John Deere 6068 manual

P OWER T ECH  4.5 and 6.8 L 4045 and 6068 Tier 2 / Stage II OEM Diesel Engines OPERATOR’S MANUAL P OWER T ECH 4.5 and 6.8 L Tier 2 / Stage II OEM Diesel Engines OMRG33324 Issue 7Aug06 (ENGLISH) CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defect[...]

Introduction OURGP11,000006E –19–04AUG06–1/2 Foreword THIS MANUAL CONTAINS INFORMATION to operate and service the following Tier 2 / Stage II emission-certified 1 engines: Saran-built (France) Tier 2 Mechanically Controlled Engines: • CD4045DF270 • CD4045TF270 Saran-built (France) Tier 2 Electronically Controlled Engines: • CD4045TF275 [...]

Introduction OURGP11,000006E –19–04AUG06–2/2 IMPORTANT: This manual covers only P OWER T ECH  Tier 2 / Stage II emission certified 4.5 and 6.8 L OEM engines listed. These engines meet Tier 2 emission certification standards. 2 (This is for both the U.S. EPA and European Union Council (EU) standards.) Engines with mechanical controls which [...]

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Introduction OURGP11,0000251 –19–27JUL06–1/1 Engine Owner John Deere Engine Owner: Don’t wait until you need warranty or other service to meet your local John Deere Engine Distributor or Service Dealer. To register your engine for warranty via the Internet, use the following URL: http://www.johndeere.com/enginewarranty Learn who your dealer[...]

Introduction OUOD002,0000162 –19–04AUG06–1/1 P OWER T ECH  4.5 L Engines With Electronic Fuel Systems (Tier 2 Emission Certified) (Two-Valve Cylinder Head Models) RG11931 –UN–06NOV01 4045 Engine (Stanadyne DE10 Injection Pump Shown) RG11932 –UN–06NOV01 4045 Engine P OWER T ECH is a trademark of Deere & Company. 080706 PN=6[...]

Introduction OUOD002,0000163 –19–04AUG06–1/1 P OWER T ECH  6.8 L Engines With Electronic Fuel Systems (Tier 2 Emission Certified) (Two-Valve Cylinder Head Models) RG11933 –UN–24OCT01 6068 Engine (Bosch VP44 Injection Pump Shown) RG11934 –UN–24OCT01 6068 Engine P OWER T ECH is a trademark of Deere & Company. 080706 PN=7[...]

Introduction OURGP11,000018B –19–04AUG06–1/1 P OWER T ECH  4.5/6.8 L Engines With Electronic Fuel Systems (Tier 2 Emission Certified) (Four-Valve Cylinder Head “475” Models) RG12199 –UN–24MAY02 6068HF475 Engine Shown (Level 11 Electronic Fuel System With Denso High Pressure Common Rail) RG12200 –UN–24MAY02 6068HF475 Shown P OWE[...]

Contents Page Page Record Keeping Using Touch Switches to Display Information .......................... 16-10 PowerTech Medallion ..................... 01-1 Changing Units of Measure (English or Engine Serial Number Plate ................ 01-1 Metric) .............................. 16-12 Record Engine Serial Number .............. 01-2 Viewing Engi[...]

Contents Page Page Auxiliary Gear Drive Limitations ............ 19-17 Checking Crankshaft Vibration Damper Generator Set (Standby) Applications ........ 19-17 (6-Cylinder Engine Only) ................. 35-2 Flushing and Refilling Cooling System ........ 35-3 Engine Operation- 4.5 L “270” Engines Testing Thermostats Opening Temperature .... 35-[...]

Contents Page Page Engine Wiring Layout (Electronic Fuel Lubrication and Maintenance Records Using Lubrication and Maintenance Records . . . 60-1 System With Denso High Pressure Common Daily (Prestarting) Service ................. 60-1 Rail)(4045HF475,6068HF475) ............. 45-5 500 Hour/12 Month Service ................ 60-2 Engine Wiring Diagra[...]

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Record Keeping OURGP11,0000274 –19–04AUG06–1/1 P OWER T ECH  Medallion RG11608 –UN–17OCT01 RG11609 –UN–17OCT01 A medallion is located on the rocker arm cover which identifies each engine as a John Deere P OWER T ECH  engine. NOTE: Four-valve head engines also have “16V” or “24V” printed on their medallions. The 4045HF475[...]

Record Keeping OURGP11,0000070 –19–27JUL06–1/1 Record Engine Serial Number RG11949 –UN–07NOV01 Saran Engine Serial Number Plate RG11948 –UN–06NOV01 Torreon Engine Serial Number Plate Record all of the numbers and letters found on your engine serial number plate in the spaces provided below. This information is very important for repai[...]

Record Keeping RG,RG34710,5508 –19–27JUL06–1/2 Engine Option Codes RG11946 –UN–06NOV01 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 par[...]

Record Keeping RG,RG34710,5508 –19–27JUL06–2/2 NOTE: Your engine option code label may not contain all option codes if an option has been added after the engine left the producing factory. If option code label is lost or destroyed, consult your servicing dealer or engine distributor selling the engine for a replacement. An additional option c[...]

Record Keeping OURGP12,00000AD –19–27JUL06–1/1 Record Engine Control Unit (ECU) Serial Number RG13799 –UN–18NOV04 Record Engine Control Unit (ECU) Serial Number A—Serial Number Label Record the part number and serial number information found on the serial number label (A) on the Engine Control Unit (ECU) mounted on or near the engine. P[...]

Safety DX,ALERT –19–29SEP98–1/1 Recognize Safety Information T81389 –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. Follow recommended precautions and safe operating practices. DX,SIGNAL –19–03MAR93–1/1 Understand Signal Words TS187[...]

Safety DX,SIGNS1 –19–04JUN90–1/1 Replace Safety Signs TS201 –UN–23AUG88 Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement. RG,RG34710,7508 –19–27JUL06–1/1 Prevent Bypass Starting RG5419 –UN–28FEB89 Prevent Bypass Starting Avoid possible injury or death from engine runa[...]

Safety DX,FIRE2 –19–03MAR93–1/1 Prepare for Emergencies TS291 –UN–23AUG88 Be prepared if a fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone. DX,FIRE3 –19–16APR92–1/1 Handle Starting Fluid Safely TS1356 –UN–18MAR[...]

Safety OURGP12,00001DA –19–27JUL06–1/1 Service Engines Safely TS228 –UN–23AUG88 Moving Parts Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result. Remove rings and other jewelry to prevent el[...]

Safety DX,MSDS,NA –19–03MAR93–1/1 Handle Chemical Products Safely TS1132 –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. A Material Safety Data Sheet (MSDS) provides specific detail[...]

Safety DX,SERV –19–17FEB99–1/1 Practice Safe Maintenance TS218 –UN–23AUG88 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 equ[...]

Safety DX,FLUID –19–03MAR93–1/1 Avoid High-Pressure Fluids X9811 –UN–23AUG88 Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protec[...]

Safety DX,PAINT –19–24JUL02–1/1 Remove Paint Before Welding or Heating TS220 –UN–23AUG88 Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. Remove paint before heating: • Remove paint a minimum of 100 mm (4 in.) from area to be affected by heating. If pa[...]

Safety OUOD006,000009D –19–27JUL06–1/1 Install Fan Guards TS677 –UN–21SEP89 Rotating Fan Rotating cooling system fans can cause serious injury. Keep fan guards in place at all times during engine operation. Wear close fitting clothes. Stop the engine and be sure fan is stopped before making adjustments or connections, or cleaning near the[...]

Safety DX,DUST –19–15MAR91–1/1 Avoid Harmful Asbestos Dust TS220 –UN–23AUG88 Avoid breathing dust that may be generated when handling components containing asbestos fibers. Inhaled asbestos fibers may cause lung cancer. Components in products that may contain asbestos fibers are brake pads, brake band and lining assemblies, clutch plates,[...]

Safety DX,REPAIR –19–17FEB99–1/1 Use Proper Tools TS779 –UN–08NOV89 Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards. Use power tools only to loosen threaded parts and fasteners. For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fastene[...]

Safety DPSG,OUO1004,2758 –19–27JUL06–1/1 Handling Batteries Safely TS204 –UN–23AUG88 Explosion TS203 –UN–23AUG88 Acid CAUTION: Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check battery electrolyte level. Never check battery charge by placing a metal object across the posts. Use a voltmeter [...]

Safety DX,SPRAY –19–16APR92–1/1 Protect Against High Pressure Spray TS1343 –UN–18MAR92 Spray from high pressure nozzles can penetrate the skin and cause serious injury. Keep spray from contacting hands or body. If an accident occurs, see a doctor immediately. Any high pressure spray injected into the skin must be surgically removed within[...]

Fuels, Lubricants, and Coolant DX,FUEL1 –19–17NOV05–1/1 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 ar[...]

Fuels, Lubricants, and Coolant DX,FUEL4 –19–19DEC03–1/1 Handling and Storing 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 duri[...]

Fuels, Lubricants, and Coolant DX,FUEL7 –19–14NOV05–1/1 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, EN 14214, or equivalent specification. It is recommended to purchas[...]

Fuels, Lubricants, and Coolant DX,FUEL10 –19–16DEC05–1/2 Minimizing the Effect of Cold Weather on Diesel Engines John Deere diesel engines are designed to operate effectively in cold weather. However, for effective starting and cold weather operation, a little extra care is necessary. The information below outlines steps that can minimize the[...]

Fuels, Lubricants, and Coolant DX,FUEL10 –19–16DEC05–2/2 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[...]

Fuels, Lubricants, and Coolant DX,ENOIL7 –19–23NOV05–1/1 Diesel Engine Oil TS1675 –UN–31OCT03 Use oil viscosity base on the expected air temperature range during the period between oil changes. John Deere PLUS-50  oil is preferred. Oil meeting one of the following specifications are also recommended: • ACEA Oil Sequence E7 • ACEA O[...]

Fuels, Lubricants, and Coolant OURGP11,0000012 –19–27JUL06–1/3 Diesel Engine Oil and Filter Service Intervals The oil and filter service intervals in the following charts should be used as guidelines. Actual service intervals depend on operation and maintenance practices. Use oil analysis to determine the actual useful life of the oil and to [...]

