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Ariens 926302-ST1332LE Snow Blower User Manual

1. SE 1 ENGINE START COMPONENTS B1 Analog Throttle F1 Fuse 30 Amp Harness G1 Alternator K1 Starter Relay Mi Starter Motor N1i Transient Voltage Protector Pi Optional Gauge P2 Optional Gauge P3 Oil Pressure Gauge P4 Coolant Temperature Gauge P5 Tachometer Display P6 Hour Meter Diagnostic Gauge 1 lgnition Key Switch S2 Speed Select Switch Momentary Switch V1 Diode Connect 45 8 422 STARTER RELAY SOLENOID 002 BAT RU i B st Fi AML lian A 30AB x 12V rat ls pump ij hacc OF ENABLE S EA EE prii f ET 7 l am Le A BUMP UP OFF amp BUMP DN i F gt 5 ETTA C TO SINGLE POINT TO TO T TO X31 GROUND jsd ECU ECU ECU ECU S3 Bump Enable Switch Momentary S4 High Low Speed Select 5 Override Shutdown Switch Momentary X1 Vehicle Harness or 464 S5 OFF OVERRIDE SHUTDOWN SE 2 INSTRUMENT PANEL CONTINUED NEXT PAGE ANALOG THROTTLE RG13354 UN 22JAN04 X2 Alternator Harness Connector X3 Single Point Ground X4 CAN Terminator X5 Analog Throttle Connector OURGP11 0000271 19 27JUL06 1 1 080706 PN 202 Troubleshooting Engine Wiring Diagram With Later Full Featured Electronic Instrument Panel Continued 464 OVERRIDE SHUTDOWN RETURN 020 CAN SHIELD 904 CAN H 905 CAN L 012 IGN 12V OR 24V 412 ACC 422 STARTER R
2. 800 scsicsseetesact 2600 161 L 1636 siisi ToT aeea 24V wievseues 82 110 2400 ooann COO ccssecsaaatesans 2600 161K TOS css T atustcnciecressaanaiet TAN Serene 84 112 1800 TISO esan 1870 161L WCB sss 7293 sccvncnissnneunisieieonmsanents 24V naaien 84 112 1800 1150 ssassn 1870 4045HF275 1061F T090 sss O an 12V nena 104 140 2400 ooann GOO ersa 2600 161G 163K ccs TADI aii 24V aaia 104 140 2400 800 acteet en 2600 161 1030 is a O E A E E A 12V raria 93 125 2400 onna BOO saini 2600 161G 163K TA O aeir 24V naaien 93 125 2400 BOO sssi 2600 1611F 1690 sss T2BD icaaagscasmuseetenrionrs 12V aaan 104 140 2200 nasasa BOO seradas 2400 161G 163K ccs TOBE aandienden 24V aaan 104 140 2200 aasian DOO i 2400 161F 1630 aan pA e E E eee 93 125 aas 2200 800 setae 2400 161G 163K TUT sae PAN oisin 93 125 s 2200 ais BOO saini 2400 161F 163G 7268 siueumtoaciaeneemaes 12V aaan 86 115 2000 800 scccessestacsices 2100 1610 163K ssas 7269 sesesswossantirasvedtanseties 24V aaia BO 115 arrer 2000 siaran GOU ssrdsn 2100 1561F 16390 css TATU aeran TAN pussies 108 145 1800 o n TISO ceren 1870 1610 163K nsa TEEN serap 24V aaien 108 145 1800 1150 eeteheshceste 1870 Power ratings are for bare engines without drag effect of cooling
3. nnna anaana aana 30 14 PN SUC ETELE E E ws hw a teeter 25 1 DAMP CNS x cs os oe seek te a ee ee el eet 35 2 OIE AI seei ead he be i a E i i a R iA 55 6 Engine crankcase oil fill 55 6 Index 3 080706 PN 3 Page Fuel injection pump and power ratings 55 3 General OEM sccccatavaadme eewueeeee vs 55 1 Standby power units 19 17 20 4 Starting engine except 4045DF TF270 Eae ae ks cs ie eed oe OR E 19 4 Starting engine 4045DF TF270 engine 20 4 Stopping engine except 4045DF TF270 19 16 Stopping engine 4045DF TF270 20 10 Storage GuidelineS 2 2 0 0 cee eee 50 1 Long TCI 5 sm eon anaana 50 2 Removing froM 0 00 eee ee eee 90 3 Storing fuel 0 ee 10 2 Storing lubricants 0 5 86 600 eee wm wee we eek 10 11 Supplemental coolant additives R pIONISNING zes oct eee hear doa eet 30 17 T Tensioner belt Automatic aaa anaa aaa 30 14 VENI sw E E EE E E ET E E T 30 4 Thermostat el E E EE EE EEEE SENEE ee oe Ss 35 6 Remove 0 ce eee 35 6 Test opening temperature 35 6 Touch switches earlier engines 16 10 Trouble codes Electronic systems and Bosch VP44 45 24 Electronic systems and Denso High Pressure Common Rail 000 0c eee 45 26 Electronic systems and Stanadyne DE10 45 22 Troubleshooting General engine 5 45 10 U Units of measure changing earlier engines
4. A CAUTION To prevent accidental starting of engine while performing valve adjustments always disconnect NEGATIVE battery terminal IMPORTANT Valve clearance MUST BE checked and adjusted with engine COLD RG7408 UN O06AUG96 A l 1 Remove rocker arm cover and crankcase ventilator Flywheel Housing Timing Holes tube A Timing Rotation Hole IMPORTANT Visually inspect contact surfaces of i Eels 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 DPSG RG41165 137
5. Prevent Bypass Starting Avoid possible injury or death from engine runaway Do not start engine by shorting across starter terminal Engine will start with PTO engaged if normal circuitry is bypassed Start engine only from operator s station with PTO disengaged or in neutral RG5419 UN 28FEB89 Prevent Bypass Starting RG RG34710 7508 19 27JULO06 1 1 Handle Fuel Safely Avoid Fires Handle fuel with care it is highly flammable Do not refuel 9 the machine while smoking or when near open flame or sparks Always stop engine before refueling machine Fill fuel tank outdoors Prevent fires by keeping machine clean of accumulated trash grease and debris Always clean up spilled fuel TS202 UN 23AUG88 DX FIRE1 19 03MAR93 1 1 05 2 080706 PN 17 Safety Prepare for Emergencies Be prepared if a fire starts Keep a first aid kit and fire extinguisher handy Keep emergency numbers for doctors ambulance service hospital and fire department near your telephone TS291 UN 23AUG88 DX FIRE2 19 03MAR93 1 1 Handle Starting Fluid Safely Starting fluid is highly flammable Keep all sparks and flame away when using it Keep starting fluid away from batteries and cables To prevent accidental discharge when storing the pressurized can keep the cap on the container and store in a cool protected location TS1356 UN 18MAR92 Do not incinerate or puncture a starting fluid
6. RG13132 UN O9SEP03 A Diagnostic Gauge Engine hours B Menu Key Engine rom C Arrow Keys System voltage D Enter Key Percent engine load at the current rom E Red STOP ENGINE Indicator Light Coolant temperature F Amber WARNING Indicator Light Oil pressure Throttle position Intake manifold temperature Current fuel consumption Active service diagnostic codes Stored service diagnostic codes from the engine Set the units for display View the engine configuration parameters NOTE Engine parameters which can be accessed will vary with the engine application Six languages for readouts are available and can be selected during setup of gauge The diagnostic gauge includes a graphical backlit Liquid Crystal Display LCD screen The display can show either a single parameter or a quadrant display showing four parameters simultaneously The diagnostic gauge uses two arrow keys C for scrolling through the engine parameter list and viewing the menu list and an enter key D for selecting highlighted items The red E and amber F lights are used to signal active trouble code received by the diagnostic gauge OURGP11 0000074 19 27JUL06 1 1 17 4 080706 PN 67 Instrument Panel Elect Cont Later Engines Main Menu Navigation 98 1000 RPM LOAD RPM ENG RPM NOTE The engine does not need to be running to 1800 RPM navigate the diagnostic gauge screens If engine COOL TEMP ell AS Sta
7. UN O6FEB04 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 OURGP11 000007C 19 27JULO06 1 1 20 8 080706 PN 123 Engine Operation 4 5 L 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 850 rom 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 soeed may not have a slow idle function These engines will idle at no load governed speed high idle 20 9 OURGP
8. gt O Z T Z T O N N op e Use only service parts meeting John Deere specifications DX REPAIR 19 17FEB99 1 1 05 11 080706 PN 26 Safety Handling Batteries Safely CAUTION Battery gas can explode Keep sparks and flames away from batteries Use a flashlight to check battery electrolyte level Never check battery charge by placing a metal object across the posts Use a voltmeter or hydrometer TS204 UN 23AUG88 Always remove grounded battery clamp first and replace it last Explosion A 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 tease e 4 Coeeecs If you spill acid on yourself Flush your skin with water 2 Apply baking soda or lime to help neutralize the acid 3 Flush your eyes with water for 15 30 minutes Get medical attention immediately If acid is swallowed 1 Do not induce vomiting 2 Drink large amounts of water or milk but do not exceed 2 L 2 qt Acid 3 Get medical attention immediately TS203 UN 23AUG88 WARNING Battery posts terminals and
9. l q o0 Y w 5 oc Instrument Panel For Earlier Engines Continued on next page OURGP11 000027A 19 07AUG06 3 7 1 6 3 080706 PN 49 Instrument Panel Elect Cont 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 indicating the engine can now be started Key Start Switch The three position key start 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 Switch will be present but may not be active depending on engine controller ECU options originally selected If switch is active pressing the upper half of the override shutdown switch M will override an engine shutdown signal The switch must be pressed within 30 seconds to prevent undesired shutdown of engine Pressing this switch will override the engine shutdown for 30 seconds at a time to move vehicle to a safe location High Low Speed Select Rocker Switch This instrument panel has two versions one with a two position switch as shown and one with a three position switch The two position switch has high low and is used s to set the engine operating speeds at slow turtle or fast 8 rabbit F
10. 13 Press the Enter key to select the parameter for inclusion in the Single Engine Parameter Display PNE STEE PERCENT LOAD AT CURRENT RPM 2 14 Continue to scroll through and select additional ENGINE OIL PRESSURE 1 parameters for the custom 1 Up Display Press the ENGINE COOLANT TEMP Menu key at any time to return to the Custom Setup menu RG13220 UN 26SEP03 Select Parameters For Display OURGP11 00000B1 19 27JUL06 13 18 Automatic Scan Selecting the scan function will o DEFAULTS allow the 1 Up Display to scroll through the selected set of parameters one at a time Use the Arrow keys CUSTOM SETUP to scroll to the Automatic Scan function AUTOMATIC SCAN OFF RG13221 UN 26SEP03 OCO Automatic Scan Off Continued on next page OURGP11 00000B1 19 27JUL06 14 18 17 24 080706 PN 87 Instrument Panel Elect Cont Later Engines 16 Press the Enter key to toggle the Automatic Scan 7 function on USE DEFAULTS CUSTOM SETUP AUTOMATIC SCAN ON RG13222 UN 26SEP03 Automatic Scan On OURGP11 00000B1 19 27JUL06 15 18 17 ii E a again to toggle the Automatic USE DEFAULTS va Tae CUSTOM SETUP AUTOMATIC SCAN OFF Automatic Scan Off RG13223 UN 26SEP03 Continued on next page OURGP11 00000B1 19 27JULO6 16 18 17 25 080706 PN 88 Instrument Panel Elect Cont Later Engines 18 Once the Use Defaults Custom Setup and P USE DEFAULTS Automatic Sc
11. 19 27JUL06 1 8 45 10 080706 PN 204 Troubleshooting Symptom Engine hard to start or will not start Engine knocks Problem Engine starting under load Improper starting procedure No fuel Air in fuel line Cold weather Slow starter speed Crankcase oil too heavy Improper type of fuel Water dirt or air in fuel system Clogged fuel filter Dirty or faulty injection nozzles Defective glow plugs Cold weather starting 4045HF475 6068HF475 Electronic fuel system problem if equipped Low engine oil level Low coolant temperature Engine overheating Engine cold Continued on next page 45 11 Solution Disengage PTO Review starting procedure Check fuel tank Bleed fuel line Use cold weather starting aids See Starter Cranks Slowly Use oil of proper viscosity Consult fuel supplier use proper type fuel for operating conditions Drain flush fill and bleed system Replace filter element Have authorized servicing dealer or engine distributor check injectors Test glow plugs See 2000 hour 24 month maintenance section See your John Deere distributor or servicing dealer Add oil to engine crankcase Remove and check thermostat See Engine Overheats Wrong or defective thermostat Remove and check thermostat RG RG34710 5608 19 27JUL06 2 8 080706 PN 205 Symptom Engine runs irregularly or stalls frequently Below normal engi
12. Contents Page Page Engine Wiring Layout Electronic Fuel Lubrication and Maintenance Records System With Denso High Pressure Common Using Lubrication and Maintenance Records 60 1 Rail 4045HF475 6068HF475 45 5 Daily Prestarting Service 60 1 Engine Wiring Diagram With Earlier 500 Hour 12 Month Service 60 2 Electronic Instrument Panel 45 6 2000 Hour 24 Month Service 60 3 Engine Wiring Diagram Engines With Service as Required 000 eee 60 4 Electronic Instrument Panel 45 7 Engine Wiring Diagram With Later Emission System Warranty Full Featured Electronic Instrument Panel 45 8 U S EPA Emmission Control Warranty Engine Wiring Diagram With Later Statement 0 0 ee ees 65 1 Full Featured Electronic Instrument Panel Emission Control System Certification Label 65 2 Continued 0 0 cee ee 45 9 Engine Troubleshooting 45 10 Blink Code Method for Retrieving Diagnostic Trouble Codes All Except Early VP44 Pump Engines 45 17 Blink Code Method for Retrieving Diagnostic Trouble Codes Early VP44 Pump Engines Only anaana doen dew 45 18 Instrument Panel Method for Retrieving Diagnostic Trouble Codes 45 20 Displaying Of Diagnostic Trouble Codes DTO SJ eee E E e G r a ee 45 21 Listing of Diagnostic Trouble Codes DTCs Engines With Electronic Fuel
13. Lubrication amp 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 JT07298 Coolant Battery Tester to ensure that the desired freeze point is maintained Follow manufacturer s instructions provided with Coolant Battery Tester Add the manufacturers 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 OQUOD002 1921 19 27JUL06 2 2 3 0 E 1 8 080706 PN 155 Lubrication amp Maintenance 500 Hour 12 Month Testing Diesel Engine Coolant Maintaining adequate concentrations of glycol and Compare the results to the supplemental coolant inhibiting additives in the coolant Is critical to protect additive SCA chart to determine the amount of the engine and cooling system against freezing inhibiting additives in your coolant and whether more corrosion and cylin
14. TS1356 UN 18MAR92 Block Heat RG11521 19 10JAN01 OURGP11 0000078 19 27JUL06 1 2 080706 PN 107 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 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 19 10 OURGP11 0000078 19 27JUL06 2 2 080706 PN 108 Engine Operation Except 4 5L 270 Engines Using a Booster Battery or Charger A 12 volt booster battery can be connected in parallel with battery ies on the unit to aid in cold weather starting ALWAYS use heavy duty jumper cables CAUTION Gas given off by battery is explosive Keep sparks and flames away from battery Before connecting or
15. 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 A CAUTION Before starting engine in a confined building install proper outlet exhaust ventilation equipment Always use safety approved fuel storage and piping TS220 UN 23AUG88 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 Perform all prestarting checks outlined in Lubrication amp Maintenance Daily Section later in this manual Open the fuel supply shut off valve if equipped Disengage clutch if equipped controlling any engine drivelines Continued on next page OURGP11 0000076 19 27JUL06 1 3 19 4 080706 PN 102 Engine Operation Except 4 5L 270 Engines 4 Set slow idle as follows Panels with high low speed select rocker switch B only Set slow speed by pressing lower half of switch Panels with optional analog throttle s A Set high low speed select rocker switch to slow turtle then push in on analog throttle handle or turn full counterclockwise to set analog throttle s to slow speed IMPORTANT Do not operate the starter for more than 30 seconds at a time To do so may i overheat t
16. Wait 2 minutes and crank engine an additional 20 seconds to assure bearing surfaces are adequately lubricated 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 On the first day of operation after storage check overall engine for leaks and check all gauges for correct operation RG RG34710 5613 19 27JULO6 1 1 080706 PN 227 Specifications General OEM Engine Specifications ITEM 4045DF270 4045TF270 4045TF HF275 4045HF475 6068TF HF275 6068HF475 Number of Cylinders 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 mm 5 0 in 5 0 in 5 0 in 5 0 in 5 0 in 5 0 in Displacement 4 5L 4 5L 4 5L 4 5L 6 8L 6 8 L 276 cu in 276 cu in 276 cu in 276 cu in 414 cu in 414 cu in 1 Exhaust 1 Exhaust 1 Exhaust 2 Exhaust 1 Exhaust 2 Exhaust Valve Clearance Cold Intake Checking 0 31 0 38 mm 0 31 0 38 mm 0 31 0 38 mm 0 31 0 38 mm 0 31 0 38 mm 0 31 0 38 mm 0 012 0 015 in 0 012 0 015 in 0 012 0 015 in 0 012 0 015 in 0 012 0 015 in 0 012 0 015 in Exhaust Checking 0 41 0 48 mm 0 41 0 48 mm 0 41 0 48 mm 0 41 0 48 mm 0 41 0 48 mm 0 41 0 48 mm 0 016 0 019 in 0 016 0 019 in 0 016 0 019 in 0 016 0 019 in 0 016 0 019 in 0 016 0 019 in Intake Adjusting 0
