OUOD002,1928 –19–25MAR03–1/1
15-15
040103
PN=60
Engine Operation- Except 4.5L “270” Engines
RG10021
–19–28OCT99
Viewing Stored Service Codes (DTC) In The Engine ECU
Viewing Stored Service Codes
The diagnostic gauge can request Stored Service
Codes (DTCs) from the engine. The Stored Service
Codes may be used for diagnostic and service needs.
To view the Stored Service Codes, it is necessary to
select the DM2Codes Sub-Menu by pressing the UP
or DOWN switches until the top line of the display
reads “DM2Codes”. Then press BOTH the UP and
DOWN switches at the same time to select the
DM2Codes Sub-Menu. The gauge will display the
Stored Service Codes according to the menus shown
in the diagram.
DPSG,OUOD002,1929 –19–19DEC00–1/1
15-16
040103
PN=61
Engine Operation- Except 4.5L “270” Engines
Engine Break-In Service
–UN–06JAN99
The engine is ready for normal operation. However, extra
care during the first 100 hours of operation will result in
more satisfactory long-term engine performance and life.
DO NOT exceed 100 hours of operation with break-in oil.
RG8009
1. This engine is factory-filled with John Deere ENGINE
BREAK-IN OIL (SAE 10W-30). Operate the engine at
heavy loads with minimal idling during the break-in
period.
Check Engine Oil
2. If the engine has significant operating time at idle,
constant speeds, and/or light load usage, or makeup
oil is required in the first 100 hour period, a longer
break-in period may be required. In these situations, an
additional 100 hour break-in period is recommended
using a new change of John Deere ENGINE
BREAK-IN OIL and a new John Deere oil filter.
Continued on next page
15-17
RG,RG34710,5553 –19–25FEB03–1/4
040103
PN=62
Engine Operation- Except 4.5L “270” Engines
RG8028A –UN–15JAN99
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.
Crosshatch Pattern On Dipstick
A—Crosshatch Pattern On Dipstick
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.
Specification
Engine1—Oil Pressure at Full
Load Rated Speed ................................. 345 ± 103 kPa (3.45 ± 1.03 bar)
(50 ± 15 psi)
Minimum Oil Pressure at 850 rpm ................. 105 kPa (1.05 bar) (15 psi)
Coolant Temperature Range ................................ 82°–94°C (180°–202°F)
PLUS-50 is a trademark of Deere & Company.
1
At normal operating temperature of 115°C (240°F) oil sump.
Continued on next page
15-18
RG,RG34710,5553 –19–25FEB03–2/4
040103
PN=63
Engine Operation- Except 4.5L “270” Engines
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.
NOTE: Some increase in oil consumption may be
expected when low viscosity oils are used. Check
oil levels more frequently.
RG11616
–UN–24OCT01
5. Before the first 100 hours (maximum), change engine
oil and replace engine oil filter (A). (See CHANGING
ENGINE OIL AND REPLACING FILTER in Lubrication
and Maintenance/500 Hour/12 Month Section.) Fill
crankcase with seasonal viscosity grade oil. (See
DIESEL ENGINE OIL, in Fuels, Lubricants, and
Coolant Section.)
Engine Oil Filter
A—Engine Oil Filter
If air temperature is below -10°C (14°F), use an
engine block heater.
RG,RG34710,5553 –19–25FEB03–3/4
–UN–08NOV01
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.
7. Check poly-vee belt for proper alignment and seating
in pulley grooves.
RG11944
NOTE: When the coolant temperature gauge reads
approximately 115°C (239°F), the engine will
shutdown automatically, if equipped with safety
controls.
Electronic Instrument Panel
A—Coolant Temperature Gauge
RG,RG34710,5553 –19–25FEB03–4/4
15-19
040103
PN=64
Engine Operation- Except 4.5L “270” Engines
Starting the Engine
–UN–23AUG88
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.
TS220
CAUTION: Before starting engine in a confined
building, install proper outlet exhaust
ventilation equipment. Always use safety
approved fuel storage and piping.
Use Proper Ventilation
NOTE: If temperature is below 0°C (32°F), it may be
necessary to use cold weather starting aids (See
COLD WEATHER OPERATION, later in this
section).
1. Perform all prestarting checks outlined in Lubrication &
Maintenance/Daily Section later in this manual.
2. Open the fuel supply shut-off valve, if equipped.
3. Disengage clutch (if equipped) controlling any engine
drivelines.
Continued on next page
15-20
RG,RG34710,5557 –19–12NOV01–1/2
040103
PN=65
Engine Operation- Except 4.5L “270” Engines
NOTE: Hand throttle (A) may have an analog
potentiometer for changing engine speeds (See
“Changing Engine Speeds” later in this section).
4. Turn the throttle (A) clockwise 1/3 of the way (see
illustration). (If not equipped with an analog throttle, move
throttle control 1/3 of the distance away from slow idle
stop.)
5. Turn the key switch (B) 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.
RG11936
–UN–06NOV01
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.
Electronic Instrument Panel
A—Hand Throttle
B—Key Start Switch
C—Oil Pressure Gauge
D—Coolant Temperature Gauge
IMPORTANT: Should the engine die when operating
under load, immediately disengage any
driveline clutch to remove load and
restart the engine. Overheating of
turbocharger parts may occur when oil
flow is stopped.
6. Check all gauges for normal engine operation. If
operation is not normal, stop the engine and determine
the cause.
RG,RG34710,5557 –19–12NOV01–2/2
15-21
040103
PN=66
Engine Operation- Except 4.5L “270” Engines
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 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
15-22
040103
PN=67
Engine Operation- Except 4.5L “270” Engines
Warming Engine
The electronically-controlled engines will operate at an
accelerated slow idle of 1050 rpm until the engine coolant
warms up to 20° C (68° F).
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).
RG9917
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.
–UN–16NOV99
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.
Electronic Instrument Panel
A—Oil Pressure Gauge
B—Coolant Temperature Gauge
NOTE: On certain engines, the oil pressure and coolant
temperature gauges are replaced by indicator
warning lights. The lights must be "OFF" when
engine is running.
2. Watch coolant temperature gauge (B). Do not place
engine under full load until it is properly warmed up.
The normal engine coolant temperature range is 82°—
94°C (180°—202°F).
NOTE: It is a good practice to operate the engine under a
lighter load and at lower speeds than normal for
the first few minutes after start-up.
RG,RG34710,5560 –19–23NOV01–1/1
15-23
040103
PN=68
Engine Operation- Except 4.5L “270” Engines
Cold Weather Operation
–UN–18MAR92
CAUTION: DO NOT use starting fluid on
engines equipped with air intake heaters or
glow plugs. Ether injector starting fluid is highly
flammable and may explode, causing serious
injury.
TS1356
DO NOT use starting fluid near fire, sparks, or
flames. DO NOT incinerate or puncture a
starting fluid container.
Handle Starting Fluid with Care
Engines may be equipped with intake air heaters, coolant
heaters, fuel heaters, or ether injectors as cold weather
starting aids. Later “475” 4-valve cylinder head engines
are equipped with glow plugs as an automatic cold
weather starting aid.
Starting aids are required below 0°C (32°F). They will
enhance starting performance above these temperatures
and may be needed to start applications that have high
parasitic loads during cranking and/or start acceleration to
idle.
–19–10JAN01
Using correct grade of oil (per engine and machine
operator’s manual) is critical to achieving adequate cold
weather cranking speed.
RG11521
Other cold weather starting aids are required at
temperatures below -30°C (-22°F) or at altitudes above
1500 m (5000 ft).
1. Follow steps 1—4 as listed under STARTING THE
ENGINE, earlier in this section, then proceed as
follows according to the instrument (gauge) panel on
your engine.
Cold Weather Starting Guidelines
2. 275-Series Engines Without Air Intake Heaters:
Manually activate ether injectors.
Continued on next page
15-24
RG,RG34710,5050 –19–25FEB03–1/2
040103
PN=69
Engine Operation- Except 4.5L “270” Engines
NOTE: Air intake heaters (275 engines) and glow plugs
(475 engines) operate automatically through the
ECU. The Engine Preheater Indicator light on
these engines, located above the key switch,
should always illuminate when the switch is turned
ON. In warm weather, the light illuminates briefly
as a light check. In cold weather, the light remains
on during the automatic operation of the air intake
heater or glow plugs. Operating time depends on
temperature. Do not crank engine until light turns
off.
275-Series Engines with Air Intake Heaters and
475-Series Engines with Glow Plugs: Turn key ON,
but DO NOT crank engine until Engine Preheater
Indicator light turns off.
3. Follow remaining steps 5—6 as listed under earlier in
this section.
Additional information on cold weather operation is
available from your authorized servicing dealer.
RG,RG34710,5050 –19–25FEB03–2/2
15-25
040103
PN=70
Engine Operation- Except 4.5L “270” Engines
Using a Booster Battery or Charger
–UN–23AUG88
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.
TS204
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.
Exploding Battery
–UN–14DEC88
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.
RG4678
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.
12-Volt System
1. Connect booster battery or batteries to produce the
required system voltage for your engine application.
–UN–14DEC88
NOTE: To avoid sparks, DO NOT allow the free ends of
jumper cables to touch the engine.
RG4698
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.
24-Volt System
A—12-Volt Machine Battery (ies)
B—12-Volt Booster Battery (ies)
C—Booster Cable
D—Cable to Starting Motor
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).
Continued on next page
15-26
RG,RG34710,5564 –19–20MAY96–1/2
040103
PN=71
Engine Operation- Except 4.5L “270” Engines
6. Start the engine. Disconnect jumper cables
immediately after engine starts. Disconnect NEGATIVE
(–) cable first.
RG,RG34710,5564 –19–20MAY96–2/2
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.
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).
Once an engine is warmed to normal operating
temperatures, engine should be idled at slow idle
RG,RG34710,5562 –19–20MAY96–1/1
15-27
040103
PN=72
Engine Operation- Except 4.5L “270” Engines
Changing Engine Speeds
NOTE: On later engines with 2-state throttles, speeds are
not adjustable. These throttles allows operation
only at the preset rated speed or at idle using the
single switch (A).
Changing from slow to fast speed using Standard
High-Low Speed Select Rocker Switch (A) (Early
Engines):
–UN–16NOV99
• For slow speed, press lower half of switch (indicated by
turtle symbol).
• For fast speed, press upper half of switch (indicated by
rabbit symbol).
RG9918
NOTE: To adjust preset fast or slow speeds for High-Low
Speed Select Rocker Switch:
1. Select fast (rabbit) or slow (turtle) position on
High-Low Speed Select Rocker Switch (A).
2. Press and hold top or bottom half of Bump
Speed Enable Rocker Switch (B) while using
Speed Select Rocker Switch (C).
3. Use Speed Select Rocker Switch (C) to bump
engine speed up (+) or down (-).
Changing Engine Speed
A—High-Low Speed Select Rocker Switch
(Standard Switch Shown)
B—Bump Speed Enable Rocker Switch
C—Speed Select Rocker Switch
D—Analog Potentiometer Throttle (Optional)
NOTE: Once the speed has been set, the Bump Speed
Enable Switch (B) must be pressed and released
three times within two seconds to commit the new
slow or fast speed to memory. If not done, the
engine’s new slow or fast speed will only be
effective until the key switch is shut off. Then the
speed will revert to its previous setting.
Changing from slow to fast speed using Adjustable
High-Low Speed Select Rocker Switch (A) (Later
Engines):
Later engines have an adjustable three-position rocker
switch (A) that can be used to select slow idle, fast idle, or
an adjustable (“ADJ”) intermediate speed.
• For slow speed, press lower half of rocker switch
(indicated by turtle symbol).
• For fast speed, press upper half of rocker switch
(indicated by rabbit symbol).
Continued on next page
15-28
DPSG,OUOD002,1827 –19–21MAR03–1/2
040103
PN=73
Engine Operation- Except 4.5L “270” Engines
NOTE: To adjust preset fast or slow speeds with
adjustable High-Low Speed Select Rocker Switch:
1. Select middle position (ADJ) or slow (turtle)
position on the optional Adjustable Three-State
Speed Select Rocker Switch (A).
2. Press and hold top or bottom half of Bump
Speed Enable Rocker Switch (B) while using
Speed Select Rocker Switch (C).
3. Use Speed Select Rocker Switch (C) to bump
engine speed up (+) or down (-).
Changing engine speed using optional analog
potentiometer throttle (D):
RG9918
NOTE: Once the speed has been set, the Bump Speed
Enable Switch (B) must be pressed and released
three times within two seconds to commit the new
slow or fast speed to memory. If not done, the
engine’s new slow or fast speed will only be
effective until the key is shut off. Then the speed
will revert to its previous setting.
–UN–16NOV99
NOTE: Slow (turtle) position is factory preset at low
engine idle, while middle (ADJ) position is factory
set at high engine idle.
Changing Engine Speed
A—High-Low Speed Select Rocker Switch
(Standard Switch Shown)
B—Bump Speed Enable Rocker Switch
C—Speed Select Rocker Switch
D—Analog Potentiometer Throttle (Optional)
NOTE: Pushing in on analog potentiometer will
immediately take engine to slow idle speed.
1. Set High-Low Speed Select Rocker Switch (A) to low
speed position.
2. Turn potentiometer throttle clockwise to increase speed
or counterclockwise to decrease speed.
NOTE: Engine Control Unit (ECU) reads the higher of the
High-Low Speed Select Rocker Switch or the
Analog Throttle(s) Speed Settings. With High-Low
switch at low speed, Analog Throttle(s) will control
speed higher than low idle setting.
DPSG,OUOD002,1827 –19–21MAR03–2/2
15-29
040103
PN=74
Engine Operation- Except 4.5L “270” Engines
Stopping The Engine
1. Disengage clutch, if equipped, controlling engine power
driveline.
IMPORTANT: Before stopping an engine that has
been operating at working load, idle
engine at least 2 minutes at 1000—1200
rpm to cool hot engine parts.
–UN–16NOV99
Engines in generator set applications
where the ECU is locked at a specified
speed and no slow idle function is
available, run engine for at least 2
minutes at fast idle and no load.
Panels with High-Low Speed Select Rocker Switch (B)
only: Set rpm using Bump Speed Enable Switch (C) with
Speed Select Rocker Switch (D).
RG9916
2. Run engine at 1000—1200 rpm for at least 2 minutes
to cool.
Electronic Instrument Panel
Panels with optional Analog Throttle (E): Set either
High-Low Speed Select Switch (B) or Analog Throttle (E)
to low idle, and set desired speed with remaining control.
–UN–18NOV99
NOTE: Engine Control Unit (ECU) reads the higher of the
High-Low Speed Select Rocker Switch or the
Analog Throttle(s) Speed settings.
RG9933
3. Push in on analog throttle potentiometer handle (if
equipped) so that engine goes to slow idle, or set slow
speed with High-Low Speed Select Rocker Switch.
Exhaust Stack Rain Cap
4. Turn key switch (A) to “OFF” position to stop the
engine. Remove ignition key.
IMPORTANT: Make sure that exhaust stack rain cap
(F) is installed when engine is not
running. This will prevent water and dirt
from entering engine.
A—Key Switch
B—High-Low Speed Select Rocker Switch
C—Bump Speed Enable Switch
D—Speed Select Rocker Switch
E—Analog Throttle (Optional)
F—Exhaust Stack Rain Cap
DPSG,OUOD002,1829 –19–12NOV01–1/1
15-30
040103
PN=75
Engine Operation- Except 4.5L “270” Engines
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
RG7634A
–UN–22JAN99
A—Auxiliary Gear Drive
Auxiliary Gear Drive
RG,RG34710,5555 –19–20MAY96–1/1
Generator Set (Standby) Applications
To assure that your engine will deliver efficient standby
operation when needed, start engine and run at rated
speed (with 50%—70% load) for 30 minutes every 2
weeks. DO NOT allow engine to run extended period of
time with no load.
RG,RG34710,5556 –19–20MAY96–1/1
15-31
040103
PN=76
Engine Operation- 4.5L “270” Engines
Instrument (Gauge) Panel
–UN–07JAN03
All controls and gauges are optional equipment for John
Deere 4.5 L suffix “270” OEM Engines. They may be
provided by the equipment manufacturer instead of John
Deere. The following information applies only to the basic
controls required for these engines.
RG6574A
IMPORTANT: Any time an electric gauge or meter
does not register correctly, replace it
with a new one. Do not attempt to repair
it.
Instrument Panel and Gauges (4.5 L “270” Engines)
Following is a brief description of the components on a
basic instrument (gauge) panel:
A—Tachometer with Hourmeter
B—Coolant Temperature Gauge
C—Oil Pressure Gauge
D—Pre-Heat Indicator Lamp
E—Charge Indicator Lamp
F—Oil Pressure Indicator Lamp
G—Coolant Temperature Indicator Lamp
H—Key Switch
A—Tachometer with Hourmeter - The optional
tachometer with hourmeter indicates engine speed in
revolutions per minute (rpm) and shows the operating
hours of the engine while key switch is in the “ON”
position. The hour meter should be used as a guide for
scheduling periodic service.
B—Coolant Temperature Gauge - The coolant
temperature gauge indicates the engine coolant
temperature. It is connected to a warning lamp to warn
the operator if coolant temperature rises above the preset,
safe operating temperature.
C—Oil Pressure Gauge - The oil pressure gauge
indicates engine oil pressure. It is connected to a warning
lamp to warn the operator if engine oil pressure falls
below a safe operating pressure.
D—Pre-Heat Indicator Lamp - This indicator lamp is
initially turned on when the key switch is turned to the
“HEAT” position to activate glow plugs for cold weather
starting. Lamp is connected to a timer that turns the lamp
off after 15 seconds when the key switch is held at
“HEAT” position. When the lamp goes out, start the
engine.
E—Charge Indicator Lamp - Indicates whether the
charging circuit is adequately replacing battery voltage as
it is used by the electrical system. If the lamp is lit while
the engine is running above 1300 rpm, stop engine
immediately and check charging circuit.
Continued on next page
16-1
OURGP12,00001E4 –19–05MAR03–1/2
040103
PN=77
Engine Operation- 4.5L “270” Engines
F—Oil Pressure Indicator Lamp - Warns operator that
engine oil pressure is below a safe operating level. If lamp
stays lit while engine is running faster than slow idle, stop
engine immediately and check engine oil level.
RG6574A
H—Key Switch - The key switch controls the electrical
system. Positions of key switch are marked as follows:
OFF, ON, and START.
–UN–07JAN03
G—Coolant Temperature Indicator Lamp - Warns
operator that engine coolant temperature exceeds safe
operating level. If lamp is lit during full load operation, the
engine is overheated. Stop engine and immediately check
fan belt tension and coolant level in radiator.
Instrument Panel and Gauges (4.5 L “270” Engines)
OURGP12,00001E4 –19–05MAR03–2/2
16-2
040103
PN=78
Engine Operation- 4.5L “270” Engines
Normal Engine Operation
Before starting, fill engine with oil and coolant meeting
specifications. (See DIESEL ENGINE BREAK-IN OIL and
DIESEL ENGINE COOLANT SPECIFICATIONS in Fuels,
Lubricants, and Coolant section.)
• Observe engine coolant temperature and engine oil
pressure. Temperatures and pressures will vary
between engines and with changing operating
conditions, temperatures, and loads.
• Normal engine coolant operating temperature range is
90° – 100° C (194° – 212° F). If coolant temperature
rises above 105° C (221° F), reduce load on engine.
Unless temperature drops quickly, stop engine and
determine cause before resuming operation.
• Operate the engine under a lighter load and at slower
than normal speed for first 15 minutes after start-up. DO
NOT run engine at slow idle.
• Stop engine immediately if there are any signs of part
failure. Symptoms that may be early signs of engine
problems are:
– Sudden drop in oil pressure
– Abnormal coolant temperatures
– Unusual noise or vibration
– Sudden loss of power
– Excessive black exhaust
– Excessive fuel consumption
– Excessive oil consumption
– Fluid leaks
RG41183,000002D –19–28MAR03–1/1
16-3
040103
PN=79
Engine Operation- 4.5L “270” Engines
Break-In Service
–UN–07FEB03
Before starting, fill engine with seasonal viscosity grade oil
and with coolant meeting specifications. (See DIESEL
ENGINE OIL and DIESEL ENGINE COOLANT
SPECIFICATIONS in Fuels, Lubricants, and Coolant
Section.)
RG12692
1. During the first 20 hours, avoid prolonged periods of
engine idling or sustained maximum load operation.
Warm-up engine carefully and operate at normal loads.
If engine will idle longer than 5 minutes, stop engine.
Check Engine Oil Level Daily
2. Check oil level daily or every 10 hours during engine
break-in period. If oil must be added during this period,
use seasonal viscosity grade oil. (See DIESEL
ENGINE OIL in Fuels, Lubricants, and Coolant
section.)
OURGP12,00001DE –19–26FEB03–1/3
3. Watch oil pressure (A) and coolant temperature (B)
closely during break-in period. Also check coolant level
daily or every 10 hours and check for leaks.
RG6574
–UN–17FEB03
4. Check poly-vee belt for proper alignment and seating
in pulley grooves.
Oil Pressure and Coolant Temperature Gauges
Continued on next page
16-4
OURGP12,00001DE –19–26FEB03–2/3
040103
PN=80
Engine Operation- 4.5L “270” Engines
–UN–24OCT01
5. Change engine oil and oil filter after the first 100 hours
of use. After break-in period, change oil and filter every
500 hours/12 months. (See CHANGE ENGINE OIL
AND FILTER in Lubrication and Maintenance/500 Hour
Section.) Fill crankcase with seasonal viscosity grade
oil. (See DIESEL ENGINE OIL, in Fuels, Lubricants,
and Coolant Section.)
RG11616
IMPORTANT: DO NOT operate engine when oil level
is below ADD mark on dipstick. Check
oil level before starting engine for the
first time.
Engine Oil Filter
OURGP12,00001DE –19–26FEB03–3/3
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
RG7634A
–UN–22JAN99
A—Auxiliary Gear Drive
Auxiliary Gear Drive
RG,RG34710,5555 –19–20MAY96–1/1
16-5
040103
PN=81
Engine Operation- 4.5L “270” Engines
Generator Set (Standby) Power Units
To assure that your engine will deliver efficient standby
operation when needed, start engine and run at rated
speed (with 50%—70% load) for 30 minutes every 2
weeks. DO NOT allow engine to run extended period of
time with no load.
RG41183,000002F –19–16DEC02–1/1
Starting The Engine
–UN–23AUG88
The controls and instruments for your engine may be
different from those shown here. Always follow
manufacturer’s instructions and familiarize yourself with
the correct starting procedure.
TS220
CAUTION: Before starting engine in a confined
building, install proper outlet exhaust
ventilation equipment. Always use safety
approved fuel storage and piping.
Use Proper Ventilation
NOTE: If temperature is below 0° C (32° F), it may be
necessary to use cold weather starting aids. (See
COLD WEATHER OPERATION, later in this
section).
1. Perform all prestarting checks outlined in Lubrication &
Maintenance/Daily Section later in this manual.
2. Disengage engine rear driveline (if equipped) or gen
set drive.
3. Open the fuel supply shut-off valve, if equipped.
4. Place the speed control lever in the “START” position,
if equipped.