Fuels, Lubricants, and Coolant OURGP11,0000012 –19–27JUL06–2/3 4.5 L Engine Oil and Filter Service Intervals in Hours of Operation Oil Pan Option Codes Power Fuel Sulfur Content a 1901, 1902 1903 1904 1923 1976 Rating Interval Interval Interval Interval Interval kW (hp) Std Prem Std Oil Prem Std Prem Std Oil Prem Std Oil Prem Oil Oil Oil Oil [...]

Fuels, Lubricants, and Coolant OURGP11,0000012 –19–27JUL06–3/3 6.8 L Engine Oil and Filter Service Intervals in Hours of Operation Oil Pan Option Codes Power Fuel Sulfur Content a 1956 1907, 1908, 1924 19AC 1961 Rating 1909, 1944 Interval Interval Interval Interval Interval kW (hp) Std Prem Std Prem Std Prem Std Prem Std Prem Oil Oil Oil Oil [...]

Fuels, Lubricants, and Coolant DX,FILT –19–18MAR96–1/1 Oil Filters Filtration of oils is critical to proper operation and lubrication. Always change filters regularly as specified in this manual. Use filters meeting John Deere performance specifications. DX,OILSCAN –19–02DEC02–1/1 OILSCAN  and COOLSCAN  T6828AB –UN–15JUN89 T68[...]

Fuels, Lubricants, and Coolant DX,ALTER –19–15JUN00–1/1 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 i[...]

Fuels, Lubricants, and Coolant DX,GREA1 –19–07NOV03–1/1 Grease TS1673 –UN–31OCT03 Use grease based on NLGI consistency numbers and the expected air temperature range during the service interval. John Deere SD POLYUREA GREASE is preferred. The following greases are also recommended • John Deere HD LITHIUM COMPLEX GREASE • John Deere HD[...]

Fuels, Lubricants, and Coolant DX,COOL3 –19–27OCT05–1/2 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). If protection at lower temperatures is required, consult your John Deere dealer for recommendation[...]

Fuels, Lubricants, and Coolant DX,COOL3 –19–27OCT05–2/2 Water quality is important to the performance of the cooling system. Distilled, deionized, or demineralized water is recommended for mixing with ethylene glycol and propylene glycol base engine coolant concentrate. IMPORTANT: Do not use cooling system sealing additives or antifreeze that[...]

Fuels, Lubricants, and Coolant DX,COOL4 –19–07NOV03–1/1 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 t[...]

Fuels, Lubricants, and Coolant DX,COOL6 –19–18MAR96–1/1 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 coo[...]

Instrument Panel Identification OURGP11,0000071 –19–27JUL06–1/2 Instrument Panels - Identification RG13343 –UN–24NOV03 Instrument Panel For Earlier Mechanically Controlled “270” Engines (See Section 18) RG13359 –UN–06FEB04 Deluxe Instrument Panel For Later Mechanically Controlled “270” Engines (See Section 18) The instrument p[...]

Instrument Panel Identification OURGP11,0000071 –19–27JUL06–2/2 RG13273 –UN–20NOV03 Instrument Panel For Earlier Electronically Controlled Engines (See Section 16) RG13274 –UN–28OCT03 Full-Featured Instrument Panel For Later Electronically Controlled Engines (See Section 17) RG13275 –UN–21OCT03 Basic Instrument Panel For Later Ele[...]

Instrument Panel - Elect. Cont. Earlier Engines OURGP11,000027A –19–07AUG06–1/7 Instrument Panel RG11169 –UN–01NOV00 Instrument Panel (Earlier Electronically Controlled Engines) A—Engine Oil Pressure Gauge B—Amber “WARNING” Indicator C—Red “STOP ENGINE” Indicator D—Diagnostic Gauge/Hour Meter E—Touch Switch F—Touch Swi[...]

Instrument Panel - Elect. Cont. Earlier Engines OURGP11,000027A –19–07AUG06–2/7 RG11169 –UN–01NOV00 Instrument Panel 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 electronic controls found[...]

Instrument Panel - Elect. Cont. Earlier Engines OURGP11,000027A –19–07AUG06–3/7 RG11169 –UN–01NOV00 Instrument Panel For Earlier Engines Touch Switches 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 var[...]

Instrument Panel - Elect. Cont. Earlier Engines OURGP11,000027A –19–07AUG06–4/7 RG11169 –UN–01NOV00 Instrument Panel For Earlier Engines 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, indicat[...]

Instrument Panel - Elect. Cont. Earlier Engines OURGP11,000027A –19–07AUG06–5/7 RG11169 –UN–01NOV00 Instrument Panel For Earlier Engines Bump Speed Enable Rocker Switch This is a three-position switch (O) with the center position as “OFF” (locked). With this switch in the “OFF” position, the speed select switch (P) is also locked,[...]

Instrument Panel - Elect. Cont. Earlier Engines OURGP11,000027A –19–07AUG06–6/7 RG11169 –UN–01NOV00 Instrument Panel For Earlier Engines Tachometer The tachometer (R) indicates engine speed in hundreds of revolutions per minute (rpm). Percent Load (Optional) The power meter (S) shows percent of available power being used by the engine. Vo[...]

Instrument Panel - Elect. Cont. Earlier Engines OURGP11,000027A –19–07AUG06–7/7 The cancel/resume function is intended for applications like agricultural 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 ope[...]

Instrument Panel - Elect. Cont. Earlier Engines OURGP11,0000072 –19–27JUL06–1/2 Using Diagnostic Gauge to Access Engine Information RG10031 –UN–28OCT99 Diagnostic Gauge (Earlier Engines) A—Diagnostic Gauge B—Touch Switches C—Lights The diagnostic gauge (A) allows the operator to view many readouts of engine functions and diagnostic [...]

Instrument Panel - Elect. Cont. Earlier Engines OURGP11,0000072 –19–27JUL06–2/2 • Electrical potential (voltage) • Battery potential (voltage), switched • Transmission oil pressure • Transmission oil temperature • Injector metering rail #1 pressure • Injector metering rail #2 pressure • Estimated percent fan speed • Active ser[...]

Instrument Panel - Elect. Cont. Earlier Engines DPSG,OUOD007,2841 –19–27JUL06–1/2 Using Touch Switches to Display Information RG9947 –19–09DEC99 Using Touch Switches 16-10 080706 PN=56 Continued on next page[...]

Instrument Panel - Elect. Cont. Earlier Engines DPSG,OUOD007,2841 –19–27JUL06–2/2 The touch switches on the diagnostic gauge allow quick and easy navigation through the menu to find the information needed. The diagram on the preceding page is a typical Main Menu of Engine Parameters. The Main Menu has 14 entries; the first 10 are engine data [...]

Instrument Panel - Elect. Cont. Earlier Engines DPSG,OUOD007,2842 –19–27JUL06–1/1 Changing Units of Measure (English or Metric) RG10018 –19–28OCT99 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 Su[...]

Instrument Panel - Elect. Cont. Earlier Engines 16-13 080706 PN=59[...]

Instrument Panel - Elect. Cont. Earlier Engines DPSG,OUOD007,2842 –19–27JUL06–1/2 Viewing Engine Configuration Data RG10019 –19–28OCT99 Viewing Engine Configuration Data 16-14 080706 PN=60 Continued on next page[...]

Instrument Panel - Elect. Cont. Earlier Engines DPSG,OUOD007,2842 –19–27JUL06–2/2 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 switch until the top line of the display reads “E-Config”[...]

Instrument Panel - Elect. Cont. Earlier Engines DPSG,OUOD002,1928 –19–27JUL06–1/1 Viewing Active Engine Service Codes/Diagnostic Trouble Codes (DTCs) RG11170 –UN–02NOV00 Viewing Active Service Codes/Diagnostic Trouble Codes (DTCs) The diagnostic gauge continuously monitors all messages broadcast over the Control Area Network (CAN) and dis[...]

Instrument Panel - Elect. Cont. Earlier Engines OUOD006,000006B –19–27JUL06–1/1 Viewing Stored Service Codes/Diagnostic Trouble Codes (DTCs) in the Engine ECU RG10021 –19–28OCT99 Viewing Stored Service Codes/Diagnostic Trouble Codes (DTCs) The diagnostic gauge can request stored service codes (DTCs) from the engine. The stored service cod[...]

Instrument Panel - Elect. Cont. Later Engines OURGP11,0000073 –19–04AUG06–1/3 Instrument Panels RG13276 –UN–28OCT03 Full-Featured Instrument Panel RG13277 –UN–22OCT03 Basic Instrument Panel A—Diagnostic Gauge/Hour F—Key Switch K—Analog Throttle Control O—Arrow Keys Meter G—Override Shutdown Rocker (Optional) P—Enter Key B?[...]

Instrument Panel - Elect. Cont. Later Engines OURGP11,0000073 –19–04AUG06–2/3 Instrument Panel (Continued) A—Diagnostic Gauge/Hour Meter The diagnostic gauge (A) displays diagnostic trouble codes (DTCs) as they are accessed. Other information on the engine can be accessed using the touch keys (N, O and P). The hour meter feature shows the o[...]

Instrument Panel - Elect. Cont. Later Engines OURGP11,0000073 –19–04AUG06–3/3 How To Select Preset Operating Speeds (Bump Speeds) First select Turtle (Slow) or Adj by pressing speed select switch (J) to “Turtle” (slow) or “Adj”(center). Then you can press either the upper or lower portion of the bump speed enable switch (H) to unlock [...]

Instrument Panel - Elect. Cont. Later Engines OURGP11,0000074 –19–27JUL06–1/1 Using Diagnostic Gauge to Access Engine Information RG13132 –UN–09SEP03 Diagnostic Gauge (Later Engines) A—Diagnostic Gauge B—Menu Key C—Arrow Keys D—Enter Key E—Red “STOP ENGINE” Indicator Light F—Amber “WARNING” Indicator Light The diagnost[...]