17. on upper alternator bracket 5 Continue to hold tension with torque wrench and tighten upper alternator bracket cap screw 6 Check position of reference mark to see if alternator moved while tightening If alternator moved loosen upper alternator bracket cap screw and repeat the tension adjustment procedure 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 k Scribe Reference Mark OUOD002 000016D RG11814 UN 310CT01 RG11815 UN 310CT01 19 27JUL06 2 2 30 6 080706 PN 143 Lubrication amp Maintenance 500 Hour 12 Month Changing Engine Oil and Replacing Filter IMPORTANT 6 Cylinder engines with oil pan option codes 1907 1908 and 1909 require the oil to be changed at every 250 hours or less regardless of oil specification used Your engine is equipped with a special oil filter A NOTE During break in change engine oil and filter for the first time before 100 hours maximum of operation RG11616 UN 240CT01 After break in if John Deere PLUS 50 or ACEA E7 E6 E5 E4 engine oil and a John Deere special oil filter are used along with a large sump oil pan the oil and filter change interval is 500 hours or every 12 months whichever comes first NOTE If the above recommendations are not followed the oil and filter change interv
18. 140 2000 24V Loe 104 140 2000 12V aiia 123 165 1800 DAN ispite 123 165 aac 1800 12V aci 116 155 2500 24V ne T16 155 s 2500 12V aisia 127 170 2500 24V woe 127 170 2500 VON sin 123 165 sac 2400 12V aci 105 141 1500 24V wee 105 141 1500 VO ascents 168 225 2400 2AN cnan 168 225 2400 12V wo 149 200 2400 PAV woe 149 200 2400 VAN asr 149 200 2200 24V wee 149 200 2200 TAN siii 138 185 2400 2AN crisma 138 185 s 2400 VAN orisa 149 200 2200 24V naaa 149 200 2200 12V aiaia 187 250 2400 24V woe 187 250 2400 TAN auss 168 225 2200 24V woe 168 225 2200 12V saes 157 210 2000 PAN risici 157 210 2000 VAN irea 129 173 Secu 2000 2AN inene 129 173 2000 12V wo 164 220 1800 24V Loe 164 220 1800 12V eiis 187 250 s 1800 DAN iniiis 187 250 1800 12V ein 210 282 1800 Continued on next page 55 4 Slow Idle Fast Idle rpm rpm T150 ne 1870 1150 ccn 1870 800 nann 2600 TAO iriden 1575 1400 wow 15 5 GOU ccatecertace 2600 BOO sieiscirctttneese 2400 TADO sinis 1870 1400 sissiirassita 1560 800 naan 2600 800 nann 2400 BOO sizio 2400 COU cosssiaceere nan 2400 BOG arrinin 2400 BOD vtec 2100 800 descardcnvancctses 2100 1150 sssr 1870 T50 sunnies
19. 19 27JULO6 1 5 35 9 080706 PN 167 Lubrication amp 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 27JULO6 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 Specification RG7409 UN O06AUG96 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 Nem 20 lb ft Adjusting Valves A Adjusting Screw Jam Nut 6 Replace rocker arm cover and crankcas
20. 40 21 080706 PN 194 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 A reliable program for troubleshooting engine problems should include the following basic diagnostic thought process 45 1 Know the engine and all related systems e Study the problem thoroughly e Relate the symptoms to your knowledge of engine and systems Diagnose the problem starting with the easiest things first e Double check before beginning the disassembly Determine cause and make a thorough repair e 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 DIAGNOST
21. Analog Throttle Optional F is installed when engine is not F Exhaust Stack Rain Cap running This will prevent water and dirt from entering engine OURGP11 0000139 19 27JUL06 1 1 19 16 080706 PN 114 Engine Operation Except 4 5L 270 Engines Auxiliary Gear Drive Limitations DA Ve d wer fenenens t 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 p Te kS a5 N r f so et S s see Sars Ura e 30 kW 40 hp Continuous Operation at 2500 rpm e 37 kW 50 hp Intermittent Operation at 2500 rom A Auxiliary Gear Drive UN 22JAN99 lt x lap N xX Auxiliary Gear Drive RG RG34710 5555 19 27JUL06 1 1 Generator Set Standby Applications To assure that your engine will deliver efficient standby operation when needed start engine and run at rated speed with 50 70 load for 30 minutes every 2 weeks DO NOT allow engine to run extended period of time with no load RG RG34710 5556 19 27JUL06 1 1 19 17 080706 PN 115 Engine Operation 4 5 L 270 Engines Normal Engine Operation Before starting fill engine with oil and coolant meeting specifications Gee DIESEL ENGINE BREAK IN OIL and DIESEL ENGINE COO
22. Arrow Keys Optional P Enter Key L Oil Pressure Gauge Q Amber WARNING M Coolant Temperature Indicator Light Gauge R Red STOP ENGINE N Menu Key Indicator Light Following is a brief description of the available optional electronic controls and gauges found on John Deere provided instrument panels Refer to manufacturer s literature for information on controls not provided by Deere Continued on next page OURGP11 0000073 19 04AUG06 1 3 1 7 1 080706 PN 64 Instrument Panel Elect Cont Later Engines 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 operating hours of the engine and should be used as a guide for scheduling periodic maintenance If the diagnostic gauge receives a trouble code from an engine control unit the current display will switch to a warning or shutdown depending on the severity of the code screen that will display the trouble code number the description of the code and the corrective action needed B Tachometer The tachometer B indicates engine speed in hundreds of revolutions per minute rpm C Voltmeter Optional The voltmeter C indicates system battery voltage The amber Warning light Q will illuminate when battery voltage is too
23. Do not mix used diesel engine oil or Cold Filter Plugging Point CFPP below the any other type of lubricating oil with expected low temperature OR Cloud Point at least diesel fuel 5 C 9 F below the expected low temperature IMPORTANT Improper fuel additive usage may Fuel lubricity should pass a minimum level of 3100 cause damage on fuel injection grams as measured by ASTM D6078 or maximum equipment of diesel engines DX FUEL1 19 17NOVO05 1 1 Lubricity of Diesel Fuel Most diesel fuels manufactured in the United States Fuel lubricity should pass a minimum load level of Canada and the European Union have adequate 3100 grams as measured by ASTM D6078 or a lubricity to ensure proper operation and durability of maximum scar diameter of 0 45 mm as measured by fuel injection system components However diesel ASTM D6079 or ISO 12156 1 fuels manufactured in some areas of the world may lack the necessary lubricity If fuel of low or unknown lubricity is used add John Deere PREMIUM DIESEL FUEL CONDITIONER or IMPORTANT Make sure the diesel fuel used in equivalent at the specified concentration your machine demonstrates good lubricity characteristics DX FUEL5 19 270CT05 1 1 10 1 080706 PN 29 Fuels Lubricants and Coolant Handling and Storing Diesel Fuel When using bio diesel fuel the fuel filter may require A eee vane we carey eet more frequent replacement due to premature plugging the fuel tank when engine
24. Press and hold in the reset button A while turning key switch B 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 Continue to hold in the reset button until the oil pressure is ata safe operating level Warm up engine for at least 5 minutes before applying a load See WARMING UP ENGINE later in this section Check all gauges for normal operation If operation is not normal stop engine immediately and determine Cause A Reset Button B Key Switch 20 5 B RG6580 UN 20JAN93 RG13366 UN 12FEB04 Starting Engine Using Reset Button and Key Switch Later Engines OURGP11 000016A 19 27JUL06 2 2 080706 PN 120 Engine Operation 4 5 L 270 Engines Cold Weather Starting When outside temperatures fall below 0 C 82 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 or lower viscosity oil may also be used See your local John Deere engine distributor or servicing dealer for recommendations Also see Using a Booster Battery or Charger later in this section 1 Perform all prestarting checks outlined in Lubrication amp Maintenance Daily Section later in this manual Disengage engine rear driveline
25. RG9905 UN O6JAN99 Inspect overall condition of vibration isolators if equipped Replace isolators as necessary if rubber has deteriorated or mounts have collapsed A Mounting Bracket OURGP11 0000110 19 27JUL06 1 1 3 0 E 1 080706 PN 138 Lubrication amp Maintenance 500 Hour 12 Month Servicing Battery CAUTION Battery gas can explode Keep sparks and flames away from batteries Use a flashlight to check battery electrolyte level Never check battery charge by placing a metal object across the posts Use a voltmeter or hydrometer TS204 UN 23AUG88 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 solu
26. Use the Arrow keys to scroll through the engine ENGINE SPEED PT 1 configuration data 1000 RPM lt NEXT gt OGOO Use Arrow Keys To Scroll OURGP11 00000AB_ 19 27JUL06 4 6 RG13166 UN 29SEP03 5 Press the Menu key to return to the main menu ENGINE SPEED PT 1 1000 RPM lt NEXT gt Co Return To Main Menu Continued on next page OURGP11 00000AB_ 19 27JUL06 5 6 17 7 080706 PN 70 RG13167 UN 29SEP03 Instrument Panel Elect Cont Later Engines 6 Press the Menu key to exit the main menu and return 98 T000 RPN to the engine parameter display LOAD RPM ENG RPM 1800 RPM COOL TEMP ae Ee Exit Main Menu RG13159 UN 26SEP03 OURGP11 00000AB 19 27JUL06 6 6 Accessing Stored Trouble Codes 98 1000 RPM LOAD RPM ENG RPM NOTE The engine does not need to be running to 1800 RPM navigate the diagnostic gauge screens If engine Ee coo TEMP hee he Start up is desired See Starting The Engine All of M asi alll For description of trouble codes see chart in Menu Key Troubleshooting Section RG13159 UN 26SEP03 1 Turn the key switch to the ON position Starting at the single or four engine parameter display press the Menu key OURGP11 00000AC 19 27JULO6 1 6 The main menu will be displayed Use the Arrow keys GO TO 1 UP DISPLAY to scroll through the menu until Stored Codes is STORED CODES highlighted ENGINE CONFIG SETUP 1 U
27. at the time the message is Sub Menu shows the process for selecting active broadcast The word SrvcCode is displayed on the service codes DTCs and their values second line The display will cycle every 5 seconds between the currently displayed parameter and the NOTE For a list of Service Codes or Diagnostic SrvcCode message until the active service code Trouble Codes DTCs and their causes refer DTC clears To view the active codes select the to TROUBLESHOOTING Section 45 later in Service Code Sub Menu by pressing the UP or DOWN this manual An alternate method of accessing switch until the top line of the display reads trouble codes for engines for engines without SrvcCode Then press BOTH the UP and DOWN the diagnostic gauge is the blink code method switches at the same time to select the Service Code See Section 45 DPSG OQUOD002 1928 19 27JUL06 1 1 16 16 080706 PN 62 Instrument Panel Elect Cont Earlier Engines Viewing Stored Service Codes Diagnostic Trouble Codes DTCs in the Engine ECU DM2 CODES SUB MENU if DM2 data is available User may exit the Service Code Display routine by pressing BOTH First SPN FMI keys at any time combination Exit SrvcCodes Indication of NO DM2 Data User may exit the Service Code Display routine by pressing BOTH keys at ANY time RG10021 19 280CT99 Viewing Stored Service Codes Diagnostic Trouble Codes DTCs The diagnostic gauge
28. contact your John Deere Dealer dealer to reference DTAC solution OURGP11 0000012 19 27JUL06 3 3 Mixing of Lubricants In general avoid mixing different brands or types of oil Consult your John Deere dealer to obtain specific Oil manufacturers blend additives in their oils to meet information and recommendations certain specifications and performance requirements Mixing different oils can interfere with the proper functioning of these additives and degrade lubricant performance DX LUBMIX 19 18MAR96 1 1 1 0 9 080706 PN 37 Fuels Lubricants and Coolant 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 FILT 19 18MAR96 1 1 OILSCAN and COOLSCAN OILSCAN and COOLSCAN are John Deere sampling programs to help you monitor machine performance and identify potential problems before they cause serious damage Oil and coolant samples should be taken from each system prior to its recommended change interval Check with your John Deere dealer for the availability of OILSCAN and COOLSCAN kits O 00 Z 5 LO T Z 5 m lt oe N 00 T6829AB UN 180CT88 OILSCAN is a registered trademark of Deere amp Company COOLSCAN is a trademark of Deere amp Company DX OILSCAN 19 02DEC02 1 1 10 10 080706 PN
29. if necessary Use correct grade of fuel Use proper type of fuel Service air cleaner Reduce load See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor Check thermostat RG RG34710 5608 19 27JUL06 6 8 080706 PN 209 Symptom Undercharged electrical system Battery uses too much water Batteries will not charge Starter will not crank Starter cranks slowly Troubleshooting Problem Excessive electrical load from added accessories Excessive engine idling Poor electrical connections on battery ground strap starter or alternator Defective battery Defective alternator Cracked battery case Defective battery Battery charging rate too high Loose or corroded connections Sulfated or worn out batteries Stretched poly vee belt or defective belt tensioner PTO engaged Loose or corroded connections Low battery output voltage Faulty start circuit relay Blown main system fuse MDL 25 Low battery output Crankcase oil too heavy Loose or corroded connections Continued on next page 45 16 Solution Remove accessories or install higher output alternator Increase engine rom when heavy electrical load is used Inspect and clean as necessary Test battery
30. if equipped or gen set drive Open the fuel supply shut off valve if equipped Place the speed control lever in the START position if equipped POWERTECH is a trademark of Deere amp Company Continued on next page 20 6 OURGP11 000007B 19 27JUL06 1 2 080706 PN 121 Engine Operation 4 5 L 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 5 Earlier Engines Shown Turn key switch to HEAT position and hold until heat indicator lamp on instrument panel goes out Turn key switch to START and hold until engine starts Release key switch once engine starts key automatically returns to ON position and instrument panel gauges start operating RG6580 UN 20JAN93 Le Later Engines Turn key switch to ON position and Starting Engine hold PREHEAT button if equipped with preheat option in for up to 30 seconds Turn key switch to START while continuing to hold the PREHEAT button and the reset button Hold until engine starts Release key and PREHEAT button once engine starts key automatically returns to ON position and instrument panel gauges start operating Release reset button when oil pressure is at a
31. op O O O am am 6068 Engine Bosch VP44 Injection Pump Shown 6068 Engine POWERTECH s a trademark of Deere amp Company OUOD002 0000163 19 04AUG06 1 1 080706 PN 7 Introduction POWERTECH 4 5 6 8 L Engines With Electronic Fuel Systems Tier 2 Emission Certified Four Valve Cylinder Head 475 Models N oO gt lt al Z O e gt al O o RG12200 UN 24MAY02 6068HF475 Engine Shown Level 11 Electronic Fuel System With GO0G68HF475 Shown Denso High Pressure Common Rail POWERTECH s a trademark of Deere amp Company OURGP11 000018B 19 04AUG06 1 1 080706 PN 8 Contents Page Record Keeping PowerTech Medallion 01 1 Engine Serial Number Plate 01 1 Record Engine Serial Number 01 2 Engine Option Codes 0000 01 3 Record Engine Control Unit ECU Serial Number 0 0 0 0000 cee eee ee eee 01 5 Record Fuel Injection Pump Model Number 01 5 Safety eee ee ee 05 1 Fuels Lubricants and Coolant Diesel FUG cxscewwce ae qoeeoendseceneada 10 1 Lubricity of Diesel Fuel 10 1 Handling and Storing Diesel Fuel 10 2 Testing Diesel Fuel 20008 10 2 Bio Diesel Fuel 0 00002 eee eee 10 3 Minimizing the Effect of Cold Weather on Diesel Engines 00 0c eee 10 4 Diesel Engine Break In Oil 10 5 Diesel Engine Oil 02 000