Continued on next page
16-6
OURGP12,00001E5 –19–05MAR03–1/2
040103
PN=82
Engine Operation- 4.5L “270” Engines
IMPORTANT: Do not operate the starter for more than
15 seconds at a time. To do so may
overheat the starter. If the engine does
not start the first time, wait at least 2
minutes before trying again. If engine
does not start after four attempts, see
Troubleshooting Section.
RG6580
–UN–20JAN93
5. Turn key switch to “START” position as shown and
hold until engine starts. Release key once engine
starts; key automatically returns to “ON” position and
instrument panel gauges start operating.
6. Warm-up engine for at least 5 minutes before applying
a load. (See WARMING-UP ENGINE, later in this
section.)
Starting Engine Using Key Switch
7. Check all gauges for normal operation. If operation is
not normal, stop engine immediately and determine
cause.
OURGP12,00001E5 –19–05MAR03–2/2
Cold Weather Starting
When outside temperatures fall below 0°C (32° F) it may
be necessary to consider using cold weather starting aids.
Your POWERTECH Engines may be fitted with a block
heater, and increased capacity battery and/or lower
viscosity oil may also be used. See your local John Deere
engine distributor or servicing dealer for
recommendations.
1. Perform all prestarting checks outlined in Lubrication &
Maintenance/Daily Section later in this manual.
2. Disengage engine rear driveline (if equipped) or gen
set drive.
3. Open the fuel supply shut-off valve, if equipped.
4. Place the speed control lever in the “START” position,
if equipped.
POWERTECH is a trademark of Deere & Company
Continued on next page
16-7
OURGP12,00001E6 –19–05MAR03–1/2
040103
PN=83
Engine Operation- 4.5L “270” Engines
IMPORTANT: Do not operate the starter for more than
15 seconds at a time. To do so may
overheat the starter. If the engine does
not start the first time, wait at least 2
minutes before trying again. If engine
does not start after four attempts, see
Troubleshooting Section.
RG6580
–UN–20JAN93
5. Turn key switch to “START” position and hold until
engine starts. Release key once engine starts; key
automatically returns to “ON” position and instrument
panel gauges start operating.
6. Warm-up engine for at least 5 minutes before applying
a load. (See WARMING ENGINE, later in this section.)
Starting Engine
OURGP12,00001E6 –19–05MAR03–2/2
16-8
040103
PN=84
Engine Operation- 4.5L “270” Engines
Warming Engine
RG6574
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.
–UN–17FEB03
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.
Instrument Panel Gauges
A—Oil Pressure Gauge
B—Coolant Temperature Gauge
1. Check oil pressure gauge (A) as soon as engine starts.
If gauge needle does not rise above minimum oil
pressure specification of 105 kPa (1.05 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). This oil pressure can vary from 35 psi to 65
psi.
NOTE: On certain engines, the oil pressure and coolant
temperature gauges are replaced by indicator
warning lights. The lights must be "OFF" when
engine is running.
2. Watch coolant temperature gauge (B). Do not place
engine under full load until it is properly warmed up.
The normal engine coolant temperature range is 90°–
100° C (194°–212° F).
NOTE: It is a good practice to operate the engine under a
lighter load and at lower speeds than normal for
the first few minutes after start-up.
RG41183,0000033 –19–16DEC02–1/1
16-9
040103
PN=85
Engine Operation- 4.5L “270” Engines
Avoid Excessive Engine Idling
Avoid excessive engine idling. Prolonged idling may cause
the engine coolant temperature to fall below its normal
range. This, in turn, causes crankcase oil dilution, due to
incomplete fuel combustion, and permits formation of
gummy deposits on valves, pistons, and piston rings. It
also promotes rapid accumulation of engine sludge and
unburned fuel in the exhaust system.
Once an engine is warmed to normal operating
temperatures, engine should be idled at slow idle speed.
Slow idle speed for this engine is 900 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).
RG41183,0000034 –19–16DEC02–1/1
16-10
040103
PN=86
Engine Operation- 4.5L “270” Engines
Stopping the Engine
IMPORTANT: Stopping the engine immediately when
it has been working under load, can
result in overheating and accelerated
wear of the engine components.
ALWAYS run the engine at slow idle
and no load to allow hot engine parts to
cool before shutdown (if possible).
On engines with variable speed
governors, remove load from engine
and run engine for at least 2 minutes
Run turbocharged engines for 3 to 5
minutes.
On generator set engines with
governors locked at a specific speed,
remove electrical load from engine (if
possible) and run at fast idle and no
load for at least 2 minutes.
1. Drop engine speed to slow idle (variable speed
governors only).
RG41183,0000035 –19–16DEC02–1/3
RG6574B
–UN–07JAN03
2. Turn key switch (A) to "OFF" position to stop the
engine. After engine stops, close valve on fuel supply
to prevent accidental starting.
Key Switch on Instrument Panel
Continued on next page
16-11
RG41183,0000035 –19–16DEC02–2/3
040103
PN=87
Engine Operation- 4.5L “270” Engines
IMPORTANT: Make sure that exhaust stack cap (rain
cap) is in place when engine is not
running. This will prevent water and dirt
from entering engine.
RG10616
–UN–16JUN00
3. Fill fuel tank to minimize possible water condensation
problems. Filling tanks at end of day drives out
moisture-laden air.
Exhaust Stack Rain Cap
RG41183,0000035 –19–16DEC02–3/3
Using a Booster Battery or Charger
A 12-Volt booster battery can be connected in parallel
with batteries on the engine to aid cold weather starting.
ALWAYS use heavy-duty jumper cables. For details and
precautions, see USING A BOOSTER BATTERY OR
CHARGER in the previous section.
OURGP12,00001E7 –19–05MAR03–1/1
16-12
040103
PN=88
Lubrication and Maintenance
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.
–UN–26OCT01
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.
RG11613
A—Hour Meter (Electronic Panel Shown)
Electronic Instrument Panel Hour Meter
DPSG,OUOE003,20 –19–25FEB03–1/1
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.
TS100
IMPORTANT: Use only fuels, lubricants, and coolants
meeting specifications outlined in
Fuels, Lubricants, and Coolant Section
when servicing your John Deere
Engine.
–UN–23AUG88
Use Correct Fuels, Lubricants, and Coolant
DPSG,OUOE003,20 –19–06JAN99–1/1
20-1
040103
PN=89
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/Water Bowl
•
Check Air Cleaner Dust Unloader Valve & Restriction Indicator
Gaugea
•
Visual Walk Around Inspection
•
Check Lamps (4045DF/TF270)
•
500 Hour/
12 Month
Service Fire Extinguisher
•
Check Engine Mounts
•
Service Battery
•
Check Manual Belt Tensioner and Belt Wear
•
Change Engine Oil And Replace Oil Filterb, c
•
Clean Crankcase Vent Tube
•
Check Air Intake Hoses, Connections, & System
•
Replace Fuel Filter Elements and Bleed System
•
Check Automatic Belt Tensioner and Belt Wear
•
Check Engine Electrical Ground Connection
•
Check Cooling System
•
Coolant Solution Analysis-Add SCAs as required
•
Pressure Test Cooling System
•
Check Engine Speeds
•
2000 Hour/
24 Month
As Required
•
Check Crankshaft Vibration Damper (6.8 L Engines)d
Flush and Refill Cooling System
•
Test Thermostats
•
Check and Adjust Engine Valve Clearance
•
Test Glow Plugs (4045HF475, 6068HF475)
•
e
•
Add Coolant
a
Replace primary air cleaner element when restriction indicator shows a vacuum of 625 mm (25 in.) H2O.
b
During engine break-in, change the oil and filter for the first time before 100 hours of operation.
c
If the recommended engine oils, John Deere PLUS-50 or ACEA-E4/E5, are not used, the oil and filter change interval is reduced to every
250 hours. If diesel fuel with a sulfur content greater than 0.05% is used, the oil and filter change interval is also reduced.
d
Replace crankshaft damper every 4500 hours or 60 months, whichever occurs first.
e
If John Deere COOL-GARD is used, the flushing interval may be extended to 3000 hours or 36 months. If John Deere COOL-GARD is used
and the coolant is tested annually AND additives are replenished as needed by adding a supplemental coolant additive, the flushing interval
may be extended to 5000 hours or 60 months, whichever occurs first.
Continued on next page
20-2
RG,RG34710,7559 –19–25FEB03–1/2
040103
PN=90
Lubrication and Maintenance
Lubrication and Maintenance Service Intervals
Item
Daily
500 Hour/
12 Month
2000 Hour/
24 Month
As Required
Replace Air Cleaner Elements
•
Replace Poly-vee Belt
•
Check Fuses
•
Check Air Compressor (If Equipped)
•
Bleed Fuel System
•
RG,RG34710,7559 –19–25FEB03–2/2
20-3
040103
PN=91
Lubrication and Maintenance
Lubrication and Maintenance Service Interval
Chart—Generator (Standby) Applications
NOTE: Use service intervals listed below for generator
(standby) applications. Match service items below
to titles in Lubrication and Maintenance Sections
for procedures.
Lubrication and Maintenance Service Intervals
Item
Every 2 Weeks
Operate Engine at Rated Speed and 50%–70% Load a Minimum
of 30 Minutes
•
Check Engine Oil and Coolant Level
•
Check Fuel Filter/Water Bowl
•
Check Air Cleaner Dust Unloader Valve & Restriction Indicator
Gaugea
•
Visual Walk Around Inspection
•
Check Lamps (4045DF/TF270)
•
500 Hours or
12 Months
Service Fire Extinguisher
•
Check Engine Mounts
•
Service Battery
•
Check Manual Belt Tensioner and Belt Wear
•
Change Engine Oil And Replace Oil Filterb, c
•
Clean Crankcase Vent Tube
•
Check Air Intake Hoses, Connections, & System
•
Replace Fuel Filter Elements—Bleed Fuel System
•
Check Automatic Belt Tensioner and Belt Wear
•
Check Engine Electrical Ground Connection
•
Check Cooling System
•
Coolant Solution Analysis-Add SCAs as required
•
Pressure Test Cooling System
•
Check Engine Speeds
•
2000 Hours or
24 Months
As Required
•
Adjust Variable Speed (Droop) (4.5 L “270” Engines)
Check Crankshaft Vibration Damper (6.8 L Engines)
•
Flush and Refill Cooling System
•
Test Thermostats
•
Check and Adjust Engine Valve Clearance
•
d
a
Replace primary air cleaner element when restriction indicator shows a vacuum of 625 mm (25 in.) H2O.
b
During engine break-in, change the oil and filter for the first time before 100 hours of operation.
c
If the recommended engine oils, John Deere PLUS-50 or ACEA-E4/E5, are not used, the oil and filter change interval is reduced to every
250 hours. If diesel fuel with a sulfur content greater than 0.05% is used, the oil and filter change interval is also reduced.
d
Replace crankshaft damper every 4500 hours or 60 months, whichever occurs first.
Continued on next page
20-4
RG,RG34710,7560 –19–25FEB03–1/2
040103
PN=92
Lubrication and Maintenance
Lubrication and Maintenance Service Intervals
Item
Every 2 Weeks
500 Hours or
12 Months
2000 Hours or
24 Months
As Required
•
Test Glow Plugs (4045HF475, 6068HF475)
Add Coolant
•
Replace Air Cleaner Elements
•
Replace Poly-vee Belt
•
Check Fuses
•
Check Air Compressor (If Equipped)
•
Bleed Fuel System
•
RG,RG34710,7560 –19–25FEB03–2/2
20-5
040103
PN=93
Lubrication & Maintenance/Daily
Daily Prestarting Checks
Do the following BEFORE STARTING THE ENGINE for
the first time each day:
–UN–16JUN00
IMPORTANT: DO NOT add makeup oil until the oil
level is BELOW the crosshatch marks
on the dipstick.
RG8009A
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.)
Left Side Oil Filler Cap
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.
RG8054A
–UN–16JUN00
IMPORTANT: DO NOT fill above the top mark on the
dipstick. Oil levels anywhere within
crosshatch (D) are considered in the
acceptable operating range.
A—Left Side Oil Filler Cap
B—Right Side Oil Filler Cap
C—Cover Oil Filler Cap
D—Crosshatch On Dipstick
RG8025B
–UN–16JUN00
Right Side Oil Filler Cap
Rocker Arm Cover Filler Cap
RG8028B –UN–15JAN99
Crosshatch on Dipstick
Continued on next page
25-1
OURGP12,00001E2 –19–04MAR03–1/5
040103
PN=94
Lubrication & Maintenance/Daily
CAUTION: Explosive release of fluids from
pressurized cooling system can cause serious
burns.
–UN–23AUG88
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.
TS281
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.
High-Pressure Fluids
NOTE: Refer to your vehicle’s operator’s manual for
recommendations for non-John Deere supplied
accessories.
RG4675
–UN–14DEC88
A—Fill Radiator
Fill Radiator
Continued on next page
25-2
OURGP12,00001E2 –19–04MAR03–2/5
040103
PN=95
Lubrication & Maintenance/Daily
NOTE: Engine may be equipped with a water sensor at
the fuel filter. In this case, an indicator light will
signal the operator that water should be drained
from the filter bowl.
–UN–24MAY02
3. Check the fuel filters for water or debris. If filter is fitted
with a see-through bowl, drain as needed based on a
daily visual inspection.
RG12222
IMPORTANT: Drain water into a suitable container
and dispose of properly.
Drain Final Fuel Filter
a. Loosen drain plugs (A) at bottom of fuel filters or
bowls, if equipped, two or three turns.
b. Loosen air bleed plug (B) two full turns on fuel filter
mounting and drain water from bottom until fuel
starts to drain out.
c. When fuel starts to drain out, tighten drain plugs
securely.
RG11955
–UN–05DEC01
After draining water from the fuel filters, the filters must
be primed by bleeding all air from the fuel system. See
BLEEDING FUEL SYSTEM in Service As Required
Section, later in this manual
Drain Primary Fuel Filter (If Equipped)
A—Drain Plug
B—Air Bleed Plug
Continued on next page
25-3
OURGP12,00001E2 –19–04MAR03–3/5
040103
PN=96
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.
–UN–22JAN99
If equipped with air intake restriction indicator gauge
(B), check gauge to determine if air cleaner needs to
be serviced.
RG7332A
IMPORTANT: Maximum air intake restriction is 6.25
kPa (0.06 bar) (1.0 psi) (25 in. H2O). A
clogged air cleaner element will cause
excessive intake restriction and a
reduced air supply to the engine.
Dust Unloader Valve and Indicator Gauge
A—Dust Unloader Valve
B—Air Restriction Indicator
5. Make a thorough inspection of the engine
compartment. Look for oil or coolant leaks, worn fan
and accessory drive belts, loose connections and trash
build-up. Remove trash buildup and have repairs made
as needed if leaks are found.
NOTE: Wipe all fittings, caps, and plugs before
performing any maintenance to reduce the chance
of system contamination.
Inspect:
• Radiator for leaks and trash build-up.
• Air intake system hoses and connections for cracks
and loose clamps.
• Fan, alternator, and accessory drive belts for cracks,
breaks or other damage.
• Coolant pump for coolant leaks.
NOTE: It is normal for a small amount of leakage to occur
as the engine cools down and parts contract.
Excessive coolant leakage may indicate the need
to replace the coolant pump seal. Contact your
engine distributor or servicing dealer for repairs.
Continued on next page
25-4
OURGP12,00001E2 –19–04MAR03–4/5
040103
PN=97
Lubrication & Maintenance/Daily
6. 4.5 L Suffix “270” Engines Only: Turn key switch to
“ON” position and check lamps. “WATER” lamp should
be off, while “OIL” and “CHG” lamps should be lit.
RG6578
–UN–29JAN93
Replace lamps as needed. If this does not solve any
problems, see your John Deere dealer or distributor.
Key Switch in "ON" Position (4.5 L “270” Engines)
OURGP12,00001E2 –19–04MAR03–5/5
25-5
040103
PN=98
Lubrication & Maintenance/500 Hour/12 Month
Servicing Fire Extinguisher
A fire extinguisher (A) is available from your authorized
servicing dealer or engine distributor.
RW4918
–UN–15DEC88
Read and follow the instructions which are packaged with
it. The extinguisher should be inspected at least every 500
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.
Fire Extinguisher
A—Fire Extinguisher
RG,RG34710,5567 –19–04JUN02–1/1
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.
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 –19–12NOV01–1/1
30-1
040103
PN=99
Lubrication & Maintenance/500 Hour/12 Month
Servicing Battery
–UN–23AUG88
CAUTION: Battery gas can explode. Keep
sparks and flames away from batteries. Use a
flashlight to check battery electrolyte level.
TS204
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.
Exploding Battery
WARNING: Battery posts, terminals, and related
accessories contain lead and lead compounds, chemicals
known to the State of California to cause cancer and
reproductive harm. Wash hands after handling.
1. On regular batteries, check electrolyte level. Fill each
cell to bottom of filler neck with distilled water.
NOTE: Low-maintenance or maintenance-free batteries
should require little additional service. However,
electrolyte level can be checked by cutting the
center section of decal on dash-line, and
removing cell plugs. If necessary, add clean, soft
water to bring level to bottom of filler neck.
2. Keep batteries clean by wiping them with a damp cloth.
Keep all connections clean and tight. Remove any
corrosion, and wash terminals with a solution of 1 part
baking soda and 4 parts water. Tighten all connections
securely.
NOTE: Coat battery terminals and connectors with a
mixture of petroleum jelly and baking soda to
retard corrosion.
3. Keep battery fully charged, especially during cold
weather. If a battery charger is used, turn charger off
before connecting charger to battery(ies). Attach
POSITIVE (+) battery charger lead to POSITIVE (+)
battery post. Then attach NEGATIVE (–) battery
charger lead to a good ground.
Continued on next page
30-2
RG,RG34710,5568 –19–20MAY96–1/2
040103
PN=100
Lubrication & Maintenance/500 Hour/12 Month
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:
–UN–23AUG88
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.
1. Drink large amounts of water or milk.
2. Then drink milk of magnesia, beaten eggs, or
vegetable oil.
3. Get medical attention immediately.
TS203
If acid is swallowed:
Sulfuric Acid
In freezing weather, run engine at least 30 minutes to
assure thorough mixing after adding water to battery.
If necessary to replace battery(ies), replacements must
meet or exceed the following recommended capacities at
-18°C (0°F):
Specification
12 Volt Standard Duty Starter—
Cold Cranking Amps ............................................................................ 640
12 Volt Heavy Duty Starter—Cold
Cranking Amps ..................................................................................... 800
24 Volt Standard Duty Starter—
Cold Cranking Amps ............................................................................ 570
RG,RG34710,5568 –19–20MAY96–2/2
30-3
040103
PN=101
Lubrication & Maintenance/500 Hour/12 Month
Manual Belt Tensioner Adjustment
NOTE: Two types of manual tensioners shown.
–UN–21DEC99
NOTE: Inspect belts for cracks, fraying, or stretched-out
areas. Replace if necessary.
RG10556
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.
Check Belt Tension
NOTE: If timing gear cover or alternator bracket interfere
with installation/centering of belt tension gauge
(A), install gauge with face toward engine.
–UN–21DEC99
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.)
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.
RG10557
2. Loosen cap screws (B) and (C).
Adjust Belt Tension
A—Belt Tension Gauge
B—Cap Screw
C—Cap Screw
D—Tensioner Bracket
Specification
New Belt—Tension ................................. 470—650 N (105—145 lb-force)
Used Belt—Tension.................................. 400—580 N (90—130 lb-force)
5. Tighten cap screws (B) and (C).
NOTE: After ten minutes run-in, new belts are considered
used. Belt tension must then be rechecked per
used belt specifications.
6. Run engine for ten minutes and immediately re-check
belt tension per used belt specification above.
7. Reset belt tension as necessary.
DPSG,RG41165,128 –19–04JUN02–1/1
30-4
040103
PN=102
Lubrication & Maintenance/500 Hour/12 Month
Manual Belt Tensioner Adjustment Using
Belt Tension Tool (Alternate Method For
Engines Without Auxiliary Drive)
–UN–31OCT01
NOTE: The JD1520 Belt Tension Tool may not be
compatible with all alternators. In that case, use
the preceding method for belt tensioning.
RG11812
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.
Alternator Bracket and Cap Screws
RG11813
–UN–31OCT01
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.
Belt Tension Tool
A—Upper Alternator Bracket Cap Screw
B—Lower Alternator Bracket Cap Screw
C—JDG1520 Belt Tension Tool
D—Belt
Continued on next page
30-5
OUOD002,000016D –19–05JUN02–1/2
040103
PN=103
Lubrication & Maintenance/500 Hour/12 Month
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.
–UN–31OCT01
Specification
New Belt—Tension ................................. 470—650 N (105—145 lb-force)
Used Belt—Tension.................................. 400—580 N (90—130 lb-force)
Desired Belt Tension N
(lb-force)
Applied Torque N•m (lb-ft)
445 (100)
108 (90)
489 (110)
115 (85)
534 (120)
122 (90)
623 (140)
135 (100)
RG11814
JDG1520 Belt Tensioning Tool Torque Table
Belt Tension Tool and Torque Wrench
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.
–UN–31OCT01
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.
RG11815
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
Scribe Reference Mark
OUOD002,000016D –19–05JUN02–2/2
30-6
040103
PN=104
Lubrication & Maintenance/500 Hour/12 Month
Changing Engine Oil and Replacing Filter
Your engine is equipped with a special oil filter (A).
–UN–24OCT01
NOTE: During break-in, change engine oil and filter for
the first time before 100 hours maximum of
operation.
RG11616
After break-in, if John Deere PLUS-50 or ACEA-E4/E5
engine oil and a John Deere special oil filter are used, the
oil and filter change interval is 500 hours or every 12
months, whichever comes first.
Special Oil Filter
–UN–29NOV88
NOTE: If the above recommendations are not followed,
the oil and filter change interval is every 250
hours/ or 6 months. If diesel fuel with a high sulfur
content is used, the oil and filter change interval is
also reduced. (See DIESEL ENGINE OIL in the
“Fuels, Lubricants, and Coolant” section.
RG4881
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.
Oil Pan Drain Plug
A—Oil Filter Element
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).
3. Drain crankcase oil from engine while warm.
NOTE: Drain plug location may vary, depending on the
application.
PLUS-50 is a trademark of Deere & Company.
OILSCAN is a trademark of Deere & Company.
OILSCAN PLUS is a trademark of Deere & Company.
Continued on next page
30-7
OUOD002,0000168 –19–25FEB03–1/3
040103
PN=105
Lubrication & Maintenance/500 Hour/12 Month
4. Turn filter element (A) using a suitable filter wrench to
remove. Discard oil filter element.
–UN–24OCT01
NOTE: Depending on engine application, oil filter may be
located on either side of the engine in a high- or
low-mount location.
RG11616
IMPORTANT: Filtration of oils is critical to proper
lubrication. Always change filter
regularly. Use filter meeting John Deere
performance specifications.
Oil Filter And Mounting Header
5. Apply clean engine oil to the new filter at the inner (B)
and outer (C) seals and to filter threads.
–UN–24OCT01
6. Wipe both sealing surfaces of the header (D, E) with a
clean rag. Ensure dust seal (F) is in place, replace if
damaged.