Instrument Panel - Elect. Cont. Later Engines OURGP11,00000A9 –19–27JUL06–1/5 Main Menu Navigation RG13159 –UN–26SEP03 Menu Key NOTE: The engine does not need to be running to navigate the diagnostic gauge screens. If engine start up is desired, See Starting The Engine. All of the engine values illustrated on the diagnostic gauge indicate[...]

Instrument Panel - Elect. Cont. Later Engines OURGP11,00000A9 –19–27JUL06–4/5 RG13162 –UN–26SEP03 Last Items On Main Menu 4. Pressing the right arrow key will scroll down to reveal the last items of "Main Menu" screen, highlighting the next item down. OURGP11,00000A9 –19–27JUL06–5/5 RG13163 –UN–02OCT03 Use Arrow Button[...]

Instrument Panel - Elect. Cont. Later Engines OURGP11,00000AB –19–27JUL06–2/6 RG13164 –UN–07OCT03 Select Engine Configuration 2. The main menu will be displayed. Use the "Arrow" keys to scroll through the menu until "Engine Config" is highlighted. OURGP11,00000AB –19–27JUL06–3/6 RG13165 –UN–02OCT03 Enter Key [...]

Instrument Panel - Elect. Cont. Later Engines OURGP11,00000AB –19–27JUL06–6/6 RG13159 –UN–26SEP03 Exit Main Menu 6. Press the "Menu" key to exit the main menu and return to the engine parameter display. OURGP11,00000AC –19–27JUL06–1/6 Accessing Stored Trouble Codes RG13159 –UN–26SEP03 Menu Key NOTE: The engine does not[...]

Instrument Panel - Elect. Cont. Later Engines OURGP11,00000AC –19–27JUL06–3/6 RG13169 –UN–02OCT03 Enter Key 3. Once the "Stored Codes" menu item has been highlighted press the "Enter" key to view the stored codes. OURGP11,00000AC –19–27JUL06–4/6 RG13245 –UN–02OCT03 Use Arrow Keys To Scroll 4. If the word &quo[...]

Instrument Panel - Elect. Cont. Later Engines OURGP11,00000AC –19–27JUL06–6/6 RG13159 –UN–26SEP03 Exit Main Menu 6. Press the "Menu" key to exit the main menu and return to the engine parameter display. OURGP11,00000AD –19–27JUL06–1/7 Accessing Active Trouble Codes RG13172 –UN–26SEP03 Normal Operation NOTE: The engine [...]

Instrument Panel - Elect. Cont. Later Engines OURGP11,00000AD –19–27JUL06–3/7 RG13241 –UN–30SEP03 Use Arrow Keys To Scroll 3. If the word "Next" appears above the arrow keys, there are more trouble codes that can be viewed by using the arrow keys to scroll to the next trouble code. OURGP11,00000AD –19–27JUL06–4/7 RG13242 ?[...]

Instrument Panel - Elect. Cont. Later Engines OURGP11,00000AD –19–27JUL06–7/7 RG13243 –UN–01OCT03 Active Trouble Code Condition 7. The single or four parameter screen will display the warning icon until the trouble code condition is corrected. OURGP11,00000AE –19–27JUL06–1/6 Engine Shutdown Codes RG13172 –UN–26SEP03 Normal Opera[...]

Instrument Panel - Elect. Cont. Later Engines OURGP11,00000AE –19–27JUL06–4/6 RG13179 –UN–26SEP03 Flashing Shutdown Icon 4. The display will return to the single or four parameter display, but the display will contain the "Shutdown" icon. Pressing the "Enter" key will redisplay the hidden trouble code. IMPORTANT: Ignor[...]

Instrument Panel - Elect. Cont. Later Engines OURGP11,0000237 –19–27JUL06–2/6 RG13181 –UN–02OCT03 Select Adjust Backlight 2. The main menu will be displayed. Use the "Arrow" keys to scroll through the menu until "Adjust Backlight" is highlighted. OURGP11,0000237 –19–27JUL06–3/6 RG13182 –UN–02OCT03 Press Enter[...]

Instrument Panel - Elect. Cont. Later Engines OURGP11,0000237 –19–27JUL06–5/6 RG13184 –UN–26SEP03 Return To Main Menu 5. Press the "Menu" key to return to the main menu. OURGP11,0000237 –19–27JUL06–6/6 RG13159 –UN–26SEP03 Exit Main Menu 6. Press the "Menu" key to exit the main menu and return to the engine pa[...]

Instrument Panel - Elect. Cont. Later Engines OURGP11,00000AF –19–27JUL06–2/6 RG13161 –UN–02OCT03 Select Adjust Contrast 2. The main menu will be displayed. Use the "Arrow" keys to scroll through the menu until "Adjust Contrast" is highlighted. OURGP11,00000AF –19–27JUL06–3/6 RG13185 –UN–02OCT03 Press Enter K[...]

Instrument Panel - Elect. Cont. Later Engines OURGP11,00000AF –19–27JUL06–5/6 RG13187 –UN–26SEP03 Return To Main Menu 5. Press the "Menu" key to return to the main menu. OURGP11,00000AF –19–27JUL06–6/6 RG13159 –UN–26SEP03 Exit Main Menu 6. Press the "Menu" key to exit the main menu and return to the engine pa[...]

Instrument Panel - Elect. Cont. Later Engines OURGP11,00000B0 –19–27JUL06–2/7 RG13188 –UN–02OCT03 Select Units 2. The main menu will be displayed. Use the "Arrow" keys to scroll through the menu until "Select Units" is highlighted. OURGP11,00000B0 –19–27JUL06–3/7 RG13189 –UN–02OCT03 Press Enter Key 3. Once th[...]

Instrument Panel - Elect. Cont. Later Engines OURGP11,00000B0 –19–27JUL06–5/7 RG13191 –UN–30SEP03 Press Enter Key to Select 5. Press the "Enter" key to select the highlighted units. OURGP11,00000B0 –19–27JUL06–6/7 RG13192 –UN–26SEP03 Return To Main Menu 6. Press the "Menu" key to return to the main menu. OURG[...]

Instrument Panel - Elect. Cont. Later Engines OURGP11,00000B1 –19–27JUL06–1/18 Setup 1-Up Display RG13159 –UN–26SEP03 Menu Key 1. Turn the key switch to the ON position. Starting at the single engine parameter display, press the "Menu" key. OURGP11,00000B1 –19–27JUL06–2/18 RG13193 –UN–02OCT03 Setup 1-Up Display 2. Use [...]

Instrument Panel - Elect. Cont. Later Engines OURGP11,00000B1 –19–27JUL06–4/18 RG13196 –UN–26SEP03 1-Up Display Options 4. Three options are available for modification of the 1-Up Display. a. Use Defaults – This option contains the following engine parameters for display: Engine Hours, Engine Speed, Battery Voltage, % Load, Coolant Temp[...]

Instrument Panel - Elect. Cont. Later Engines OURGP11,00000B1 –19–27JUL06–6/18 RG13197 –UN–29SEP03 Defaults Selected 6. Press the "Enter" key to activate the "Use Defaults" function. OURGP11,00000B1 –19–27JUL06–7/18 RG13149 –UN–24SEP03 Restored To Defaults 7. The display parameters are reset to the factory de[...]

Instrument Panel - Elect. Cont. Later Engines OURGP11,00000B1 –19–27JUL06–9/18 RG13199 –UN–26SEP03 Engine Parameters 9. Press the "Enter" key to display a list of engine parameters. OURGP11,00000B1 –19–27JUL06–10/18 RG13150 –UN–24SEP03 Select Parameters 10. Use the "Arrow" keys to scroll to and highlight a se[...]

Instrument Panel - Elect. Cont. Later Engines OURGP11,00000B1 –19–27JUL06–12/18 RG13151 –UN–24SEP03 Select Desired Parameters 12. Use the "Arrow" keys to scroll and highlight the desired parameter that has not been selected for display (parameter without a number to right of it). OURGP11,00000B1 –19–27JUL06–13/18 RG13220 ?[...]

Instrument Panel - Elect. Cont. Later Engines OURGP11,00000B1 –19–27JUL06–15/18 RG13222 –UN–26SEP03 Automatic Scan On 16. Press the "Enter" key to toggle the "Automatic Scan" function on. OURGP11,00000B1 –19–27JUL06–16/18 RG13223 –UN–26SEP03 Automatic Scan Off 17. Press the "Enter" key again to togg[...]

Instrument Panel - Elect. Cont. Later Engines OURGP11,00000B1 –19–27JUL06–17/18 RG13224 –UN–26SEP03 Menu Key 18. Once the "Use Defaults", "Custom Setup" and "Automatic Scan" functions have been set, press the "Menu" key to return to the main menu. OURGP11,00000B1 –19–27JUL06–18/18 RG13159 –U[...]

Instrument Panel - Elect. Cont. Later Engines OURGP11,00000B2 –19–27JUL06–2/14 RG13225 –UN–02OCT03 Select Setup 4-Up Display 2. The main menu will be displayed. Use the "Arrow" keys to scroll through the menu until "Setup 4-Up Display" is highlighted. OURGP11,00000B2 –19–27JUL06–3/14 RG13226 –UN–02OCT03 Press[...]

Instrument Panel - Elect. Cont. Later Engines OURGP11,00000B2 –19–27JUL06–4/14 RG13244 –UN–02OCT03 Select Factory Defaults 4. Two options are available for the 4-Up Display. a. Use Defaults – This option contains the following engine parameters for display: Engine Speed, Battery Voltage, Coolant Temperature and Oil Pressure. b. Custom S[...]

Instrument Panel - Elect. Cont. Later Engines OURGP11,00000B2 –19–27JUL06–7/14 RG13228 –UN–26SEP03 Select Parameters 7. The quadrant with the highlighted parameter value is the current selected parameter. Use the "Arrow" keys to highlight the value in the quadrant you wish to change to a new parameter. OURGP11,00000B2 –19–27[...]

Instrument Panel - Elect. Cont. Later Engines OURGP11,00000B2 –19–27JUL06–10/14 RG13231 –UN–26SEP03 Enter Selected Parameter 10. Press the "Enter" key to change the selected parameter in the quadrant to the new parameter. OURGP11,00000B2 –19–27JUL06–11/14 RG13232 –UN–26SEP03 Return To 4-Up Custom Setup 11. Use the &quo[...]