32. or low mount location IMPORTANT Filtration of oils is critical to proper lubrication Always change filter regularly Use filter meeting John Deere performance specifications RG11616 UN 240CT01 5 Apply clean engine oil to the new filter at the inner B and outer C seals and to filter threads 6 Wipe both sealing surfaces of the header D E witha clean rag Ensure notches in dust seal F are properly installed in the slots in the housing Replace dust seal if damaged IMPORTANT When installing filter element HAND TIGHTEN only A filter wrench may be used for REMOVAL ONLY Be sure notches in dust seal F are properly Oil Filter Seals installed in the slots in the housing RG11617 UN 240CT01 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 8 Tighten drain plug to specifications Specification Oil Pan Drain Plug With Copper Weasher T Orque cccccccecececeeceeeauenseassesseeeeeeeseeeeeees 70 Nem 52 Ib ft Oil Pan Drain Plug With O Ring DOF ea ceso sig tectecenss EE 50 Nem 37 lb ft Filter And Mounting Header Oil Pan Drain Plug With Packing 6068 Engine Code 1961 Steel A Oil Filter Element Oil PAP TOP GU Osicicincssrescisscssssassssnsconongecaanvnssandeoneeevensteeds 40 Nem 29 Ib ft B Inner Seal C Outer Seal D Sealing Surface On Header E Sealing S
33. 16 12 Units of measure changing later engines 17 17 V Valves Clearance check and adjust All except 475 engines 35 9 ATO COMINGS 55 05 ee eed acer cart act aee 35 12 Vibration damper sis cb bed id dd Sih eee ae ee 35 2 Index 4 Page W Warming engine except 4045DF TF270 19 8 Warming engine 4045DF TF270 20 8 Warranty Emission System 0000 0c eee 65 2 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 080706 PN 4
34. 19 27JUL06 6 6 98 LOAD RPM 1000 RPM ENG RPM 1800 RPM Fea CooL TEMP Menu Key 57 PSI OIL PRES 14 2 BAT VOLT Continued on next page 17 13 RG13159 UN 26SEP03 OURGP11 0000237 19 27JUL06 1 6 080706 PN 76 Instrument Panel Elect Cont Later Engines 2 The main menu will be displayed Use the Arrow keys foo TOUP DISPLAY to scroll through the menu until Adjust Backlight is STORED CODES highlighted ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT RG13181 UN 020CT03 Select Adjust Backlight OURGP11 0000237 19 27JUL06 2 6 3 Once the Adjust Backlight menu item has been GO TO 1 UP DISPLAY highlighted press the Enter key to activate the STORED CODES Adjust Backlight function ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT COO RG13182 UN 02O0CT03 Press Enter Key OURGP11 0000237 19 27JUL06 3 6 4 Use the Arrow keys to select the desired backlight intensity ADJUST BACKLIGHT Om 1c lt gt qoo Adjust Backlight Intensity Continued on next page OURGP11 0000237 19 27JUL06 4 6 RG13183 UN 29SEP03 17 14 080706 PN 77 Instrument Panel Elect Cont Later Engines i k rn he main menu 5 Press the Menu key to return to the main menu ADJUST CONTRAST RG13184 UN 26SEP03 Return To Main Menu OURGP11 0000237 19 27JUL06 5 6
35. 19 27JULO06 1 2 30 12 080706 PN 149 Lubrication amp 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 counterclockwise 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 OURGP11 000021F 19 27JUL06 2 2 30 13 080706 PN 150 Lubrication amp Maintenance 500 Hour 12 Month Checking Belt Tensioner Spring Tension and Belt Wear Automatic Tensioner Belt drive syst
36. 2006 DEERE amp COMPANY Moline Illinois All rights reserved A John Deere ILLUSTRUCTION Manual Previous Editions Copyright 2001 2002 2003 2004 2006 080706 PN 1 Contents Page Auxiliary Gear Drive Limitations 19 17 Generator Set Standby Applications 19 17 Engine Operation 4 5 L 270 Engines Normal Engine Operation 20 1 Break In Service 0 2 2 000 20 2 Auxiliary Gear Drive Limitations 20 3 Generator Set Standby Power Units 20 4 Starting The Engine 0008 20 4 Cold Weather Starting 045 20 6 Warming Engine 4104884 06 66 46 446 4 64 20 8 Avoid Excessive Engine Idling 20 9 Stopping the Engine 0 20 10 Using a Booster Battery or Charger 20 11 Lubrication and Maintenance Observe Service Intervals 00 21 1 Use Correct Fuels Lubricants and Coolant 21 1 Lubrication and Maintenance Service Interval Chart Standard Industrial Engines 21 2 Lubrication and Maintenance Service Interval Chart Generator Standby APPIICAIONS wideqacagdacaenadgeeuaguand 21 4 Lubrication amp Maintenance Daily Daily Prestarting Checks 25 1 Lubrication amp Maintenance 500 Hour 12 Month Servicing Fire Extinguisher 30 1 Checking Engine Mounts 30 1 Servicing Battery 00 002 e eee 30 2 Manual Belt Tensi
37. 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 27JUL06 2 2 080706 PN 14 Record Keeping Record Engine Control Unit ECU Serial Number Record the part number and serial number information found on the serial number label A on the Engine Control Unit ECU mounted on or near the engine Part No Serial No RG13799 UN 18NOV04 A Serial Number Label Record Engine Control Unit ECU Serial Number OURGP12 00000AD 19 27JULO6 1 1 Record Fuel Injection Pump Model Number Record the fuel injection pump model and serial information found on the serial number plate A Model No gt gt gt RPM Manufacturer s No Serial No A Serial Number Plate T 1 ip tal au A i i as Ba i i i Record Injection Pump Serial Number RG11943 UN O6NOV01 RG RG34710 5511 19 27JULO6 1 1 01 5 080706 PN 15 Safety Recognize Safety Information This is a safety alert symbol When you see this symbol on your machine or in this manual be alert to the potential for personal injury Follow recommended precautions and safe operating practices T81389 UN 07DEC88 D
38. Cont Later Engines 7 The quadrant with the highlighted parameter value is the current selected parameter Use the Arrow keys 125 F 4000 RPM to highlight the value in the quadrant you wish to COOL TEMP ENG RPM change to a new parameter 57 PSI BAT VOLT OIL PRES OGP Select Parameters RG13228 UN 26SEP03 OURGP11 00000B2 19 27JUL06 7 14 8 Press the Enter key and a list of engine parameters will be displayed 125 F 1000 RPM COOL TEMP ENG RPM 57 PSI BAT VOLT OIL PRES RG13229 UN 26SEP03 List Of Engine Parameters OURGP11 00000B2_ 19 27JUL06 8 14 9 The parameter that is highlighted is the selected ENGINE SPEED 3 The number to the right of the ENGINE HOURS arameter indicates the quadrant parameter for the screen Use the arrow keys to ETEO ie dereen highlight the new parameter to be placed in the 4 Up BATTERY POTENTIAL 1 Upper Left Quadrent Display ENGINE OIL TEMPERATURE 2 Lower Left Quadrent ENGINE OIL PRESSURE 3 Upper Right Quadrent 4 Lower Right Quadrent RG13230 UN 26SEP03 OGP Select Desired Engine Parameter Continued on next page OURGP11 00000B2 19 27JUL06 9 14 17 29 080706 PN 92 Instrument Panel Elect Cont Later Engines 10 Press the Enter key to change the selected parameter in the quadrant to the new parameter ENGINE HOURS ENGINE COOLANT TEMPERATURE 1 BATTERY POTENTIAL 2 ENGINE OIL TEMPERATURE ENGINE OIL PRESSURE a Enter Selected
39. N O1 oO oO oO aly N O O Class 8 8 or 9 8 o1 o rme O INININI gt O ice o1 O1 O1 ice NO oo ak u O1 0 TS1670 UN 01MAY03 Class 12 9 Lubricated Class 10 9 Lubricated w lt o w lt o w z o Blo lp 7 KR IPM Ola N d C OloO lalo o1 NJ o1 BK oO Pp S o po a IN C en ou oe S oO on lbt o _h O s ol s oO N l oO O1 s N NO 2l N D Oo N TA o O amp O INJ NJ Nh O1 CO J o o o o O1 o1 o AR i mM OIOIOQOQOIO lt e f gt O IOJIJIOIO O1 N o1 iN O O N O1 O N O1 aN O O N O Ol O wolrmlrm OlN olo A oOlalolo D gloj N oO aloalo o1 N COlola lala on oO aN 00 O N N O1 Ol oO O1 N O O 00 O 00 O1 O O N O1 oh O 00 O 00 O O N O O 00 O ok a O1 O 00 Ol O eek O 00 O 00 O O a O ee 00 O1 a oO Ql O _ O O hk N O a Nh O1 O hk Ol 00 oO _ ak O O 200 270 2 3700 2730 2100 3200 2350 4050 3000 3750 2770 4750 3500 Shear bolts are designed to fail under predetermined loads Always replace shear bolts with identical property class Replace fasteners with the same or higher property class If higher property class fasteners are used tighten these to the strength of the original Make sure faste
40. Parameter OURGP11 00000B2 19 27JUL06 10 14 RG13231 UN 26SEP03 11 Use the Menu keys to return to the 4 Up Custom ENGINE SPEED 3 Setup screen ENGINE HOURS ENGINE COOLANT TEMPERATURE 1 BATTERY POTENTIAL ENGINE OIL TEMPERATURE Note the number to the right of ENGINE OIL PRESSURE the selected parameter indicating that the parameter is now assigned to that display location RG13232 UN 26SEP03 QOO Return To 4 Up Custom Setup OURGP11 00000B2 19 27JULO6 11 14 12 The selected quadrant has now changed to the new selected parameter 125 F 1000 RPM COOL TEMP ENG RPM 143 F 57 PSI OIL TEMP OIL PRES 4 Up Display Continued on next page OURGP11 00000B2 19 27JULO6 12 14 RG13153 UN 24SEP03 17 30 080706 PN 93 Instrument Panel Elect Cont Later Engines 13 Repeat the parameter selection process until all spaces are as desired 125 F E 1000 RPM COOL TEMP ENG RPM 14 Press the Menu key to return to the main menu 143 F 57 PSI OIL TEMP OIL PRES RG13154 UN 24SEP03 Return To Main Menu OURGP11 00000B2 19 27JUL06 13 14 i i GO TO 1 UP DISPLAY 15 Press the Menu key to exit the main menu and een cones 125 1000 RPM return to the engine parameter display ENGINE CONFIG cook Tau ENG RPM SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS 143 F 57 PSI ADJUST BACKLIGHT OIL TEMP OIL PRES Poe Select Remaining Parameters RG13155 UN 07OCT03 OUR
41. Press the Enter key to display a list of engine parameters IUSE DEFAULTS CUSTOM SETUP AUTOMATIC SCAN OFF RG13199 UN 26SEP03 OTO Engine Parameters OURGP11 00000B1 19 27JUL06 9 18 10 Use the Arrow keys to scroll to and highlight a ENGINE SPEED selected parameter parameter with a number to right PERCENT LOAD AT CURRENT RPM 3 of it ENGINE OIL PRESSURE This number indicates ENGINE COOLANT TEMPERATURE the order of display for the parameters and that the parameter is selected for display OGO Select Parameters RG13150 UN 24SEP03 OURGP11 00000B1 19 27JUL06 10 18 11 Press the Enter key to deselect the selected parameter removing it from the list of parameters being displayed on the 1 Up Display ENGINE SPEED PERCENT LOAD AT CURRENT RPM 3 ENGINE OIL PRESSURE 2 ENGINE COOLANT TEMPERATURE Deselect Parameters RG13219 UN 26SEP03 Continued on next page OURGP11 00000B1 19 27JUL06 11 18 17 23 080706 PN 86 Instrument Panel Elect Cont Later Engines 12 Use the Arrow keys to scroll and highlight the ENGINE SPEED desired parameter that has not been selected for PERCENT LOAD AT CURRENT RPM 2 display parameter without a number to right of it ENGINE OIL PRESSURE 1_ Note that the numbers ENGINE COOLANT TEMP now indicate the new order of display for the parameters Select Desired Parameters RG13151 UN 24SEP03 OURGP11 00000B1 19 27JUL06 12 18
42. TS1663 UN 100CT97 DX SERVLIT 19 31JUL03 1 2 080706 PN 242 John Deere Service Literature Available Fundamentals of Machine Operation manuals explain machine capacities and adjustments how to improve machine performance and how to eliminate unnecessary field operations DX SERVLIT 19 31JUL03 2 2 10 2 080706 PN 243 John Deere Service Literature Available 10 3 080706 PN 244 Index Page A Acid burnS sec detes 08 Besar sae See he oD Ge i dp Ft edn Sp 30 2 Adjust Valves all except 475 engines 35 9 Valves 475 engineS 205 39 12 Air cleaner Air intake restriction indicator 25 1 Dust unloader valve 20005 25 1 Replace single stage element 40 5 Air compressor 65 naive see eee ea ee wee 40 11 Air intake system check 30 11 Alternator Dells cee ee uege ese dad ewes ea 40 10 Auxiliary gear drive limitations 19 17 20 3 B Batteries Charge Boost 0005 19 11 20 11 SENICE a tates ispre REEERE ERINN a 30 2 Battery id DUNS 22406 4s ne ne Beene eee 30 2 Battery explosion 0 0 00 0 ce eee 30 2 Belt tensioner Manual tensioner adjust 30 4 Manual tensioner adjust with tool 30 5 Belt tensioner automatic 30 14 Belts fan and alternator FICOIACIING eee 3 6 ors 8 6 A 40 10 Bleeding fuel system DETO DUMP sas seeuveneeee esos eee s 4
43. a 2V BUMP OFB ENABLE S4 aT OG N B A K1 S PT Lren IDLE THROTTLE A C ALL LOW IDLE g E BUMP UP ee lt OFF A A B l org BUMP DN g l i 5 A l E A X6 To REMOTE ON OFF B Ecu PLUG a wo amp 5 SINGLE a a Q POINT TO TO TO TO TO X3 GROUND 050 ECU ECU ECU ECU ECU z 8 se eNaINe starr components SE 2 INSTRUMENT PANEL CONTINUED NEXT PAGE oc B1i Analog Throttle or Ni Transient Voltage 1 lIgnition Key Switch V1 Diode Emulator Protector S2 Speed Select Switch X1 Vehicle Harness E1 Back Light Regulator N2 Voltage Regulator for Momentary Connector 24V or Plug 12V 24V Operation S3 Bump Enable Switch X2 Alternator Harness F1 Fuse 10 Amp for Pi Optional Gauge Momentary X3 Single Point Ground harness P2 Optional Gauge S4 High Low Speed Switch X4 CAN Terminator F2 Fuse 5 Amp for P3 Oil Pressure Gauge 5 Override Shutdown X5 Analog Throttle instrument panel P4 Coolant Temperature Switch Momentary Connector G1 Alternator Gauge S6 Dimmer Control or X6 Remote On Off Plug K1i Starter Relay P5 Tachometer Display Jumper Plug M1 Starter Motor P6 Hourmeter Diagnostic Meter OURGP11 000026F 19 27JUL06 1 1 45 6 080706 PN 200 Troubleshooting Engine Wiring Diagram With Earlier Electronic Instrument Panel Continued 464 OVERRIDE SHUTDOWN RETURN 020 CAN SHIELD 904 CAN H 905 CAN L 012 IGN 12V OR 24V 412 ACC 422 STARTER R
44. 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 OURGP12 00001EA 19 27JUL06 1 2 45 18 080706 PN 212 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 45 19 OURGP12 00001EA 19 27JUL06 2 2 080706 PN 213 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 ag
45. 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 e 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 70 1 THE PRECISION FARMING GUIDE FOR on ene Continued on next page reas 4 a i r Ja a Sa pM 1 P Fa em ra lt lt N Z 5 l O on KE rr TS191 UN 02DEC88 TS224 UN 17JAN89
46. at right and electronically controlled earlier engines and electronically controlled later engines shown on next page The electronically controlled earlier instrument panel operation is covered in Section 16 The electronically controlled later instrument panels Full Featured and Basic versions are covered in Section Instrument Panel For Earlier Mechanically Controlled 270 Engines 17 The mechanically controlled 270 series engines are See Section 18 covered in Section 18 RG13343 UN 24NOV03 RG13359 UN O6FEB04 Deluxe Instrument Panel For Later Mechanically Controlled 270 Engines See Section 18 Continued on next page OURGP11 0000071 19 27JULO6 1 2 15 1 080706 PN 45 Eg Acie fe en el eal Ze Wwe RG13273 UN 20NOVO03 Instrument Panel For Earlier Electronically Controlled Engines See Section 16 15 2 Instrument Panel Identification RG13274 UN 280CT03 Full Featured Instrument Panel For Later Electronically Controlled Engines See Section 17 RG13275 UN 210CT03 Basic Instrument Panel For Later Electronically Controlled Engines See Section 17 OURGP11 0000071 19 27JUL06 2 2 080706 PN 46 Instrument Panel Elect Cont Earlier Engines Instrument Panel This instrument panel for earlier POWERTECH 4 5 L and 6 8 L electronically controlled engines is electronically linked to the John Deere engine control unit ECU Th
47. be held down as the speed select switch J is used to change the setting by pressing to increase speed or to decrease speed Once the slow idle speed has been set the bump speed enable switch must be pressed and released three times within two seconds to commit the new operating speed to memory If not done the engine s new speed will only be effective until the key switch is shut off Then the speed will revert back to the previous setting The fast idle speed is not adjustable It will always go back to the factory preset fast idle speed K Analog Throttle Control Optional The throttle control K is used to control engine speed This control is available only on engines with analog throttle L Engine Oil Pressure Gauge The oil pressure gauge L indicates engine oil pressure An audible alarm D warns the operator if engine oil pressure falls below a safe operating pressure M Engine Coolant Temperature Gauge The engine coolant temperature gauge M indicates engine coolant temperature An audible alarm D warns the operator if coolant temperature rises above the preset safe operating temperature N Menu Key The menu key is pressed to either enter or exit the menu screens on the diagnostic gauge O Arrow Keys Use the arrow keys O to change the display on the window of the diagnostic gauge and to access engine performance data Pressing the left arrow to scroll to the left or upward or