RG11617
IMPORTANT: When installing filter element, HAND
TIGHTEN only. A filter wrench may be
used for REMOVAL ONLY.
7. Install and tighten oil filter by hand until firmly against
dust seal (F). DO NOT apply an extra 3/4 to 1-1/4 turn
after gasket contact as done with standard filters.
Oil Filter Seals
–UN–24OCT01
8. Tighten drain plug to specifications.
RG11618
Specification
Oil Pan Drain Plug With Copper
Washer—Torque ............................................................. 70 N•m (52 lb ft)
Oil Pan Drain Plug With O-Ring—
Torque ............................................................................. 50 N•m (37 lb ft)
Oil Pan Drain Plug With Packing
(6068 Engine Code 1961, Steel
Oil Pan)—Torque............................................................. 40 N•m (29 lb ft)
Filter And Mounting Header
A—Oil Filter Element
B—Inner Seal
C—Outer Seal
D—Sealing Surface On Header
E—Sealing Surface On Header
F—Dust Seal
Continued on next page
30-8
OUOD002,0000168 –19–25FEB03–2/3
040103
PN=106
Lubrication & Maintenance/500 Hour/12 Month
–UN–24OCT01
9. Fill engine crankcase with correct John Deere engine
oil through rocker arm cover opening (A) or either side
oil filler (B) depending on engine application. (See
DIESEL ENGINE OIL in Fuels, Lubricants, and Coolant
Section for determining correct engine oil.)
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.
RG11619
To determine the correct oil fill quantity for your engine,
see ENGINE CRANKCASE OIL FILL QUANTITIES in
the Specifications Section of this manual.
Rocker Arm Cover Oil Filler Opening
–UN–24OCT01
NOTE: Crankcase oil capacity may vary slightly.
ALWAYS fill crankcase within crosshatch marks
on dipstick. DO NOT overfill.
10. Start engine and run to check for possible leaks.
RG11942
11. Stop engine and check oil level after 10 minutes. Oil
level reading should be within crosshatch of dipstick.
Oil Filler At Side Of Engine
A—Rocker Arm Cover Oil Filler Opening
B—Oil Filler At Side Of Engine
OUOD002,0000168 –19–25FEB03–3/3
Cleaning Crankcase Vent Tube
If you operate the engine in dusty conditions, clean the
tube at shorter intervals.
–UN–19JUN00
1. Remove and clean crankcase vent tube (A).
A—Crankcase Vent Tube
RG8017A
2. Install the vent tube. Be sure the O-ring fits correctly in
the rocker arm cover for elbow adapter. Tighten hose
clamp securely.
Crankcase Vent Tube
RG,RG34710,5574 –19–12NOV01–1/1
30-9
040103
PN=107
Lubrication & Maintenance/500 Hour/12 Month
Checking Air Intake System
–UN–20DEC88
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.
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.
RG4689
1. Inspect all intake hoses (piping) for cracks. Replace as
necessary.
Check Clamps
–UN–22JAN99
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.
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.
RG7332B
IMPORTANT: ALWAYS REPLACE primary air cleaner
element when air restriction indicator
shows a vacuum of 625 mm (25 in.)
H2O, is torn, or visibly dirty.
Underloader Valve and Air Restriction Indicator
A—Clamps
B—Dust Unloader Valve
C—Air Restriction Indicator
RG,RG34710,5575 –19–23NOV01–1/1
30-10
040103
PN=108
Lubrication & Maintenance/500 Hour/12 Month
Replacing Fuel Filter Elements
–UN–23AUG88
Engines may be equipped with either a primary fuel filter
(or pre-filter) with water bowl and a final filter, or only a
final filter including water bowl. Both filters are replaced at
the same 500-hour interval.
X9811
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.
High-Pressure Fluids
RG7721
–UN–15JAN99
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.
Final Fuel Filter
1. Close fuel shut-off valve, if equipped.
2. Thoroughly clean fuel filter assemblies and surrounding
areas.
3. Disconnect water sensor wiring (if equipped).
–UN–05DEC01
4. Loosen drain plugs (C) and drain fuel into a suitable
container.
NOTE: Lifting up on retaining ring (A) as it is rotated
helps to get it past raised locators.
RG11954
5. Firmly grasp the retaining ring (A) and rotate it
counterclockwise 1/4 turn. Remove ring with filter
element (B).
Primary Fuel Filter (or Pre-Filter, If Equipped)
6. Inspect filter mounting base for cleanliness. Clean as
required.
A—Retaining Ring
B—Filter Element
C—Drain Plug
D—Bleed Plug
E—Water Bowl
Continued on next page
30-11
RG,RG34710,5576 –19–05JUN02–1/2
040103
PN=109
Lubrication & Maintenance/500 Hour/12 Month
NOTE: Raised locators on fuel filter canisters must be
indexed properly with slots in mounting base for
correct installation.
7. Install new filter elements onto mounting bases. Be
sure elements are properly indexed and firmly seated
on bases. It may be necessary to rotate filters for
correct alignment.
If equipped with water separator bowl (E), remove filter
element from separator bowl. Drain and clean
separator bowl. Dry with compressed air. Install bowl
onto new element. Tighten securely.
8. Align keys on filter element with slots in filter base.
9. Install retaining ring onto mounting base making certain
dust seal is in place on filter base. Hand tighten ring
(about 1/3 turn) until it “snaps” into the detent. DO
NOT overtighten retaining ring.
NOTE: The proper installation is indicated when a "click"
is heard and a release of the retaining ring is felt.
A plug is provided with the new element for
plugging the used element.
10. Reconnect water sensor wiring (if equipped).
11. Open fuel shut-off valve and bleed the fuel system.
(See BLEEDING FUEL SYSTEM in Service As
Required Section.) Tighten bleed plug (D).
RG,RG34710,5576 –19–05JUN02–2/2
30-12
040103
PN=110
Lubrication & Maintenance/500 Hour/12 Month
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.
RG,RG34710,5578 –19–05JUN02–1/3
Checking Belt Wear
–UN–18NOV97
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.
RG8098
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).
Cast Stops
A—Cast Stops
B—Cast Stop
Continued on next page
30-13
RG,RG34710,5578 –19–05JUN02–2/3
040103
PN=111
Lubrication & Maintenance/500 Hour/12 Month
Checking Tensioner Spring Tension
–UN–14NOV97
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:
RG7977
1. Release tension on belt using a breaker bar and
socket on tension arm. Remove belt from pulleys.
2. Release tension on tension arm and remove breaker
bar.
Marks on Tensioner
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.
RG8037C
6. Record torque wrench measurement and compare with
specification below. Replace tensioner assembly as
required.
–UN–11SEP00
5. Install torque wrench (C) so that it is aligned with
centers of pulley and tensioner. Rotate the swing arm
using a torque wrench until marks (A and B) are
aligned.
Align Marks
Specification
Spring Tension—Torque ....................................... 18-22 N•m (13-16 lb-ft)
–UN–28JAN02
NOTE: Threads on belt tensioner roller cap screw are
LEFT-HAND threads
RG12065
A—Mark On Swing Arm
B—Mark On Tensioner Mounting Base
C—Torque Wrench
Align Torque Wrench With Pulley and Tensioner
RG,RG34710,5578 –19–05JUN02–3/3
30-14
040103
PN=112
Lubrication & Maintenance/500 Hour/12 Month
Checking Engine Electrical Ground
Connections
Keep all engine ground connections clean and tight to
prevent electrical arcing which can damage electronic
components.
Also see precautions in Troubleshooting Section when
welding on engine or machine.
OUOD002,0000169 –19–23NOV01–1/1
Checking Cooling System
–UN–23AUG88
CAUTION: Explosive release of fluids from
pressurized cooling system can cause serious
burns.
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.
TS281
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.
High-Pressure Fluids
1. Visually check entire cooling system for leaks. Tighten
all clamps securely.
2. Thoroughly inspect all cooling system hoses for hard,
flimsy, or cracked condition. Replace hoses if any of
the above conditions are found.
RG,RG34710,5580 –19–12NOV01–1/1
30-15
040103
PN=113
Lubrication & Maintenance/500 Hour/12 Month
Replenishing Supplemental Coolant
Additives (SCAs) Between Coolant Changes
IMPORTANT: Do not add supplemental coolant
additives when the cooling system is
drained and refilled with John Deere
COOL-GARD
–UN–08DEC97
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.
RG6261
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.
Radiator Coolant Check
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.
–UN–05DEC97
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.
COOL-GARD is a trademark of Deere & Company
COOLSCAN is a trademark of Deere & Company
COOLSCAN PLUS is a trademark of Deere & Company
RG6262
Test the coolant solution at 500 hours or 12 months of
operation using either John Deere coolant test strips or a
COOLSCAN or COOLSCAN PLUS analysis. If a
COOLSCAN or COOLSCAN PLUS analysis is not
available, recharge the system per instructions printed on
label of John Deere Liquid Coolant Conditioner.
JTO7298 Coolant/Battery Tester
Continued on next page
30-16
DPSG,OUOD002,1921 –19–25FEB03–1/2
040103
PN=114
Lubrication & Maintenance/500 Hour/12 Month
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 –19–25FEB03–2/2
30-17
040103
PN=115
Lubrication & Maintenance/500 Hour/12 Month
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.
Compare the results to the supplemental coolant
additive (SCA) chart to determine the amount of
inhibiting additives in your coolant and whether more
John Deere COOLANT CONDITIONER should be
added.
Test the coolant solution at intervals of 12 months or
less and whenever excessive coolant is lost through
leaks or overheating.
COOLSCAN Or COOLSCAN PLUS
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.
For a more thorough evaluation of your coolant,
perform a COOLSCAN or COOLSCAN PLUS analysis.
See your John Deere dealer for information about
COOLSCAN or COOLSCAN PLUS.
OUOD002,0000175 –19–23NOV01–1/1
30-18
040103
PN=116
Lubrication & Maintenance/500 Hour/12 Month
RG6557
–UN–20JAN93
–UN–20JAN93
Pressure Testing Cooling System
RG6558
Test Radiator Cap
Test Cooling System
If gauge does not hold pressure, replace radiator
cap.
CAUTION: Explosive release of fluids from
pressurized cooling system can cause
serious burns.
Shut off engine. Only remove filler cap when
cool enough to touch with bare hands.
Slowly loosen cap to first stop to relieve
pressure before removing completely.
NOTE: These tests apply only to John Deere
radiators. For other brands, see manufacturers
literature.
Test Radiator Cap
1. Remove radiator cap and attach to D05104ST
Tester as shown.
2. Pressurize cap to specification listed. Gauge should
hold pressure for 10 seconds at least to pressure
listed if cap is acceptable.
Specification
Radiator Cap Holding Pressure
(Not Opening For 10
Seconds)-All engines except
6068HF275 with VP44 fuel
system on non Gen-Set
applications and 6068HF475 on
non Gen-Set applications—
Pressure....................................................... 70 kPa (0.7 bar) (10 psi)
Radiator Cap Holding Pressure
(Not Opening For 10
Seconds)-6068HF275 with
VP44 fuel system on non
Gen-Set applications and
6068HF475 on non Gen-Set
applications—Pressure .............................. 100 kPa (1.0 bar) (15 psi)
3. Remove the cap from gauge, turn it 180°, and
retest cap. This will verify that the first
measurement was accurate.
Continued on next page
30-19
RG,RG34710,5586 –19–24MAY02–1/2
040103
PN=117
Lubrication & Maintenance/500 Hour/12 Month
4. With pressure applied, check all cooling system
hose connections, radiator, and overall engine for
leaks.
Test Cooling System
NOTE: Engine should be warmed up to test overall
cooling system.
If leakage is detected, correct as necessary and
pressure test system again.
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.
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.
3. Connect gauge and adapter to radiator filler neck.
Pressurize cooling system to specification listed for
radiator cap.
RG,RG34710,5586 –19–24MAY02–2/2
Checking and Adjusting Engine Speeds
RG12607
–UN–24OCT02
If equipped with a tachometer (A) on the instrument panel,
observe tachometer reading to verify engine speeds.
(Refer to ENGINE POWER RATINGS AND FUEL
SYSTEM SPECIFICATIONS in Specifications Section
later in this manual for engine speed specifications.) If
engine speed adjustment is required, see your authorized
servicing dealer or engine distributor.
A—Tachometer
Using Tachometer to Check Engine Speeds
OURGP12,00001DB –19–25FEB03–1/1
30-20
040103
PN=118
Lubrication & Maint./2000 Hour/24 Month
Adjusting Variable Speed (Droop) — 4.5 L
“270” Generator Set Engines 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.
–UN–29JAN02
4. Run engine at fast idle, then apply load until reaching
rated speed.
5. Check power. Adjust with the screw (A) if needed.
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
6. Remove load from engine.
Droop Adjustment Screw
A—Adjustment Screw
B—Fast Idle Adjustment
C—Slow Idle Adjustment
9. Reinstall throttle linkage if previously removed.
OURGP12,00001ED –19–14MAR03–1/1
35-1
040103
PN=119
Lubrication & Maint./2000 Hour/24 Month
Checking Crankshaft Vibration Damper
(6-Cylinder Engine Only)
1. Remove belts (shown removed).
RG8018
IMPORTANT: The vibration damper assembly is not
repairable and should be replaced every
4500 hours or 60 months, whichever
occurs first.
–UN–15JAN99
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.
Grasp Vibration Damper
3. Check vibration damper radial runout by positioning a
dial indicator (A) so probe contacts damper outer
diameter.
–UN–23NOV97
4. With engine at operating temperature, rotate crankshaft
using either JD281A, JDE81-4, or JDE83 Flywheel
Turning Tool.
Specification
Vibration Damper—Maximum
Radial Runout ............................................................. 1.50 mm (0.060 in.)
RG7508
5. Note dial indicator reading. If runout exceeds
specifications given below, replace vibration damper.
Check Runout
RG,RG34710,5585 –19–12NOV01–1/1
35-2
040103
PN=120
Lubrication & Maint./2000 Hour/24 Month
Flushing and Refilling Cooling System
–UN–23AUG88
CAUTION: Explosive release of fluids from
pressurized cooling system can cause serious
burns.
TS281
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).
High-Pressure Fluids
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.
–UN–13FEB03
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.)
RG12833
2. Slowly open the engine cooling system filler cap or
radiator cap (A) to relieve pressure and allow coolant
to drain faster.
Radiator Cap
Continued on next page
35-3
RG,RG34710,5587 –19–25FEB03–1/3
040103
PN=121
Lubrication & Maint./2000 Hour/24 Month
3. All Except 4045HF475 and 6068HF475 Engines:
Open engine block drain valve (A) on left side of
engine. Drain all coolant from engine block.
–UN–19JUN00
NOTE: On 475 engines, the engine block drain valve is
located behind the fuel rail, and is not easily
accessible.
RG8019A
4045HF475 and 6068HF475 Engines: Open drain
plug (B) or (C) on oil cooler housing. Drain all coolant
from engine block.
Engine Block Drain Valve- Except 475 Engines
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.
–UN–11JUN02
4. Open radiator drain valve. Drain all coolant from
radiator.
RG12223
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. Close all drain valves after coolant has drained.
Engine Block Coolant Drain Plug- 475 Engines
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.
A—Engine Block Drain Valve
B—Engine Block Drain Plug
C—Engine Block Drain Plug
7. Fill the cooling system with clean water. Run the
engine about 10 minutes to stir up possible rust or
sediment.
8. Stop engine, pull off lower radiator hose and remove
radiator cap. Immediately drain the water from system
before rust and sediment settle.
Continued on next page
35-4
RG,RG34710,5587 –19–25FEB03–2/3
040103
PN=122
Lubrication & Maint./2000 Hour/24 Month
9. 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.
10. 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.
11. Close all drain valves on engine and radiator.
Reinstall radiator hose and tighten clamps securely.
Install thermostats using a new gasket. (See
TESTING THERMOSTATS OPENING
TEMPERATURE later in this section.)
IMPORTANT: Air must be expelled from cooling
system when system is refilled. Loosen
temperature sending unit fitting at rear
of cylinder head or plug in thermostat
housing to allow air to escape when
filling system. Retighten fitting or plug
after filling cooling system.
12. 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)
13. 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).
14. After running engine, check coolant level and entire
cooling system for leaks.
Fleetguard is a trademark of Cummins Engine Company, Inc.
RESTORE is a trademark of Fleetguard.
RESTORE PLUS is a trademark of Fleetguard.
RG,RG34710,5587 –19–25FEB03–3/3
35-5
040103
PN=123
Lubrication & Maint./2000 Hour/24 Month
Testing Thermostats Opening Temperature
To Remove Thermostat(s)
TS281
–UN–23AUG88
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.
High Pressure Fluids
2. Remove radiator pressure cap and partially drain
cooling system.
–UN–15JAN98
3. Remove thermostat cover-to-coolant pump tube (A)
and seal.
RG8115A
A—Cover-To-Coolant Pump Tube
Thermostat Cover-to-Coolant Pump Tube
DPSG,RG34710,112 –19–23NOV01–1/5
4. Remove thermostat cover (B) with gasket.
5. Remove thermostat(s)
–UN–13NOV97
6. Remove and discard all gasket material. Clean gasket
surfaces.
RG7921A
7. Clean and check cover for cracks or damage.
B—Thermostat Cover
Thermostat Cover
Continued on next page
35-6
DPSG,RG34710,112 –19–23NOV01–2/5
040103
PN=124
Lubrication & Maint./2000 Hour/24 Month
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.
–UN–23NOV97
3. Suspend thermostat and a thermometer in a container
of water.
RG5971
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.
Rating
71°C
77°C
82°C
89°C
90°C
92°C
96°C
99°C
(160°F)
(170°F)
(180°F)
(192°F)
(195°F)
(197°F)
(205°F)
(210°F)
Testing Thermostat Opening Temperature
THERMOSTAT TEST SPECIFICATIONS
Initial Opening (Range)
Full Open
(Nominal)
69—72°C (156—162°F)
84°C (182°F)
74—78°C (166—172°F)
89°C (192°F)
80—84°C (175—182°F)
94°C (202°F)
86—90°C (187—194°F)
101°C (214°F)
89—93°C (192—199°F)
103°C (218°F)
89—93°C (193—200°F)
105°C (221°F)
94—97°C (201—207°F)
100°C (213°F)
96—100°C (205—212°F)
111°C (232°F)
5. Remove thermostat and observe its closing action as it
cools. In ambient air the thermostat should close
completely. Closing action should be smooth and slow.
6. Replace any defective thermostat. On a dual
thermostat engine, replace both thermostats.
Continued on next page
35-7
DPSG,RG34710,112 –19–23NOV01–3/5
040103
PN=125
Lubrication & Maint./2000 Hour/24 Month
To Install Thermostats
–UN–06NOV97
IMPORTANT: Install manifold gasket so that smaller
(round) holes are at lower left and
upper right corners of manifold
(matching studs A).
RG7614A
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.
Installing Thermostat Cover
3. Install thermostat(s) with jiggle wire facing up in the 12
o’clock position.
–UN–13NOV97
4. Using a screwdriver to hold thermostat(s) in place,
install thermostat(s) and coolant manifold/thermostat
cover.
5. Tighten cover cap screws to 70 N•m (52 lb-ft).
RG7921B
6. Lubricate new O-ring with PT507 Multi-Purpose
Grease. Install seal (B) in thermostat cover.
A—Guide Studs
B—Seal
Thermostat Cover Seal
DPSG,RG34710,112 –19–23NOV01–4/5
7. Install coolant manifold/thermostat cover-to-coolant
pump tube (C). Tighten clamps.
RG8115B
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.
–UN–15JAN98
8. If not already done, fill cooling system and check for
leaks.
Cover-To-Coolant Pump Tube
C—Cover-To-Coolant Pump Tube
DPSG,RG34710,112 –19–23NOV01–5/5
35-8
040103
PN=126
Lubrication & Maint./2000 Hour/24 Month
Check and Adjust Valve Clearance (All
Engines Except 4045HF475 And 6068HF475)
–UN–06AUG96
CAUTION: To prevent accidental starting of
engine while performing valve adjustments,
always disconnect NEGATIVE (—) battery
terminal.
RG7408
IMPORTANT: Valve clearance MUST BE checked and
adjusted with engine COLD.
1. Remove rocker arm cover and crankcase ventilator
tube.
Flywheel Housing Timing Holes
A—Timing/Rotation Hole
B—Timing Pin Hole
IMPORTANT: Visually inspect contact surfaces of
valve tips and rocker arm wear pads.
Check all parts for excessive wear,
breakage, or cracks. Replace parts that
show visible damage.
Rocker arms that exhibit excessive
valve clearance should be inspected
more thoroughly to identify damaged
parts.
2. Remove plastic plugs or cover plate from engine
timing/rotation hole (A) and timing pin hole (B).
NOTE: Some engines are equipped with flywheel
housings which do not allow use of an engine
flywheel rotation tool. These engines may be
rotated from front nose of engine, using JDG966
Crankshaft Front/Rear Rotation Adapter.
3. Using JDE83 or JDG281AFlywheel Turning Tool, rotate
engine flywheel in running direction (clockwise viewed
from front) until No. 1 cylinder is at TDC compression
stroke. Insert JDG1571 Timing Pin in flywheel.
If No.1 cylinder rocker arms are loose, the engine is at
No. 1 TDC compression.
If No. 1 cylinder rocker arms are not loose, rotate
engine one full revolution (360°) to No. 1 TDC
compression.
Continued on next page
35-9
DPSG,RG41165,137 –19–12MAR03–1/5
040103
PN=127
Lubrication & Maint./2000 Hour/24 Month
4. With engine lock-pinned at TDC of No. 1 piston’s
compression stroke, check valve clearance to following
specifications. (Use sequence for 4-cylinder or
6-cylinder engines as outlined on next page.)
Specification
Intake Valve Clearance For
Checking (Rocker Arm-to-Valve
Tip) (Engine Cold)—Clearance ......................................... 0.31—0.38 mm
(0.012—0.015 in.)
Exhaust Valve Clearance For
Checking (Rocker Arm-to-Valve
Tip) (Engine Cold)—Clearance ......................................... 0.41—0.48 mm
(0.016—0.019 in.)
DPSG,RG41165,137 –19–12MAR03–2/5
RG7409
–UN–06AUG96
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)
Adjusting Valves
A—Adjusting Screw Jam Nut
6. Replace rocker arm cover and crankcase ventilator
tube.
Continued on next page
35-10
DPSG,RG41165,137 –19–12MAR03–3/5
040103
PN=128
Lubrication & Maint./2000 Hour/24 Month
4-Cylinder Engine:
NOTE: Firing order is 1-3-4-2.
–UN–31OCT97
1. Using JDE81-4 Timing Pin, lock No. 1 piston at TDC
compression stroke (B).
RG4776
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-Cylinder Engine Valve Adjustment
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
DPSG,RG41165,137 –19–12MAR03–4/5
6-Cylinder Engine:
NOTE: Firing order is 1-5-3-6-2-4.
–UN–31OCT97
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.
RG4777
3. Turn crankshaft 360°. Lock No. 6 piston at TDC
compression stroke (C).
6-Cylinder Engine Valve Adjustment
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
DPSG,RG41165,137 –19–12MAR03–5/5
35-11
040103
PN=129
Lubrication & Maint./2000 Hour/24 Month
Check and Adjust Valve Clearance
(4045HF475 And 6068HF475 Engines)
CAUTION: To prevent accidental starting of
engine while performing valve adjustments,
always disconnect NEGATIVE (—) battery
terminal.