Instrument Panel - Elect. Cont. Later Engines OURGP11,00000B2 –19–27JUL06–13/14 RG13154 –UN–24SEP03 Return To Main Menu 13. Repeat the parameter selection process until all spaces are as desired. 14. Press the "Menu" key to return to the main menu. OURGP11,00000B2 –19–27JUL06–14/14 RG13155 –UN–07OCT03 Select Remaining [...]

Instrument Panel - Mech. Cont. “270” Engines OURGP11,000018E –19–27JUL06–1/2 Instrument Panel (Earlier 4.5 L “270” Engines) RG6574A –UN–07JAN03 Instrument Panel and Gauges (Earlier 4.5 L “270” Engines) A—Tachometer with Hourmeter B—Coolant Temperature Gauge C—Oil Pressure Gauge D—Pre-Heat Indicator Lamp E—Charge Indi[...]

Instrument Panel - Mech. Cont. “270” Engines OURGP11,000018E –19–27JUL06–2/2 RG6574A –UN–07JAN03 Instrument Panel and Gauges (4.5 L “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 i[...]

Instrument Panel - Mech. Cont. “270” Engines OURGP11,0000160 –19–27JUL06–1/2 Instrument Panel (Later 4.5 L “270” Engines) RG13360 –UN–06FEB04 Instrument Panel and Gauges (Later 4.5 L “270” Engines) A—Tachometer with Hourmeter (Optional) B—Oil Pressure Gauge C—Voltmeter Gauge D—Coolant Temperature Gauge E—Preheat Butt[...]

Instrument Panel - Mech. Cont. “270” Engines OURGP11,0000160 –19–27JUL06–2/2 H—Key Switch - The key switch controls the electrical system. Positions of key switch are marked as follows: OFF, ON, and START. I—Throttle (Optional) - The throttle control is used to control engine speed. J—Hourmeter (Optional) - The hourmeter indicates t[...]

Engine Operation - Except 4.5L “270” Engines OURGP11,0000075 –19–27JUL06–1/4 Engine Break-In Service RG8009 –UN–06JAN99 Check Engine Oil 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 o[...]

Engine Operation - Except 4.5L “270” Engines OURGP11,0000075 –19–27JUL06–2/4 RG8028A –UN–15JAN99 Crosshatch Pattern On Dipstick A—Crosshatch Pattern On Dipstick 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 d[...]

Engine Operation - Except 4.5L “270” Engines OURGP11,0000075 –19–27JUL06–3/4 RG11616 –UN–24OCT01 Engine Oil Filter A—Engine Oil Filter 4. During the first 20 hours, avoid prolonged periods of engine idling or sustained maximum load operation. If engine will idle longer than 5 minutes, stop engine. 5. Before the first 100 hours (maxi[...]

Engine Operation - Except 4.5L “270” Engines OURGP11,0000076 –19–27JUL06–1/3 Starting the Engine TS220 –UN–23AUG88 Use Proper Ventilation 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 f[...]

Engine Operation - Except 4.5L “270” Engines OURGP11,0000076 –19–27JUL06–2/3 RG13279 –UN–30OCT03 Analog Throttle Control and Speed Select Switch On Earlier Panel (Left) or Later Panel (Right) A—Analog Throttle Control (Optional) B—Speed Select Rocker Switch 4. Set slow idle as follows: Panels with high-low speed select rocker swit[...]

Engine Operation - Except 4.5L “270” Engines OURGP11,0000076 –19–27JUL06–3/3 RG13280 –UN–30OCT03 Start And Idle Engine On Earlier Panel (Left) or Later Panel (Right) A—Key Start Switch B—High-Low Speed Select Rocker Switch C—Bump Speed Enable Rocker Switch D—Speed Select Rocker Switch E—Analog Throttle Control (Optional) 5. [...]

Engine Operation - Except 4.5L “270” Engines OURGP11,0000077 –19–27JUL06–1/1 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 ° ?[...]

Engine Operation - Except 4.5L “270” Engines OURGP11,0000137 –19–27JUL06–1/1 Warming Engine RG13281 –UN–30OCT03 Oil Pressure and Coolant Temperature Gauges On Earlier Panel (Left) or Later Panel (Right) A—Engine Oil Pressure Gauge B—Engine Coolant Temperature Gauge The electronically-controlled engines will operate at an accelerat[...]

Engine Operation - Except 4.5L “270” Engines OURGP11,0000078 –19–27JUL06–1/2 Cold Weather Operation TS1356 –UN–18MAR92 Handle Starting Fluid with Care RG11521 –19–10JAN01 Cold Weather Starting Guidelines CAUTION: DO NOT use starting fluid on engines equipped with air intake heaters or glow plugs. Ether injector starting fluid is h[...]

Engine Operation - Except 4.5L “270” Engines OURGP11,0000078 –19–27JUL06–2/2 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,[...]

Engine Operation - Except 4.5L “270” Engines RG,RG34710,5564 –19–27JUL06–1/2 Using a Booster Battery or Charger TS204 –UN–23AUG88 Exploding Battery RG4678 –UN–14DEC88 12-Volt System RG4698 –UN–14DEC88 24-Volt System A—12-Volt Machine Battery (ies) B—12-Volt Booster Battery (ies) C—Booster Cable D—Cable to Starting Moto[...]

Engine Operation - Except 4.5L “270” Engines RG,RG34710,5564 –19–27JUL06–2/2 6. Start the engine. Disconnect jumper cables immediately after engine starts. Disconnect NEGATIVE (–) cable first. RG,RG34710,5562 –19–27JUL06–1/1 Avoid Excessive Engine Idling Prolonged idling may cause the engine coolant temperature to fall below its n[...]

Engine Operation - Except 4.5L “270” Engines OURGP11,0000079 –19–27JUL06–1/3 Changing Engine Speed RG13282 –UN–30OCT03 Changing Engine Speed On Earlier Panel (Left) or Later Panel (Right) A—High-Low Speed Select Rocker Switch B—Bump Speed Enable Rocker Switch C—Speed Select Rocker Switch D—Analog Throttle Control (Optional) NO[...]

Engine Operation - Except 4.5L “270” Engines OURGP11,0000079 –19–27JUL06–2/3 • For fast speed, press upper half of rocker switch (indicated by rabbit symbol). NOTE: To adjust preset fast or slow speeds with adjustable High-Low Speed Select Rocker Switch: 1. Select middle position (ADJ) or slow (turtle) position on the optional Adjustabl[...]

Engine Operation - Except 4.5L “270” Engines OURGP11,0000079 –19–27JUL06–3/3 RG13289 –UN–30OCT03 Changing Engine Speed With Basic Panel E—High-Low Speed Select Rocker Switch Changing engine speeds on later engines equipped with the Basic Instrument Panel The basic instrument panel has a “ramp” throttle switch (E) with a spring l[...]

Engine Operation - Except 4.5L “270” Engines OURGP11,0000139 –19–27JUL06–1/1 Stopping The Engine RG13280 –UN–30OCT03 Stopping the Engine On Earlier Panel (Left) or Later Panel (Right) RG9933 –UN–18NOV99 Exhaust Stack Rain Cap A—Key Switch B—High-Low Speed Select Rocker Switch C—Bump Speed Enable Switch D—Speed Select Rocke[...]

Engine Operation - Except 4.5L “270” Engines RG,RG34710,5555 –19–27JUL06–1/1 Auxiliary Gear Drive Limitations RG7634A –UN–22JAN99 Auxiliary Gear Drive A—Auxiliary Gear Drive 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 [...]

Engine Operation- 4.5 L “270” Engines OURGP11,000007A –19–27JUL06–1/1 Normal Engine Operation RG13343 –UN–24NOV03 Instrument Panel (Earlier 4.5 L “270” Engines) RG13359 –UN–06FEB04 Instrument Panel (Later 4.5 L “270” Engines) Before starting, fill engine with oil and coolant meeting specifications. (See DIESEL ENGINE BREAK[...]

Engine Operation- 4.5 L “270” Engines OURGP11,0000169 –19–27JUL06–1/3 Break-In Service RG12692 –UN–07FEB03 Check Engine Oil Level Daily 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 Coolan[...]

Engine Operation- 4.5 L “270” Engines OURGP11,0000169 –19–27JUL06–3/3 RG11616 –UN–24OCT01 Engine Oil Filter 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.) Fi[...]

Engine Operation- 4.5 L “270” Engines RG41183,000002F –19–27JUL06–1/1 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. [...]

Engine Operation- 4.5 L “270” Engines OURGP11,000016A –19–27JUL06–2/2 RG6580 –UN–20JAN93 Starting Engine Using Key Switch (Earlier Engines) RG13366 –UN–12FEB04 Starting Engine Using Reset Button and Key Switch (Later Engines) A—Reset Button B—Key Switch IMPORTANT: Do not operate the starter for more than 15 seconds at a time. [...]

Engine Operation- 4.5 L “270” Engines OURGP11,000007B –19–27JUL06–1/2 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, glow plugs, air intake heater and increased capacity battery and/o[...]

Engine Operation- 4.5 L “270” Engines OURGP11,000007B –19–27JUL06–2/2 RG6580 –UN–20JAN93 Starting Engine 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 f[...]

Engine Operation- 4.5 L “270” Engines OURGP11,000007C –19–27JUL06–1/1 Warming Engine RG6574 –UN–17FEB03 Oil Pressure and Coolant Temperature Gauges (Earlier Engines) RG13361 –UN–06FEB04 Oil Pressure and Coolant Temperature Gauges (Later Engines) A—Oil Pressure Gauge B—Coolant Temperature Gauge IMPORTANT: To assure proper lubri[...]

Engine Operation- 4.5 L “270” Engines OURGP11,000007D –19–27JUL06–1/1 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 deposit[...]

Engine Operation- 4.5 L “270” Engines OURGP11,0000134 –19–27JUL06–1/2 Stopping the Engine RG6574B –UN–07JAN03 Key Switch on Instrument Panel (Earlier Engines) RG13362 –UN–06FEB04 Key Switch on Instrument Panel (Later Engines) IMPORTANT: Stopping the engine immediately when it has been working under load, can result in overheating [...]