48. can request stored service or DOWN switch until the top line of the display reads codes DTCs from the engine The stored service DM2 Codes Then press BOTH the UP and DOWN codes may be used for diagnostic and service needs switches at the same time to select the DM2 Codes To view the stored service codes it is necessary to Sub Menu The gauge will display the stored service select the DM2 Codes Sub Menu by pressing the UP codes according to the menus shown in the diagram OUOD006 000006B 19 27JUL06 1 1 16 17 080706 PN 63 Instrument Panel Elect Cont Later Engines Instrument Panels S O O ee 2 T T O oc Full Featured Instrument Panel A Diagnostic Gauge Hour F Key Switch Meter G Override Shutdown Rocker B Tachometer Switch C Voltmeter Optional H Bump Enable Rocker D Audible Alarm Optional Switch E Audible Alarm Override I Speed Select Rocker Switch Button J High Low Speed Select Rocker Switch Later Tier 2 John Deere POWERTECH OEM Engines have an electronic control system which has the following controls and gauges as shown The following information applies only to those controls and gauges supplied by John Deere Refer to your engine application manual for specific guidelines if John Deere sourced controls and instrumentation are not used POWERTECH is a trademark of Deere amp Company RG13277 UN 220CT03 Basic Instrument Panel K Analog Throttle Control O
49. code and return to the single or four parameter display press the Enter Key 5 The display will return to the single or four parameter display but the display will contain the warning icon Pressing the Enter key will redisplay the hidden trouble code IMPORTANT Ignoring active trouble codes can result in severe engine damage 6 Pressing the Enter key once again will hide the trouble code and return the screen to the single or four parameter display 1 of x WARNING SPN 94 FMI 18 FAULT FUEL DELIVERY PRESSURE CORRECTIVE ACTION CHECK FUEL FILTER AND LINES lt NEXT gt Use Arrow Keys To Scroll RG13241 UN 30SEP03 OURGP11 00000AD 19 27JUL06 3 7 1 of x WARNING SPN 94 FMI 18 FAULT FUEL DELIVERY PRESSURE CORRECTIVE ACTION CHECK FUEL FILTER AND LINES lt NEXT gt Hide Trouble Codes RG13242 UN 30SEP03 OURGP11 00000AD 19 27JULO06 4 7 98 1000 RPM LOAD RPM ENG RPM 1800 RPM OCO OCD Stems COOL TEMP 14 2 ST re RG13176 UN 26SEP03 Active Trouble Code Icon OURGP11 00000AD 19 27JULO6 5 7 WARNING SPN 94 FMI 18 CORRECTIVE ACTION CHECK FUEL FILTER AND LINES lt NEXT gt Enter Key Continued on next page 17 11 RG13242 UN 30SEP03 OURGP11 00000AD 19 27JUL06 6 7 080706 PN 74 Instrument Panel Elect Cont Later Engines 7 The single or four parameter screen will display the Al 98 000 RPN warning icon un
50. container DX FIRE3 19 16APR92 1 1 Handle Fluids Safely Avoid Fires When you work around fuel do not smoke or work near heaters or other fire hazards Store flammable fluids away from fire hazards Do not incinerate or puncture pressurized containers Make sure machine is clean of trash grease and debris Do not store oily rags they can ignite and burn spontaneously TS227 UN 23AUG88 DX FLAME 19 29SEP98 1 1 05 3 080706 PN 18 Safety Service Engines Safely Tie long hair behind your head Do not wear a necktie scarf loose clothing or necklace when you work near machine tools or moving parts If these items were to get caught severe injury could result Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts TS228 UN 23AUG88 Moving Parts OURGP12 00001DA 19 27JULO6 1 1 Wear Protective Clothing Wear close fitting clothing and safety equipment appropriate to the job Prolonged exposure to loud noise can cause impairment or loss of hearing Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises PLB TS206 UN 23AUG88 Operating equipment safely requires the full attention of the operator Do not wear radio or music headphones while operating machine DX WEAR 19 10SEP90 1 1 Protect Against Noise Prolonged exposure to loud noise can cause i
51. 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 TS204 UN 23AUG88 WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling IMPORTANT Be sure polarity is correct before making connections Reversed polarity will damage electrical system Always connect positive to positive and negative to ground Always use 12 volt booster battery for 12 volt electrical systems and 24 volt booster battery ies for 24 volt electrical systems RG4678 UN 14DEC88 1 Connect booster battery or batteries to produce the required system voltage for your engine application NOTE To avoid sparks DO NOT allow the free ends of jumper cables to touch the engine 2 Connect one end of jumper cable to the POSITIVE post of the booster battery RG4698 UN 14DEC88 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 4 Connect one end of the other jumper cable to the B 12 Volt Booster Battery ies NEGATIVE post of the booster battery C Booster Cable D Cable to Starting Motor 5 ALWAYS complete the hookup by making the last con
52. distribution network OURGP11 000006E 19 04AUG06 1 2 080706 PN 2 Introduction IMPORTANT This manual covers only non emission certified or Tier 1 POWERTECH Tier 2 Stage Il Stage emission certified U S and emission certified 4 5 and 6 8 L OEM EU are covered in a separate engines listed These engines meet operators manual OMRG25204 Tier 2 emission certification standards This is for both the U S NOTE This manual covers engines provided to OEM EPA and European Union Council Original Equioment Manufacturers For EU standards Engines with engines in Deere machines refer to the mechanical controls which are machine operator s manual POWERTECH s a trademark of Deere amp Company Two exceptions The 4045HF475 and 6068HF475 for generator applications at 1500 rom are still emission non certified OURGP11 000006E 19 04AUG06 2 2 080706 PN 3 Introduction 080706 PN 4 Introduction 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 is and where he is At your first convenience go meet him He ll want to get to know you and to learn what your needs might be Aux Utilisateurs De Moteurs John Deere N attendez pas d tre o
53. familiar with this type of system can perform repairs See your John Deere dealer a TS1343 UN 18MAR92 DX WW HPCR1 19 07JAN03 1 1 05 7 080706 PN 22 Safety Remove Paint Before Welding or Heating Avoid potentially toxic fumes and dust Hazardous fumes can be generated when paint is heated by welding soldering or using a torch Remove paint before heating e 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 UN 23AUG88 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 24JULO02 1 1 Service Cooling System Safely Explosive release of fluids from pressurized cooling system can cause serious burns Shut off engine Only remove filler cap when cool enough to touch with bare hands Slowly loosen cap to first stop to relieve pressure before removing completely TS281 UN 23AUG88 DX RCAP 19 04JUN9
54. has been opened up This includes e After fuel filter changes e After pump or nozzle replacement e Anytime fuel lines have been disconnected e 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 OURGP11 000000E 19 27JULO06 1 3 40 12 080706 PN 185 Service as Required 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 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 a A 1 Ignition ON Bleed Fuel System UN 20JUN01 continually through the fuel return line B when ignition is ON RG11719A A Bleed Orifice in Final Fuel Filter Base 2 Allow 40 seconds for electronic transfer pump to B Fuel Return Line complete priming 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 OURGP11 000000E 19 27JUL06 2 3 Bleed Fuel System at Fuel Injection Nozzles IMPORTANT Always use a backup wrench when loosening or tightening fuel lines at nozzles
55. in failures or permanent damage to the engine A Hour Meter RG13283 UN 300CT03 Hour Meter On Earlier Panel Left or Later Panel Right Except 4 5 L 270 Engines OURGP11 0000241 19 27JUL06 1 1 Use Correct Fuels Lubricants and Coolant IMPORTANT Use only fuels lubricants and coolants meeting specifications outlined in Fuels Lubricants and Coolant Section when servicing your John Deere Engine ie Es 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 John Deere Parts Network TS100 UN 23AUG88 DPSG QUOE003 20 19 27JUL06 1 1 21 1 080706 PN 128 Lubrication and Maintenance Lubrication and Maintenance Service Interval Chart Standard Industrial Engines NOTE The service intervals below are for standard industrial engines See details in Sections which follow these charts Lubrication and Maintenance Service Intervals 500 Hour 2000 Hour Daily 12 24 As ss Check Engine Oil and Coolant Level Check Fuel Filter Water Bowl Check Air Cleaner Dust Unloader Valve amp Restriction Indicator eae a ne es ooo Service Fire Extinguisher S S S e l l Check Engine Mounts S S S e l l Serice Batey o o S e
56. long as airborne dust containing asbestos is not generated TS220 UN 23AUG88 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 Prevent Battery Explosions Keep sparks lighted matches and open flame away from the top of battery Battery gas can explode Never check battery charge by placing a metal object across the posts Use a volt meter or hydrometer Do not charge a frozen battery it may explode Warm battery to 16 C 60 F TS204 UN 23AUG88 DX SPARKS 19 03MAR93 1 1 Use Proper Lifting Equipment Lifting heavy components incorrectly can cause severe injury or machine damage Follow recommended procedure for removal and installation of components in the manual TS226 UN 23AUG88 DX LIFT 19 04JUN90 1 1 0 5 z 1 0 080706 PN 25 Safety Use tools appropriate to the work Makeshift tools and procedures can create safety hazards Use power tools only to loosen threaded parts and fasteners For loosening and tightening hardware use the correct size tools DO NOT use U S measurement tools on metric fasteners Avoid bodily injury caused by slipping wrenches O fee
57. oil and with coolant meeting specifications See DIESEL ENGINE OIL and DIESEL ENGINE COOLANT SPECIFICATIONS in Fuels Lubricants and Coolant section 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 RG12692 UN 07FEB0O3 Check Engine Oil Level Daily 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 OURGP11 0000169 19 27JUL06 1 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 Check poly vee belt for proper alignment and seating in pulley grooves A Oil Pressure Gauge B Coolant Temperature Gauge RG6574 UN 17FEB03 PREHEAT RG13361 UN O6FEB04 1 nN 15 MID Pay va Oil Pressure and Coolant Temperature Gauges Later Engines Continued on next page OURGP11 0000169 19 27JULO06 2 3 20 2 080706 PN 117 Engine Operation 4 5 L 270 Engines 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 Maintenan
58. the electrical system Positions of key switch are marked as follows OFF ON and START There is also a HEAT position for cold weather starting Instrument Panel and Gauges 4 5 L 270 Engines OURGP11 000018E 19 27JUL06 2 2 18 2 080706 PN 96 Instrument Panel Mech Cont 270 Engines Instrument Panel Later 4 5 L 270 Engines 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 IMPORTANT Any time an electric gauge or meter does not register correctly replace it with a new one Do not attempt to repair it Following is a brief description of the components on a basic instrument gauge panel A Tachometer with Hourmeter Optional The tachometer with hourmeter indicates engine speed in revolutions per minute rom 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 Oil Pressure Gauge The oil pressure gauge indicates engine oil pressure If the engine oil pressure falls below a safe operating pressure the engine will shut down C Voltmeter Gauge The voltmeter indicates system battery voltage D Coolant Temperature Gauge The coolant temperature gauge indicates the engine coolant temperature If coolant temperature rises above the preset safe
59. the right arrow to scroll to the right or downward This will allow you to view various engine parameters and any diagnostic trouble codes that occur Refer to the following story for accessing engine information on the diagnostic gauge using the touch keys P Enter Key The enter key is pressed to select the parameter that is highlighted on the screen Q Amber WARNING Indicator Light When light comes on an abnormal condition exists It is not necessary to shutdown engine immediately but problem should be corrected as soon as possible R Red STOP ENGINE Indicator Light When light comes on stop engine immediately or as soon as Safely possible to prevent engine damage Correct problem before restarting OURGP11 0000073 19 04AUG06 3 3 080706 PN 66 Instrument Panel Elect Cont Later Engines Using Diagnostic Gauge to Access Engine Information The diagnostic gauge A allows the operator to view many readouts of engine functions and trouble codes DTCs The gauge is linked to the electronic control system and its sensors This allows the operator to monitor engine functions and to troubleshoot the engine systems when needed Press the menu key B to access the various engine functions in sequence The displays can be selected as either customary English or metric units The following menu of engine parameters can be displayed on the diagnostic gauge window Diagnostic Gauge Later Engines
60. typical Main line of the display shows the desired information Menu of Engine Parameters The Main Menu has 14 entries the first 10 are engine data parameters and Selecting Sub Menus the last four are sub menu entry points Press either the UP or DOWN switch until the top line Accessing the Menus of the display shows the label of the desired sub menu Then press BOTH the UP and DOWN The following two rules are used for accessing the switches at the same time This action will select the various items on the menus sub menu and the next screen on the display will list the sub menu items This is also the way to access 1 To scroll through the parameter list press either diagnostic trouble codes DTCs the UP or DOWN touch switch 2 To select or exit a sub menu simultaneously press the UP and DOWN switches DPSG QUOD007 2841 19 27JUL06 2 2 16 11 080706 PN 57 Instrument Panel Elect Cont Earlier Engines Changing Units of Measure English or Metric Line 1 shows the current units designation M Metric E English Line 2 shows the current units designation full text Line 1 shows the current units designation M Metric E English Line 2 shows the alternate units selection Line 1 shows the current units designation M Metric E English Line 2 shows the alternate units selection The diagnostic gauge can display engine data in either English or Metric units To toggle between these the Units Sub Me
61. zinc flake coating Dry means plain or zinc plated without any lubrication or 1 4 to 3 4 in fasteners with JDM F13B zinc flake coating 55 7 TORQ1 19 24APR03 1 1 080706 PN 234 Specifications Metric Bolt and Screw Torque Values Class 4 8 Lubricated Lubricated 0 lt ro lal oo p3 oh N P NO Sz oO ine i ol NO D gt N N ok O gt N NO JIN ao oOo oO O1 i o o o o O1 N O fay p a O1 oO 0 M N O i O pay O BN NO olna oO OlKIoO o SS ae ee SI po on N olan Oo co p O O1 s O1 D O NO D O1 oo N O1 NO N O1 D N O1 oo n i o R IN N gt O o1 O11 O oO oO oo N O1 O O1 O fay 00 O ee NO O N O O s N O O O1 oO O ie oO 850 145 1075 2250 1650 285 Torque values listed are for general use only based on the strength of the bolt or screw DO NOT use these values if a different torque value or tightening procedure is given for a specific application For stainless steel fasteners or for nuts on U bolts see the tightening instructions for the specific application Tighten plastic insert or crimped steel type lock nuts by turning the nut to the dry torque shown in the chart unless different instructions are given for the specific application a O O1 ak ek Ol oO
62. 0 1 1 05 8 080706 PN 23 Safety Install Fan Guards Rotating cooling system fans can cause serious injury Keep fan guards in place at all times during engine operation Wear close fitting clothes Stop the engine and be sure fan is stopped before making adjustments or connections or cleaning near the front of the engine TS677 UN 21SEP89 Rotating Fan OUOD006 000009D 19 27JUL06 1 1 Avoid Hot Parts Avoid skin contact with exhaust manifolds turbochargers and mufflers Keep flammable materials clear of the turbocharger External dry exhaust parts become very hot during operation Turbochargers and exhaust manifolds may reach temperatures as high as 600 C 1112 F under full TSS TRTE load This may ignite paper cloth or wooden materials b Parts on engines that have been at full load and reduced ae to no load idle will maintain approximately 150 C 302 F TS271 UN 23AUG88 Hot Surface OURGP12 0000135 19 27JUL06 1 1 05 9 080706 PN 24 Safety Avoid Harmful Asbestos Dust Avoid breathing dust that may be generated when handling components containing asbestos fibers Inhaled asbestos fibers may cause lung cancer Components in products that may contain asbestos fibers are brake pads brake band and lining assemblies clutch plates and some gaskets The asbestos used in these components is usually found in a resin or sealed in some way Normal handling is not hazardous as