–UN–03JUL02
IMPORTANT: Valve clearance MUST BE checked and
adjusted with engine COLD.
RG12168
1. Remove rocker arm cover and crankcase ventilator
tube.
IMPORTANT: Visually inspect contact surfaces of
valve tips, bridges and rocker arm wear
pads. Check all parts for excessive
wear, breakage, or cracks. Replace
parts that show visible damage.
Flywheel Housing Timing Holes
A—Timing/Rotation Hole
B—Timing Pin Hole
Rocker arms that exhibit excessive
valve clearance should be inspected
more thoroughly to identify damaged
parts.
2. Remove plastic plugs or cover plate from engine
timing/rotation hole (A) and timing pin hole (B).
NOTE: Some engines are equipped with flywheel
housings which do not allow use of an engine
flywheel rotation tool. These engines with straight
nose crankshafts may be rotated from front nose
of engine, using JDG966 Crankshaft Front/Rear
Rotation Adapter.
3. Using JDE83 or JDG820 Flywheel Turning Tool, rotate
engine flywheel in running direction (clockwise viewed
from front) until No. 1 (front) cylinder is at TDC
compression stroke. Insert JDG1571 or JDE81-4
Timing Pin in flywheel.
If No. 1 cylinder rocker arms are loose, the engine is at
No. 1 TDC compression.
If No. 1 cylinder rocker arms are not loose, rotate
engine one full revolution (360°) to No. 1 TDC
compression.
Continued on next page
35-12
OUO1089,0000208 –19–12MAR03–1/5
040103
PN=130
Lubrication & Maint./2000 Hour/24 Month
4. With engine lock-pinned at TDC of No. 1 piston’s
compression stroke, check valve clearance to following
specifications. (Use sequence for 4-cylinder or
6-cylinder engines as outlined on next page.)
Specification
Intake Valve Clearance Checking
(Rocker Arm-to-Bridge) (Engine
Cold)—Clearance ................................ 0.31—0.38 mm (0.012—0.015 in.)
Exhaust Valve Clearance
Checking (Rocker Arm-to-Bridge)
(Engine Cold)—Clearance................... 0.41—0.48 mm (0.016—0.019 in.)
OUO1089,0000208 –19–12MAR03–2/5
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.
RG12169
–UN–03JUL02
Specification
Intake Valve Clearance
Adjustment (Rocker
Arm-to-Bridge) (Engine Cold)—
Clearance ................................................................... 0.36 mm (0.014 in.)
Exhaust Valve Clearance
Adjustment (Rocker
Arm-to-Bridge) (Engine Cold)—
Clearance ................................................................... 0.46 mm (0.018 in.)
Rocker Arm Adjusting Screw Jam
Nut—Torque .................................................................... 27 N•m (20 lb-ft)
Adjusting Valves
A—Adjusting Screw Jam Nut
NOTE: While rocker arm cover is removed, test glow
plugs. (See following procedure.)
6. Install rocker arm cover and crankcase ventilator tube.
7. Reconnect battery terminal.
Continued on next page
35-13
OUO1089,0000208 –19–12MAR03–3/5
040103
PN=131
Lubrication & Maint./2000 Hour/24 Month
4-Cylinder Engine:
E
NOTE: Firing order is 1-3-4-2.
A
3
4
E
I
1. Using JDG1571 or JDE81-4 Timing Pin, lock No. 1
piston at TDC compression stroke (B).
1
2
I
E
I
E
I
E
I
E
I
I
RG12357
2. Adjust valve clearance on No. 1 and 3 exhaust valves
and No. 1 and 2 intake valves.
E
I
1
2
3
4
E
–UN–29MAY02
B
C
3. Turn crankshaft 360°. Lock No. 4 piston at TDC
compression stroke (C).
4-Cylinder Valve Adjustment
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
OUO1089,0000208 –19–12MAR03–4/5
NOTE: Firing order is 1-5-3-6-2-4.
I
E
I
E
A
3
4
5
6
E
E
I
1. Lock No. 1 piston at TDC compression stroke (B).
1
2
I
E
I
E
I
E
I
E
I
B
3. Turn crankshaft 360°. Lock No. 6 piston at TDC
compression stroke (C).
I
E
I
E
1
2
3
E
I
I
RG12170
E
4
5
6
2. Adjust valve clearance on No. 1, 3 and 5 exhaust
valves and No. 1, 2, and 4 intake valves.
–UN–21MAY02
6-Cylinder Engine:
C
6-Cylinder Valve Adjustment
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
OUO1089,0000208 –19–12MAR03–5/5
35-14
040103
PN=132
Lubrication & Maint./2000 Hour/24 Month
Test Glow Plugs for Continuity (4045HF475
And 6068HF475 Engines)
CAUTION: To prevent accidental starting of
engine while performing this test, always
disconnect NEGATIVE (—) battery terminal.
While checking valve clearance with rocker arm cover
removed, check each glow plug for continuity using a
multimeter.
Check continuity between glow plug and ground on
cylinder head. If resistance is infinite (no current), the glow
plug is damaged and must be replaced.
Install new glow plugs and torque to specifications.
Specification
Glow Plug—Torque ............................................ 12—18 N•m (9—13 lb-ft)
Reinstall rocker arm cover and crankcase ventilator tube.
OUOD006,0000018 –19–05JUN02–1/1
35-15
040103
PN=133
Service as Required
Additional Service Information
RG4624
–UN–15DEC88
This is not a detailed service manual. If you want more
detailed service information, use the Publications
Information in the back of this manual to order a
component technical manual.
Component Technical Manual
RG,RG34710,5591 –19–23NOV01–1/1
40-1
040103
PN=134
Service as Required
Do Not Modify Fuel System
CAUTION: Do not open high-pressure fuel
system.
TS1343
–UN–18MAR92
High-pressure fluid remaining in fuel lines can
cause serious injury. Do not disconnect or
attempt repair of fuel lines, sensors, or any
other components between the high-pressure
fuel pump and nozzles on engines with High
Pressure Common Rail (HPCR) fuel system.
High-Pressure Fuel Lines
Only technicians familiar with this type of
system can perform repairs. (See your John
Deere dealer.)
RG11953
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.
–UN–26NOV01
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.
Fuel Injection Pump
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.)
RG,RG34710,5592 –19–25MAR03–1/1
40-2
040103
PN=135
Service as Required
Adding Coolant
–UN–23AUG88
CAUTION: Explosive release of fluids from
pressurized cooling system can cause serious
burns.
TS281
Shut off engine. Only remove filler cap when
cool enough to touch with bare hands. Slowly
loosen cap to first stop to relieve pressure
before removing completely.
IMPORTANT: Never pour cold liquid into a hot
engine, as it may crack cylinder head or
block. DO NOT operate engine without
coolant for even a few minutes.
High-Pressure Fluids
John Deere TY15161 Cooling System
Sealer may be added to the radiator to
stop leaks. DO NOT use any other
stop-leak additives in the cooling
system.
Air must be expelled from cooling
system when coolant is added.
–UN–14DEC88
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.
RG4675
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.)
Radiator and Coolant
A—Radiator
Do not overfill cooling system. A
pressurized system needs space for
heat expansion without overflowing at
top of radiator.
2. Fill radiator (A) until coolant level touches bottom of
radiator filler neck.
3. Tighten plugs and fittings when air has been expelled
from system.
Continued on next page
40-3
RG,RG34710,5593 –19–05MAR03–1/2
040103
PN=136
Service as Required
4. Run engine until it reaches operating temperature.
RG,RG34710,5593 –19–05MAR03–2/2
40-4
040103
PN=137
Service as Required
Replacing Single Stage Air Cleaner
–UN–06SEP00
IMPORTANT: ALWAYS REPLACE air cleaner when air
restriction indicator shows a vacuum of
625 mm (25 in.) H2O, is torn, or visibly
dirty.
RG11319A
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.
Single Stage Air Filter
1. If equipped, loosen body clamp.
2. Loosen clamp around outlet neck (A).
3. Remove air cleaner.
–UN–07SEP00
4. Install new filter so that overlap (B) of air cleaner outlet
neck and engine intake pipe is to specification below.
RG11320
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.)
Installation of Single Stage Air Cleaner
A—Outlet Neck Clamp
B—Filter to Engine Overlap
IMPORTANT: Do NOT overtighten body clamp.
Overtightening may cause crushing of
air cleaner body. Tighten body clamp
only until snug.
6. If equipped, tighten body clamp until snug.
IMPORTANT: Whenever the air cleaner has been
serviced or removed, ALWAYS fully
depress the air restriction indicator
reset button (if equipped) to assure
accurate readings.
7. If equipped, fully depress air restriction indicator reset
button and release to reset indicator.
RG,RG34710,5594 –19–20MAY96–1/1
40-5
040103
PN=138
Service as Required
Replacing Axial Seal Air Cleaner Filter
Element
–UN–20DEC88
IMPORTANT: ALWAYS REPLACE primary air cleaner
element when air restriction indicator
shows a vacuum of 625 mm (25 in.)
H2O, is torn, or visibly dirty.
RG4686
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.
Wing Nut and Primary Element
1. Remove wing nut and remove canister cover shown in
small illustration inset.
2. Remove wing nut (A) and remove primary element (B)
from canister.
–UN–20DEC88
3. Thoroughly clean all dirt from inside canister.
RG4687
NOTE: Some engines may have a dust unloader valve
(C) on the air cleaner. If equipped, squeeze valve
tip to release any trapped dirt particles.
IMPORTANT: Remove secondary (safety) element (E)
ONLY for replacement. DO NOT attempt
to clean, wash, or reuse secondary
element. Replacement of secondary
element is usually necessary ONLY
when primary element has a hole in it.
Dust Unloader Valve
RG11068
–UN–26JUN00
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.
Retaining Nut and Secondary Element
A—Wing Nut
B—Primary Element
C—Dust Unloader Valve
D—Retaining Nut
E—Secondary Element
Continued on next page
40-6
RG41165,000008A –19–12NOV01–1/2
040103
PN=139
Service as Required
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.
RG41165,000008A –19–12NOV01–2/2
40-7
040103
PN=140
Service as Required
Replacing Radial Seal Air Cleaner Filter
Element
–UN–08SEP00
IMPORTANT: ALWAYS REPLACE primary air cleaner
element when air restriction indicator
shows a vacuum of 625 mm (25 in.)
H2O, is torn, or visibly dirty.
RG11321A
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.
Dust Cup/Cover
1. Unlatch and remove dust cup/cover (A) of air cleaner.
2. Move end of filter (B) back and forth gently to break
seal.
–UN–08SEP00
3. Pull filter (B) off outlet tube and out of housing.
RG11322A
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.
Primary Filter Element
–UN–08SEP00
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.
RG11327A
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.
Secondary Filter Element
A—Dust Cap/Cover
B—Primary Filter Element
C—Secondary Filter Element
7. Close housing with dust unloader valve aimed down
and latch latches.
Continued on next page
40-8
RG41165,000008B –19–06SEP00–1/2
040103
PN=141
Service as Required
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.
RG41165,000008B –19–06SEP00–2/2
40-9
040103
PN=142
Service as Required
Replacing Fan and Alternator Belts
–UN–07NOV01
Refer to CHECKING BELT TENSIONER SPRING
TENSION AND BELT WEAR in Lubrication and
Maintenance/500 Hour/12 Month Section for additional
information on the belt tensioner.
1. Inspect belts for cracks, fraying, or stretched out areas.
Replace if necessary.
RG11950
2. To replace belt with automatic tensioner, release
tension on belt using a breaker bar and socket on
tension arm.
290 mm (11.4 in.) Fan Height and Lower*
To replace belt with manual tensioner, release tension
at belt tensioner (See MANUAL BELT TENSIONER
ADJUSTMENT in Lubrication and Maintenance/500
Hour/12 Month Section.)
3. Remove poly-vee belt from pulleys and discard belt.
–UN–07NOV01
4. Install new belt, making sure belt is correctly seated in
all pulley grooves. Refer to belt routing at right for your
application.
RG11951
5. Apply tension to belt with tensioner. Remove socket.
6. Start engine and check belt alignment.
338 mm (13.3 in.) Fan Height and Higher Without Freon
Compressor*
*Measured from crank centerline to fan drive center.
RG11952
–UN–07NOV01
A—Alternator
CSP—Crankshaft Pulley
FC—Freon (A/C) Compressor
FD—Fan Drive
I—Idler Pulley
T—Tensioner
CP—Coolant Pump
402 mm (15.8 in.) Fan Height With Freon Compressor*
RG,RG34710,5599 –19–05JUN02–1/1
40-10
040103
PN=143
Service as Required
Checking Fuses
Check fuse (A) located in fuse holder on face of
instrument panel. If defective, replace with a 5-amp fuse.
NOTE: On 4045DF/TF 270 engines, refer to supplier’s
instructions and diagrams for fuse location and
type.
RG11938
On 4045HF475 and 6068HF475 engines, a separate
wiring harness for glow plugs (not shown) has fuse
protection. To replace fuse, remove cap from holder on
jumper cable and replace with a 50-amp fuse.
–UN–06NOV01
A separate wiring harness fuse (10 amp) and a main
system fuse (20 amp) are shown in the Wiring Diagrams
in the Troubleshooting Section.
Engines with Electronic Instrument Panel
A—5 Amp Fuse
RG,RG34710,5601 –19–05MAR03–1/1
Checking Air Compressors (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).
RG12836
–UN–27FEB03
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.
Air Compressor (Optional)
OURGP12,00001E0 –19–26FEB03–1/1
40-11
040103
PN=144
Service as Required
Bleeding the Fuel System (Engines With
Electronic Fuel Systems And Bosch VP44
Pump)
X9811
–UN–23AUG88
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.
High-Pressure Fluids
If ANY fluid is injected into the skin, it must be
surgically removed within a few hours by a
doctor familiar with this type injury or gangrene
may result. Doctors unfamiliar with this type of
injury may call the Deere & Company Medical
Department in Moline, Illinois, or other
knowledgeable medical source.
Bleed the fuel system anytime the fuel system has been
opened up. This includes:
•
•
•
•
After fuel filter changes.
After pump or nozzle replacement.
Anytime fuel lines have been disconnected.
After engine has run out of fuel.
This fuel system can only be bled by the electronic
transfer pump or at the injection nozzles. BLEEDING
SHOULD NOT BE PERFORMED at any location on the
Bosch VP44 injection pump.
Continued on next page
40-12
OUOD002,000016A –19–25FEB03–1/3
040103
PN=145
Service as Required
Bleed Using Electronic Transfer Pump
–UN–20JUN01
The bleed is automatically performed by a small orifice (A)
inside the final fuel filter base connected to the overflow
valve on injection pump. The system allows air to escape
continually through the fuel return line (B) when ignition is
ON.
RG11719A
1. Ignition ON.
2. Allow 40 seconds for electronic transfer pump to
complete priming.
Bleed Fuel System
3. If additional system bleeding is required, bleed the
circuit by loosening fuel line connections at injection
nozzles. See the next procedure, BLEED FUEL SYSTEM
AT FUEL INJECTION NOZZLES.
A—Bleed Orifice in Final Fuel Filter Base
B—Fuel Return Line
OUOD002,000016A –19–25FEB03–2/3
Bleed Fuel System at Fuel Injection Nozzles
–UN–08JAN97
IMPORTANT: Always use a backup wrench when
loosening or tightening fuel lines at
nozzles and/or injection pump to avoid
damage.
2. Crank engine over with starter motor for 15 seconds
(but do not start engine) until fuel free from bubbles
flows out of loosened connection. Retighten connection
to specifications.
RG7725
1. Using two open-end wrenches, loosen two fuel line
connections at injection nozzles.
Bleed At Fuel Injection Nozzles
Specification
Fuel Injection Nozzle Delivery
Line—Torque ................................................................... 27 N•m (20 lb-ft)
3. Repeat procedure for remaining injection nozzles (if
necessary) until all air has been removed from fuel
system.
OUOD002,000016A –19–25FEB03–3/3
40-13
040103
PN=146
Service as Required
Bleed the Fuel System (Engines with
Electronic Fuel Systems and Stanadyne
DE10 Pump)
X9811
–UN–23AUG88
CAUTION: Escaping fluid under pressure can
penetrate the skin causing serious injury. Avoid
hazards by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure
fluids.
High Pressure Fluids
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be
surgically removed within a few hours or
gangrene may result. Doctors unfamiliar with
this type of injury may call the Deere &
Company Medical Department in Moline, Illinois,
or other knowledgeable medical source.
Bleed the fuel system anytime the fuel system has been
opened up. This includes:
•
•
•
•
After fuel filter changes.
After pump or nozzle replacement.
Anytime fuel lines have been disconnected.
After engine has run out of fuel.
The fuel system may be bled at one of several locations.
Choose the best location for your engine/machine
application.
Continued on next page
40-14
OUOD002,000016F –19–25FEB03–1/5
040103
PN=147
Service as Required
1. Loosen the air bleed vent screw (A) two full turns by
hand on fuel filter base.
RG11805
–UN–25OCT01
A—Bleed Vent Screw
Final Fuel Filter Bleed Vent Screw
OUOD002,000016F –19–25FEB03–2/5
2. Operate fuel supply pump primer lever (B) or primer
button on fuel filter base (if equipped).
–UN–25OCT01
3. Tighten bleed plug securely, continue operating primer
until pumping action is not felt
4. Start engine and check for leaks.
RG11806
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.
Fuel Supply Pump Primer Lever
B—Primer Lever
Continued on next page
40-15
OUOD002,000016F –19–25FEB03–3/5
040103
PN=148
Service as Required
At Fuel Injection Pump
1. Loosen fuel return line (A) at fuel injection pump.
–UN–25OCT01
2. Operate fuel supply pump primer lever or primer button
on fuel filter base (if equipped).
Specification
Fuel Injection Pump Return
Line—Torque ................................................................... 27 N•m (20 lb-ft)
RG11807
3. As soon as fuel flow is free from air bubbles, tighten
fuel return line to specifications. Primer lever is
spring-loaded and will return to normal position.
Fuel Injection Pump Return Line
A—Fuel Return Line
OUOD002,000016F –19–25FEB03–4/5
At Fuel Injection Nozzles
–UN–25OCT01
IMPORTANT: Always use a backup wrench when
loosening or tightening fuel lines at
nozzles and/or injection pump to avoid
damage.
2. Crank engine over with starter motor for 15 seconds
(but do not start engine) until fuel free from bubbles
flows out of loosened connection. Retighten connection
to specifications.
RG11808
1. Using two open-end wrenches, loosen two fuel line
connections at injection nozzles.
Nozzle Fuel Pressure Line
Specification
Fuel Injection Nozzle Delivery
Lines—Torque ................................................................. 27 N•m (20 lb-ft)
3. Repeat procedure for remaining injection nozzles (if
necessary) until all air has been removed from fuel
system.
If engine still will not start, see your authorized servicing
dealer or engine distributor.
OUOD002,000016F –19–25FEB03–5/5
40-16
040103
PN=149
Service as Required
–UN–18MAR92
Bleed the Fuel System (Engines with
Electronic Fuel Systems and Denso High
Pressure Common Rail) (4045HF475,
6068HF475)
TS1343
CAUTION: High-pressure fluid remaining in fuel
lines can cause serious injury. Do not
disconnect or attempt repair of fuel lines,
sensors, or any other components between the
high-pressure fuel pump and nozzles on
engines with High Pressure Common Rail
(HPCR) fuel system. Only technicians familiar
with this type of system can perform repairs.
(See your John Deere dealer.)
High-Pressure Fuel Lines
X9811
–UN–23AUG88
Escaping fluid under pressure can penetrate the
skin causing serious injury. Avoid hazards by
relieving pressure before disconnecting
hydraulic or other lines. Tighten all connections
before applying pressure. Search for leaks with
a piece of cardboard. Protect hands and body
from high pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be
surgically removed within a few hours or
gangrene may result. Doctors unfamiliar with
this type of injury may call the Deere &
Company Medical Department in Moline, Illinois,
or other knowledgeable medical source.
High Pressure Fluids
Any time the fuel system has been opened up for service
(lines disconnected or filters removed), it will be necessary
to bleed air from the system.
Continued on next page
40-17
OUOD006,0000015 –19–23MAY02–1/3
040103
PN=150
Service as Required
NOTE: These are the 4-valve cylinder head 4.5 L and 6.8
L engines with Denso HP3 pumps and High
Pressure Common Rail (HPCR) fuel systems.
–UN–24MAY02
IMPORTANT: Four valve cylinder head engines are
especially sensitive to fuel
contamination. Do not crack any fuel
lines to bleed the fuel system.
RG12220
1. Loosen the air bleed vent screw (A) two full turns by
hand on fuel filter base.
Final Fuel Filter Bleed Vent Screw
A—Bleed Vent Screw
OUOD006,0000015 –19–23MAY02–2/3
2. Operate fuel supply pump primer lever (B), or primer
button on fuel filter base (if equipped), until fuel flows
out of bleed vent screw.
3. Tighten bleed vent screw securely. Continue operating
primer until pumping action is not felt.
–UN–24MAY02
4. Start engine and check for leaks.
If engine will not start, repeat steps 1-4.
RG12221
B—Primer Lever
Fuel Supply Pump Primer Lever
OUOD006,0000015 –19–23MAY02–3/3
40-18
040103
PN=151
Service as Required
Bleed the Fuel System (4045DF270,
4045TF270)
X9811
–UN–23AUG88
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.
High-Pressure Fluids
If ANY fluid is injected into the skin, it must be
surgically removed within a few hours by a
doctor familiar with this type injury or gangrene
may result. Doctors unfamiliar with this type of
injury may call the Deere & Company Medical
Department in Moline, Illinois, or other
knowledgeable medical source.
IMPORTANT: Do not operate the engine at high
speeds or full loads just before
bleeding the fuel system as this may
cause fuel injection pump failure.
Bleed the fuel system anytime the fuel system has been
opened up. This includes:
•
•
•
•
After fuel filter changes.
After pump or nozzle replacement.
Anytime fuel lines have been disconnected.
After engine has run out of fuel.
Continued on next page
40-19
OURGP12,00001E9 –19–05MAR03–1/5
040103
PN=152
Service as Required
1. Loosen the air bleed vent screw (A) two full turns by
hand on fuel filter base.
RG7947
–UN–13NOV97
A—Vent Screw
Air Bleed Vent Screw
OURGP12,00001E9 –19–05MAR03–2/5
2. Operate supply pump primer lever (B) until fuel flow is
free from air bubbles.
–UN–15JAN99
3. Tighten bleed plug securely, continue operating hand
primer until pumping action is not felt. Push hand
primer inward (toward engine) as far as it will go.
4. Start engine and check for leaks.
RG8013A
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.
Fuel Supply Pump Primer Lever
B—Fuel Supply Pump Primer Lever
Continued on next page
40-20
OURGP12,00001E9 –19–05MAR03–3/5
040103
PN=153
Service as Required
At Fuel Injection Pump
1. Slightly loosen fuel return line connector (A) at fuel
injection pump.
–UN–03NOV97
2. Operate fuel supply pump primer lever until fuel,
without air bubbles, flows from fuel return line
connection.