Engine Operation- 4.5 L “270” Engines RG,RG34710,5564 –19–27JUL06–1/2 Using a Booster Battery or Charger TS204 –UN–23AUG88 Exploding Battery RG4678 –UN–14DEC88 12-Volt System RG4698 –UN–14DEC88 24-Volt System A—12-Volt Machine Battery (ies) B—12-Volt Booster Battery (ies) C—Booster Cable D—Cable to Starting Motor A 12-[...]

Engine Operation- 4.5 L “270” Engines RG,RG34710,5564 –19–27JUL06–2/2 6. Start the engine. Disconnect jumper cables immediately after engine starts. Disconnect NEGATIVE (–) cable first. 20-12 080706 PN=127[...]

Lubrication and Maintenance OURGP11,0000241 –19–27JUL06–1/1 Observe Service Intervals RG13283 –UN–30OCT03 Hour Meter On Earlier Panel (Left) or Later Panel (Right) (Except 4.5 L “270” Engines) A—Hour Meter Using hour meter (A) on diagnostic gauge as a guide, perform all services at the hourly intervals indicated on following pages. [...]

Lubrication and Maintenance OURGP11,000007E –19–27JUL06–1/2 Lubrication and Maintenance Service Interval Chart—Standard Industrial Engines NOTE: The service intervals below are for standard industrial engines. See details in Sections which follow these charts. Lubrication and Maintenance Service Intervals 500 Hour/ 2000 Hour/ Item Daily 12 [...]

Lubrication and Maintenance OURGP11,000007E –19–27JUL06–2/2 Lubrication and Maintenance Service Intervals 500 Hour/ 2000 Hour/ Item Daily 12 Month 24 Month As Required Test Glow Plugs (4045HF475, 6068HF475) • Add Coolant • Replace Air Cleaner Elements • Replace Fan and Alternator Belts • Check Fuses • Check Air Compressor (If Equipp[...]

Lubrication and Maintenance OURGP11,000007F –19–27JUL06–1/2 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[...]

Lubrication and Maintenance OURGP11,000007F –19–27JUL06–2/2 Lubrication and Maintenance Service Intervals 500 Hours or 2000 Hours or Item Every 2 Weeks 12 Months 24 Months As Required Check and Adjust Engine Valve Clearance • Test Glow Plugs (4045HF475, 6068HF475) • Add Coolant • Replace Air Cleaner Elements • Replace Fan and Alternat[...]

Lubrication & Maintenance/Daily OURGP11,000018F –19–27JUL06–1/5 Daily Prestarting Checks RG8009A –UN–16JUN00 Left Side Oil Filler Cap RG8054A –UN–16JUN00 Right Side Oil Filler Cap RG8025B –UN–16JUN00 Rocker Arm Cover Filler Cap RG8028B –UN–15JAN99 Crosshatch on Dipstick A—Left Side Oil Filler Cap B—Right Side Oil Fille[...]

Lubrication & Maintenance/Daily OURGP11,000018F –19–27JUL06–2/5 TS281 –UN–23AUG88 High-Pressure Fluids RG4675 –UN–14DEC88 Fill Radiator A—Fill Radiator CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. Only remove filler cap when engine is cold or when cool enough to touch with bare ha[...]

Lubrication & Maintenance/Daily OURGP11,000018F –19–27JUL06–3/5 RG12222 –UN–24MAY02 Drain Final Fuel Filter RG11955 –UN–05DEC01 Drain Primary Fuel Filter (If Equipped) A—Drain Plug B—Air Bleed Plug NOTE: Engine may be equipped with a water sensor at the fuel filter. In this case, an indicator light will signal the operator tha[...]

Lubrication & Maintenance/Daily OURGP11,000018F –19–27JUL06–4/5 RG7332A –UN–22JAN99 Dust Unloader Valve and Indicator Gauge A—Dust Unloader Valve B—Air Restriction Indicator 4. If the air cleaner has an automatic dust unloader valve (A), squeeze the unloader valve on air cleaner assembly to clear away any dust buildup. If equipped[...]

Lubrication & Maintenance/Daily OURGP11,000018F –19–27JUL06–5/5 RG6578 –UN–29JAN93 Key Switch in "ON" Position (4.5 L “270” Engines) 6. 4.5 L Suffix “270” Earlier Engines Only: Turn key switch to “ON” position and check lamps. “WATER” lamp should be off, while “OIL” and “CHG” lamps should be lit. Repl[...]

Lubrication & Maintenance/500 Hour/12 Month OURGP11,000015F –19–27JUL06–1/1 Servicing Fire Extinguisher RW4918 –UN–15DEC88 Fire Extinguisher A—Fire Extinguisher A fire extinguisher (A) is available from your authorized servicing dealer or engine distributor. Read and follow the instructions which are packaged with it. The extinguish[...]

Lubrication & Maintenance/500 Hour/12 Month RG,RG34710,5568 –19–27JUL06–1/2 Servicing Battery TS204 –UN–23AUG88 Exploding Battery CAUTION: Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check battery electrolyte level. Never check battery charge by placing a metal object across the posts. Use [...]

Lubrication & Maintenance/500 Hour/12 Month RG,RG34710,5568 –19–27JUL06–2/2 TS203 –UN–23AUG88 Sulfuric Acid 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.[...]

Lubrication & Maintenance/500 Hour/12 Month DPSG,RG41165,128 –19–27JUL06–1/1 Manual Belt Tensioner Adjustment RG10556 –UN–21DEC99 Check Belt Tension RG10557 –UN–21DEC99 Adjust Belt Tension A—Belt Tension Gauge B—Cap Screw C—Cap Screw D—Tensioner Bracket NOTE: Two types of manual tensioners shown. NOTE: Inspect belts for cr[...]

Lubrication & Maintenance/500 Hour/12 Month OUOD002,000016D –19–27JUL06–1/2 Manual Belt Tensioner Adjustment Using Belt Tension Tool (Alternate Method For Engines Without Auxiliary Drive) RG11812 –UN–31OCT01 Alternator Bracket and Cap Screws RG11813 –UN–31OCT01 Belt Tension Tool A—Upper Alternator Bracket Cap Screw B—Lower Alt[...]

Lubrication & Maintenance/500 Hour/12 Month OUOD002,000016D –19–27JUL06–2/2 RG11814 –UN–31OCT01 Belt Tension Tool and Torque Wrench RG11815 –UN–31OCT01 Scribe Reference Mark A—Alternator B—Belt Tensioning Tool C—Torque Wrench D—Reference Mark E—Alternator Upper Bracket Notch 3. Place torque wrench (C) on belt tensioning [...]

Lubrication & Maintenance/500 Hour/12 Month OURGP11,000008C –19–27JUL06–1/4 Changing Engine Oil and Replacing Filter RG11616 –UN–24OCT01 Special Oil Filter RG4881 –UN–29NOV88 Oil Pan Drain Plug A—Oil Filter Element IMPORTANT: 6-Cylinder engines with oil pan option codes 1907, 1908, and 1909 require the oil to be changed at every[...]

Lubrication & Maintenance/500 Hour/12 Month OURGP11,000008C –19–27JUL06–2/4 3. Drain crankcase oil from engine while warm. NOTE: Drain plug location may vary, depending on the application. OURGP11,000008C –19–27JUL06–3/4 RG11616 –UN–24OCT01 Oil Filter And Mounting Header RG11617 –UN–24OCT01 Oil Filter Seals RG11618 –UN–2[...]

Lubrication & Maintenance/500 Hour/12 Month OURGP11,000008C –19–27JUL06–4/4 RG11619 –UN–24OCT01 Rocker Arm Cover Oil Filler Opening RG11942 –UN–24OCT01 Oil Filler At Side Of Engine A—Rocker Arm Cover Oil Filler Opening B—Oil Filler At Side Of Engine 9. Fill engine crankcase with correct John Deere engine oil through rocker arm[...]

Lubrication & Maintenance/500 Hour/12 Month OURGP11,000014F –19–27JUL06–2/2 RG12426 –UN–20NOV03 Closed Crankcase Vent RG12427 –UN–03FEB04 Closed Crankcase Vent A—Closed Crankcase Ventilation (CCV) Valve B—Hose, CCV Valve to Intake Manifold C—Hose, Valve Cover to CCV Valve D—Valve Cover Vent Fitting E—Intake Manifold Fitt[...]

Lubrication & Maintenance/500 Hour/12 Month RG,RG34710,5575 –19–27JUL06–1/1 Checking Air Intake System RG4689 –UN–20DEC88 Check Clamps RG7332B –UN–22JAN99 Underloader Valve and Air Restriction Indicator A—Clamps B—Dust Unloader Valve C—Air Restriction Indicator IMPORTANT: The air intake system must not leak. Any leak, no mat[...]

Lubrication & Maintenance/500 Hour/12 Month OURGP11,000021F –19–27JUL06–1/2 Replacing Fuel Filter Elements X9811 –UN–23AUG88 High-Pressure Fluids RG7721 –UN–15JAN99 Final Fuel Filter RG11954 –UN–05DEC01 Primary Fuel Filter (or Pre-Filter, If Equipped) A—Retaining Ring B—Filter Element C—Drain Plug D—Bleed Plug E—Wate[...]

Lubrication & Maintenance/500 Hour/12 Month OURGP11,000021F –19–27JUL06–2/2 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 [...]

Lubrication & Maintenance/500 Hour/12 Month OURGP11,0000080 –19–27JUL06–1/3 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[...]

Lubrication & Maintenance/500 Hour/12 Month OURGP11,0000080 –19–27JUL06–3/3 RG7977 –UN–14NOV97 Marks on Tensioner RG8037C –UN–11SEP00 Align Marks RG12065 –UN–28JAN02 Align Torque Wrench With Pulley and Tensioner A—Mark On Swing Arm B—Mark On Tensioner Mounting Base C—Torque Wrench Checking Tensioner Spring Tension A belt[...]