63. 0 14 High Pressure Common Rail 40 17 VP44 pUMp once ees CE a oe ee a 40 12 4045DF TF270 cadacadnadadaawegegaga ae 40 19 Blink codes Bosch VP44 pump 0005 45 24 High Pressure Common Rail 45 26 Reading DTCs 0 00 ee eae 45 18 Break in engine Ol 1 0 0 2 00000 eae 10 5 Break in engine Except 4045DF TF270 19 1 4045DF TF270 wr 66 boo 6 bee oo Ke nee ows 20 2 C Chart service interval 21 2 21 4 Check and adjust Valves all except 475 engines 35 9 Valves 475 engines 06 35 12 Check engine electrical ground 30 16 Index 1 Page Cold weather aids 00005 35 15 Except 4045DF TF270 scene aap one ender 19 9 404A5DF TF270 ecae tauaeee dee aes ak 20 6 Compressor aif 0 0 ee ee 40 11 Configuration data viewing earlier engines 16 14 Configuration data viewing later engines 17 6 Coolant PAGQUING ssa oa 0 0 6 0 As aceencbeacaaks aoe a eae 40 3 Diesel engine 0 00 eee eee 10 13 DISPOSING e esras awe ees Ge ata ta daca 10 16 Replenishing supplemental additives 30 17 Supplemental additives 10 15 Testing naucesecnans soe se oe oe oe 10 15 30 19 Warm temperature climates 10 16 Cooling system Adding coolant 0000 ceca 40 3 CG so we sep op ee EE ae we eae ee er 30 16 US hs 5 ETET es eee ee ale 3070 Pressure TOS a se n n a
64. 0 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 bar 50 15 psi 50 15 psi 50 15 psi 50 15 psi 50 15 psi 50 15 psi Oil Pressure At Low Idle 103 kPa 103 kPa 103 kPa 103 kPa 103 kPa 103 kPa Minimum 15 psi 15 psi 15 psi 15 psi 15 psi 15 psi Length 860 mm 860 mm 860 mm 860 mm 1123 mm 1123 mm 33 9 in 33 9 in 33 9 in 33 9 in 44 2 in 44 2 in Width 612 mm 612 mm 612 mm 612 mm 623 mm 608 mm 24 1 in 24 1 in 24 1 in 24 1 in 24 5 in 23 9 in Height 856 mm 994 mm 994 mm 994 mm 1015 mm 1044 mm 33 7 in 39 1 in 39 1 in 39 1 in 40 0 in 41 1 in Weight 387 kg 451 kg 451 kg 451 kg 587 kg 587 kg 853 Ib 993 Ib 993 Ib 993 Ib 1290 Ib 1290 Ib OURGP11 0000089 19 27JUL06 2 2 55 2 080706 PN 229 Specifications Engine Power Ratings And Fuel System Specifications 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 TOAT cicaveupinticuces DERES IAR 12V assisas 36 48 2250 anaana B50 sssioseiinnski 2450 Mechanical TOI arae EEEE E a 24V aaao 36 48 2200 asaras BO
65. 11 000007D 19 27JULO06 1 1 080706 PN 124 Engine Operation 4 5 L 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 Reduce engine speed to slow idle variable speed governors only 2 Turn key switch A to OFF position to stop the engine After engine stops close valve on fuel supply to prevent accidental starting 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 3 Fill fuel tank to minimize possible water condensation problems Filling tanks at end of day drives out moisture laden air 20 10 RG6574B UN O7JANO3 RG13362 UN O6FEB04 Key Switch on Instrument Panel Later Engines OURGP11 0000134 19 27JUL06 1 2 RG10616 UN 16JUNO00 Exhaust Stack Rain Cap OURGP11 0000134 19 27JUL06 2 2 08070
66. 19DEC03 1 1 080706 PN 43 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 Improperly disposing of engine coolant can threaten the environment and ecology Use leakproof containers when draining fluids Do not use food or beverage containers that may mislead someone into drinking from them Do not pour waste onto the ground down a drain or into any water source TS1133 UN 26NOV90 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 27JUL06 1 1 10 16 080706 PN 44 Instrument Panel Identification Instrument Panels Identification The instrument panels shown compare the panel offered for mechanically controlled 270 series engines shown
67. 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 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 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 RG11812 UN 310CT01 RG11813 UN 310CT01 Continued on next page OUOD002 000016D 19 27JUL06 1 2 30 5 080706 PN 142 Lubrication amp 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 Specification New Belt Tension c cccecceeeeeeees 470 650 N 105 145 Ib force Used Belt Tension cceeeeeeeeees 400 580 N 90 130 Ib force JDG1520 Belt Tensioning Tool Torque Table Desired Belt Tension N Applied Torque Nem lb ft Ib force 445 100 108 90 489 110 115 85 85 122 90 623 140 135 100 4 While holding tension with torque wrench B scribe a reference mark D on alternator in line with notch E
68. 36 mm 0 36 mm 0 36 mm 0 36 mm 0 36 mm 0 36 mm 0 014 in 0 014 in 0 014 in 0 014 in 0 014 in 0 014 in Exhaust Adjusting 0 46 mm 0 46 mm 0 46 mm 0 46 mm 0 46 mm 0 46 mm 0 018 in 0 018 in 0 018 in 0 018 in 0 018 in 0 018 in Max Crank Pressure 0 5 kPa 0 5 kPa 0 5 kPa 0 5 kPa 0 5 kPa 0 5 kPa 2 H20 2 H20 2 H20 2 H20 2 H20 2 H20 Vibration Damper 1 50 mm 1 50 mm 1 50 mm 1 50 mm 1 50 mm 1 50 mm Maximum Radial Runout 0 060 in 0 060 in 0 060 in 0 060 in 0 060 in 0 060 in Battery Capacities CCA 12 Volt System 640 640 640 640 800 800 24 Volt System 570 570 570 570 570 570 Governor Regulation 7 10 7 10 7 10 7 10 7 10 7 10 Industrial Governor Regulation 5 5 5 5 5 5 Generator Thermostat Start To 82 C 82 C 82 C 82 C 82 C 82 C Open Temperature 180 F 180 F 180 F 180 F 180 F 180 F Thermostat Fully Open 94 C 94 C 94 C 94 C 94 C 94 C Temperature 202 F 202 F 202 F 202 F 202 F 202 F Coolant Capacity GoL 8 5 L 8 5 L SoL 11 3 L 11 3 L 9 qt 9 qt 9 qt 9 qt 12 qt 12 qt Recommended Radiator 70 kPa 70 kPa 70 kPa 70 kPa 70 kPa 70 kPa Pressure Cap 10 psi 10 psi 10 psi 10 psi 10 psi 10 psi Crankcase Oil Fill See Engine Crankcase Oil Fill Quantities later in this section Capacity Continued on next page OURGP11 0000089 19 27JUL06 1 2 55 1 080706 PN 228 Specifications ITEM 4045DF27
69. 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 Lubricant Storage Your equipment can operate at top efficiency only when clean lubricants are used Use clean containers to handle all lubricants Whenever possible store lubricants and containers in an area protected from dust moisture and other contamination Store containers on their side to avoid water and dirt accumulation DX ALTER 19 15JUN00 1 1 Make certain that all containers are properly marked to identify their contents Properly dispose of all old containers and any residual lubricant they may contain DX LUBST 19 18MAR96 1 1 1 0 1 1 080706 PN 39 Fuels Lubricants and Coolant Grease Use grease based on NLGI consistency numbers and the expected air temperature range during the service interval John Deere SD
70. 4 Thoroughly clean all dirt from inside housing and from outlet bore UN 08SEP00 RG11322A 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 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 UN 08SEP00 6 Install new primary filter element Apply pressure by hand at outer rim of filter RG11327A IMPORTANT Do NOT use latches on cover to force Secondary Filter Element filter into air cleaner Using cover to force filter will damage cleaner housing 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 RG41165 000008B 19 27JUL06 1 2 40 8 080706 PN 181 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 27JUL06 2 2 40 9 080706 PN 182 Service as Required Repl
71. 5 Engines A CAUTION To prevent accidental starting of engine while performing valve adjustments always disconnect NEGATIVE battery terminal IMPORTANT Valve clearance MUST BE checked and adjusted with engine COLD N 1 Remove rocker arm cover and crankcase ventilator E tube 5 Wa IMPORTANT Visually inspect contact surfaces of a valve tips bridges and rocker arm wear T pads Check all parts for excessive Flywheel Housing Timing Holes wear breakage or cracks Replace ap A Timing Rotation Hole parts that show visible damage 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
72. 6 PN 125 Engine Operation 4 5 L 270 Engines Using a Booster Battery or Charger A 12 volt booster battery can be connected in parallel with battery ies on the unit to aid in cold weather starting ALWAYS use heavy duty jumper cables CAUTION Gas given off by battery is explosive Keep sparks and flames away from battery Before connecting or disconnecting a battery charger turn charger off Make last connection and first disconnection at a point away from battery Always connect NEGATIVE cable last and disconnect this cable first TS204 UN 23AUG88 WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling IMPORTANT Be sure polarity is correct before making connections Reversed polarity will damage electrical system Always connect positive to positive and negative to ground Always use 12 volt booster battery for 12 volt electrical systems and 24 volt booster battery ies for 24 volt electrical systems RG4678 UN 14DEC88 1 Connect booster battery or batteries to produce the required system voltage for your engine application NOTE To avoid sparks DO NOT allow the free ends of jumper cables to touch the engine 2 Connect one end of jumper cable to the POSITIVE post of the booster battery RG4698 UN 14DEC88 3 Connect the other en
73. 6 Press the Menu key to exit the main menu and return 98 1000 RPH to the engine parameter display LOAD RPM ENG RPM 1800 RPM EXeGGI coo TEMP aly a Exit Main Menu RG13159 UN 26SEP03 OURGP11 0000237 19 27JUL06 6 6 Adjusting Contrast 98 1000 RPM LOAD RPM ENG RPM 1 Turn the key switch to the ON position Starting at the 1800 RPM single or four engine parameter display press the CIUIN Coot Temp ae gis Menu key Menu Key RG13159 UN 26SEP03 Continued on next page OURGP11 00000AF 19 27JULO6 1 6 17 15 080706 PN 78 Instrument Panel Elect Cont Later Engines 2 The main menu will be displayed Use the Arrow keys FAEERE to scroll through the menu until Adjust Contrast is STORED CODES highlighted ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT RG13161 UN 020CT03 Select Adjust Contrast OURGP11 00000AF 19 27JULO06 2 6 3 Once the Adjust Contrast menu item has been STORED CODES highlighted press the Enter key to activate the ENGINE CONFIG Adjust Contrast function SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT ADJUST CONTRAST Press Enter Key oe e Q O A 1 Zz 7 LO ee op 0 am OURGP11 00000AF 19 27JUL06 3 6 4 Use the Arrow keys to select the desired contrast intensity ADJUST CONTRAST Om io gt OOO Adjust Contrast Intensity Continued o
74. 80706 PN 75 RG13239 UN 29SEP03 Instrument Panel Elect The display will return to the single or four parameter display but the display will contain the Shutdown icon Pressing the Enter key will redisplay the hidden trouble code IMPORTANT Ignoring the shutdown message can result in severe engine damage 5 Pressing the Enter key once again will hide the trouble code and return the screen to the single or four parameter display 6 The single or four parameter screen will display the shutdown icon until the trouble code condition is corrected IMPORTANT Ignoring the shutdown message can result in severe engine damage Adjusting Backlighting 1 Turn the key switch to the ON position Starting at the single or four engine parameter display press the Menu key Cont Later Engines 0 1800 RPM eee COOL TEMP OCF OCOP Flashing Shutdown Icon 98 LOAD amp RPM 1000 RPM ENG RPM 57 PSI OIL PRES 14 2 BAT VOLT RG13179 UN 26SEP03 OURGP11 00000AE 19 27JUL06 4 6 SHUTDOWN SPN 100 FMI 1 FAULT ENGINE OIL PRESSURE LOW CORRECTIVE ACTION CHECK OIL LEVEL 1 of x lt NEXT gt aT Redisplay Trouble Code HIDE RG13239 UN 29SEP03 OURGP11 00000AE 19 27JUL06 5 6 o 1800 RPM ANE COOL TEMP BAT VOLT Shutdown Icon 98 LOAD amp RPM 1000 RPM ENG RPM 57 PSI OIL PRES 14 2 RG13180 UN 26SEP03 OURGP11 00000AE
75. 9 27JUL06 1 1 4 5 2 0 080706 PN 214 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 45 21 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 FMls using the following list determine the equivalent 2 digit code and have your dealer use the diagnostic procedure in the component technic
76. AY SELECT UNITS ADJUST BACKLIGHT e O Press Enter Key RG13189 UN 020CT03 OURGP11 00000BO 19 27JUL06 3 7 4 There are three choices for units of measurement ENGLISH English Metric kPa or Metric Bar English is for Imperial units with pressures displayed in PSI and temperatures in F Metric kPa and Metric bar are for IS units with pressures displayed in kPa and bar respectively and temperatures in C RG13190 UN 26SEP03 Use the Arrow keys to highlight the desired units of measurement Select Desired Units Continued on next page OURGP11 00000BO 19 27JULO6 4 7 17 18 080706 PN 81 Instrument Panel Elect Cont Later Engines 5 Press the Enter key to select the highlighted units ENGLISH METRIC KPA METRIC BAR RG13191 UN 30SEP03 Press Enter Key to Select OURGP11 00000B0 19 27JUL06 5 7 6 Press the Menu key to return to the main menu ENGLISH METRIC KPA METRIC BAR RG13192 UN 26SEP03 o O Return To Main Menu OURGP11 00000BO 19 27JUL06 6 7 7 Press the Menu key to return to the engine 98 TORP parameter display LOAD RPM ENG RPM 1800 RPM ERNE cool Temp 142 oLa Press Menu Key RG13159 UN 26SEP03 OURGP11 00000B0 19 27JUL06 7 7 17 19 080706 PN 82 Instrument Panel Elect Cont Later Engines Setup 1 Up Display 98 1000 RPM LOAD RPM ENG RPM 1 Turn the key switch to the ON position Starting at
77. EA Oil Sequence E6 e ACEA Oil Sequence E5 14 F e ACEA Oil Sequence E4 40F oP Extended service intervals may apply when John Deere z PLUS 50 ACEA E7 ACEA E6 ACEA E5 or ACEA E4 aC j 2AF i engine oils are used Consult your John Deere dealer for ae 7 more information se Other oils may be used if they meet one or more of the following e John Deere TORQ GARD SUPREME e API Service Category Cl 4 PLUS e API Service Category Cl 4 e API Service Category CH 4 e ACEA Oil Sequence E3 Multi viscosity diesel engine oils are preferred Diesel fuel quality and fuel sulfur content must comply with all existing emissions regulations for the area in which the engine operates DO NOT use diesel fuel with sulfur content greater than 1 0 10 000 ppm PLUS 50 is a trademark of Deere amp Company TORQ GARD SUPREME is a trademark of Deere amp Company DX ENOIL7 19 23NOV05 1 1 10 6 080706 PN 34 Fuels Lubricants and Coolant Diesel Engine Oil and Filter Service Intervals The oil and filter service intervals in the following charts should be used as guidelines Actual service intervals depend on operation and maintenance practices Use oil analysis to determine the actual useful life of the oil and to aid in selection of the proper oil and filter service interval Oil and filter service intervals are based on a combination of oil pan capacity type of engine oil and filter used and sulfur content of the diesel fuel Diesel fuel sulfu
78. ELAY SOLENOID 002 BAT 050 SPG B1i Analog Throttle F1 Fuse 30 Amp Harness G1 Alternator K1 Starter Relay M1i Starter Motor Ni Transient Voltage Protector P1i Optional Gauge P2 Optional Gauge 050 SPG SE 2 INSTRUMENT PANEL CONTINUED P3 Oil Pressure Gauge P4 Coolant Temperature Gauge P5 Tachometer Display P6 Hour Meter Diagnostic Gauge 1 Ignition Key Switch S2 Speed Select Switch Momentary S3 Bump Enable Switch Momentary S4 High Low Speed Select Switch S5 Override Shutdown Switch Momentary V1 Diode X1 Vehicle Harness Connector 45 9 X2 Alternator Harness Connector X3 Single Point Ground X4 CAN Terminator X5 Analog Throttle Connector RG13272 UN 26JAN04 OURGP11 0000272 19 27JUL06 1 1 080706 PN 203 Engine Troubleshooting Symptom Engine cranks but will not start Troubleshooting Problem Incorrect starting procedure No fuel Exhaust restricted Fuel filter plugged or full of water Injection pump not getting fuel or air in fuel system Faulty injection pump or nozzles Continued on next page Solution Verify correct starting procedure Check fuel in tank Check and correct exhaust restriction Replace fuel filter or drain water from filter Check fuel flow at supply pump or bleed fuel system Consult authorized diesel repair station for repair or replacement RG RG34710 5608
79. ELAY SOLENOID 002 BAT C BEFA A F EB A F A HE DC mM WO Ww S my LO o T Ay N sty oO Ay N LO st st my Qo SHIELDED PAIR g O Z T F T g oc oc O Bi 4 lt S lt y O a Ee E a H oj o T N lt q al YN a q q q oo 4 A Al a 4 a A co co N n 050 SPG 050 SPG SE 2 INSTRUMENT PANEL CONTINUED B1 Analog Throttle or N1 fTransient Voltage S1 lgnition Key Switch V1 Diode Emulator Protector S2 Speed Select Switch X1 Vehicle Harness E1 Back Light Regulator N2 Voltage Regulator for Momentary Connector 24V or Plug 12V 24V Operation S3 Bump Enable Switch X2 Alternator Harness F1 Fuse 10 Amp for Pi Optional Gauge Momentary X3 Single Point Ground harness P2 Optional Gauge S4 High Low Speed Switch X4 CAN Terminator F2 Fuse 5 Amp for P3 Oil Pressure Gauge 5 Override Shutdown X5 Analog Throttle instrument panel P4 Coolant Temperature Switch Momentary Connector G1 Alternator Gauge S6 Dimmer Control or X6 Remote On Off Plug K1 Starter Relay P5 Tachometer Display Jumper Plug M1 Starter Motor P6 Hourmeter Diagnostic Meter RG10040 19 18MAY99 OURGP11 0000270 19 27JUL06 1 1 45 7 080706 PN 201 Troubleshooting Engine Wiring Diagram With Later Full Featured Electronic Instrument Panel 464 OVERRIDE SHUTDOWN RETURN X1 020 CAN SHIELD 904 CAN H 905 CAN L 012 IGN 12V OR 24V 412 ACC