4. Primer lever is spring-loaded and will return to normal
position.
RG6264
3. Tighten return line connector to 27 N•m (20 lb-ft).
Stanadyne Rotary Fuel Injection Pump
A—Fuel Return Line Connector
OURGP12,00001E9 –19–05MAR03–4/5
At Fuel Injection Nozzles
–UN–08JAN97
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.
RG7725
3. Crank engine over with starter motor, (but do not start
engine), until fuel free from bubbles flows out of
loosened connection.
Fuel Line 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.
If engine still will not start, see your authorized
servicing dealer or engine distributor.
OURGP12,00001E9 –19–05MAR03–5/5
40-21
040103
PN=154
Troubleshooting
General Troubleshooting Information
Troubleshooting engine problems can be difficult. An
engine wiring diagram is provided in this section to
help isolate electrical problems on power units using
John Deere wiring harness and instrument (gauge)
panel.
Wiring diagrams are shown for the electronic
instrument panel and harness offered for these
engines.
Later in this section is a list of possible engine
problems that may be encountered accompanied by
possible causes and corrections. The illustrated
diagrams and troubleshooting information are of a
general nature; final design of the overall system for
your engine application may be different. See your
engine distributor or servicing dealer if you are in
doubt.
• Know the engine and all related systems.
• Study the problem thoroughly.
• Relate the symptoms to your knowledge of engine
and systems.
• Diagnose the problem starting with the easiest
things first.
• Double-check before beginning the disassembly.
• Determine cause and make a thorough repair.
• After making repairs, operate the engine under
normal conditions to verify that the problem and
cause was corrected.
NOTE: The engines covered in this manual have
electronic control systems which send
diagnostic trouble codes to signal problems
(see DIAGNOSTIC TROUBLE CODE
PROCEDURE, later in this section).
A reliable program for troubleshooting engine problems
should include the following basic diagnostic thought
process:
RG,RG34710,5605 –19–12NOV01–1/1
45-1
040103
PN=155
Troubleshooting
Precautions For Welding On Engines
Equipped With Electronic Engine Control
Unit (ECU)
IMPORTANT: ALWAYS disconnect Electronic Control
Unit (ECU) connectors and engine
control system-to-machine ground
before welding on engine or machine.
High currents or electro-static
discharge in electronic components
from welding may cause permanent
damage.
1. Remove the ground connection for the engine control
system-to-machine frame.
2. Disconnect the connectors from the ECU.
3. Connect the welder ground close to the welding point
and be sure ECU or other electronic components are not
in the ground path.
OUOD002,000016B –19–08OCT01–1/1
45-2
040103
PN=156
Troubleshooting
RG12201
–UN–24MAY02
Engine Wiring Layout (Electronic Fuel System With Stanadyne DE10 Injection Pump)
A—Coolant Temperature
Sensor Connector
B—Fuel Temperature Sensor
Connector
C—Injection Pump Solenoid
Connector
D—SAE 1939 CAN Connector
E—Crankshaft Position Sensor
Connector
F—ECU Connector
G—Starter Relay Connector
H—Oil Pressure Sensor
Connector
I—Main System Fuse (10 amp)
J—Power and Ground Battery
Connections
K—Fuse Holder
L—Transient Voltage
Protection (TVP) Module
Connector
M—Remote ON/ OFF
Connector
N—CAN Network Diagnostic
Connector
O—Instrument Panel
Connector Harness
P—23-pin Optional Feature
Connector (Extendedfeature ECU only)
Q—21-pin Instrument Panel
Connector
R—Engine Wiring Harness
S—Fuel Heater Connector
T—Manifold Air Temperature
(MAT) Sensor Connector
U—Alternator Ignition
Connector
V—Optional Instrument Panel
OUOD005,0000180 –19–26APR02–1/1
45-3
040103
PN=157
Troubleshooting
RG11939A
–UN–05JUN02
Engine Wiring Layout (Electronic Fuel System With Bosch VP44 Injection Pump)
A—Oil Pressure Sensor
B—Fuel Pump Relay
C—Fuel Pump Relay Fuse
D—Crankshaft Position Sensor
E—Fuel Injection Pump Event
Sensor
F—Coolant Temperature
Sensor
G—Fuel Injection Pump
Connector
H—Alternator Ignition
Connector
I—Manifold Air Temperature
(MAT) Sensor
J—Fuel Transfer Pump
K—Fuel Heater
L—Fuel Temperature Sensor
M—Network CAN Connector
N—Isochronous Governor
Select Connector
O—Transient Voltage
Protection (TVP) Module
P—Main System Fuse (20
Amp)
Q—Engine Control Unit (ECU)
R—ECU Connector
S—System Ground (ECU must
also be grounded to frame)
T—CAN Network Diagnostic
Connector
U—Blink-Code Diagnostic
Connector
V—Secondary Analog Throttle
Connector
W—Remote ON/OFF
Connector
X—Instrument Panel
Connector
Y—Optional Instrument Panel
Z—Starter Relay Connections
AA—Power and Ground
Battery Connections
BB—Optional Wire Extensions
OUOD002,000016C –19–26APR02–1/1
45-4
040103
PN=158
Troubleshooting
RG12224
–UN–19JUN02
Engine Wiring Layout (Electronic Fuel System With Denso High Pressure Common
Rail)(4045HF475,6068HF475)
6068HF475 Engine Shown
A—Engine Coolant
Temperature (ECT) Sensor
B—Electronic Injector
Connector
C—Manifold Air Temperature
(MAT) Sensor
D—(ECU) Connector
E—Optional Instrument Panel
F—Engine Wiring Harness
G—Engine Oil Pressure
Sensor Connector
H—Power and Ground Battery
Connections
I—Fuel Rail Pressure Sensor
J—Crankshaft Position Sensor
K—Pump Position Sensor
L—Pump Control Valve
Solenoid
M—Fuel Temperature Sensor
OUOD005,0000186 –19–06MAR03–1/1
45-5
040103
PN=159
Troubleshooting
Engine Wiring Diagram (Electronic Instrument Panel)
464 SENSOR RETURN 2
020 CAN SHIELD
904 CAN H
905 CAN L
X1
012 IGN +12V OR +24V
412 ACC
422 STARTER RELAY SOLENOID
A
X2
RUN
S5
ACC.
OFF
RUN
START
OFF
B
F1
B
BAT
012
422
+12V
032
022
K1
050
A
B
S2
N1
B
A
A
B
TO TO TO
ECU ECU ECU
TO
ECU
TO
ECU
–19–24OCT01
050
911
915
414
936
REMOTE ON/OFF
PLUG
TO
ECU
RG11568
X3
TO
ECU
SINGLE
POINT
GROUND
414
X6
050
050
OFF
BUMP UP
OFF
BUMP DN
C
TVP
(12V
OR 24V)
SE-2 INSTRUMENT PANEL (CONTINUED NEXT PAGE)
SE-1 ENGINE START COMPONENTS
B1—Analog Throttle or
Emulator
E1—Back Light Regulator
(24V) or Plug (12V)
F1—Fuse (10 Amp) (for
harness)
F2—Fuse (5 Amp) (for
instrument panel)
G1—Alternator
K1—Starter Relay
M1—Starter Motor
C
B
A
947
B
012
A
B
A
923
A
M1
022
G1
ANALOG
THROTTLE A
C
M1 S
923
G1
HIGH IDLE
LOW IDLE
A
955
S
S4
ALL
B
GND
409
BAT
IGN
C
2
X5
C B A
BUMP
ENABLE
OFF
BUMP
OFF ENABLE
A
B
947
OUT
OUTPUT
ACC
510
OHM
C B A
TO
ECU
S3
IGN
A10AB
002
002
002
V1
032
022
4700
OHM
A
918
ST
B1
ANALOG THROTTLE
EMULATOR
OFF
OVERRIDE
SHUTDOWN
B
A
464
012
S1
012
422
012
002
422
012
002 BAT
N1—Transient Voltage
Protector
N2—Voltage Regulator (for
24V Operation)
P1—Optional Gauge
P2—Optional Gauge
P3—Oil Pressure Gauge
P4—Coolant Temperature
Gauge
P5—Tachometer Display
P6—Hourmeter/Diagnostic
Meter
S1—Ignition Key Switch
S2—Speed Select Switch
(Momentary)
S3—Bump Enable Switch
(Momentary)
S4—High Low Speed Switch
S5—Override Shutdown
Switch (Momentary)
S6—Dimmer Control or
Jumper Plug
V1—Diode
X1—Vehicle Harness
Connector
X2—Alternator Harness
X3—Single Point Ground
X4—CAN Terminator
X5—Analog Throttle
Connector
X6—Remote On-Off Plug
DPSG,OUOD002,1922 –19–12NOV01–1/1
45-6
040103
PN=160
Troubleshooting
RG10040
–19–18MAY99
Engine Wiring Diagram (Electronic Instrument Panel)—Continued
B1—Analog Throttle or
Emulator
E1—Back Light Regulator
(24V) or Plug (12V)
F1—Fuse (10 Amp) (for
harness)
F2—Fuse (5 Amp) (for
instrument panel)
G1—Alternator
K1—Starter Relay
M1—Starter Motor
N1—Transient Voltage
Protector
N2—Voltage Regulator (for
24V Operation)
P1—Optional Gauge
P2—Optional Gauge
P3—Oil Pressure Gauge
P4—Coolant Temperature
Gauge
P5—Tachometer Display
P6—Hourmeter/Diagnostic
Meter
S1—Ignition Key Switch
S2—Speed Select Switch
(Momentary)
S3—Bump Enable Switch
(Momentary)
S4—High Low Speed Switch
S5—Override Shutdown
Switch (Momentary)
S6—Dimmer Control or
Jumper Plug
V1—Diode
X1—Vehicle Harness
Connector
X2—Alternator Harness
X3—Single Point Ground
X4—CAN Terminator
X5—Analog Throttle
Connector
X6—Remote On-Off Plug
DPSG,OUOD002,1923 –19–12NOV01–1/1
45-7
040103
PN=161
Troubleshooting
Engine Troubleshooting
Symptom
Problem
Solution
Engine cranks but will not start
Incorrect starting procedure.
Verify correct starting procedure.
No fuel.
Check fuel in tank.
Exhaust restricted.
Check and correct exhaust
restriction.
Fuel filter plugged or full of water.
Replace fuel filter or drain water
from filter.
Injection pump not getting fuel or air
in fuel system.
Check fuel flow at supply pump or
bleed fuel system.
Faulty injection pump or nozzles.
Consult authorized diesel repair
station for repair or replacement.
Continued on next page
45-8
RG,RG34710,5608 –19–28MAR03–1/8
040103
PN=162
Troubleshooting
Symptom
Problem
Solution
Engine hard to start or will not
start
Engine starting under load.
Disengage PTO.
Improper starting procedure.
Review starting procedure.
No fuel.
Check fuel tank.
Air in fuel line.
Bleed fuel line.
Cold weather.
Use cold weather starting aids.
Slow starter speed.
See “Starter Cranks Slowly”.
Crankcase oil too heavy.
Use oil of proper viscosity.
Improper type of fuel.
Consult fuel supplier; use proper
type fuel for operating conditions.
Water, dirt, or air in fuel system.
Drain, flush, fill, and bleed system.
Clogged fuel filter.
Replace filter element.
Dirty or faulty injection nozzles.
Have authorized servicing dealer or
engine distributor check injectors.
Defective glow plugs (Cold weather
starting-4045HF475, 6068HF475)
Test glow plugs (See 2000 hour/24
month maintenance section)
Electronic fuel system problem (if
equipped)
See your John Deere distributor or
servicing dealer.
Low engine oil level.
Add oil to engine crankcase.
Low coolant temperature.
Remove and check thermostat.
Engine overheating.
See “Engine Overheats”.
Engine cold
Wrong or defective thermostat.
Remove and check thermostat.
Engine knocks
Continued on next page
45-9
RG,RG34710,5608 –19–28MAR03–2/8
040103
PN=163
Troubleshooting
Symptom
Problem
Solution
Engine runs irregularly or stalls
frequently
Low coolant temperature.
Remove and check thermostat.
Clogged fuel filter.
Replace fuel filter element.
Water, dirt, or air in fuel system.
Drain, flush, fill, and bleed system.
Dirty or faulty injection nozzles.
Have authorized servicing dealer or
engine distributor check injectors.
Electronic fuel system problem
See your John Deere distributor or
servicing dealer.
Defective thermostat.
Remove and check thermostat.
Defective temperature gauge or
sender.
Check gauge, sender, and
connections.
Below normal engine
temperature
Continued on next page
45-10
RG,RG34710,5608 –19–28MAR03–3/8
040103
PN=164
Troubleshooting
Symptom
Problem
Solution
Lack of power
Engine overloaded.
Reduce load.
Intake air restriction.
Service air cleaner.
Clogged fuel filter.
Replace filter elements.
Improper type of fuel.
Use proper fuel.
Overheated engine.
See “Engine Overheats”.
Below normal engine temperature.
Remove and check thermostat.
Improper valve clearance.
See your authorized servicing dealer
or engine distributor.
Dirty or faulty injection nozzles.
Have authorized servicing dealer or
engine distributor check injectors.
Injection pump out of time.
See your authorized servicing dealer
or engine distributor.
Electronic fuel system problem
See your John Deere distributor or
servicing dealer.
Turbocharger not functioning.
(Turbocharger engines only.)
See your authorized servicing dealer
or engine distributor.
Leaking exhaust manifold gasket.
See your authorized servicing dealer
or engine distributor.
Defective aneroid control line.
See your authorized servicing dealer
or engine distributor.
Restricted fuel hose.
Clean or replace fuel hose.
Low fast idle speed.
See your authorized servicing dealer
or engine distributor.
Low oil level.
Add oil.
Improper type of oil.
Drain, fill crankcase with oil of proper
viscosity and quality.
Low oil pressure
Continued on next page
45-11
RG,RG34710,5608 –19–28MAR03–4/8
040103
PN=165
Troubleshooting
Symptom
Problem
Solution
High oil consumption
Crankcase oil too light.
Use proper viscosity oil.
Oil leaks.
Check for leaks in lines, gaskets,
and drain plug.
Restricted crankcase vent tube.
Clean vent tube.
Defective turbocharger.
See your authorized servicing dealer
or engine distributor.
Improper type of fuel.
Use proper fuel.
Low engine temperature.
Warm up engine to normal operating
temperature.
Defective thermostat.
Remove and check thermostat.
Defective injection nozzles.
See your authorized servicing dealer
or engine distributor.
Defective glow plugs (4045HF475,
6068HF475)
Test glow plugs (See 2000 hour/24
month maintenance section)
Improper type of fuel.
Use proper fuel.
Clogged or dirty air cleaner.
Service air cleaner.
Engine overloaded.
Reduce load.
Injection nozzles dirty.
See your authorized servicing dealer
or engine distributor.
Electronic fuel system problem
See your authorized servicing dealer
or engine distributor.
Turbocharger not functioning.
See your authorized servicing dealer
or engine distributor.
Engine emits white smoke
Engine emits black or gray
exhaust smoke
Continued on next page
45-12
RG,RG34710,5608 –19–28MAR03–5/8
040103
PN=166
Troubleshooting
Symptom
Problem
Solution
Engine overheats
Engine overloaded.
Reduce load.
Low coolant level.
Fill radiator to proper level, check
radiator and hoses for loose
connections or leaks.
Faulty radiator cap.
Have technician check.
Stretched poly-vee belt or defective
belt tensioner.
Check automatic belt tensioner and
check belts for stretching. Replace
as required.
Low engine oil level.
Check oil level. Add oil as required.
Cooling system needs flushing.
Flush cooling system.
Defective thermostat.
Remove and check thermostat.
Defective temperature gauge or
sender.
Check coolant temperature with
thermometer and replace, if
necessary.
Incorrect grade of fuel.
Use correct grade of fuel.
Improper type of fuel.
Use proper type of fuel.
Clogged or dirty air cleaner.
Service air cleaner.
Engine overloaded.
Reduce load.
Improper valve clearance.
See your authorized servicing dealer
or engine distributor.
Injection nozzles dirty.
See your authorized servicing dealer
or engine distributor.
Electronic fuel system problem
See your authorized servicing dealer
or engine distributor.
Defective turbocharger.
See your authorized servicing dealer
or engine distributor.
Low engine temperature.
Check thermostat.
High fuel consumption
Continued on next page
45-13
RG,RG34710,5608 –19–28MAR03–6/8
040103
PN=167
Troubleshooting
Symptom
Problem
Solution
Undercharged electrical system
Excessive electrical load from added
accessories.
Remove accessories or install higher
output alternator.
Excessive engine idling.
Increase engine rpm when heavy
electrical load is used.
Poor electrical connections on
battery, ground strap, starter, or
alternator.
Inspect and clean as necessary.
Defective battery.
Test battery.
Defective alternator.
Test charging system.
Cracked battery case.
Check for moisture and replace as
necessary.
Defective battery.
Test battery.
Battery charging rate too high.
Test charging system.
Loose or corroded connections.
Clean and tighten connections.
Sulfated or worn-out batteries.
See your authorized servicing dealer
or engine distributor.
Stretched poly-vee belt or defective
belt tensioner.
Adjust belt tension or replace belts.
PTO engaged.
Disengage PTO.
Loose or corroded connections.
Clean and tighten loose connections.
Low battery output voltage.
See your authorized servicing dealer
or engine distributor.
Faulty start circuit relay.
See your authorized servicing dealer
or engine distributor.
Blown main system fuse (MDL-25)
Replace fuse.
Low battery output.
See your authorized servicing dealer
or engine distributor.
Crankcase oil too heavy.
Use proper viscosity oil.
Loose or corroded connections.
Clean and tighten loose connections.
Battery uses too much water
Batteries will not charge
Starter will not crank
Starter cranks slowly
Continued on next page
45-14
RG,RG34710,5608 –19–28MAR03–7/8
040103
PN=168
Troubleshooting
Symptom
Problem
Solution
Starter and hour meter functions;
rest of electrical system does not
function
Blown fuse on magnetic switch.
Replace fuse.
Entire electrical system does not
function
Faulty battery connection.
Clean and tighten connections.
Sulfated or worn-out batteries.
See your authorized servicing dealer
or engine distributor.
Blown main system fuse.
Replace fuse.
RG,RG34710,5608 –19–28MAR03–8/8
45-15
040103
PN=169
Troubleshooting
Blink Code Method for Retrieving Diagnostic
Trouble Codes (All Except Early VP44 Pump
Engines)
NOTE: If engine has an electronic instrument panel with
diagnostic gauge, refer to “Instrument Panel
Method for Retrieving Diagnostic Trouble Codes”
later in this section.
On OEM applications that have a Fault Lamp, the ECU
has the ability to display DTCs using blinking sequence of
the fault lamp. To retrieve DTCs from the ECU using the
“blink code” method:
NOTE: The ECU blinks the codes in 2-digit codes only.
See LISTING OF DIAGNOSTIC TROUBLE
CODES (DTCS) later in this Group.
1. Turn the ignition switch “ON”.
2. Press down Override Shutdown Switch (if equipped)
for a few seconds.
3. The Fault Lamp will begin to flash a code number. For
example, flash three times...short pause...flash two
times...long pause. This example is code 32.
4. The ECU begins the flashing sequence by flashing a
code 32, this indicates the start of blinking active
codes. If there are any active DTCs, the ECU will flash
it’s 2–digit number. If there is more than one active
DTC, the ECU will flash each code in numerical order.
If there are no active DTCs, the Fault Lamp will flash a
code 88.
5. Following the active codes, the Fault Lamp will flash a
code 33. This indicates the start of blinking stored
codes. If there are any stored DTCs, the Fault Lamp
will flash its 2–digit number. If there is more than one
stored DTC, the ECU will flash each code in numerical
order. If there are no stored DTCs, the Fault Lamp will
flash a code 88.
6. Once complete, this sequence will repeat.
7. When complete, turn ignition “OFF”.
Continued on next page
45-16
OURGP12,00001EB –19–11MAR03–1/2
040103
PN=170
Troubleshooting
As an example, if an engine had an active DTC 18 and
stored DTC 53, the flashing sequence would be: flash
three times...short pause...flash two times...long
pause...flash one time...short pause...flash eight
times...long pause...flash three times...short pause...flash
three times...long pause...flash five times...short
pause...flash three times.
OURGP12,00001EB –19–11MAR03–2/2
45-17
040103
PN=171
Troubleshooting
Blink Code Method for Retrieving Diagnostic
Trouble Codes (Early VP44 Pump Engines
Only)
–UN–13JUL01
On OEM applications that have a Fault Lamp, the ECU
has the ability to display Diagnostic Trouble Codes
(DTCs) using blinking sequence of the fault lamp. To
retrieve DTCs from the ECU using the “blink code”
method:
RG11754A
NOTE: The ECU blinks the codes in 2-digit codes only.
See LISTING OF DIAGNOSTIC TROUBLE
CODES (DTCS) later in this Group.
1. Locate and uncap the 4–way METRI-PACK
diagnostic blink code connector (A).
Diagnostic Blink Code Connector
A—Diagnostic Blink Code Connector
B—Diagnostic Connector
C—ECU
2. Using a short piece of wire, jump terminals A and B in
the diagnostic blink code connector together.
3. Turn the ignition switch “ON”.
4. The Fault Lamp will begin to flash a code number. For
example, flash three times...short pause...flash two
times...long pause. This example is code 32.
5. The ECU begins the flashing sequence by flashing a
code 32, this indicates the start of blinking active
codes. If there are any active DTCs, the ECU will flash
it’s 2–digit number. If there is more than one active
DTC, the ECU will flash each code in numerical order.
If there are no active DTCs, the Fault Lamp will flash a
code 88.
6. Following the active codes, the Fault Lamp will flash a
code 33, this indicates the start of blinking stored
codes. If there are any stored DTCs, the Fault Lamp
will flash its 2–digit number. If there is more than one
stored DTC, the ECU will flash each code in numerical
order. If there are no stored DTCs, the Fault Lamp will
flash a code 88.
7. Once complete, this sequence will repeat.
METRI-PACK is a trademark of Packard Electric Inc.
Continued on next page
45-18
OURGP12,00001EA –19–11MAR03–1/2
040103
PN=172
Troubleshooting
8. When complete, turn ignition “OFF”, remove jumper
wire, and recap the diagnostic reader connector.
As an example, if an engine had an active DTC 18 and
stored DTC 53, the flashing sequence would be: flash
three times...short pause...flash two times...long
pause...flash one time...short pause...flash eight
times...long pause...flash three times...short pause...flash
three times...long pause...flash five times...short
pause...flash three times.
OURGP12,00001EA –19–11MAR03–2/2
45-19
040103
PN=173
Troubleshooting
Instrument Panel Method for Retrieving
Diagnostic Trouble Codes
IMPORTANT: Care should be used during diagnostic
procedures to avoid damaging the
terminals of connectors, sensors, and
actuators. Probes should not be poked
into or around the terminals or damage
will result. Probes should only be
touched against the terminals to make
measurements.
–UN–16NOV99
Diagnosis of the Deere electronic control system on
engines with Deere electronic instrument panel (shown)
should be performed as follows:
NOTE: Liquid Crystal Display [LCD] will always default to
last menu item. If an active Diagnostic Trouble
Code (DTC) is present, display will alternately
flash from the hour meter reading to DTC(s).