Lubrication & Maintenance/500 Hour/12 Month OUOD002,0000169 –19–27JUL06–1/1 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. OURGP11,0000151[...]

Lubrication & Maintenance/500 Hour/12 Month DPSG,OUOD002,1921 –19–27JUL06–1/2 Replenishing Supplemental Coolant Additives (SCAs) Between Coolant Changes RG6261 –UN–08DEC97 Radiator Coolant Check RG6262 –UN–05DEC97 JT07298 Coolant/Battery Tester IMPORTANT: Do not add supplemental coolant additives when the cooling system is drained[...]

Lubrication & Maintenance/500 Hour/12 Month DPSG,OUOD002,1921 –19–27JUL06–2/2 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 JT07298 Coolant/Battery Tester to ensure [...]

Lubrication & Maintenance/500 Hour/12 Month OUOD002,0000175 –19–27JUL06–1/1 Testing Diesel Engine Coolant Maintaining adequate concentrations of glycol and inhibiting additives in the coolant is critical to protect the engine and cooling system against freezing, corrosion, and cylinder liner erosion and pitting. Test the coolant solution [...]

Lubrication & Maintenance/500 Hour/12 Month OURGP11,0000220 –19–27JUL06–1/1 Pressure Testing Cooling System RG6557 –UN–20JAN93 Test Radiator Cap RG6558 –UN–20JAN93 Test Cooling System CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off engine. Only remove filler cap when cool enou[...]

Lubrication & Maintenance/500 Hour/12 Month OURGP12,00001DB –19–27JUL06–1/1 Checking and Adjusting Engine Speeds RG12607 –UN–24OCT02 Using Tachometer to Check Engine Speeds A—Tachometer If equipped with a tachometer (A) on the instrument panel, observe tachometer reading to verify engine speeds. (Refer to ENGINE POWER RATINGS AND FU[...]

Lubrication & Maint./2000 Hour/24 Month OURGP12,00001ED –19–27JUL06–1/1 Adjusting Variable Speed (Droop) — 4.5 L “270” Generator Set Engines Only RG12066 –UN–29JAN02 Droop Adjustment Screw A—Adjustment Screw B—Fast Idle Adjustment C—Slow Idle Adjustment 1. Warm engine to normal operating temperature. 2. When necessary, dis[...]

Lubrication & Maint./2000 Hour/24 Month RG,RG34710,5585 –19–27JUL06–1/1 Checking Crankshaft Vibration Damper (6-Cylinder Engine Only) RG8018 –UN–15JAN99 Grasp Vibration Damper RG7508 –UN–23NOV97 Check Runout 1. Remove belts (shown removed). 2. Grasp vibration damper with both hands and attempt to turn it in both directions. If rot[...]

Lubrication & Maint./2000 Hour/24 Month OURGP11,0000081 –19–27JUL06–1/4 Flushing and Refilling Cooling System TS281 –UN–23AUG88 High-Pressure Fluids RG12833 –UN–13FEB03 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[...]

Lubrication & Maint./2000 Hour/24 Month OURGP11,0000081 –19–27JUL06–2/4 RG8019A –UN–19JUN00 Engine Block Drain Valve- Except 475 Engines RG12223 –UN–11JUN02 Engine Block Coolant Drain Plug- 475 Engines A—Engine Block Drain Valve B—Engine Block Drain Plug C—Engine Block Drain Plug 3. All Except 4045HF475 and 6068HF475 Engines[...]

Lubrication & Maint./2000 Hour/24 Month OURGP11,0000081 –19–27JUL06–3/4 10. After draining water, close drain valves. Reinstall radiator cap and radiator hose and clamp. Fill the cooling system with clean water and a heavy duty cooling system cleaner such as Fleetguard  RESTORE  and RESTORE PLUS  . Follow manufacturer’s directi[...]

Lubrication & Maint./2000 Hour/24 Month OURGP11,0000081 –19–27JUL06–4/4 16. Inspect the fan belt for wear and check belt tension. (See Checking Belt Tensioner Spring Tension and Belt Wear in Lubrication and Maintenance 500 Hour/12 Month section. DPSG,RG34710,112 –19–27JUL06–1/5 Testing Thermostats Opening Temperature TS281 –UN–2[...]

Lubrication & Maint./2000 Hour/24 Month DPSG,RG34710,112 –19–27JUL06–3/5 RG5971 –UN–23NOV97 Testing Thermostat Opening Temperature 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[...]

Lubrication & Maint./2000 Hour/24 Month DPSG,RG34710,112 –19–27JUL06–4/5 RG7614A –UN–06NOV97 Installing Thermostat Cover RG7921B –UN–13NOV97 Thermostat Cover Seal A—Guide Studs B—Seal To Install Thermostats IMPORTANT: Install manifold gasket so that smaller (round) holes are at lower left and upper right corners of manifold (m[...]

Lubrication & Maint./2000 Hour/24 Month DPSG,RG41165,137 –19–27JUL06–1/5 Check and Adjust Valve Clearance (All Engines Except 4045HF475 And 6068HF475) RG7408 –UN–06AUG96 Flywheel Housing Timing Holes A—Timing/Rotation Hole B—Timing Pin Hole CAUTION: To prevent accidental starting of engine while performing valve adjustments, alway[...]

Lubrication & Maint./2000 Hour/24 Month DPSG,RG41165,137 –19–27JUL06–2/5 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[...]

Lubrication & Maint./2000 Hour/24 Month DPSG,RG41165,137 –19–27JUL06–4/5 RG4776 –UN–31OCT97 4-Cylinder Engine Valve Adjustment A—Front of Engine B—No. 1 Piston TDC Compression C—No. 4 Piston TDC Compression E—Exhaust Valve I—Intake Valve 4-Cylinder Engine: NOTE: Firing order is 1-3-4-2. 1. Using JDE81-4 Timing Pin, lock No. [...]

Lubrication & Maint./2000 Hour/24 Month OUO1089,0000208 –19–27JUL06–1/5 Check and Adjust Valve Clearance (4045HF475 And 6068HF475 Engines) RG12168 –UN–03JUL02 Flywheel Housing Timing Holes A—Timing/Rotation Hole B—Timing Pin Hole CAUTION: To prevent accidental starting of engine while performing valve adjustments, always disconnec[...]

Lubrication & Maint./2000 Hour/24 Month OUO1089,0000208 –19–27JUL06–2/5 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-Brid[...]

Lubrication & Maint./2000 Hour/24 Month OUO1089,0000208 –19–27JUL06–4/5 A B E I 4 E 3 I E 2 I E 1 I E 4 I E 3 I E 2 I E 1 I C RG12357 –UN–29MAY02 4-Cylinder Valve Adjustment A—Front of Engine B—No. 1 Piston TDC Compression C—No. 4 Piston TDC Compression E—Exhaust Valve I—Intake Valve 4-Cylinder Engine: NOTE: Firing order is [...]

Lubrication & Maint./2000 Hour/24 Month OURGP11,0000082 –19–27JUL06–1/1 Test Glow Plugs for Continuity (4045HF475 And 6068HF475 Engines) RG13802 –UN–18NOV04 Test Glow Plugs for Continuity A—Glow Plug CAUTION: To prevent accidental starting of engine while performing this test, always disconnect NEGATIVE (—) battery terminal. While[...]

Service as Required RG,RG34710,5591 –19–27JUL06–1/1 Additional Service Information RG4624 –UN–15DEC88 Component Technical Manual 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. 40-1 080706 PN=174[...]

Service as Required OURGP11,0000083 –19–27JUL06–1/1 Do Not Modify Fuel System TS1343 –UN–18MAR92 High-Pressure Fuel Lines RG11953 –UN–26NOV01 Fuel Injection Pump CAUTION: Do not open high-pressure fuel system. High-pressure fluid remaining in fuel lines can cause serious injury. Do not disconnect or attempt repair of fuel lines, senso[...]

Service as Required OURGP11,0000222 –19–27JUL06–1/2 Adding Coolant TS281 –UN–23AUG88 High-Pressure Fluids RG13295 –UN–20NOV03 Radiator and Coolant A—Radiator Filler Neck B—Radiator CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off engine. Only remove filler cap when cool enough [...]

Service as Required OURGP11,0000222 –19–27JUL06–2/2 3. Tighten plugs and fittings when air has been expelled from system. 4. Run engine until it reaches operating temperature. 40-4 080706 PN=177[...]

Service as Required RG,RG34710,5594 –19–27JUL06–1/1 Replacing Single Stage Air Cleaner RG11319A –UN–06SEP00 Single Stage Air Filter RG11320 –UN–07SEP00 Installation of Single Stage Air Cleaner A—Outlet Neck Clamp B—Filter to Engine Overlap IMPORTANT: ALWAYS REPLACE air cleaner when air restriction indicator shows a vacuum of 625 m[...]

Service as Required OURGP11,000013A –19–27JUL06–1/2 Replacing Axial Seal Air Cleaner Filter Element RG8719B –UN–03SEP99 Air restriction Indicator IMPORTANT: ALWAYS REPLACE primary air cleaner element when air restriction indicator (A) shows a vacuum of 625 mm (25 in.) H 2 O, is torn, or visibly dirty. NOTE: This procedure applies to John [...]

Service as Required OURGP11,000013A –19–27JUL06–2/2 RG4686 –UN–20DEC88 Wing Nut and Primary Element RG4687 –UN–20DEC88 Dust Unloader Valve and Restriction Indicator RG11068 –UN–26JUN00 Retaining Nut and Secondary Element A—Wing Nut B—Primary Element C—Dust Unloader Valve D—Retaining Nut E—Secondary Element 1. Remove wing[...]

Service as Required RG41165,000008B –19–27JUL06–1/2 Replacing Radial Seal Air Cleaner Filter Element RG11321A –UN–08SEP00 Dust Cup/Cover RG11322A –UN–08SEP00 Primary Filter Element RG11327A –UN–08SEP00 Secondary Filter Element A—Dust Cap/Cover B—Primary Filter Element C—Secondary Filter Element IMPORTANT: ALWAYS REPLACE prim[...]

Service as Required RG41165,000008B –19–27JUL06–2/2 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. 40-[...]