80. GP11 00000B2 19 27JULO6 14 14 17 31 080706 PN 94 Instrument Panel Mech Cont 270 Engines Instrument Panel Earlier 4 5 L 270 Engines 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 IMPORTANT Any time an electric gauge or meter does not register correctly replace it with a new one Do not attempt to repair it Following is a brief description of the components on a basic instrument gauge panel A Tachometer with Hourmeter The optional tachometer with hourmeter indicates engine speed in revolutions per minute rom 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 the preheater for cold weather star
81. I is also locked to prevent accidental changes in operating speed Pressing upper or lower half of switch H will unlock or enable the bump speed switch to take effect using speed select switch l I Speed Select Rocker Switch The speed select switch I is used to bump engine speed up or down in small increments during operation This switch must be used with the bump speed enable switch H in the unlocked position top or bottom half of button depressed J High Low Speed Select Rocker Switch The high low speed select switch J is used to set the engine operating speeds at slow turtle or fast rabbit Factory preset idle speeds can also be adjusted using bump speed enable switch H with speed select switch l The basic instrument panel will have the high low speed select switch only Press and hold up or down to adjust engine speed as desired The engine speed selected will not be held in the memory To adjust engine speeds See Changing Engine Speeds in Section 18 Continued on next page OURGP11 0000073 19 04AUG06 2 3 1 1 2 080706 PN 65 Instrument Panel Elect Cont Later Engines How To Select Preset Operating Speeds Bump Speeds First select Turtle Slow or Adj by pressing speed select switch J to Turtle slow or Adj center Then you can press either the upper or lower portion of the bump speed enable switch H to unlock the setting The bump speed enable must
82. IC TROUBLE CODE PROCEDURE later in this section RG RG34710 5605 19 27JULO06 1 1 080706 PN 195 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 Precautions for Electrical System When Steam Cleaning Engine IMPORTANT Do not steam clean any electrical or electronic components while steam cleaning the engine as it could damage sensitive parts 45 2 OUOD002 000016B 19 27JUL06 1 1 OURGP11 000012A 19 27JUL06 1 1 080706 PN 196 Troubleshooting Engine Wiring Layout Electronic Fuel System With Stanadyne DE10 Injection Pump sone x om air d Teed os FF SA Bn esa fi Naad aA PASEET a eAtetaen at Mey nO O me r Ps A p aM a os nent O a S lt ss is Z UN Le e g O oc A Coolant Temperature G Starter Relay Connector M Remote ON OFF R Engine Wiring Harness Se
83. LANT SPECIFICATIONS in Fuels Lubricants and Coolant section e 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 Engine oil pressure should be at least 103 kPa 1 03 bar 15 psi at slow idle and should reach at least 241 kPa 2 41 bar 35 psi at rated speed under full load 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 20 1 RG13343 UN 24NOV03 RG13359 UN O6FEB04 Instrument Panel Later 4 5 L 270 Engines OURGP11 000007A 19 27JUL06 1 1 080706 PN 116 Engine Operation 4 5 L 270 Engines Break In Service Before starting fill engine with seasonal viscosity grade
84. O sanra 2450 Controls TOAN weet caters eenenr ee 12N eee 60 80 2500 aasan GOW sanaan 2700 Le E S S E 24V aan 60 80 2500 850 scesansesincevens 2700 MOGUL ann E S 12V saisis 55 74 o eceeeee 2500 COU cenutupasnesans 2700 TOAN aenga A OAV sosa 55 74 o eeeeee 2000 sasise GOU cae 2700 TOZO nan AE 12N asrasa 50 67 sisis 1800 o n 1400 nieesesnnnnn 1870 TOAD aee S easeanaues T N pn 50 67 oaa 19000 siisii 1400 sics 1870 TOAG asrasin o aR E 24V aaaea 50 67 oaan 1800 1400 ee 1870 4045TF270 MODY pea A 12V asa 74 99 oo 2000 sssicani OOU sars 2700 Mechanical TOAN ccitediethoiva SA PAV soais 74 99 ou 2500 a n OOO arianna 2700 Controls TOAD a a enero TAV Seen 74 99 2200 aias BOO saia 2400 TOAL seian PANEER AEA 24V ee 74 99 annn 2200 850 naaaoosoosesenn 2400 163N 164X aaao ceesnsnensieraanandanianicndensioscmes 12V aaan 74 99 0 0 1800 nanana 1400 oiana 1870 1O4 e EA PAV ssi 74 99 ooann 1800 o an 1400 srr 1870 TEAR csreissnikisss oneni ena 12V sess 63 84 n n 2500 850 scnscnteancexsces 2700 TOI a A 24V aaaiannn 63 84 n 0 2500 a n 850 aiaee 2700 4045TF275 161K 1639H siss VAG E EAE AE E A eee 86 115 siss 2500 a n 800 scesaceicxicves 2700 16 1L 1636 scs yae E EE BAN asiaa 86 115 ez 2500 nanana BOOS rna 2700 161K 163H 7290 sireucatcrasieemtne 12V saisis 82 110 2400
85. P DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT Select Stored Codes RG13168 UN 020CT03 Continued on next page OURGP11 00000AC 19 27JULO6 2 6 17 8 080706 PN 71 Instrument Panel Elect Cont Later Engines 3 Once the Stored Codes menu item has been GO TO 1 UP DISPLAY highlighted press the Enter key to view the stored STORED CODES codes ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT TT Enter Key RG13169 UN 020CT03 OURGP11 00000AC 19 27JUL06 3 6 4 If the word Next appears above the Arrow keys dofx there are more stored codes that may be viewed Use SPN 94 FMI 18 the Arrow key to scroll to the next stored code BoT FUEL DELIVERY PRESSURE CORRECTIVE ACTION CHECK FUEL FILTER AND LINES lt NEXT gt OCPO Use Arrow Keys To Scroll RG13245 UN 02O0CT03 OURGP11 00000AC 19 27JUL06 4 6 5 Press the Menu key to return to the main menu dofx SPN 110 FMI 16 FAULT ENGINE COOLANT TEMERATURE HIGH CORRECTIVE ACTION CHECK COOLING SYSTEM REDUCE POWER lt NEXT gt HIDE T Return To Main Menu RG13246 UN 02O0CT03 Continued on next page OURGP11 00000AC 19 27JUL06 5 6 17 9 080706 PN 72 Instrument Panel Elect Cont Later Engines 6 Press the Menu key to exit the main menu and return 98 T000 RPN to the engine parameter display LOAD RPM ENG RPM 1800 RPM COOL TEMP 14 2
86. POLYUREA GREASE is preferred The following greases are also recommended NLGI Number 2 e John Deere HD LITHIUM COMPLEX GREASE e John Deere HD WATER RESISTANT GREASE e John Deere GREASE GARD le John Deere GREASE GARD a lt 2 3 6 j sS oO 5 a F QF D J T mE o 2 c 8 6 Oo ec A 6 J John Deere HD WATER RESISTANT NLGI Number 1 Other greases may be used if they meet the following k NLGI Number 0 NLGI Performance Classification GC LB IMPORTANT Some types of grease thickeners are not compatible with others Consult your grease supplier before mixing different types of grease TS1673 UN 310CT03 GREASE GARD is a trademark of Deere amp Company DX GREA1 19 07NOV03 1 1 1 0 1 2 080706 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 If protection at lower temperatures is required consult your John Deere dealer for recommendations John Deere COOL GARD Prediluted Coolant is preferred for service John Deere COOL GARD Prediluted Coolant is available in a concentration of either 50 ethylene glycol or 55 propylene glycol Additional recommended coolants The following engine coolant is also recommended e John Deere COOL GARD Coolant Concentrate in a 40 to 60 mixture of concentrate with qu
87. POWERTECH 4 5 and 6 8 L 4045 and 6068 Tier 2 Stage Il OEM Diesel Engines OPERATOR S MANUAL POWERTECH 4 5 and 6 8 L Tier 2 Stage Il 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 defects and other reproductive harm If this product contains a gasoline engine A 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 Tier 2 Stage Il emission certified engines Saran built France Tier 2 Mechanically Controlled Engines e CD4045DF270 e CD4045TF270 Saran built France Tier 2 Electronically Controlled Engines e CD4045TF275 CD4045HF275 CD4045HF475 CD6068TF275 CD6068HF275 CD6068HF475 DE10 Fuel System DE10 Fuel System HPCR System 4 Valve Head DE10 Fuel System DE10 VP44 Fuel System HPCR System 4 Valve Head NON ae Torreon built Mexico Tier 2 Mechanically Controlled Engines e PE4045DF270 e PE4045TF270 Torreon built Mexico Tier 2 Electronically Controlled Engines e PE4045TF275 DE10 Fuel System PE4045HF275 DE10 Fuel
88. 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 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 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 01 4 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
89. System PE4045HF475 HPCR System 4 Valve Head PE6068TF275 DE10 Fuel System PE6068HF275 DE10 VP44 Fuel System Emission certified for United States as EPA Tier 2 and for European Union as Stage II e 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 operators manual applies only to the engine and those options available through the John Deere
90. 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 475 EngineS 0 0c cee eee 45 26 Error Codes Displayed With Early Electronic Panels 1s ee aneene aus na d an 45 28 Intermittent Fault Diagnostics With PICCIFONIC COMMONS ous s rarawe acne ads 45 29 Displaying Diagnostic Gauge Software Later EngineS 000000 eae 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 55 1 Engine Power Ratings And Fuel System Specifications x ccseceee we eed tence waned 55 3 Engine Crankcase Oil Fill Quantities 55 6 Unified Inch Bolt and Screw Torque Values 55 7 Metric Bolt and Screw Torque Values 55 8 lil 080706 PN 3 Contents iV 080706 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 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 valv
91. T DO NOT apply excessive pressure to cooling system doing so may Test Radiator Cap damage radiator and hoses 3 Connect gauge and adapter to radiator filler neck Pressurize cooling system to specification listed for 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 4 With pressure applied check all cooling system hose connections radiator and overall engine for leaks If gauge does not hold pressure replace radiator If leakage is detected correct as necessary and oar pressure test system again Specification a Radiator Cap Holding Pressure If no leakage is detected but the gauge indicated a Not Opening For 10 drop in pressure coolant may be leaking internally SECONAS PYESSULE scccceeceeeeeeeeeaeeeees 70 kPa 0 7 bar 10 psi within the system or at the block to head gasket Have your engine distributor or servicing dealer 3 Remove the Cap from Qauge turn it 180 and correct this problem immediately retest cap This will verify that the first measurement was accurate OURGP11 0000220 19 27JUL06 1 1 3 0 2 0 080706 PN 157 Lubrication amp Maintenance 500 Hour 12 Month Checking and Adjusting Engine Speeds If equipped with a tachometer A on the instrument panel observe tachometer reading to verify engine speeds Refer
92. Test charging system Check for moisture and replace as necessary Test battery Test charging system Clean and tighten connections See your authorized servicing dealer or engine distributor Adjust belt tension or replace belts Disengage PTO Clean and tighten loose connections See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor Replace fuse See your authorized servicing dealer or engine distributor Use proper viscosity oil Clean and tighten loose connections RG RG34710 5608 19 27JUL06 7 8 080706 PN 210 Troubleshooting Symptom Problem Starter and hour meter functions rest of electrical system does not function Entire electrical system does not function Sulfated or worn out batteries Blown main system fuse Blown fuse on magnetic switch Faulty battery connection Solution Replace fuse Clean and tighten connections See your authorized servicing dealer or engine distributor Replace fuse RG RG34710 5608 19 27JUL06 8 8 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 bl
93. UN 020CT03 Continued on next page OURGP11 00000B2 19 27JULO06 3 14 17 27 080706 PN 90 Instrument Panel Elect Cont Later Engines 4 Two options are available for the 4 Up Display USE DEFAULTS a Use Defaults This option contains the following CUSTOM SETUP engine parameters for display Engine Speed Battery Voltage Coolant Temperature and Oil Pressure Custom Setup This option contains a list of engine parameters Engine parameters from this list can be selected to replace any or all of the default parameters RG13244 UN 020CT03 Select Factory Defaults OURGP11 00000B2 19 27JUL06 4 14 5 To reset the display parameters to the factory defaults scroll to and highlight Use Defaults Press the Enter key to activate the Use Defaults function A message RESTORED TO indicating the display parameters are reset to the DEFAULTS factory defaults will be displayed then the display will return to the Setup 4 Up Display menu Restored To Defaults cD A LUI ie bs il Z D l D lt mM oc OURGP11 00000B2 19 27JUL06 5 14 6 Custom Setup To perform a custom setup of the USE DEFAULTS 4 Up Display use the arrow buttons to scroll to and CUSTOM SETUP highlight Custom Setup on the display RG13227 UN 26SEP03 OOG Custom Setup Continued on next page OURGP11 00000B2 19 27JUL06 6 14 17 28 080706 PN 91 Instrument Panel Elect
94. URGP11 000012B 19 27JUL06 2 4 3 Once Utilities is highlighted press Enter to activate the utilities function STORED CODES ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY UTILITIES m O O O N T Z l N m N m CE Select Utilities OURGP11 000012B 19 27JUL06 3 4 4 Scroll to the Software Version Press Enter to view the software version Press the menu button twice to return to the main menu SOFTWARE VERSION JD X XX Software Version RG13236 UN 130CT03 OURGP11 000012B 19 27JUL06 4 4 4 5 3 0 080706 PN 224 Storage Engine Storage Guidelines 1 John Deere engines can be stored outside for up to 4 John Deere engines expected to be stored more three 3 months with no long term preparation IF than six 6 months MUST have long term storage COVERED BY WATERPROOF COVERING No preparation See PREPARING ENGINE FOR outside storage is recommended without a LONG TERM STORAGE later in this section waterproof covering Long term storage includes the use of a stabilized John Deere engines can be stored in a standard rust preventive oil to protect internal metal overseas shipping container for up to three 3 components of the engine This oil should be an months with no long term preparation SAE 10 oil with 1 4 percent morpholine or equivalent vapor corrosion inhibitor These rust John Deere engines can be stored inside for up to preventive oils are av
95. X ALERT 19 29SEP98 1 1 Understand Signal Words 4A DANGER A signal word DANGER WARNING or CAUTION is used with the safety alert symbol DANGER identifies the most serious hazards DANGER or WARNING safety signs are located near A WARNING specific hazards General precautions are listed on m O fap CAUTION safety signs CAUTION also calls attention to ji A CAUTION 3 safety messages in this manual DX SIGNAL 19 03MAR93 1 1 Follow Safety Instructions Carefully read all safety messages in this manual and on your machine safety signs Keep safety signs in good condition Replace missing or damaged safety signs Be sure new equipment components and repair parts include the current safety signs Replacement safety signs are available from your John Deere dealer Learn how to operate the machine and how to use controls properly Do not let anyone operate without instruction TS201 UN 23AUG88 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 0 5 E 1 080706 PN 16 Safety Replace Safety Signs Replace missing or damaged safety signs See the machine operator s manual for correct safety sign placement TS201 UN 23AUG88 DX SIGNS1 19 04JUN90 1 1
96. acing Fan and Alternator Belts 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 2 To replace belt with automatic tensioner release tension on belt using a breaker bar and socket on tension arm RG11950 UN O7NOVO1 290 mm 11 4 in Fan Height and Lower To replace belt with manual tensioner release tension at belt tensioner See MANUAL BELT TENSIONER CA ADJUSTMENT in Lubrication and Maintenance 500 Hour 12 Month Section 3 Remove poly vee belt from pulleys and discard belt bearings Rotate and feel for hard turning or any unusual sounds If pulleys or bearings need replacement see your John Deere dealer NOTE While belt is removed inspect pulleys and CSP 4 Install new belt making sure belt is correctly seated in all pulley grooves Refer to belt routing at right for your application 338 mm 13 3 in Fan Height and Higher Without Freon Compressor RG11951 UN O7NOVO1 5 Apply tension to belt with tensioner Remove socket 6 Install fan guard if removed oS 7 Start engine and check belt alignment C O Measured from crank centerline to fan drive center A Alternator Ce CSP Crankshaft Pulley FC Freon A C Compressor FD Fan Drive I Idler Pulley T Tension