RG9923
1. Make sure all engine mechanical and other systems not
related to the electronic control system are operating
properly.
Diagnostic Gauge - Electronic Instrument Panels
A—LCD Display on Diagnostic Gauge
B—Touch Switch (DOWN)
C—Touch Switch (UP)
The code number will appear on the first line and
the words SrvcCode on the second line. Active
DTC(s) can be viewed by selecting “SrvcCode” on
the menu and pressing both touch switches at the
same time. Pressing touch switches (B) and (C)
scrolls through various engine parameters and
diagnostic trouble codes.
2. Read and record DTC(s) displayed on LCD of
diagnostic gauge (A). For procedure to access diagnostic
trouble codes, refer to “Using Diagnostic Gauge to Access
Engine Information”, earlier in this manual.
3. Go to the LISTING OF DIAGNOSTIC TROUBLE
CODES (DTCs) later in this section, to interpret to the
DTC(s) present.
4. Contact your nearest engine distributor or servicing
dealer with a list of DTC(s) so that necessary repairs can
be made.
DPSG,OUOD002,1590 –19–11MAR03–1/1
45-20
040103
PN=174
Troubleshooting
Displaying Of Diagnostic Trouble Codes
(DTCs)
There are several different methods for displaying both
stored and active DTCs from the ECU via a fault lamp or
a diagnostic gauge on the electronic instrument panel.
2-DIGIT CODES
Some engines display Service Codes or DTCs as 2-digit
codes read from a fault lamp which gives blink codes.
SPN/FMI CODES
Stored and active diagnostic trouble codes are output on
the diagnostic gauge on the Deere electronic instrument
panel according to the J1939 standard as a two-part code
as shown on the tables on the following pages.
The first part is a six-digit Suspect Parameter Number
(SPN) followed by a two-digit Failure Mode Identifier (FMI)
code. In order to determine the exact failure, both parts
(SPN and FMI) of the code are needed.
The SPN identifies the system or the component that has
the failure; for example SPN 000110 indicates a failure in
the engine coolant temperature circuit.
The FMI identifies the type of failure that has occurred; for
example FMI 03 indicates value above normal. Combining
SPN 000110 with FMI 03 yields engine coolant
temperature input voltage too high, or the equivalent of
2-digit fault code 18.
If diagnosing an application that shows DTCs as SPNs
and FMIs, using the following list, determine the
equivalent 2-digit code and have your dealer use the
diagnostic procedure in the component technical manual
for that 2-digit code.
Always contact your servicing dealer for help in correcting
diagnostic trouble codes which are displayed for your
engine.
DPSG,OUOD002,1591 –19–25FEB03–1/1
45-21
040103
PN=175
Troubleshooting
Listing of Diagnostic Trouble Codes (DTCs)
(Engines With Electronic Fuel Systems And
Stanadyne DE10 Pump)
NOTE: Not all of these codes are used on all OEM
engine applications.
“2-Digit Codes” are for Blink Code Method use
only.
Trouble Codes
DTC’s Listing in Ascending SPN/FMI Codes
SPN
FMI
2-Digit
Codes
000028
03
13
04
14
000029
03
15
04
16
14
—
000084
31
—
000091
03
11
04
12
07
—
10
—
13
—
14
—
000097
03
—
04
—
16
—
000100
01
65
03
23
04
24
18
64
000105
03
25
04
26
16
66
000110
00
69
03
18
04
19
15
62
16
63
000111
00
—
03
—
04
—
000158
17
54
000160
02
—
000174
03
37
04
38
16
81
000189
00
—
000190
00
42
16
42
Definition
Throttle Voltage High
Throttle Voltage Low
Throttle Voltage High
Throttle Voltage Low
Throttle Voltage Out of Range
Vehicle Speed Mismatch
Throttle Voltage High
Throttle Voltage Low
Throttle Calibration Invalid
Throttle Voltage Low
Throttle Calibration Invalid
Throttle Voltage Out of Range
Water in Fuel Input Voltage High
Water in Fuel Input Voltage Low
Water in Fuel Detected
Engine Oil Pressure Extremely Low
Engine Oil Pressure Input Voltage High
Engine Oil Pressure Input Voltage Low
Engine Oil Pressure Moderately Low
Manifold Air Temperature Input Voltage High
Manifold Air Temperature Input Voltage Low
Manifold Air Temperature Moderately High
Engine Coolant Temperature High Most Severe
Engine Coolant Temperature Input Voltage High
Engine Coolant Temperature Input Voltage Low
Engine Coolant Temperature High Least Severe
Engine Coolant Temperature High Moderately Severe
Loss of Coolant Temperature Extremely High
Loss of Coolant Temperature Input Voltage High
Loss of Coolant Temperature Input Voltage Low
ECU Power Down Error
Wheel Speed Input Noise
Fuel Temperature Input Voltage High
Fuel Temperature Input Voltage Low
Fuel Temperature Moderately High
Engine Speed Derate
Engine Overspeed Extreme
Engine Overspeed Moderate
Continued on next page
45-22
OURGP12,00001EF –19–20MAR03–1/2
040103
PN=176
Troubleshooting
SPN
FMI
000620
03
04
04
13
02
10
13
03
05
09
31
31
09
31
00
01
03
05
06
07
10
13
03
04
31
31
04
31
06
13
2-Digit
Codes
21
22
—
28
39
39
55
—
—
—
83
84
—
—
71
72
77
73
74
75
76
—
—
—
—
82
—
68
79
78
N/A
N/A
N/A
32
33
88
000627
000629
000637
000639
000729
000898
000970
000971
001069
001076
001079
001109
001110
001568
001569
002000
N/A
N/A
N/A
Definition
Sensor Supply Voltage High
Sensor Supply Voltage Low
ECU Unswitched Power Missing
ECU Error
Crank Position Input Noise
Crank Position Input Pattern Error
CAN Error
Inlet Air Heater Signal High
Inlet Air Heater Signal Low
Vehicle Speed Invalid/Missing
Auxiliary Engine Shutdown Switch Active
External Engine Derate Switch Active
Tire Speed Invalid
Tire Speed Error
Pump Control Valve Closure Too Long
Pump Control Valve Closure Too Short
Pump Solenoid Current High
Pump Solenoid Circuit Open
Pump Solenoid Circuit Severely Shorted
Pump Control Valve Closure Not Detected
Pump Solenoid Circuit Moderately Shorted
Pump Current Decay Time Invalid
Sensor Supply Voltage High
Sensor Supply Voltage Low
Engine Shutdown Warning
Engine Shutdown
Torque Curve Select Voltage Low
Fuel Derate
Internal ECU Failure
Security Violation
When reading blink codes, signifies the start of active codes.
When reading blink codes, signifies the start of previously active codes.
When reading blink codes, signifies that no fault codes are in the buffer.
OURGP12,00001EF –19–20MAR03–2/2
45-23
040103
PN=177
Troubleshooting
Listing of Diagnostic Trouble Codes (DTCs)
(Engines With Electronic Fuel Systems And
Bosch VP44 Pump)
NOTE: Not all of these codes are used on all OEM
engine applications
“2-Digit Codes” are for Blink Code Method use
only.
Trouble Codes
DTC’s Listing in Ascending SPN/FMI Codes
SPN
FMI
2-Digit
Code
000028
03
13
04
14
000029
03
15
04
16
000084
02
91
000091
03
11
04
12
09
—
000094
01
58
03
27
04
28
18
57
000097
00
—
16
—
000100
01
75
03
23
04
24
18
74
000105
00
56
03
25
04
26
16
55
000107
00
—
000110
00
63
03
18
04
19
15
61
16
62
000111
01
64
000158
17
54
000174
00
67
15
53
16
71
31
98
000189
00
—
31
48
000190
00
42
16
42
Definition
Throttle Volts High
Throttle Volts Low
Throttle Volts High
Throttle Volts Low
Vehicle Speed Mismatch
Throttle Volts High
Throttle Volts Low
Throttle Invalid
Fuel Supply Pressure Extremely Low
Fuel Supply Pressure Input Voltage High
Fuel Supply Pressure Input Voltage Low
Fuel Supply Pressure Moderately Low
Water in Fuel Continuously Detected
Water in Fuel Detected
Engine Oil Pressure Extremely Low
Engine Oil Pressure Input Voltage High
Engine Oil Pressure Input Voltage Low
Engine Oil Pressure Moderately Low
Manifold Air Temperature Extremely High
Manifold Air Temperature Input Voltage High
Manifold Air Temperature Input Voltage Low
Manifold Air Temperature Moderately High
Air Filter Differential Pressure
Engine Coolant Temperature Extremely High
Engine Coolant Temperature Input Voltage High
Engine Coolant Temperature Input Voltage Low
Engine Coolant Temperature High Least Severe
Engine Coolant Temperature Moderately High
Engine Coolant Level Low
ECU Power Down Error
Fuel Temperature High Most Severe
Fuel Temperature High Least Severe
Fuel Temperature High Moderately Severe
Fuel Temperature Sensor Faulty
Engine Speed Derate
Engine Speed Derate
Engine Overspeed Extreme
Engine Overspeed Moderate
Continued on next page
45-24
OURGP12,00001EE –19–20MAR03–1/2
040103
PN=178
Troubleshooting
SPN
FMI
000620
03
04
04
13
19
02
05
02
08
10
02
08
10
03
05
02
09
02
31
31
02
02
07
11
12
19
31
07
11
31
03
04
03
04
31
31
02
31
13
000627
000629
000632
000636
000637
000729
000810
000898
000970
000971
001069
001076
001077
001078
001079
001080
001109
001110
001485
001569
002000
2-Digit
Code
21
22
76
34
34
37
86
44
43
44
39
38
39
—
—
92
77
—
83
84
93
66
35
68
97
96
36
95
87
94
21
22
51
52
—
82
89
47
—
Definition
Sensor Supply Voltage High
Sensor Supply Voltage Low
ECU Unswitched Power Missing
ECU Error
ECU to Pump Communication Error
Fuel Shutoff Error
Fuel Shutoff Non-Functional
Pump Position Input Noise
Pump Position Input Missing
Pump Position Input Pattern Error
Crank Position Input Noise
Crank Position Input Missing
Crank Position Input Pattern Error
Inlet Air Heater Signal High
Inlet Air Heater Signal Low
Calculated Vehicle Speed Input Noise
Vehicle Speed Invalid/Missing
Auxiliary Engine Shutdown Switch Signal Invalid
Auxiliary Engine Shutdown Switch Active
External Engine Derate Switch Active
Tire Size Error
Pump Detected Defect
Attempting to Fuel Without Command
Pump Supply Voltage Out of Range
Pump Self Test Error
Pump Detected Communication Error
Pump Initiated Engine Protection
ECU/Pump Timing Moderately Out of Sync
ECU/Pump Speed Out of Sync
ECU/Pump Timing Extremely Out of Sync
Sensor Supply 1 Voltage High
Sensor Supply 1 Voltage Low
Sensor Supply 2 Voltage High
Sensor Supply 2 Voltage Low
Engine Shutdown Warning
Engine Shutdown
Pump Power Relay Fault
Fuel Derate
Security Violation
OURGP12,00001EE –19–20MAR03–2/2
45-25
040103
PN=179
Troubleshooting
Listing of Diagnostic Trouble Codes (DTCs)
(Engines With Electronic Fuel Systems And
Denso High Pressure Common Rail)
NOTE: Not all of these codes are used on all OEM
engine applications
“2-Digit Codes” are for Blink Code Method use
only.
Trouble Codes
DTC’s Listing in Ascending SPN/FMI Codes
SPN
FMI
2-Digit Code
000028
03
15
04
—
000029
03
13
04
—
000084
31
—
000091
03
11
04
12
09
—
000094
03
27
04
28
10
86
13
—
17
85
000097
00
—
03
—
04
—
16
—
000100
01
75
03
23
04
24
18
74
000105
00
—
03
25
04
26
16
55
000107
00
—
000110
00
63
03
18
04
19
15
61
16
62
000111
01
64
000158
17
54
000160
02
—
000174
00
—
03
37
04
38
16
71
000189
00
—
Description
Analog Throttle (B) Voltage High
Analog Throttle (B) Voltage Low
Analog Throttle (A) Voltage High
Analog Throttle (A) Voltage Low
Vehicle Speed Mismatch
Multi-state Throttle Voltage High
Multi-state Throttle Voltage Low
Throttle Invalid
Fuel Rail Pressure Input Voltage High
Fuel Rail Pressure Input Voltage Low
Fuel Rail Pressure Loss Detected
Fuel Rail Pressure Higher Than Expected
Fuel Rail Pressure Not Developed
Water in Fuel Continuously Detected
Water in Fuel Signal Voltage High
Water in Fuel Signal Voltage Low
Water in Fuel Detected
Engine Oil Pressure Extremely Low
Engine Oil Pressure Input Voltage High
Engine Oil Pressure Input Voltage Low
Engine Oil Pressure Moderately Low
Manifold Air Temperature Extremely High
Manifold Air Temperature Input Voltage High
Manifold Air Temperature Input Voltage Low
Manifold Air Temperature Moderately High
Air Filter Differential Pressure
Engine Coolant Temperature High Most Severe
Engine Coolant Temperature Input Voltage High
Engine Coolant Temperature Input Voltage Low
Engine Coolant Temperature High Least Severe
Engine Coolant Temperature High Moderately Severe
Engine Coolant Level Low
ECU Power Down Error
Wheel Speed Input Noise
Fuel Temperature High Most Severe
Fuel Temperature Input Voltage High
Fuel Temperature Input Voltage Low
Fuel Temperature High Moderately Severe
Engine Speed Derate
Continued on next page
45-26
OUOD006,0000016 –19–18MAR03–1/3
040103
PN=180
Troubleshooting
SPN
000190
000611
000620
000627
000629
000636
000637
000639
000651
000652
000653
000654
000655
000656
000676
000898
000970
000971
001069
001079
001080
001109
001110
001347
001568
001569
002000
FMI
00
16
03
04
03
04
01
13
02
08
10
02
07
08
10
13
05
06
07
05
06
07
05
06
07
05
06
07
05
06
07
05
06
07
03
05
09
31
31
09
31
03
04
03
04
31
31
03
05
07
02
31
13
2-Digit Code
42
42
98
99
21
22
97
—
44
43
44
39
45
41
39
—
31
91
65
29
92
66
17
93
59
34
94
67
35
95
56
36
96
68
—
—
—
83
84
—
—
51
52
49
48
—
82
79
77
78
—
—
—
Description
Engine Overspeed Extreme
Engine Overspeed Moderate
Electronic Injector Wiring Shorted to Power Source
Electronic Injector Wiring Shorted to Ground
Sensor Supply 2 Voltage High
Sensor Supply 2 Voltage Low
Electronic Injector Supply Voltage Problem
ECU Error
Pump Position Sensor Input Noise
Pump Position Sensor Input Missing
Pump Position Sensor Input Pattern Error
Crank Position Input Noise
Crank/Pump Timing Moderately Out of Sync
Crank Position Input Missing
Crank Position Input Pattern Error
CAN Bus Error
Cylinder #1 EI Circuit Open
Cylinder #1 EI Circuit Shorted
Cylinder #1 EI Delivery Failure
Cylinder #2 EI Circuit Open
Cylinder #2 EI Circuit Shorted
Cylinder #2 EI Delivery Failure
Cylinder #3 EI Circuit Open
Cylinder #3 EI Circuit Shorted
Cylinder #3 EI Delivery Failure
Cylinder #4 EI Circuit Open
Cylinder #4 EI Circuit Shorted
Cylinder #4 EI Delivery Failure
Cylinder #5 EI Circuit Open
Cylinder #5 EI Circuit Shorted
Cylinder #5 EI Delivery Failure
Cylinder #6 EI Circuit Open
Cylinder #6 EI Circuit Shorted
Cylinder #6 EI Delivery Failure
Glow Plug Relay Voltage High
Glow Plug Relay Voltage Low
Vehicle Speed or Torque Message Invalid
Engine Shutdown - Auxiliary Request
External Fuel Derate Switch Active
Tire Size Invalid
Tire Size Error
Sensor Supply 1 Voltage High
Sensor Supply 1 Voltage Low
Fuel Rail Pressure Sensor Supply Voltage High
Fuel Rail Pressure Sensor Supply Voltage Low
Engine Protection Shutdown Warning
Engine Protection Shutdown
Pump Return Shorted High
Pump Control Valve Error
Fuel Rail Pressure Control Error
Torque Curve Selection Invalid
Fuel Derate
Security Violation
Continued on next page
45-27
OUOD006,0000016 –19–18MAR03–2/3
040103
PN=181
Troubleshooting
SPN
N/A
N/A
N/A
FMI
N/A
N/A
N/A
2-Digit Code
32
33
88
Description
When reading blink codes, signifies the start of active codes.
When reading blink codes, signifies the start of stored codes.
When reading blink codes, signifies that no fault codes are in the buffer.
OUOD006,0000016 –19–18MAR03–3/3
Error Codes Displayed (With Diagnostic
Gauge on Electronic Panels)
NOTE: The Diagnostic Gauge on the electronic
instrument panel can have communication
problems that result in Error Codes being shown
on its LCD display window. The following Error
Codes all indicate that there is a Diagnostic
Gauge communication error with the ECU.
Contact your servicing dealer for help in correcting
these codes:
EE—Error
ACP—Err
No Addr
ACP—Err
BUS—EP
XXXXX—EP
No Data
XXXXX—BO
No Data
XXXXX—BR
No Data
OURGP12,00001F0 –19–25MAR03–1/1
45-28
040103
PN=182
Troubleshooting
Intermittent Fault Diagnostics (With Electronic Controls)
Intermittent faults are problems that periodically “go
away”. A problem such as a terminal that intermittently
doesn’t make contact can cause an intermittent fault.
Other intermittent may be set only under certain
operating conditions such as heavy load, extended
idle, etc. When diagnosing intermittent faults, take
special note of the condition of wiring and connectors,
since a high percentage of intermittent problems
originate here. Check for loose, dirty or disconnected
connectors. Inspect the wiring routing, looking for
possible shorts caused by contact with external parts
(for example, rubbing against sharp sheet metal
edges). Inspect the connector vicinity, looking for wires
that have pulled out of connectors, poorly positioned
terminals, damaged connectors and corroded or
damaged splices and terminals. Look for broken wires,
damaged splices, and wire-to-wire shorts. Use good
judgement if component replacement is thought to be
required.
NOTE: The engine control unit (ECU) is the
component LEAST likely to fail.
• If the problem is intermittent, try to reproduce the
operating conditions that were present when the
diagnostic trouble code (DTC) set.
• If a faulty connection or wire is suspected to be the
cause of the intermittent problem: clear DTCs, then
check the connection or wire by wiggling it while
watching the diagnostic gauge to see if the fault
resets.
Possible causes of intermittent faults:
• Faulty connection between sensor or actuator
harness.
• Faulty contact between terminals in connector.
• Faulty terminal/wire connection.
• Electromagnetic interference (EMI) from an
improperly installed 2-way radio, etc., can cause
faulty signals to be sent to the ECU.
NOTE: Refer to wiring diagrams earlier in this section
as a guide to connection and wiring.
Suggestions for diagnosing intermittent faults:
OUOD007,0000036 –19–26FEB03–1/1
45-29
040103
PN=183
Storage
Engine Storage Guidelines
1. John Deere engines can be stored outside for up to
three (3) months with no long term preparation IF
COVERED BY WATERPROOF COVERING.
4. John Deere engines expected to be stored more
than six (6) months, long term storage preparation
MUST BE taken. ( See PREPARING ENGINE FOR
LONG TERM STORAGE, later in this section.)
2. John Deere engines can be stored in a standard
overseas shipping container for up to three (3)
months with no long term preparation.
3. John Deere engines can be stored inside,
warehoused, for up to six (6) months with no long
term preparation.
RG,RG34710,5610 –19–23NOV01–1/1
50-1
040103
PN=184
Storage
Preparing Engine for Long Term Storage
The following storage preparations are good for long
term engine storage up to one year. After that, the
engine should be started, warmed up, and retreated
for an extended storage period.
IMPORTANT: Any time your engine will not be
used for over six (6) months, the
following recommendations for
storing it and removing it from
storage will help to minimize
corrosion and deterioration.
Coolant Section and ADDING COOLANT in Service
As Required Section.)
4. Crank the engine several revolutions with starter
(do not allow the engine to start).
5. Remove fan/alternator poly-vee belt, if desired.
6. Remove and clean batteries. Store them in a cool,
dry place and keep them fully charged.
7. Disengage the clutch for any driveline.
1. Change engine oil and replace filter. Used oil will
not give adequate protection. (See CHANGE
ENGINE OIL AND FILTER in Lubrication and
Maintenance/500 Hour Section.)
2. Service air cleaner. (See REPLACING AIR
CLEANER FILTER ELEMENTS in Service As
Required Section.)
3. Draining and flushing of cooling system is not
necessary if engine is to be stored only for several
months. However, for extended storage periods of a
year or longer, it is recommended that the cooling
system be drained, flushed, and refilled. Refill with
appropriate coolant. (See RECOMMENDED
ENGINE COOLANT in Fuels, Lubricants, and
8. Clean the exterior of the engine with salt-free water
and touchup any scratched or chipped painted
surfaces with a good quality paint.
9. Coat all exposed (machined) metal surfaces with
grease or corrosion inhibitor if not feasible to paint.
10. Seal all openings on engine with plastic bags and
tape.
11. Store the engine in a dry protected place. If
engine must be stored outside, cover it with a
waterproof canvas or other suitable protective
material and use a strong waterproof tape.
RG,RG34710,5612 –19–23NOV01–1/1
50-2
040103
PN=185
Storage
Removing Engine from Long Term Storage
Refer to the appropriate section for detailed services
listed below or have your authorized servicing dealer
or engine distributor perform services that you may not
be familiar with.
IMPORTANT: DO NOT operate starter more than
30 seconds at a time. Wait at least 2
minutes for starter to cool before
trying again.
1. Remove all protective coverings from engine.
Unseal all openings in engine and remove covering
from electrical systems.
6. Crank engine for 20 seconds with starter (do not
allow the engine to start). Wait 2 minutes and crank
engine an additional 20 seconds to assure bearing
surfaces are adequately lubricated.
2. Remove the batteries from storage. Install batteries
(fully charged) and connect the terminals.
3. Install fan/alternator poly-vee belt if removed.
4. Fill fuel tank.
5. Perform all appropriate prestarting checks. ( See
DAILY PRESTARTING CHECKS in Lubrication and
Maintenance/Daily Section.)
7. Start engine and run at low idle and no load for
several minutes. Warm up carefully and check all
gauges before placing engine under load.
8. On the first day of operation after storage, check
overall engine for leaks and check all gauges for
correct operation.
RG,RG34710,5613 –19–20MAY96–1/1
50-3
040103
PN=186
Specifications
General OEM Engine Specifications
ITEM
4045DF270
4045TF270
4045TF/HF275
4045HF475
6068TF/HF275
6068HF475
4
4
4
4
6
6
Bore
106 mm
(4.19 in.)
106 mm
(4.19 in.)
106 mm
(4.19 in.)
106 mm
(4.19 in.)
106 mm
(4.19 in.)
106 mm
(4.19 in.)