Service as Required OURGP11,000013B –19–27JUL06–1/1 Replacing Fan and Alternator Belts RG11950 –UN–07NOV01 290 mm (11.4 in.) Fan Height and Lower* RG11951 –UN–07NOV01 338 mm (13.3 in.) Fan Height and Higher Without Freon Compressor* RG11952 –UN–07NOV01 402 mm (15.8 in.) Fan Height With Freon Compressor* A—Alternator CSP—Cranks[...]

Service as Required OURGP11,000013C –19–27JUL06–1/1 Checking Fuses RG11938 –UN–06NOV01 Early Engines with Electronic Instrument Panel A—5 Amp Fuse NOTE: The instrument panels for later electronically controlled engines as described in Section 17 do not have this fuse. Check fuse (A) located in fuse holder on face of instrument panel. If[...]

Service as Required OURGP11,000000E –19–27JUL06–1/3 Bleeding the Fuel System (Engines With Electronic Fuel Systems And Bosch VP44 Pump) X9811 –UN–23AUG88 High-Pressure Fluids CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting fuel or other lines. Tighten all connecti[...]

Service as Required OURGP11,000000E –19–27JUL06–2/3 RG11719A –UN–20JUN01 Bleed Fuel System A—Bleed Orifice in Final Fuel Filter Base B—Fuel Return Line IMPORTANT: NEVER pressurize the fuel tank to prime the fuel system as it could rupture seals in the injection pump. Bleed Using Electronic Transfer Pump The bleed is automatically perf[...]

Service as Required OUOD002,000016F –19–27JUL06–1/5 Bleed the Fuel System (Engines with Electronic Fuel Systems and Stanadyne DE10 Pump) X9811 –UN–23AUG88 High Pressure Fluids CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid hazards by relieving pressure before disconnecting hydraulic or other li[...]

Service as Required OUOD002,000016F –19–27JUL06–2/5 RG11805 –UN–25OCT01 Final Fuel Filter Bleed Vent Screw A—Bleed Vent Screw 1. Loosen the air bleed vent screw (A) two full turns by hand on fuel filter base. OUOD002,000016F –19–27JUL06–3/5 RG11806 –UN–25OCT01 Fuel Supply Pump Primer Lever B—Primer Lever 2. Operate fuel supp[...]

Service as Required OUOD002,000016F –19–27JUL06–4/5 RG11807 –UN–25OCT01 Fuel Injection Pump Return Line A—Fuel Return Line At Fuel Injection Pump 1. Loosen fuel return line (A) at fuel injection pump. 2. Operate fuel supply pump primer lever or primer button on fuel filter base (if equipped). 3. As soon as fuel flow is free from air bub[...]

Service as Required OURGP11,000000F –19–27JUL06–1/3 Bleed the Fuel System (Engines with Electronic Fuel Systems and Denso High Pressure Common Rail) (4045HF475, 6068HF475) TS1343 –UN–18MAR92 High-Pressure Fuel Lines X9811 –UN–23AUG88 High Pressure Fluids CAUTION: High-pressure fluid remaining in fuel lines can cause serious injury. Do[...]

Service as Required OURGP11,000000F –19–27JUL06–2/3 RG12220 –UN–24MAY02 Final Fuel Filter Bleed Vent Screw A—Bleed Vent Screw IMPORTANT: NEVER pressurize the fuel tank to prime the fuel system as it could rupture seals in the injection pump. NOTE: These are the 4-valve cylinder head 4.5 L and 6.8 L “475” model engines with Denso HP3[...]

Service as Required OURGP11,0000010 –19–27JUL06–1/5 Bleed the Fuel System (4045DF270, 4045TF270) X9811 –UN–23AUG88 High-Pressure Fluids 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 hand[...]

Service as Required OURGP11,0000010 –19–27JUL06–2/5 RG7947 –UN–13NOV97 Air Bleed Vent Screw A—Vent Screw IMPORTANT: NEVER pressurize the fuel tank to prime the fuel system as it could rupture seals in the injection pump. 1. Loosen the air bleed vent screw (A) two full turns by hand on fuel filter base. OURGP11,0000010 –19–27JUL06–[...]

Service as Required OURGP11,0000010 –19–27JUL06–4/5 RG6264 –UN–03NOV97 Stanadyne Rotary Fuel Injection Pump A—Fuel Return Line Connector At Fuel Injection Pump 1. Slightly loosen fuel return line connector (A) at fuel injection pump. 2. Operate fuel supply pump primer lever until fuel, without air bubbles, flows from fuel return line co[...]

Troubleshooting RG,RG34710,5605 –19–27JUL06–1/1 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[...]

Troubleshooting OUOD002,000016B –19–27JUL06–1/1 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 com[...]

Troubleshooting OURGP11,0000276 –19–27JUL06–1/1 Engine Wiring Layout (Electronic Fuel System With Stanadyne DE10 Injection Pump) RG12201 –UN–24MAY02 A—Coolant Temperature G—Starter Relay Connector M—Remote ON/ OFF R—Engine Wiring Harness Sensor Connector H—Oil Pressure Sensor Connector S—Fuel Heater Connector B—Fuel Temperat[...]

Troubleshooting OURGP11,0000277 –19–27JUL06–1/1 Engine Wiring Layout (Electronic Fuel System With Bosch VP44 Injection Pump) RG11939A –UN–05JUN02 A—Oil Pressure Sensor I—Manifold Air Temperature Q—Engine Control Unit (ECU) W—Remote ON/OFF B—Fuel Pump Relay (MAT) Sensor R—ECU Connector Connector C—Fuel Pump Relay Fuse J—Fue[...]

Troubleshooting OURGP11,0000278 –19–27JUL06–1/1 Engine Wiring Layout (Electronic Fuel System With Denso High Pressure Common Rail)(4045HF475,6068HF475) RG12224 –UN–19JUN02 6068HF475 Engine Shown A—Engine Coolant D—(ECU) Connector H—Power and Ground Battery K—Pump Position Sensor Temperature (ECT) Sensor E—Optional Instrument Pan[...]

Troubleshooting OURGP11,000026F –19–27JUL06–1/1 Engine Wiring Diagram (With Earlier Electronic Instrument Panel) 414 BA T B B A B A X6 REMOTE ON/OFF PLUG 022 032 032 022 A B C 905 CAN L 012 IGN +12V OR +24V 412 ACC 422 ST ARTER RELA Y SOLENOID 002 BA T 904 CAN H 020 CAN SHIELD 464 SENSOR RETURN 2 911 915 414 SE-2 INSTRUMENT P ANEL (CONTINUED [...]

Troubleshooting OURGP11,0000270 –19–27JUL06–1/1 Engine Wiring Diagram (With Earlier Electronic Instrument Panel)—Continued RG10040 –19–18MAY99 B1—Analog Throttle or N1—Transient Voltage S1—Ignition Key Switch V1—Diode Emulator Protector S2—Speed Select Switch X1—Vehicle Harness E1—Back Light Regulator N2—Voltage Regulato[...]

Troubleshooting OURGP11,0000271 –19–27JUL06–1/1 Engine Wiring Diagram (With Later Full-Featured Electronic Instrument Panel) RG13354 –UN–22JAN04 B1—Analog Throttle P3—Oil Pressure Gauge S3—Bump Enable Switch X2—Alternator Harness F1—Fuse (30 Amp) (Harness) P4—Coolant Temperature (Momentary) Connector G1—Alternator Gauge S4?[...]

Troubleshooting OURGP11,0000272 –19–27JUL06–1/1 Engine Wiring Diagram (With Later Full-Featured Electronic Instrument Panel)— Continued RG13272 –UN–26JAN04 B1—Analog Throttle P3—Oil Pressure Gauge S3—Bump Enable Switch X2—Alternator Harness F1—Fuse (30 Amp) (Harness) P4—Coolant Temperature (Momentary) Connector G1—Alternat[...]

Troubleshooting RG,RG34710,5608 –19–27JUL06–1/8 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 d[...]

Troubleshooting RG,RG34710,5608 –19–27JUL06–2/8 Symptom Problem Solution Engine hard to start or will not Engine starting under load. Disengage PTO. start 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 ?[...]

Troubleshooting RG,RG34710,5608 –19–27JUL06–3/8 Symptom Problem Solution Engine runs irregularly or stalls Low coolant temperature. Remove and check thermostat. frequently 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 authoriz[...]

Troubleshooting RG,RG34710,5608 –19–27JUL06–4/8 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 che[...]

Troubleshooting RG,RG34710,5608 –19–27JUL06–5/8 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. Engi[...]

Troubleshooting RG,RG34710,5608 –19–27JUL06–6/8 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 Check automatic belt tensioner and[...]

Troubleshooting RG,RG34710,5608 –19–27JUL06–7/8 Symptom Problem Solution Undercharged electrical system Excessive electrical load from added Remove accessories or install higher accessories. output alternator. Excessive engine idling. Increase engine rpm when heavy electrical load is used. Poor electrical connections on Inspect and clean as n[...]

Troubleshooting RG,RG34710,5608 –19–27JUL06–8/8 Symptom Problem Solution Starter and hour meter functions; Blown fuse on magnetic switch. Replace fuse. rest of electrical system does not function Entire electrical system does not Faulty battery connection. Clean and tighten connections. function Sulfated or worn-out batteries. See your author[...]

Troubleshooting OURGP12,00001EA –19–27JUL06–1/2 Blink Code Method for Retrieving Diagnostic Trouble Codes (Early VP44 Pump Engines Only) RG11754A –UN–13JUL01 Diagnostic Blink Code Connector A—Diagnostic Blink Code Connector B—Diagnostic Connector C—ECU On OEM applications that have a Fault Lamp, the ECU has the ability to display Di[...]

Troubleshooting OURGP12,00001EA –19–27JUL06–2/2 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 pa[...]

Troubleshooting OURGP11,0000279 –19–27JUL06–1/1 Instrument Panel Method for Retrieving Diagnostic Trouble Codes RG13287 –UN–30OCT03 Trouble Code Display On Earlier Panel (Left) or Later Panel (Right) A—Diagnostic Gauge IMPORTANT: Care should be used during diagnostic procedures to avoid damaging the terminals of connectors, sensors, and[...]