97. actory preset idle speeds can also be adjusted Fo 3 using bump speed enable switch O with speed select By gt switch P 2 q o0 Y w 5 The three position switch has Slow turtle Middle Adj and Fast rabbit settings Slow turtle position is factory Peta E nnginee preset at low engine idle while middle ADJ position is factory set at high engine idle To adjust engine speeds See Changing Engine Speeds in Section 18 Continued on next page OURGP11 000027A 19 07AUG06 4 7 16 4 080706 PN 50 Instrument Panel Elect Cont 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 to prevent accidental changes in operating speed Pressing upper or lower half of switch O will unlock or enable the bump speed switch to take effect using speed select switch P 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 high low speed select switch N to turtle slow or rabbit fast Then you can press either the upper or l
98. ailable from area distributors six 6 months with no long term preparation OURGP12 00000DF 19 27JUL06 1 1 50 1 080706 PN 225 Storage 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 following recommendations for storing it and removing it from storage will help to minimize corrosion and deterioration 1 Change engine oil and replace filter See CHANGE ENGINE OIL AND FILTER in Lubrication and Maintenance 500 Hour Section Used oil will not give adequate protection Add one 1 ounce of rust preventive oil to the engine crankcase for every quart of oil This rust preventive oil should be an SAE 10 oil with 1 4 percent morpholine or equivalent vapor corrosion inhibitor 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 Coolant Section and ADDING COOLANT in Service As Required Secti
99. ainst the terminals to make measurements a 10 A EA Diagnosis of the Deere electronic control system on engines with Deere electronic instrument panel shown should be performed as follows 1 Make sure all engine mechanical and other systems not 5 related to the electronic control system are operating X properly NOTE L iquid Crysta Display L CD will a lways default to Trouble Code Display On Earlier Panel Left or Later Panel last menu item If an active Diagnostic Trouble Fignt Code DTC is present display will alternately A Diagnostic Gauge flash from the hour meter reading to DTC s 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 OURGP11 0000279 1
100. al 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 OQUOD002 1591 19 27JUL06 1 1 080706 PN 215 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 Third column below is for Blink Code retrieval method only Trouble Codes DTC s Listing in Ascending SPN FMI Codes SPN FMI Blink Codes Description of Fault 000028 03 13 Throttle Voltage High 04 14 Throttle Voltage Low 000029 03 15 Throttle Voltage High 04 16 Throttle Voltage Low 14 Throttle Voltage Out of Range 000084 31 Vehicle Speed Mismatch 000091 03 11 Throttle Voltage High 04 12 Throttle Voltage Low 07 Throttle Calibration Invalid 10 Throttle Voltage Low 13 Throttle Calibration Invalid 14 Throttle Voltage Out of Range 000097 00 Water in Fuel Input Voltage High 03 Water in Fuel Signal Voltage High 04 Water in Fuel Signal Voltage Low 16 Water in Fuel Detected 31 Water in Fuel Detected Condition Exists 000100 01 65 Engine Oil Pressure Extremely Low 03 23 Engine Oil Pressure Input Voltage High 04 24 Engine Oil Pressure Input Voltage Low 16 Engine Oil Pressure Reading Incorrect 18 64 Engine Oil Pressure Moderately Low 000105 03 20 Manifold Air Temperature Input Volta
101. al is every 250 hours 6 months or less If diesel fuel with a high sulfur content is used the oil and filter change interval is also reduced See DIESEL ENGINE fh OIL in the Fuels Lubricants and Coolant Oil Pan Drain Plug section RG4881 UN 29NOV88 A Oil Filter Element OILSCAN or OILSCAN PLUS is a John Deere sampling program to help you monitor machine performance and identify potential problems before they cause serious damage OILSCAN and OILSCAN PLUS kits are available from your John Deere engine distributor or servicing dealer Oil samples should be taken prior to the oil change Refer to instructions provided with kit To change engine oil and oil filter 1 Run engine approximately 5 minutes to warm up oil Shut engine off 2 Remove oil pan drain plug arrow PLUS 50 is a trademark of Deere amp Company OILSCAN is a trademark of Deere amp Company OILSCAN PLUS is a trademark of Deere amp Company Continued on next page OURGP11 000008C _ 19 27JULO6 1 4 30 7 080706 PN 144 Lubrication amp Maintenance 500 Hour 12 Month 3 Drain crankcase oil from engine while warm NOTE Drain plug location may vary depending on the application OURGP11 000008C 19 27JULO06 2 4 4 Turn filter element A using a suitable filter wrench to remove Discard oil filter element NOTE Depending on engine application oil filter may be located on either side of the engine in a high
102. al on rocker arm cover marked 16V BF or 24V ST REGULAMLY RG12220 UN 24MAY02 IMPORTANT Four valve cylinder head engines are especially sensitive to fuel er contamination Do not crack any fuel Final Fuel Filter Bleed Vent Screw lines to bleed the fuel system P A Bleed Vent Screw 1 Loosen the air bleed vent screw A two full turns by hand on fuel filter base OURGP11 000000F 19 27JUL06 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 4 Start engine and check for leaks If engine will not start repeat steps 1 4 B Primer Lever RG12221 UN 24MAY02 f n i Ma a Fuel Supply Pump Primer Lever OURGP11 000000F 19 27JUL06 3 3 40 18 080706 PN 191 Service as Required Bleed the Fuel System 4045DF270 4045TF270 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 X9811 UN 23AUG88 If ANY fluid is injected into the skin it
103. ality water John Deere COOL GARD coolants do not require use of supplemental coolant additives except for periodic replenishment of additives during the drain interval Other fully formulated coolants Other fully formulated low silicate ethylene or propylene glycol base coolants for heavy duty engines may be used if they meet one of the following specifications e ASTM D6210 prediluted 50 coolant e ASTM D6210 coolant concentrate in a 40 to 60 mixture of concentrate with quality water Coolants meeting ASTM D6210 do not require use of supplemental coolant additives except for periodic replenishment of additives during the drain interval Coolants requiring supplemental coolant additives COOL GARD is a trademark of Deere amp Company Other low silicate ethylene glycol base coolants for heavy duty engines may also be used if they meet one of the following specifications e ASTM D4985 ethylene glycol base prediluted 50 coolant e ASTM D4985 ethylene glycol base coolant concentrate in a 40 to 60 mixture of concentrate with quality water Coolants meeting ASTM D4985 require an initial charge of supplemental coolant additives formulated for protection of heavy duty diesel engines against corrosion and cylinder liner erosion and pitting They also require periodic replenishment of additives during the drain interval Other coolants It is possible that neither John Deere COOL GARD nor coolants meeting one of t
104. als 1 If equipped remove and clean crankcase vent tube A UN 19JUNO0 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 RG8017A A Crankcase Vent Tube Continued on next page OURGP11 000014F 19 27JULO06 1 2 30 9 080706 PN 146 Lubrication amp Maintenance 500 Hour 12 Month Closed Crankcase Ventilation System If Equipped 1 Inspect hoses C D and G for kinks blockage or other damage 2 Inspect check valve H for damage Valve is installed with black end toward crankcase 3 Verify that crankcase oil drain tube I is not plugged 4 Inspect CCV valve A for cracks or other damage 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 Fitting F Cap Screw CCV Valve to Bracket G Oil Drain Hose H Check Valve I Crankcase Oil Drain Tube 30 10 RG12426 UN 20NOV03 RG12427 UN 03FEB04 Closed Crankcase Vent OURGP11 000014F 19 27JUL06 2 2 080706 PN 147 Lubrication amp Maintenance 500 Hour 12 Month Checking Air Intake System IMPORTANT The air intake system must not leak Any leak no matter how small may result in internal engine damage due to abrasive dirt and dust entering the intake system 1 Inspect al
105. an functions have been set press the CUSTOM SETUP Menu key to return to the main menu AUTOMATIC SCAN ON Menu Key RG13224 UN 26SEP03 OURGP11 00000B1 19 27JUL06 17 18 19 Press the Menu key to exit the main menu and 98 000 RPH return to the engine parameter display LOAD RPM ENG RPM 1800 RPM EXEGRG coo Temp 142 a Exit Main Menu RG13159 UN 26SEP03 OURGP11 00000B1 19 27JUL06 18 18 Setup 4 Up Display 98 1000 RPM LOAD RPM ENG RPM 1 Turn the key switch to the ON position From the single 1800 RPM or four engine parameter display press the Menu Ee Coot TEMP oe ft key Menu Key RG13159 UN 26SEP03 Continued on next page OURGP11 00000B2 19 27JULO06 1 14 17 26 080706 PN 89 Instrument Panel Elect Cont Later Engines 2 The main menu will be displayed Use the Arrow keys feo 79 7 Up DISPLAY to scroll through the menu until Setup 4 Up Display is STORED CODES highlighted ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT OCHO Select Setup 4 Up Display RG13225 UN 02O0CT03 OURGP11 00000B2 19 27JUL06 2 14 3 Once the Setup 4 Up Display menu item has been GO TO 1 UP DISPLAY highlighted press the Enter key to activate the Setup JistoRED CODES 4 Up Display menu ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT Oc 0 Press Enter Key RG13226
106. and Maintenance 500 Hour 12 Month section OURGP11 0000081 19 27JUL06 4 4 Testing Thermostats Opening Temperature To Remove Thermostat s 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 TS281 UN 23AUG88 Visually inspect area around thermostat housing for leaks Remove radiator pressure cap and partially drain cooling system Remove thermostat cover to coolant pump tube A and seal A Cover To Coolant Pump Tube D Z lt e Ts l Z a RG8115A Thermostat Cover to Coolant Pump Tube DPSG RG34710 112 19 27JUL06 1 5 Remove thermostat cover B with gasket Remove thermostat s Remove and discard all gasket material Clean gasket surfaces Clean and check cover for cracks or damage UN 13NOV97 B Thermostat Cover RG7921A Continued on next page DPSG RG34710 112 19 27JULO6 2 5 35 6 080706 PN 164 Lubrication amp 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 A CAUTION DO NOT allow thermostat or thermometer to rest against the side or bottom of container when heating water Either may rupt
107. and or injection pump to avoid damage Using two open end wrenches loosen two fuel line connections at injection nozzles Crank engine over with starter motor for 15 seconds wed but do not start engine until fuel free from bubbles ae flows out of loosened connection Retighten connection Bleed At Fuel Injection Nozzles to specifications RG7725 UN O8JAN97 Specification Fuel Injection Nozzle Delivery Line Torque 27 Nem 20 lb ft 3 Repeat procedure for remaining injection nozzles if necessary until all air has been removed from fuel system OURGP11 000000E 19 27JUL06 3 3 40 13 080706 PN 186 Service as Required Bleed the Fuel System Engines with Electronic Fuel Systems and Stanadyne DE10 Pump 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 X9811 UN 23AUG88 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 amp Company Medical Department in Moline Illinois or other knowledgeable medical source Bleed the fuel system anytime
108. applications Third column below is for Blink Code retrieval method only Trouble Codes DTC s Listing in Ascending SPN FMI Codes SPN FMI Blink Code Description of Fault 000028 03 13 Throttle Volts High 04 14 Throttle Volts Low 000029 03 15 Throttle Volts High 04 16 Throttle Volts Low 000084 02 91 Vehicle Speed Mismatch 000091 03 11 Throttle Volts High 04 12 Throttle Volts Low 09 Throttle Invalid 000094 01 58 Fuel Supply Pressure Extremely Low 03 27 Fuel Supply Pressure Input Voltage High 04 28 Fuel Supply Pressure Input Voltage Low 18 57 Fuel Supply Pressure Moderately Low 000097 00 Water in Fuel Continuously Detected 16 Water in Fuel Detected 000100 01 75 Engine Oil Pressure Extremely Low 03 23 Engine Oil Pressure Input Voltage High 04 24 Engine Oil Pressure Input Voltage Low 18 74 Engine Oil Pressure Moderately Low 000105 00 56 Manifold Air Temperature Extremely High 03 25 Manifold Air Temperature Input Voltage High 04 26 Manifold Air Temperature Input Voltage Low 16 55 Manifold Air Temperature Moderately High 000107 00 Air Filter Differential Pressure 000110 00 63 Engine Coolant Temperature Extremely High 03 18 Engine Coolant Temperature Input Voltage High 04 19 Engine Coolant Temperature Input Voltage Low 15 61 Engine Coolant Temperature High Least Severe 16 62 Engine Coolant Temperature Moderately High 000111 01 64 Engine Coolant Level Low 000158 17 54 ECU Power Down Error 000174 00 67 Fuel Temperature High Mos
109. are hands Slowly loosen cap to first stop to relieve pressure before removing completely TS281 UN 23AUG88 IMPORTANT Never pour cold liquid into a hot engine as it may crack cylinder head or block DO NOT operate engine without coolant for even a few minutes John Deere TY15161 Cooling System Sealer may be added to the radiator to stop leaks DO NOT use any other stop leak additives in the cooling system Air must be expelled from cooling system when coolant is added Coolant level should be maintained to the bottom of the radiator filler neck A If needed as coolant as follows 1 Loosen temperature sending unit fitting at rear of cylinder head or plug in side of thermostat housing to allow air to escape when filling system IMPORTANT When adding coolant to the system use the appropriate coolant solution See ENGINE COOLANT SPECIFICATIONS in Radiator and Coolant Fuels Lubricants and Coolant Section for mixing of coolant ingredients before adding to cooling system RG13295 UN 20NOV03 A Radiator Filler Neck B Radiator Do not overfill cooling system A pressurized system needs space for heat expansion without overflowing at top of radiator 2 Fill radiator B until coolant level touches bottom of radiator filler neck A Continued on next page OURGP11 0000222 19 27JULO6 1 2 40 3 080706 PN 176 Service as Required 3 Tighten plugs and fittings when air has been expelled fro
110. ast 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 RG RG34710 5508 19 27JULO06 1 2 0 1 3 080706 PN 13 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 If option code label is lost or destroyed consult your servicing dealer or engine distributor selling the engine for a replacement Option Codes Description 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 Rocker Arm Cover Oil Fill Inlet Crankshaft Pulley Damper Flywheel Housing Flywheel Fuel Injection Pump Air Inlet Air Cleaner Oil Pan Coolant
111. ation 40 1 Do Not Modify Fuel System 40 2 Adding Coolant 0000 eee ees 40 3 Replacing Single Stage Air Cleaner 40 5 Replacing Axial Seal Air Cleaner Filter Element 264 445ennvseedceseee4oaeea ae 40 6 Replacing Radial Seal Air Cleaner Filter POMO peaccecudecaanuseeuagadaeu ees 40 8 Replacing Fan and Alternator Belts 40 10 Checking FuSeS 00 00 cece aes 40 11 Checking Air Compressors 40 11 Bleeding the Fuel System Engines With Electronic Fuel Systems And Bosch VP44 PUND ee ee ee ee ee ee ee ee 40 12 Bleed the Fuel System Engines with Electronic Fuel Systems and Stanadyne DE10 Pump nonna watac hans be Ree ee ee eo 40 14 Bleed the Fuel System Engines with Electronic Fuel Systems and Denso High Pressure Common Rail 4045HF475 6068HF475 0 ee 40 17 Bleed the Fuel System 4045DF270 4045TF270 1 ce ee eee 40 19 Troubleshooting General Troubleshooting Information 45 1 Precautions For Welding On Engines Equipped With Electronic Engine Control Unit EGU pc ese Fa uo a ae os era tare Aa 45 2 Precautions for Electrical System When Steam Cleaning Engine 45 2 Engine Wiring Layout Electronic Fuel System With Stanadyne DE10 Injection PUMP ceveoued yes ese shee eeaeeseoes 45 3 Engine Wiring Layout Electronic Fuel System With Bosch VP44 Injection Pump 45 4 Continued on next page 080706 PN 2