Stroke
127 mm
(5.0 in.)
127 mm
(5.0 in.)
127 mm
(5.0 in.)
127 mm
(5.0 in.)
127 mm
(5.0 in.)
127 mm
(5.0 in.)
4.5 L
(276 cu in.)
4.5 L
(276 cu in.)
4.5 L
(276 cu in.)
4.5 L
(276 cu in.)
6.8 L
(414 cu in.)
6.8 L
(414 cu in.)
Number of Cylinders
Displacement
Compression Ratio
17.6:1
17.0:1
17.0:1
17.0:1
17.0:1
17.0:1
Aspiration
Natural
Turbocharged
Turbocharged
Turbocharged
Turbocharged
Turbocharged
Engine Firing Order
1-3-4-2
1-3-4-2
1-3-4-2
1-3-4-2
1-5-3-6-2-4
1-5-3-6-2-4
Valves Per Cylinder
1 Intake
1 Exhaust
1 Intake
1 Exhaust
1 Intake
1 Exhaust
2 Intake
2 Exhaust
1 Intake
1 Exhaust
2 Intake
2 Exhaust
0.31-0.38 mm
(0.012-0.015 in)
0.31-0.38 mm
(0.012-0.015 in)
0.31-0.38 mm
(0.012-0.015 in)
0.31-0.38 mm
(0.012-0.015 in)
0.31-0.38 mm
(0.012-0.015 in)
0.31-0.38 mm
(0.012-0.015 in)
0.41-0.48 mm
(0.016-0.019 in)
0.41-0.48 mm
(0.016-0.019 in)
0.41-0.48 mm
(0.016-0.019 in)
0.41-0.48 mm
(0.016-0.019 in)
0.41-0.48 mm
(0.016-0.019 in)
0.41-0.48 mm
(0.016-0.019 in)
Intake (Adjusting)
0.36 mm
(0.014 in.)
0.36 mm
(0.014 in.)
0.36 mm
(0.014 in.)
0.36 mm
(0.014 in.)
0.36 mm
(0.014 in.)
0.36 mm
(0.014 in.)
Exhaust (Adjusting)
0.46 mm
(0.018 in.)
0.46 mm
(0.018 in.)
0.46 mm
(0.018 in.)
0.46 mm
(0.018 in.)
0.46 mm
(0.018 in.)
0.46 mm
(0.018 in.)
0.5 kPa
(2 H2O)
0.5 kPa
(2 H2O)
0.5 kPa
(2 H2O)
0.5 kPa
(2 H2O)
0.5 kPa
(2 H2O)
0.5 kPa
(2 H2O)
Vibration Damper
Maximum Radial Runout
1.50 mm
(0.060 in.)
1.50 mm
(0.060 in.)
1.50 mm
(0.060 in.)
1.50 mm
(0.060 in.)
1.50 mm
(0.060 in.)
1.50 mm
(0.060 in.)
Battery Capacities (CCA)
12-Volt System
24-Volt System
640
570
640
570
640
570
640
570
800
570
800
570
Governor Regulation
(Industrial)
7—10 %
7—10 %
7—10 %
7—10 %
7—10 %
7—10 %
Governor Regulation
(Generator)
5%
5%
5%
5%
5%
5%
Thermostat Start To
Open Temperature
82°C
(180°F)
82°C
(180°F)
82°C
(180°F)
82°C
(180°F)
82°C
(180°F)
82°C
(180°F)
Thermostat Fully Open
Temperature
94°C
(202°F)
94°C
(202°F)
94°C
(202°F)
94°C
(202°F)
94°C
(202°F)
94°C
(202°F)
8.5 L
(9 qt)
8.5 L
(9 qt)
8.5 L
(9 qt)
8.5 L
(9 qt)
11.3 L
(12 qt)
11.3 L
(12 qt)
70 kPa
(10 psi)
70 kPa
(10 psi)
70 kPa
(10 psi)
70 kPa
(10 psi)
70 kPa
(10 psi)a
100 kPa
(15 psi)b
Valve Clearance (Cold)
Intake (Checking)
Exhaust (Checking)
Max. Crank Pressure
Coolant Capacity
Recommended Radiator
Pressure Cap
a
Pressure cap for 6068HF275 with VP44 fuel system for non gen-set applications is 100 kPa (15 psi)
b
Pressure cap for 6068HF475 for gen-set applications is 70 kPa (10 psi)
Continued on next page
55-1
RG,RG34710,5614 –19–28FEB03–1/2
040103
PN=187
Specifications
ITEM
4045DF270
Crankcase Oil Fill
Capacity
4045TF270
4045TF/HF275
4045HF475
6068TF/HF275
6068HF475
See “Engine Crankcase Oil Fill Quantities” later in this section.
Oil Pressure At Rated
Speed, Full Load (± 15
psi)
345 kPa
(50 psi)
345 kPa
(50 psi)
345 kPa
(50 psi)
345 kPa
(50 psi)
345 kPa
(50 psi)
345 kPa
(50 psi)
Oil Pressure At Low Idle
(Minimum)
105 kPa
(15 psi)
105 kPa
(15 psi)
105 kPa
(15 psi)
105 kPa
(15 psi)
105 kPa
(15 psi)
105 kPa
(15 psi)
Length
860 mm
(33.9 in.)
860 mm
(33.9 in.)
860 mm
(33.9 in.)
860 mm
(33.9 in.)
1123 mm
(44.2 in.)
1123 mm
(44.2 in.)
Width
612 mm
(24.1 in.)
612 mm
(24.1 in.)
612 mm
(24.1 in.)
612 mm
(24.1 in.)
623 mm
(24.5 in.)
608 mm
(23.9 in.)
Height
856 mm
(33.7 in.)
994 mm
(39.1 in.)
994 mm
(39.1 in.)
994 mm
(39.1 in.)
1015 mm
(40.0 in.)
1044 mm
(41.1 in.)
Weight
387 kg
(853 lb)
451 kg
(993 lb)
451 kg
(993 lb)
451 kg
(993 lb)
587 kg
(1290 lb)
587 kg
(1290 lb)
RG,RG34710,5614 –19–28FEB03–2/2
55-2
040103
PN=188
Specifications
Engine Power Ratings1 And Fuel System
Specifications2
Engine Model
Fuel System
Option Codes
Electronic
Software Option
Codes
System
Voltage
Rated
Speed
(rpm)
Slow Idle
(rpm)
Fast Idle
(rpm)
....................
...................
....................
....................
....................
....................
Power
Rating @
Rated Speed
kW (hp)
60 (80) ........
60 (80) ........
55 (74) ........
55 (74) ........
50 (67) ........
50 (67) ........
4045DF270
(Mechanical
Controls)
164N ..................
164O .................
164L ...................
164M ..................
162Q, 164M .......
164Q ..................
...........................
...........................
...........................
...........................
...........................
...........................
12V
24V
12V
24V
12V
24V
2500
2500
2500
2500
1800
1800
..........
..........
..........
..........
..........
..........
850 ................
850 ................
850 ................
850 ................
1400 ..............
1400 ..............
2700
2700
2700
2700
1870
1870
4045TF270
(Mechanical
Controls)
164V ..................
164W .................
164T ..................
164U ..................
163N, 164X .......
164Y ..................
164R ..................
164S
...........................
...........................
...........................
...........................
...........................
...........................
...........................
...........................
12V
24V
12V
24V
12V
24V
12V
24V
....................
....................
....................
....................
....................
....................
....................
....................
74
74
74
74
74
74
63
63
(99)
(99)
(99)
(99)
(99)
(99)
(84)
(84)
2500
2500
2200
2200
1800
1800
2500
2500
..........
..........
..........
..........
..........
..........
..........
..........
850 ................
850 ................
850 ................
850 ................
1400 ..............
1400 ..............
850 ................
850 ................
2700
2700
2400
2400
1870
1870
2700
2700
(115)
(115)
(110)
(110)
(112)
(112)
........
........
........
........
........
........
........
4045TF275
161K, 163H .......
161L, 163L ........
161K, 163H .......
161L, 163L ........
161K, 163H .......
161L, 163L ........
7288
7289
7290
7291
7292
7293
...................
...................
...................
...................
...................
...................
12V
24V
12V
24V
12V
24V
....................
....................
....................
....................
....................
....................
86
86
82
82
84
84
......
......
......
......
......
......
2500
2500
2400
2400
1800
1800
..........
..........
..........
..........
..........
..........
800 ................
800 ................
800 ................
800 ................
1150 ..............
1150 ..............
2700
2700
2600
2600
1870
1870
4045HF275
161F, 163G
161G, 163K
161F, 163G
161G, 163K
.......
.......
.......
.......
7262
7263
7264
7265
...................
...................
...................
...................
161F, 163G
161G, 163K
161F, 163G
161G, 163K
161F, 163G
161G, 163K
161F, 163G
161G, 163K
.......
.......
.......
.......
.......
.......
.......
.......
7266
7267
7268
7269
7270
7271
7272
7273
...................
...................
...................
...................
...................
...................
...................
...................
12V
24V
12V
24V
12V
24V
12V
24V
12V
24V
12V
24V
12V
24V
....................
....................
....................
....................
....................
....................
....................
....................
....................
....................
....................
....................
....................
....................
104 (140) ....
104 (140) ....
93 (125) ......
93 (125) ......
104 (140) ....
104 (140) ....
93 (125) ......
93 (125) ......
86 (115) ......
86 (115) ......
108 (145) ....
108 (145) ....
117 (157) ....
117 (157) ....
2400
2400
2400
2400
2200
2200
2200
2200
2000
2000
1800
1800
1800
1800
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
800 ................
800 ................
800 ................
800 ................
800 ................
800 ................
800 ................
800 ................
800 ................
800 ................
1150 ..............
1150 ..............
1150 ..............
1150 ..............
2600
2600
2600
2600
2400
2400
2400
2400
2100
2100
1870
1870
1870
1870
1
Power ratings are for bare engines without drag effect of cooling fan or
accessories like air compressors.
2
Engine speeds listed are preset to factory specification. Slow idle speed
may be reset depending upon specific vehicle application requirements.
Refer to your machine operator’s manual for engine speeds that are
different from those preset at the factory.
Continued on next page
55-3
RG,RG34710,5616 –19–26FEB03–1/3
040103
PN=189
Specifications
Engine Model
Fuel System
Option Codes
Electronic
Software Option
Codes
System
Voltage
Power
Rating @
Rated Speed
kW (hp)
Rated
Speed
(rpm)
Slow Idle
(rpm)
Fast Idle
(rpm)
4045HF475
(4-Valve
Head)
161V
165A
161V
165A
161V
165A
161V
165A
161V
165A
72AT ..................
72CL ..................
72CX ................
72CY ..................
72AU ..................
72CM .................
72AV ..................
72CN .................
72AW .................
72CP ..................
12V
24V
12V
24V
12V
24V
12V
24V
12V
24V
....................
....................
....................
....................
....................
....................
....................
....................
....................
....................
129
129
129
129
119
119
143
143
120
120
(173)
(173)
(173)
(173)
(160)
(160)
(192)
(192)
(161)
(161)
....
....
....
....
....
....
....
....
....
....
2400
2400
2200
2200
2200
2200
1800
1800
1500
1500
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
800 ................
800 ................
800 ................
800 ................
800 ................
800 ................
1400 ..............
1400 ..............
1400 ..............
1400 ..............
2600
2600
2400
2400
2400
2400
1870
1870
1560
1560
6068TF275
161J, 163M
161H, 163F
161J, 163M
161H, 163F
161J, 163M
161H, 163F
161J, 163M
161H, 163F
161J, 163M
........
........
........
........
........
........
........
........
........
72AA ..................
72AB ..................
72AC ..................
72AD ..................
72AE ..................
72AF ..................
72AG .................
72AH ..................
72AJ ..................
24V
12V
24V
12V
24V
12V
24V
12V
24V
....................
....................
....................
....................
....................
....................
....................
....................
....................
123
101
101
112
112
104
104
123
123
(165)
(135)
(135)
(150)
(150)
(140)
(140)
(165)
(165)
....
....
....
....
....
....
....
....
....
2400
2200
2200
2200
2200
2000
2000
1800
1800
.........
..........
..........
..........
..........
..........
..........
..........
..........
800 ................
800 ................
800 ................
800 ................
800 ................
800 ................
800 ................
1150 ..............
1150 ..............
2600
2400
2400
2400
2400
2100
2100
1870
1870
6068TF275
161H, 163F
161J, 163M
161H, 163F
161J, 163M
161H, 163F
........
........
........
........
........
7294
7295
7296
7297
7298
...................
...................
...................
...................
...................
12V
24V
12V
24V
12V
....................
....................
....................
....................
....................
116
116
127
127
123
(155)
(155)
(170)
(170)
(165)
....
....
....
....
....
2500
2500
2500
2500
2400
..........
..........
.........
..........
..........
800
800
800
800
800
................
................
................
................
................
2700
2700
2700
2700
2600
6068HF275
16YS ..................
16YT ..................
16YS ..................
16YT ..................
16YS ..................
16YT ..................
16YS ..................
16YT ..................
16YS ..................
16YT ..................
16YS ..................
16YT ..................
16YS ..................
16YT ..................
161N, 163E .......
161Q, 163J ........
161N, 163E .......
161Q, 163J ........
16YS ..................
16YT ..................
16YS, 162B .......
16YT, 162C .......
7201
7202
7203
7204
7205
7206
7207
7208
7274
7275
7276
7277
7278
7279
7280
7281
7282
7283
7284
7285
7286
7287
...................
...................
...................
...................
...................
...................
...................
...................
...................
...................
...................
...................
...................
...................
...................
...................
...................
...................
...................
...................
...................
...................
12V
24V
12V
24V
12V
24V
12V
24V
12V
24V
12V
24V
12V
24V
12V
24V
12V
24V
12V
24V
12V
24V
....................
....................
....................
....................
....................
....................
....................
....................
....................
....................
....................
....................
....................
....................
....................
....................
....................
....................
....................
....................
....................
....................
168
168
149
149
138
138
149
149
187
187
168
168
157
157
129
129
164
164
187
187
210
210
(225)
(225)
(200)
(200)
(185)
(185)
(200)
(200)
(250)
(250)
(225)
(225)
(210)
(210)
(173)
(173)
(220)
(220)
(250)
(250)
(282)
(282)
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
2400
2400
2400
2400
2400
2400
2200
2200
2400
2400
2200
2200
2000
2000
2000
2000
1800
1800
1800
1800
1800
1800
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
850 ................
850 ................
800 ................
850 ................
850 ................
850 ................
800 ................
800 ................
850 ................
850 ................
800 ................
800 ................
800 ................
800 ................
800 ................
800 ................
1150 ..............
1150 ..............
1150 ..............
1150 ..............
1150 ..............
1150 ..............
2600
2600
2600
2600
2600
2600
2400
2400
2600
2600
2400
2400
2100
2100
2100
2100
1870
1870
1870
1870
1870
1870
..................
..................
..................
..................
..................
..................
..................
..................
..................
..................
Continued on next page
55-4
RG,RG34710,5616 –19–26FEB03–2/3
040103
PN=190
Specifications
Engine Model
Fuel System
Option Codes
Electronic
Software Option
Codes
System
Voltage
6068HF475
(4-Valve
Head)
161U
165B
161U
165B
161U
165B
161U
165B
72AP ..................
72CQ .................
72AQ .................
72CR .................
72AR ..................
72CS ..................
72AS ..................
72CT ..................
12V
24V
12V
24V
12V
24V
12V
24V
..................
..................
..................
..................
..................
..................
..................
..................
....................
....................
....................
....................
....................
....................
....................
....................
Power
Rating @
Rated Speed
kW (hp)
205 (275) ....
205 (275) ....
187 (250) ....
187 (250) ....
234 (314) ....
234 (314) ....
207 (278) ....
207 (278) ....
Rated
Speed
(rpm)
Slow Idle
(rpm)
Fast Idle
(rpm)
2400
2400
2200
2200
1800
1800
1500
1500
800 ................
800 ................
800 ................
800 ................
1400 ..............
1400 ..............
1400 ..............
1400 ..............
2600
2600
2400
2400
1870
1870
1560
1560
..........
..........
..........
..........
..........
..........
..........
..........
RG,RG34710,5616 –19–26FEB03–3/3
55-5
040103
PN=191
Specifications
Engine Crankcase Oil Fill Quantities
To determine the option code for the oil fill quantity of
your engine, refer to the engine option code label
affixed to the rocker arm cover. The first two digits of
the code (19) identify the oil pan option group. The last
two digits of each code identify the specific oil pan on
your engine.
NOTE: Crankcase oil capacity may vary slightly from
amount shown. ALWAYS fill crankcase to
within crosshatch on dipstick. DO NOT overfill.
The following table lists engine crankcase oil fill
quantities:
Engine Model
Oil Pan Option
Code(s)
Crankcase Oil
Capacity L (qt)
4045DF270
1901
1902
1903
1904
1923
8.5 (9.0)
8.5 (9.0)
12.0 (12.7)
13.0 (13.7)
15.0 (15.8)
4045TF270
1903
1904
1923
12.0 (12.7)
13.0 (13.7)
15.0 (15.8)
4045TF275
1903
1904
1923
12.5 (13.2)
13.5 (14.3)
15.0 (15.8)
4045HF275
1904
1923
1976
13.5 (14.3)
15.0 (15.8)
20.5 (21.6)
4045HF475
1923
1976
15.0 (15.8)
20.5 (21.6)
6068TF275
1907
1908
1909
1924
1944
1956
1961
19.5
19.0
19.0
24.2
20.0
18.0
31.5
(20.6)
(20.1)
(20.1)
(25.6)
(21.1)
(19.0)
(33.3)
6068HF275
1907
1908
1909
1924
1961
19.5
19.0
19.0
24.2
31.5
(20.6)
(20.1)
(20.1)
(25.6)
(33.3)
6068HF475
1924
1961
23.7 (25.0)
31.5 (33.3)
RG,RG34710,5617 –19–26FEB03–1/1
55-6
040103
PN=192
Specifications
TORQ1A
–UN–27SEP99
Unified Inch Bolt and Cap Screw Torque Values
Top, SAE Grade and Head Markings; Bottom, SAE Grade and Nut Markings
Grade 1 (No Mark)
Size
Lubricated
N•m(lb-ft)
b
c
Grade 2a (No Mark)
b
Dry
N•m(lb-ft)
Lubricated
N•m(lb-ft)
c
Dry
N•m(lb-ft)
Grade 5, 5.1 or 5.2
b
Lubricated
N•m(lb-ft)
c
Grade 8 or 8.2
Dry
N•m(lb-ft)
Lubricatedb
N•m(lb-ft)
Dryc
N•m(lb-ft)
1/4
3.8 (2.8)
4.7 (3.5)
6 (4.4)
7.5 (5.5)
9.5 (7)
12 (9)
13.5 (10)
17 (12.5)
5/16
7.7 (5.7)
9.8 (7.2)
12 (9)
15.5 (11.5)
19.5 (14.5)
25 (18.5)
28 (20.5)
35 (26)
3/8
13.5 (10)
17.5 (13)
22 (16)
27.5 (20)
35 (26)
44 (32.5)
49 (36)
63 (46)
7/16
22 (16)
28 (20.5)
35 (26)
44 (32.5)
56 (41)
70 (52)
80 (59)
100 (74)
1/2
34 (25)
42 (31)
53 (39)
67 (49)
85 (63)
110 (80)
120 (88)
155 (115)
9/16
48 (35.5)
60 (45)
76 (56)
95 (70)
125 (92)
155 (115)
175 (130)
220 (165)
5/8
67 (49)
85 (63)
105 (77)
135 (100)
170 (125)
215 (160)
240 (175)
305 (225)
3/4
120 (88)
150 (110)
190 (140)
240 (175)
300 (220)
380 (280)
425 (315)
540 (400)
7/8
190 (140)
240 (175)
190 (140)
240 (175)
490 (360)
615 (455)
690 (510)
870 (640)
1
285 (210)
360 (265)
285 (210)
360 (265)
730 (540)
920 (680)
1030 (760)
1300 (960)
1-1/8
400 (300)
510 (375)
400 (300)
510 (375)
910 (670)
1150 (850)
1450 (1075)
1850 (1350)
1-1/4
570 (420)
725 (535)
570 (420)
725 (535)
1280 (945)
1630 (1200)
2050 (1500)
2600 (1920)
1-3/8
750 (550)
950 (700)
750 (550)
950 (700)
1700 (1250)
2140 (1580)
2700 (2000)
3400 (2500)
1-1/2
990 (730)
1250 (930)
990 (730)
1250 (930)
2250 (1650)
2850 (2100)
3600 (2650)
4550 (3350)
a
Grade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long,
and for all other types of bolts and screws of any length.
b
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
c
"Dry" means plain or zinc plated without any lubrication.
DO NOT use these values if a different torque value or tightening
procedure is given for a specific application. Torque values listed are
for general use only. Check tightness of fasteners periodically.
Make sure fastener threads are clean and that you properly start
thread engagement. This will prevent them from failing when
tightening.
Shear bolts are designed to fail under predetermined loads. Always
replace shear bolts with identical grade.
Tighten plastic insert or crimped steel-type lock nuts to approximately
50 percent of the dry torque shown in the chart, applied to the nut,
not to the bolt head. Tighten toothed or serrated-type lock nuts to the
full torque value.
Fasteners should be replaced with the same or higher grade. If
higher grade fasteners are used, these should only be tightened to
the strength of the original.
DX,TORQ1 –19–01OCT99–1/1
55-7
040103
PN=193
Specifications
TORQ2
–UN–07SEP99
Metric Bolt and Cap Screw Torque Values
Top, Property Class and Head Markings; Bottom, Property Class and Nut Markings
Class 4.8
Size
Lubricated
N•m(lb-ft)
a
Class 8.8 or 9.8
b
Dry
N•m(lb-ft)
a
Class 10.9
b
Lubricated
N•m(lb-ft)
Dry
N•m(lb-ft)
a
Class 12.9
b
Lubricated
N•m(lb-ft)
Dry
N•m(lb-ft)
Lubricateda
N•m(lb-ft)
Dryb
N•m(lb-ft)
M6
4.7 (3.5)
6 (4.4)
9 (6.6)
11.5 (8.5)
13 (9.5)
16.5 (12.2)
15.5 (11.5)
19.5 (14.5)
M8
11.5 (8.5)
14.5 (10.7)
22 (16)
28 (20.5)
32 (23.5)
40 (29.5)
37 (27.5)
47 (35)
M10
23 (17)
29 (21)
43 (32)
55 (40)
63 (46)
80 (59)
75 (55)
95 (70)
M12
40 (29.5)
50 (37)
75 (55)
95 (70)
110 (80)
140 (105)
130 (95)
165 (120)
M14
63 (46)
80 (59)
120 (88)
150 (110)
175 (130)
220 (165)
205 (150)
260 (190)
M16
100 (74)
125 (92)
190 (140)
240 (175)
275 (200)
350 (255)
320 (235)
400 (300)
M18
135 (100)
170 (125)
265 (195)
330 (245)
375 (275)
475 (350)
440 (325)
560 (410)
M20
190 (140)
245 (180)
375 (275)
475 (350)
530 (390)
675 (500)
625 (460)
790 (580)
M22
265 (195)
330 (245)
510 (375)
650 (480)
725 (535)
920 (680)
850 (625)
1080 (800)
M24
330 (245)
425 (315)
650 (480)
820 (600)
920 (680)
1150 (850)
1080 (800)
1350 (1000)
M27
490 (360)
625 (460)
950 (700)
1200 (885)
1350 (1000)
1700 (1250)
1580 (1160)
2000 (1475)
M30
660 (490)
850 (625)
1290 (950)
1630 (1200)
1850 (1350)
2300 (1700)
2140 (1580)
2700 (2000)
M33
900 (665)
1150 (850)
1750 (1300)
2200 (1625)
2500 (1850)
3150 (2325)
2900 (2150)
3700 (2730)
M36
1150 (850)
1450 (1075)
2250 (1650)
2850 (2100)
3200 (2350)
4050 (3000)
3750 (2770)
4750 (3500)
a
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
b
"Dry" means plain or zinc plated without any lubrication.