Troubleshooting DPSG,OUOD002,1591 –19–27JUL06–1/1 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 fr[...]

Troubleshooting OURGP11,0000086 –19–27JUL06–1/2 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. Third column below is for Blink Code retrieval method only. Trouble Codes DTC’s Listing in Ascending SPN/FMI Codes SPN[...]

Troubleshooting OURGP11,0000086 –19–27JUL06–2/2 SPN FMI Blink Codes Description of Fault 04 38 Fuel Temperature Input Voltage Low 16 81 Fuel Temperature High Moderately Severe 000189 00 — Engine Speed Derate 000190 00 42 Engine Overspeed Extreme 01 — Engine Speed, Below Normal, Most Severe 16 42 Engine Overspeed Moderate 000620 03 21 Sens[...]

Troubleshooting OURGP11,0000087 –19–27JUL06–1/2 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 Third column below is for Blink Code retrieval method only. Trouble Codes DTC’s Listing in Ascending SPN/FMI Codes SPN FMI [...]

Troubleshooting OURGP11,0000087 –19–27JUL06–2/2 SPN FMI Blink Code Description of Fault 04 22 Sensor Supply Voltage Low 000627 04 76 ECU Unswitched Power Missing 000629 13 34 ECU Error 19 34 ECU to Pump Communication Error 000632 02 37 Fuel Shutoff Error 05 86 Fuel Shutoff Non-Functional 000636 02 44 Pump Position Input Noise 08 43 Pump Posit[...]

Troubleshooting OURGP11,0000088 –19–27JUL06–1/3 Listing of Diagnostic Trouble Codes (DTCs) (Engines With Electronic Fuel Systems And Denso High Pressure Common Rail) (“475” Engines) NOTE: Not all of these codes are used on all OEM engine applications Third column below is for Blink Code retrieval method only. Trouble Codes DTC’s Listing[...]

Troubleshooting OURGP11,0000088 –19–27JUL06–2/3 SPN FMI Blink Code Description of Fault 16 71 Fuel Temperature High Moderately Severe 000189 00 — Engine Speed Derate 000190 00 42 Engine Overspeed Extreme 16 42 Engine Overspeed Moderate 000611 03 98 Electronic Injector Wiring Shorted to Power Source 04 99 Electronic Injector Wiring Shorted t[...]

Troubleshooting OURGP11,0000088 –19–27JUL06–3/3 SPN FMI Blink Code Description of Fault 002000 13 — Security Violation N/A N/A 32 When reading blink codes, signifies the start of active codes. N/A N/A 33 When reading blink codes, signifies the start of stored codes. N/A N/A 88 When reading blink codes, signifies that no fault codes are in t[...]

Troubleshooting OUOD007,0000036 –19–27JUL06–1/1 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 conditio[...]

Troubleshooting OURGP11,000012B –19–27JUL06–2/4 RG13234 –UN–22OCT03 Select Utilities 2. The main menu will be displayed. Use the "Arrow" key to scroll through the menu until "Utilities" is highlighted. OURGP11,000012B –19–27JUL06–3/4 RG13237 –UN–22OCT03 Select Utilities 3. Once "Utilities" is highli[...]

Storage OURGP12,00000DF –19–27JUL06–1/1 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. No outside storage is recommended without a waterproof covering. 2. John Deere engines can be stored in a standard overseas shipping container[...]

Storage OURGP11,000006C –19–27JUL06–1/2 Preparing Engine for Long Term Storage The following storage preparations are used 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[...]

Storage OURGP11,000006C –19–27JUL06–2/2 15. 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,RG34710,5613 –19–27JUL06–1/1 Removing Engine from Long Term Storage Refer to the appropriate section for det[...]

Specifications OURGP11,0000089 –19–27JUL06–1/2 General OEM Engine Specifications ITEM 4045DF270 4045TF270 4045TF/HF275 4045HF475 6068TF/HF275 6068HF475 Number of Cylinders 4 4 4 4 6 6 Bore 106 mm 106 mm 106 mm 106 mm 106 mm 106 mm (4.19 in.) (4.19 in.) (4.19 in.) (4.19 in.) (4.19 in.) (4.19 in.) Stroke 127 mm 127 mm 127 mm 127 mm 127 mm 127 m[...]

Specifications OURGP11,0000089 –19–27JUL06–2/2 ITEM 4045DF270 4045TF270 4045TF/HF275 4045HF475 6068TF/HF275 6068HF475 Oil Pressure At Rated 345 ± 103 kPa 345 ± 103 kPa 345 ± 103 kPa 345 ± 103 kPa 345 ± 103 kPa 345 ± 103 kPa Speed, Full Load 3.45 ± 1.03 bar 3.45 ± 1.03 bar 3.45 ± 1.03 bar 3.45 ± 1.03 bar 3.45 ± 1.03 bar 3.45 ± 1.03[...]

Specifications OURGP11,000008A –19–27JUL06–1/3 Engine Power Ratings 1 And Fuel System Specifications 2 Engine Fuel System Electronic Software System Power Rated Slow Idle Fast Idle Model Option Codes Option Codes Voltage Rating @ Speed (rpm) (rpm) Rated Speed (rpm) kW (hp) 4045DF270 164J ................... ...................................[...]

Specifications OURGP11,000008A –19–27JUL06–2/3 Engine Fuel System Electronic Software System Power Rated Slow Idle Fast Idle Model Option Codes Option Codes Voltage Rating @ Speed (rpm) (rpm) Rated Speed (rpm) kW (hp) 4045HF275 161F, 163G ....... 7272 ............................ 12V ......... 117 (157) ..... 1800 .......... 1150 ............[...]

Specifications OURGP11,000008A –19–27JUL06–3/3 Engine Fuel System Electronic Software System Power Rated Slow Idle Fast Idle Model Option Codes Option Codes Voltage Rating @ Speed (rpm) (rpm) Rated Speed (rpm) kW (hp) 6068HF275 16YT, 162C ....... 7287 ............................ 24V ......... 210 (282) ..... 1800 .......... 1150 ............[...]

Specifications OURGP11,000008B –19–27JUL06–1/1 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[...]

Specifications TORQ1 –19–24APR03–1/1 Unified Inch Bolt and Screw Torque Values TS1671 –UN–01MAY03 Bolt or SAE Grade 1 SAE Grade 2 a SAE Grade 5, 5.1 or 5.2 SAE Grade 8 or 8.2 Screw Lubricated b Dry c Lubricated b Dry c Lubricated b Dry c Lubricated b Dry c Size N • m lb-in N • m lb-in N • m lb-in N • m lb-in N • m lb-in N • m [...]

Specifications DX,TORQ2 –19–24APR03–1/1 Metric Bolt and Screw Torque Values 4.8 4.8 8.8 9.8 10.9 12.9 12.9 12.9 12.9 10.9 9.8 8.8 4.8 TS1670 –UN–01MAY03 Bolt or Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9 Screw Lubricated a Dry b Lubricated a Dry b Lubricated a Dry b Lubricated a Dry b Size N • m lb-in N • m lb-in N • m lb-in N[...]

Lubrication and Maintenance Records RG,RG34710,5620 –19–27JUL06–1/1 Using Lubrication and Maintenance Records Refer to specific Lubrication and Maintenance Section for detailed service procedures. 1. Keep a record of the number of hours you operate your engine by regular observation of hour meter. 2. Check your record regularly to learn when [...]

Lubrication and Maintenance Records OURGP11,000008D –19–27JUL06–1/1 500 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 • Check crankcase vent system. • Check air intake hoses, connections, and system. • [...]

Lubrication and Maintenance Records RG,RG34710,5625 –19–27JUL06–1/1 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 [...]

Lubrication and Maintenance Records RG,RG34710,5627 –19–27JUL06–1/1 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 60-4 080706 PN=239[...]

Emission System Warranty RG,RG34710,7629 –19–27JUL06–1/1 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 equip[...]

Emission System Warranty DPSG,RG41165,133 –19–27JUL06–1/1 Emissions Control System Certification Label RG11947 –UN–06NOV01 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[...]

John Deere Service Literature Available DX,SERVLIT –19–31JUL03–1/2 Technical Information TS189 –UN–17JAN89 TS191 –UN–02DEC88 TS224 –UN–17JAN89 TS1663 –UN–10OCT97 Technical information can be purchased from John Deere. Some of this information is available in electronic media, such as CD-ROM disks, and in printed form. There ar[...]

John Deere Service Literature Available DX,SERVLIT –19–31JUL03–2/2 – Fundamentals of Machine Operation manuals explain machine capacities and adjustments, how to improve machine performance, and how to eliminate unnecessary field operations. 70-2 080706 PN=243[...]

John Deere Service Literature Available 70-3 080706 PN=244[...]

Index Page Page A Cold weather aids ....................... 35-15 Except 4045DF,TF270 .................. 19-9 Acid burns ............................. 30-2 4045DF,TF270 ........................ 20-6 Adjust Compressor, air ........................ 40-11 Valves, all except 475 engines ............ 35-9 Configuration data, viewing - earlier engines . [...]

Index Page Page Diagnostic trouble codes (DTCs) With Denso High Pressure Common Rail .... 45-5 With Stanadyne DE10 pump .............. 45-3 Stored service codes, viewing - earlier engines ........................... 16-17 Error Codes ........................... 45-28 Stored service codes, viewing - later engines ............................ 17-8 Di[...]

Index Page Page Component function - earlier engines ....... 16-1 Filler locations ......................... 25-1 Oil filter, change ......................... 30-7 Component function - later engines ......... 17-1 identification .......................... 15-1 Oil filters .............................. 10-10 Operating engine Main menu navigation - [...]

Index Page Page Fuel injection pump and power ratings ...... 55-3 W General OEM ......................... 55-1 Standby power units ................. 19-17, 20-4 Warming engine, except 4045DF,TF270 ...... 19-8 Warming engine, 4045DF,TF270 ............ 20-8 Starting engine, except 4045DF,TF270 engine ............................... 19-4 Warranty Emis[...]