DO NOT use these values if a different torque value or tightening
procedure is given for a specific application. Torque values listed are
for general use only. Check tightness of fasteners periodically.
Make sure fastener threads are clean and that you properly start
thread engagement. This will prevent them from failing when
tightening.
Shear bolts are designed to fail under predetermined loads. Always
replace shear bolts with identical property class.
Tighten plastic insert or crimped steel-type lock nuts to approximately
50 percent of the dry torque shown in the chart, applied to the nut,
not to the bolt head. Tighten toothed or serrated-type lock nuts to the
full torque value.
Fasteners should be replaced with the same or higher property class.
If higher property class fasteners are used, these should only be
tightened to the strength of the original.
DX,TORQ2 –19–01OCT99–1/1
55-8
040103
PN=194
Lubrication and Maintenance Records
Using Lubrication and Maintenance Records
Refer to specific Lubrication and Maintenance Section
for detailed service procedures.
complete listing of all items to be performed and the
service intervals required, refer to the
quick-reference chart near the front of the
Lubrication and Maintenance Section.
1. Keep a record of the number of hours you operate
your engine by regular observation of hour meter.
IMPORTANT: The service recommendations
covered in this manual are for the
accessories that are provided by
John Deere. Follow manufacturer’s
service recommendations for
servicing engine driven equipment
not supplied by Deere.
2. Check your record regularly to learn when your
engine needs service.
3. DO ALL the services within an interval section.
Write the number of hours (from your service
records) and the date in the spaces provided. For a
RG,RG34710,5620 –19–20MAY96–1/1
Daily (Prestarting) Service
•
•
•
•
Check engine oil level.
Check coolant level.
Check fuel filters/water bowls.
Check air cleaner dust unloader valve and air restriction
indicator, if equipped.
• Perform visual walkaround inspection.
RG,RG34710,5621 –19–11JUN02–1/1
60-1
040103
PN=195
Lubrication and Maintenance Records
500 Hour/12 Month Service
•
•
•
•
•
•
•
Service fire extinguisher.
Check engine mounts.
Service battery.
Check manual belt tensioner and belt wear.
Change engine oil and filter.1
Clean crankcase vent tube.
Check air intake hoses, connections, and system.
•
•
•
•
•
•
•
Replace fuel filter element.
Check automatic belt tensioner and belt wear.
Check engine electrical ground connection.
Check cooling system.
Coolant solution analysis – add SCAs as needed.
Pressure test cooling system.
Check engine speeds.
Hours
Date
Hours
Date
Hours
Date
Hours
Date
Hours
Date
Hours
Date
Hours
Date
Hours
Date
If other than John Deere PLUS 50 or ACEA-E4/E5 engine oil and
the specified filter are used, the service interval for engine oil and
filter is reduced to 250 hours.
1
RG,RG34710,5624 –19–28FEB03–1/1
60-2
040103
PN=196
Lubrication and Maintenance Records
2000 Hour/24 Month Service
• Check crankshaft vibration damper (6-cylinder only).
• Flush and refill cooling system.1
• Test thermostats.
• Check and adjust valve clearance.
• Test glow plugs (4045HF475, 6068HF475)
Hours
Date
Hours
Date
Hours
Date
Hours
Date
Hours
Date
Hours
Date
Hours
Date
Hours
Date
1
If John Deere COOL-GARD is used, the flushing interval may be
extended to 3000 hours, or 36 months. If John Deere COOL-GARD
is used and the coolant is tested annually AND additives are
replenished as needed by adding a supplemental coolant additive,
the flushing interval may be extended to 5000 hours or 60 months,
whichever occurs first.
RG,RG34710,5625 –19–05MAR03–1/1
60-3
040103
PN=197
Lubrication and Maintenance Records
Service as Required
•
•
•
•
•
•
Add coolant
Service air cleaner.
Replace poly-vee belts.
Check fuses
Check air compressor (if equipped)
Bleed fuel system
Hours
Date
Hours
Date
Hours
Date
Hours
Date
Hours
Date
Hours
Date
Hours
Date
Hours
Date
RG,RG34710,5627 –19–11MAR03–1/1
60-4
040103
PN=198
Emission System Warranty
U.S. EPA Emissions Control Warranty Statement
Emissions control-related parts and components are
warranted by John Deere for five years or 3000 hours
of operation, whichever occurs first. John Deere further
warrants that the engine covered by this warranty was
designed, built, and equipped so as to conform at the
time of sale with all U.S. emissions standards at the
time of manufacture, and that it is free of defects in
materials and workmanship which would cause it not
to meet these standards within the period of five years
or 3000 hours of operation, whichever occurs first.
Warranties stated in this manual refer only to
emissions-related parts and components of your
engine. The complete engine warranty, less
emissions-related parts and components, is provided
separately as the “John Deere New Off-Highway
Engine Warranty”.
RG,RG34710,7629 –19–30JUN97–1/1
65-1
040103
PN=199
Emission System Warranty
RG11947
–UN–06NOV01
Emissions Control System Certification Label
Emissions Label
CAUTION: Statutes providing severe
penalties for tampering with emissions
controls may apply to the user or dealer.
The emissions warranty described below applies only
to those engines marketed by John Deere that have
been certified by the United States Environmental
Protection Agency (EPA) and/or California Air
Resources Board (CARB); and used in the United
States and Canada in non-road mobile (self-propelled
or portable/transportable1) equipment. The presence of
an emissions label like the one shown signifies that the
engine has been certified with the EPA and/or CARB.
The EPA and CARB warranties only apply to new
1
engines having the certification label affixed to the
engine and sold as stated above in the geographic
areas. The presence of an EU number in the third line
of the label signifies that the engine has been certified
with the European Union countries per Directive
97/68/EC. The emissions warranty does not apply to
the EU countries.
NOTE: The hp/kW rating on the engine emissions
certification label specifies the gross engine
hp/kW, which is flywheel power without fan. In
most applications this will not be the same
rating as the advertised vehicle hp/kW rating.
Equipment moved at least once every 12 months.
DPSG,RG41165,133 –19–12NOV01–1/1
65-2
040103
PN=200
John Deere Service Literature Available
Technical Information
–UN–16MAR98
Technical information is available from John Deere. Some
of this information is available in electronic as well as
printed form. Order from your John Deere dealer or call
1-800-522-7448. Please have available the model
number, serial number, and name of the product.
RG9260
–UN–16MAR98
Parts Catalogs
–UN–16MAR98
Operator Manuals
RG9261
Component Technical Manuals
TS1663
–UN–10OCT97
• PARTS CATALOGS list service parts available for your
machine with exploded view illustrations to help you
identify the correct parts. It is also useful in assembling
and disassembling.
• OPERATOR’S MANUALS providing safety, operating,
maintenance, and service information. These manuals
and safety signs on your machine may also be available
in other languages.
• OPERATOR’S VIDEO TAPES showing highlights of
safety, operating, maintenance, and service information.
These tapes may be available in multiple languages
and formats.
• TECHNICAL MANUALS outlining service information for
your machine. Included are specifications, illustrated
assembly and disassembly procedures, hydraulic oil
flow diagrams, and wiring diagrams. Some products
have separate manuals for repair and diagnostic
information. Some components, such as engines, are
available in separate component technical manuals
• FUNDAMENTAL MANUALS detailing basic information
regardless of manufacturer:
– Agricultural Primer series covers technology in
farming and ranching, featuring subjects like
computers, the Internet, and precision farming.
– Farm Business Management series examines
“real-world” problems and offers practical solutions in
the areas of marketing, financing, equipment
selection, and compliance.
– Fundamentals of Services manuals show you how to
repair and maintain off-road equipment.
– Fundamentals of Machine Operation manuals explain
machine capacities and adjustments, how to improve
machine performance, and how to eliminate
unnecessary field operations.
RG9262
Available information includes:
Fundamental Manuals
DPSG,RG41165,134 –19–10JUL00–1/1
70-1
040103
PN=201
John Deere Service Literature Available
Publications for this Engine
Technical information is available from John Deere in
support of our products. Some of this information is
available in electronic as well as printed form. Order from
your John Deere dealer or call 1-800-522-7448. Please
have available the model number, and name of your
engine.
Publications For POWERTECH 4.5 And 6.8 L Diesel Engines (English).
Publication Type
Title
Operation And Maintenance Manual ..... POWERTECH 4.5 L and 6.8 L OEM Diesel Engines
Parts Catalogs ........................................ POWERTECH 4.5 L OEM Diesel Engines
(4045DF270, 4045TF270, 4045TF275,
4045HF275, 4045HF475) .......................................
POWERTECH 6.8 L OEM Diesel Engines
(6068TF275, 6068HF275, 6068HF475) ..................
Component Technical Manuals ............. POWERTECH 4.5 & 6.8 L Diesel Engines—Base
Engine .....................................................................
Mechanical Fuel Systems .......................................
Level 4 Electronic Fuel System With Bosch VP44
Pump .......................................................................
Level 12 Electronic Fuel System With Stanadyne
DE10 Pump .............................................................
Level 11 Electronic Fuel System With Denso High
Pressure Common Rail ...........................................
OEM Engine Accessories .......................................
Alternators And Starter Motors ...............................
Order Number
OMRG33324
PC9080
PC9081
CTM104
CTM207
CTM170
CTM331
CTM220
CTM67
CTM77
DPSG,RG34710,105 –19–26FEB03–1/1
70-2
040103
PN=202
Index
Page
A
Acid burns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-2
Adjust
Valves, all except 475 engines . . . . . . . . . . . . 35-9
Valves, 475 engines . . . . . . . . . . . . . . . . . . . 35-12
Air cleaner
Air intake restriction indicator . . . . . . . . . . . . . 25-1
Dust unloader valve . . . . . . . . . . . . . . . . . . . . 25-1
Replace single stage element . . . . . . . . . . . . . 40-5
Air compressor . . . . . . . . . . . . . . . . . . . . . . . . . 40-11
Air intake heaters . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Air intake system, check. . . . . . . . . . . . . . . . . . 30-10
Alternator belts . . . . . . . . . . . . . . . . . . . . . . . . . 40-10
Analysis
Dieselscan . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Auxiliary gear drive, limitations . . . . . . . . .15-31, 16-5
B
Batteries
Charge/Boost . . . . . . . . . . . . . . . . . . .15-26, 16-12
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-2
Battery acid burns . . . . . . . . . . . . . . . . . . . . . . . 30-2
Battery explosion . . . . . . . . . . . . . . . . . . . . . . . . 30-2
Belt tensioner
Manual tensioner, adjust . . . . . . . . . . . . . . . . . 30-4
Manual tensioner, adjust with tool . . . . . . . . . . 30-5
Belt tensioner, automatic . . . . . . . . . . . . . . . . . 30-13
Belts, fan and alternator
Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10
Bio-Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Bleeding fuel system
DE10 pump. . . . . . . . . . . . . . . . . . . . . . . . . . 40-14
High Pressure Common Rail. . . . . . . . . . . . . 40-17
VP44 pump . . . . . . . . . . . . . . . . . . . . . . . . . . 40-12
4045DF/TF270 . . . . . . . . . . . . . . . . . . . . . . . 40-19
Blink codes
Bosch VP44 pump . . . . . . . . . . . . . . . . . . . . 45-24
High Pressure Common Rail. . . . . . . . . . . . . 45-26
Blink Codes
Reading DTCs . . . . . . . . . . . . . . . . . . . . . . . 45-18
Break-in, engine
Except 4045DF,TF270 . . . . . . . . . . . . . . . . . 15-17
4045DF,TF270 . . . . . . . . . . . . . . . . . . . . . . . . 16-4
Page
Check and adjust
Valves, all except 475 engines . . . . . . . . . . . . 35-9
Valves, 475 engines . . . . . . . . . . . . . . . . . . . 35-12
Check engine electrical ground. . . . . . . . . . . . . 30-15
Cold weather aids. . . . . . . . . . . . . . . . . . .10-6, 35-15
Except 4045DF,TF270 . . . . . . . . . . . . . . . . . 15-24
4045DF,TF270 . . . . . . . . . . . . . . . . . . . . . . . . 16-7
Compressor, air . . . . . . . . . . . . . . . . . . . . . . . . 40-11
Coolant
Adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-3
Additional information . . . . . . . . . . . . . . . . . . 10-14
Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . 10-13
Disposing . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
Replenishing supplemental additives. . . . . . . 30-16
Supplemental additives . . . . . . . . . . . . . . . . . 10-16
Testing . . . . . . . . . . . . . . . . . . . . . . . .10-15, 30-18
Warm temperature climates . . . . . . . . . . . . . 10-17
Cooling system
Adding coolant . . . . . . . . . . . . . . . . . . . . . . . . 40-3
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-15
Flush. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-3
Pressure test. . . . . . . . . . . . . . . . . . . . . . . . . 30-19
Pressure test radiator cap . . . . . . . . . . . . . . . 30-19
Refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-3
Crankcase vent tube, clean . . . . . . . . . . . . . . . . 30-9
Crankshaft vibration damper. . . . . . . . . . . . . . . . 35-2
D
Damper, checking. . . . . . . . . . . . . . . . . . . . . . . . 35-2
Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . 45-20
Diagnostic procedure
Using diagnostic gauge. . . . . . . . . . . . . . . . . . 15-7
Diagnostic Trouble Codes
Blink Codes . . . . . . . . . . . . . . . . . . . . . . . . . 45-18
Diagnostic Trouble Codes (DTCs)
Electronic systems and Bosch VP44. . . . . . . 45-24
Electronic systems and Denso High Pressure
Common Rail. . . . . . . . . . . . . . . . . . . . . . . 45-26
Electronic systems and Stanadyne DE10 . . . 45-22
Diagnostic Trouble Codes (DTC’s)
Instument panel . . . . . . . . . . . . . . . . . . . . . . 45-20
Diesel engine oil. . . . . . . . . . . . . . . . . . . . . . . . . 10-9
Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Dieselscan fuel analysis . . . . . . . . . . . . . . . . . . . 10-3
E
C
Chart, service interval. . . . . . . . . . . . . . . . .20-2, 20-4
Emissions
EPA Statement . . . . . . . . . . . . . . . . . . . . . . . . 65-1
Index-1
040103
PN=1
Index
Page
Page
Engine
Adjust speed . . . . . . . . . . . . . . . . . . . . . . . . . 30-20
Break-in, except 4045DF,TF270 . . . . . . . . . . 15-17
Break-in, 4045DF,TF270 . . . . . . . . . . . . . . . . . 16-4
Check electrical ground. . . . . . . . . . . . . . . . . 30-15
Idling. . . . . . . . . . . . . . . . . . . . . . . . . .15-27, 16-10
Operation, except 4045DF,TF270 . . . . . . . . . 15-22
Operation, 4045DF,TF270. . . . . . . . . . . . . . . . 16-3
Option codes. . . . . . . . . . . . . . . . . . . . . . . . . . 01-3
Serial number . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
Starting, except 4045DF,TF270 engine . . . . . 15-20
Starting, 4045DF,TF270 engine . . . . . . . . . . . 16-6
Stopping, except 4045DF,TF270. . . . . . . . . . 15-30
Stopping, 4045DF,TF270 . . . . . . . . . . . . . . . 16-11
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 45-8
Warming, except 4045DF,TF270. . . . . . . . . . 15-23
Warming, 4045DF,TF270 . . . . . . . . . . . . . . . . 16-9
Engine coolant
Disposing of . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
Engine mounts
Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
Engine oil
Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-7
Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
Engine wiring diagram
W/electronic instrument panel . . . . . . . . . . . . . 45-6
Engine wiring layout
With Bosch VP44 pump . . . . . . . . . . . . . . . . . 45-4
With Denso High Pressure Common Rail . . . . 45-5
With Stanadyne DE10 pump . . . . . . . . . . . . . . 45-3
Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-28
Fuel filters
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-11
Fuel injection pump model number. . . . . . . . . . . 01-5
Fuel system
Bleeding (DE10 pump) . . . . . . . . . . . . . . . . . 40-14
Bleeding (High Pressure Common Rail) . . . . 40-17
Bleeding (VP44 pump) . . . . . . . . . . . . . . . . . 40-12
Bleeding (4045DF/TF270) . . . . . . . . . . . . . . . 40-19
Fuel tank
Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Fuses, checking . . . . . . . . . . . . . . . . . . . . . . . . 40-11
G
Gauges
Except 4045DF,TF270 . . . . . . . . . . . . . . . . . 15-23
4045DF,TF270 . . . . . . . . . . . . . . . . . . . . . . . . 16-9
Generator (Standby) Applications . . . . . . . . . . . . 20-4
Glow plugs
Test, 475 engines . . . . . . . . . . . . . . . . . . . . . 35-15
Grease
Extreme pressure and multipurpose . . . . . . . 10-12
I
Idling engine. . . . . . . . . . . . . . . . . . . . . .15-27, 16-10
Inch torque values . . . . . . . . . . . . . . . . . . . . . . . 55-7
Instrument panel, electronic . . . . . . . . . . . . . . . . 15-1
Intermittent fault diagnostics . . . . . . . . . . . . . . . 45-29
L
F
Fan belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10
Filter, replace
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-7
Filters, replace
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-11
Fire extinguisher, service . . . . . . . . . . . . . . . . . . 30-1
Fuel
Bio-Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Dieselscan Analysis . . . . . . . . . . . . . . . . . . . . 10-3
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Fuel filter
Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-1
Draining water. . . . . . . . . . . . . . . . . . . . . . . . . 25-1
Listing of DTCs. . . . . . . . . . . . . . 45-22, 45-24, 45-26
Lubricants
Mixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
Lubrication and Maintenance
Service Interval Chart . . . . . . . . . . . . . . .20-2, 20-4
Lubricity of diesel fuel. . . . . . . . . . . . . . . . . . . . . 10-2
M
Maintenance interval chart
Generator (Standby) applications . . . . . . . . . . 20-4
Standard industrial applications. . . . . . . . . . . . 20-2
Manual belt tensioner . . . . . . . . . . . . . . . . . . . . . 30-4
Index-2
040103
PN=2
Index
Page
Page
Manual belt tensioner - using belt tension tool . . 30-5
Metric torque values . . . . . . . . . . . . . . . . . . . . . . 55-8
Mixing lubricants. . . . . . . . . . . . . . . . . . . . . . . . 10-10
Mounts, engine
Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
Service
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-2
Fire extinguisher . . . . . . . . . . . . . . . . . . . . . . . 30-1
Intervals . . . . . . . . . . . . . . . . . . . . . . . . .20-2, 20-4
Service literature . . . . . . . . . . . . . . . . . . . . . . . . 70-2
Specifications
Battery capabilities . . . . . . . . . . . . . . . . . . . . . 30-2
Belt tensioner . . . . . . . . . . . . . . . . . . . . . . . . 30-13
Damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-2
Engine crankcase oil fill . . . . . . . . . . . . . . . . . 55-6
Fuel injection pump and power ratings . . . . . . 55-3
General OEM . . . . . . . . . . . . . . . . . . . . . . . . . 55-1
Standby power units . . . . . . . . . . . . . . . . .15-31, 16-6
Starting engine, except 4045DF,TF270
engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-20
Starting engine, 4045DF,TF270 engine . . . . . . . 16-6
Stopping engine, except 4045DF,TF270. . . . . . 15-30
Stopping engine, 4045DF,TF270 . . . . . . . . . . . 16-11
Storage
Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-1
Long term . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-2
Removing from . . . . . . . . . . . . . . . . . . . . . . . . 50-3
Storing lubricants . . . . . . . . . . . . . . . . . . . . . . . 10-11
Supplemental coolant additives
Replenishing . . . . . . . . . . . . . . . . . . . . . . . . . 30-16
O
Oil
Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
Dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-1
Fill quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-6
Filler locations. . . . . . . . . . . . . . . . . . . . . . . . . 25-1
Oil filter, change . . . . . . . . . . . . . . . . . . . . . . . . . 30-7
Operating engine
Break-in, except 4045DF,TF270 . . . . . . . . . . 15-17
Break-in, 4045DF,TF270 . . . . . . . . . . . . . . . . . 16-4
Cold weather. . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Cold weather, except 4045DF,TF270 . . . . . . 15-24
Cold weather, 4045DF,TF270 . . . . . . . . . . . . . 16-7
Normal operation, except 4045DF,TF270 . . . 15-22
Normal operation, 4045DF,TF270 . . . . . . . . . . 16-3
Option codes . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-3
T
P
Poly-vee belts
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10
Power ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-3
Precautions for welding on engines equipped
w/ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-2
R
Radiator cap testing . . . . . . . . . . . . . . . . . . . . . 30-19
Radiator shutters . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Recordkeeping
Engine option codes . . . . . . . . . . . . . . . . . . . . 01-3
Engine serial number . . . . . . . . . . . . . . . . . . . 01-1
Injection pump model number . . . . . . . . . . . . . 01-5
Tensioner, belt
Automatic . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-13
Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4
Thermostat
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-6
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-6
Test opening temperature . . . . . . . . . . . . . . . . 35-6
Torque values
Inch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-7
Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-8
Trouble codes
Electronic systems and Bosch VP44. . . . . . . 45-24
Electronic systems and Denso High Pressure
Common Rail. . . . . . . . . . . . . . . . . . . . . . . 45-26
Electronic systems and Stanadyne DE10 . . . 45-22
Troubleshooting
General, engine . . . . . . . . . . . . . . . . . . . . . . . 45-8
S
V
Serial number
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
Fuel injection pump. . . . . . . . . . . . . . . . . . . . . 01-5
Valves
Clearance, check and adjust
All except 475 engines . . . . . . . . . . . . . . . . 35-9
Index-3
040103
PN=3
Index
Page
475 engines. . . . . . . . . . . . . . . . . . . . . . . . 35-12
Vibration damper . . . . . . . . . . . . . . . . . . . . . . . . 35-2
W
Warming engine, except 4045DF,TF270 . . . . . 15-23
Warming engine, 4045DF,TF270 . . . . . . . . . . . . 16-9
Warranty
Emission System . . . . . . . . . . . . . . . . . . . . . . 65-2
Winterfronts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Wiring diagrams, engine
Engines w/electronic instrument panel . . . . . . 45-6
Wiring harness
With Bosch VP44 pump . . . . . . . . . . . . . . . . . 45-4
With Denso High Pressure Common Rail . . . . 45-5
With Stanadyne DE10 pump . . . . . . . . . . . . . . 45-3
Index-4
040103
PN=4