112. ation 0 0 0 0 0 cee ee ee 17 4 Main Menu Navigation 0 17 5 Engine Configuration Data 17 6 Accessing Stored Trouble Codes 17 8 Accessing Active Trouble Codes 17 10 Engine Shutdown Codes 17 12 Adjusting Backlighting 17 13 Adjusting Contrast 000005 17 15 Selecting Units Of Measurement 17 17 Setup 1 Up Display 17 20 Setup 4 Up Display 17 26 Instrument Panel Mech Cont 270 Engines Instrument Panel Earlier 4 5 L 270 Engines ee to Gio tn es yd gb ee HS ow B e ect 18 1 Instrument Panel Later 4 5 L 270 Engines 18 3 Engine Operation Except 4 5L 270 Engines Engine Break In Service 000 19 1 Starting the Engine ananuna a ate ee ate ee amp 19 4 Normal Engine Operation 19 7 Warming Engine 000 0c eee ee 19 8 Cold Weather Operation 19 9 Using a Booster Battery or Charger 19 11 Avoid Excessive Engine Idling 19 12 Changing Engine Speed 19 13 Stopping The Engine 19 16 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
113. auges On Earlier Panel speed Left or Later Panel Right RG13281 UN 3800CT03 A Engine Oil Pressure Gauge 1 Check oil pressure gauge A as soon as engine starts B Engine Coolant Temperature Gauge If gauge needle does not rise above minimum oil pressure specification of 105 kPa 1 05bar 15 0 psi within 5 seconds stop the engine and determine the cause Normal engine oil pressure is 345 103 kPa 3 45 1 03 bar 50 15 psi at rated full load speed 1800 2500 rpm with oil at normal operating temperature of 115 C 240 F NOTE On certain engines the oil pressure and coolant temperature gauges are replaced by indicator warning lights The lights must be OFF when engine is running 2 Watch coolant temperature gauge B Do not place engine under full load until it is properly warmed up The normal engine coolant temperature range is 82 94 C 180 202 F 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 OURGP11 0000137 19 27JUL06 1 1 1 9 8 080706 PN 106 Engine Operation Except 4 5L 270 Engines Cold Weather Operation 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 DO NOT use starting fluid near f
114. bel i e EngHrs and the bottom line displays the matching unit information i e 1246 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 OURGP11 0000072 19 27JUL06 2 2 1 6 9 080706 PN 55 Instrument Panel Elect Cont Earlier Engines Using Touch Switches to Display Information MAIN MENU of ENGINE LCD Display KEY EngHrs am am Load RPM FuelCons cba es F seras G Aly fal ama 0ilPress SrvcCode SENTE Press UD Aly am DM2Codes v PH Press UD i Aly flav Aly tial Throttle Units Press UD ee wia Aly am Aly faly ManifTmp E Config gt se Using Touch Switches Continued on next page 16 10 PARAMETERS LCD Display hd Touch Switches UP DOWN From SrvcCod SrvcCod o DM2Co des From E Config rom DM2Co des RG9947 19 09DEC99 DPSG QUOD007 2841 19 27JUL06 1 2 080706 PN 56 Instrument Panel Elect Cont Earlier Engines The touch switches on the diagnostic gauge allow Selecting Engine Data Parameters quick and easy navigation through the menu to find the information needed To read any of the engine parameters press either UP or DOWN switch as shown on diagram until the top The diagram on the preceding page is a
115. ble three position rocker switch A that can be used to select slow idle fast idle or an adjustable ADJ intermediate speed e For slow speed press lower half of rocker switch indicated by turtle symbol Continued on next page OURGP11 0000079 19 27JULO6 1 3 1 9 1 3 080706 PN 111 Engine Operation Except 4 5L 270 Engines e For fast speed press upper half of rocker switch indicated by rabbit symbol NOTE To adjust preset fast or slow speeds with adjustable High Low Speed Select Rocker Switch 1 Select middle position ADJ or slow turtle position on the optional Adjustable Three State Speed Select Rocker Switch A 2 Press and hold top or bottom half of Bump Speed Enable Rocker Switch B while using Speed Select Rocker Switch C 3 Use Speed Select Rocker Switch C to bump engine speed up or down NOTE Slow turtle position is factory preset at low engine idle while middle ADJ position is factory set at high engine idle NOTE Once the speed has been set the Bump Speed Enable Switch B must be pressed and released three times within two seconds to commit the new slow or fast soeed to memory If not done the engine s new slow or fast speed will only be effective until the key is shut off Then the speed will revert to its previous setting Changing engine speed using optional analog potentiometer throttle D NOTE Pushing in on analog potentiometer will immediately tak
116. blig d avoir recours a votre concessionnaire John Deere ou au point de service le plus proche pour vous adresser a lui Pour enregistrer votre moteur pour la garantie via Internet utilisez l adresse suivante http www johndeere com enginewarranty Renseignez vous des que possible pour l identifier et le localiser A la premiere occasion prenez contact avec lui et faites vous connaitre 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 nachstgelegenen John Deere Handler kennen zu lernen Zur Registrierung Ihres Motors f r die Garantie dient folgende Internet Adresse http www johndeere com enginewarranty Machen Sie sich bei ihm bekannt und nutzen Sie sein Service Angebot Proprietario del motore John Deere Non aspetti fino al momento di far valere la garanzia o di chiedere assistenza per fare la conoscenza del distributore dei motori John Deere o del concessionario che fornisce l assistenza tecnica Per registrare via Internet la garanzia del suo motore si collegi al seguente sito URL http www johndeere com enginewarranty Lo identifichi e si informi sulla sua ubicazione Alla prima occasione utile lo contatti Egli desidera fare la sua conoscenza e capire quali potrebbero essere le sue necessit Propietario De Equipo John Deere No espere hasta necesitar servici
117. ce The engine is ready for normal operation However extra care during the first 100 hours of operation will result in more satisfactory long term engine performance and life DO NOT exceed 100 hours of operation with break in oil 1 This engine is factory filled with John Deere ENGINE BREAK IN OIL SAE 10W 30 Operate the engine at heavy loads with minimal idling during the break in period RG8009 UN O6JAN99 If the engine has significant operating time at idle Check Engine Oil 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 OURGP11 0000075 19 27JULO6 1 4 19 1 080706 PN 99 Engine Operation Except 4 5L 270 Engines 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 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 oil or engine oils meeting any of the fo
118. ce 500 Hour Section Fill crankcase with seasonal viscosity grade oil See DIESEL ENGINE OIL in Fuels Lubricants and Coolant Section IMPORTANT DO NOT operate engine when oil level is below ADD mark on dipstick Check oil level before starting engine for the first time RG11616 UN 240CT01 Engine Oil Filter OURGP11 0000169 19 27JUL06 3 3 Auxiliary Gear Drive Limitations y Tes g a Cd 1 1 1 1 i K a a 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 eh poenncnnn2 e pmen r CPAN y sss a ate L iy e 30 kW 40 hp Continuous Operation at 2500 rom e 37 kW 50 hp Intermittent Operation at 2500 rom A Auxiliary Gear Drive UN 22JAN99 RG7634A Auxiliary Gear Drive RG RG34710 5555 19 27JULO06 1 1 20 3 080706 PN 118 Engine Operation 4 5 L 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 0 load for 30 minutes every 2 weeks DO NOT allow engine to run extended period of time with no load RG41183 000002F 19 27JUL06 1 1 Starting The Engine The controls and instruments for your engine may be d
119. ced 6 Cylinder engines with oil pan option codes 1907 1908 and 1909 require the oil to be changed at every 250 hours or less regardless of oil specification used Replace crankshaft damper every 4500 hours or 60 months whichever occurs first Continued on next page OURGP11 000007F 19 27JULO06 1 2 21 4 080706 PN 131 Lubrication and Maintenance bb rication and Maintenance Service Intervals tum evga ante tonne ZAMS AS Regios Every 2 Weeks 12 Months 24 Months As Required Check and Adjust Engine Valve Clearance Test Glow Plugs doasHFa7s oera O T Too Add Coolant a d S d O Replace Air Cleaner Elements FF Replace Fan and Alternator Belts FF Check Fuses d d d oO Check Air Compressor Equipped FF Bleed Fuel System FP S y OS OURGP11 000007F 19 27JUL06 2 2 21 5 080706 PN 132 Lubrication amp Maintenance Daily Daily Prestarting Checks Do the following BEFORE STARTING THE ENGINE for the first time each day IMPORTANT DO NOT add makeup oil until the oil level is BELOW the crosshatch marks on the dipstick 1 Check engine oil level on dipstick Add as required using seasonal viscosity grade oil See DIESEL ENGINE OIL in Fuels Lubricants and Coolant Section for oil specifications Depending on application oil may be added at left A or right B side oil filler cap and rocker arm cover filler cap C locations IMPORTANT DO NOT fill above the top mark on the dipstick Oil leve
120. ctions on label 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 Continued on next page DX FUEL10 19 16DEC05 1 2 1 0 4 080706 PN 32 Fuels Lubricants and Coolant If winterfronts are used they should never totally close the time the coolant reaches 93 C 200 F to prevent off the grill frontal area Approximately 25 area in the excessive intake manifold temperatures Manually center of the grill should remain open at all times At controlled systems are not recommended no time should the air blockage device be applied directly to the radiator core If air to air aftercooling is used the shutters must be completely open by the time the intake manifold air Radiator Shutters temperature reaches the maximum allowable temperature out of the charge air cooler If equipped with a thermostatically controlled radiator shutter system this system should be regulated in For more information see your John Deere dealer such a way that the shutters are completely open by DX FUEL10 19 16DEC05 2 2 Diesel Engine Break In Oil New engines are filled at the factory with John Deere e ACEA Oil S
121. cturer s DO ALL the services within an interval section service recommendations for Write the number of hours from your service servicing engine driven equipment records and the date in the spaces provided For a not supplied by Deere RG RG34710 5620 19 27JULO06 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 27JULO6 1 1 60 1 080706 PN 236 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 Check crankcase vent system 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 lf other than John Deere PLUS 50 or ACEA E7 ACEA E6 ACEA E5 or ACEA E4 engine oil and the specified filter are used the service interval for engine oil and filter is reduced see DIESEL ENGINE OIL AND FILTER INTERVALS chart 60 2 OURGP11 000008D 19 27JULO6 1 1 080706 PN 237 Lubrication and Maintenance Record
122. d of the jumper cable to the POSITIVE post of battery connected to starter 24 Volt System A 12 Volt Machine Battery ies 4 Connect one end of the other jumper cable to the B 12 Volt Booster Battery ies NEGATIVE post of the booster battery C Booster Cable D Cable to Starting Motor 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 RG RG34710 5564 19 27JULO06 1 2 20 11 080706 PN 126 Engine Operation 4 5 L 270 Engines 6 Start the engine Disconnect jumper cables immediately after engine starts Disconnect NEGATIVE cable first RG RG34710 5564 19 27JUL06 2 2 20 12 080706 PN 127 Lubrication and Maintenance Observe Service Intervals Using hour meter A on diagnostic gauge as a guide een perform all services at the hourly intervals indicated on SER following pages At each scheduled maintenance interval perform all previous maintenance operations in addition to ZEN the ones specified Keep a record of hourly intervals and bes services performed using charts provided in Lubrication and Maintenance Records section 6 y IMPORTANT Recommended service intervals are for i normal operating conditions Service SETEN O MORE OFTEN if engine is operated VS EN 410 under adverse conditions Neglecting E maintenance can result
123. d y Check Manual Belt Tensioner and Bet Wear e S S Change Engine Oil And Replace Oil Fites ooo o e S S Check Crankcase Vent System o e d S Check Air Intake Hoses Connections amp System o o e o S Replace Fuel Fiter Elements S e d l Check Automatic Belt Tensioner and Bet Wear Check Engine Electrical Ground Connection o e o S o Check Cooling System oo S S e l Coolant Solution Analysis Add SCAs as required e S S Pressure Test Cooling System Jooo y oO Check Engine Speeds fe Check Crankshaft Vibration Damper 6 8 L Engines o o Flush and Refill Cooling System a ie Test Thermostats o S S y Oo Check and Adjust Engine Valve Clearance FE aReplace primary air cleaner element when restriction indicator shows a vacuum of 625 mm 25 in H20 During engine break in change the oil and filter for the first time before 100 hours of operation lf the recommended engine oils John Deere PLUS 50 or ACEA E7 ACEA E6 ACEA E5 or ACEA E4 are not used the oil and filter change interval is reduced see DIESEL ENGINE OIL AND FILTER INTERVALS chart If diesel fuel with a sulfur content greater than 0 05 is used the oil and filter change interval is also reduced 6 Cylinder engines with oil pan option codes 1907 1908 and 1909 require the oil to be changed at every 250 hours or less regardless of oil specification used Replace crankshaft damper every 4500 hours or 60 months whichever occurs first elf John Deer
124. der liner erosion and pitting 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 COOLSCAN Or COOLSCAN PLUS leaks or overheating For a more thorough evaluation of your coolant Coolant Test Strips perform a COOLSCAN or COOLSCAN PLUS analysis See your John Deere dealer for information about Coolant test strips are available from your John Deere COOLSCAN or COOLSCAN PLUS dealer These test strips provide a simple effective method to check the freeze point and additive levels of your engine coolant OUOD002 0000175 19 27JUL06 1 1 3 0 E 1 9 080706 PN 156 Lubrication amp Maintenance 500 Hour 12 Month Pressure Testing Cooling System RG6557 UN 20JAN93 Test Radiator Cap RG6558 UN 20JAN93 Test Cooling System CAUTION Explosive release of fluids from Test Cooling System pressurized cooling system can cause serious burns NOTE Engine should be warmed up to test overall cooling system 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 1 Allow engine to cool then carefully remove radiator Cap 2 Fill radiator with coolant to the normal operating NOTE These tests apply only to John Deere level radiators For other brands see manufacturers Meria IMPORTAN
125. diator 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 13 Add coolant to radiator until coolant touches bottom of filler neck See specification for capacity Install radiator cap Specification 4 5 L Engine Coolant Capacity ccccceceeeeeeeeeeeeeeeenees 8 5 L 9 at 6 8 L Engine Coolant Capacity cscssseeeeereneeneenes 11 3 L 12 qt 14 Run engine until it reaches operating temperature This mixes the solution uniformly and circulates it through the entire system The normal engine coolant temperature range is 82 94 C 180 202 F 15 After running engine check coolant level and entire cooling system for leaks Fleetguard is a trademark of Cummins Engine Company Inc RESTORE is a trademark of Fleetguard RESTORE PLUS is a trademark of Fleetguard Continued on next page OURGP11 0000081 19 27JUL06 3 4 35 5 080706 PN 163 Lubrication amp Maint 2000 Hour 24 Month 16 Inspect the fan belt for wear and check belt tension See Checking Belt Tensioner Spring Tension and Belt Wear in Lubrication
126. e 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 OURGP11 000007E 19 27JULO06 1 2 21 2 080706 PN 129 Lubrication and Maintenance Co OOO ron and Maintenance Servic Intervals me o ee Daily 12 Month 24 Month As Required Test Glow Plugs 4045HF475 6068HFA75 Add Coolant ooo d S S S e y Replace Air Cleaner Elements Replace Fan and Alternator Bets Check Fuses ooo d S S e e S Check Air Compressor If Equipped rr ee eee ee eee Bleed Fuel System rs es E OURGP11 000007E 19 27JUL06 2 2 21 3 080706 PN 130 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 a Lubrication and Maintenance Service Intervals 500 Hours or 2000 Hours or Every 2 Weeks 12 Months 24 Months As Required Operate Engine at Rated Speed and 50 70 Load a Minimum of 30 Minutes Check Engine Oil and Coolant Level Check Fuel Filter Water Bow Lo l Check Air Cleaner Dust Unloader Valve amp Restric
127. e Error 001079 03 51 Sensor Supply 1 Voltage High 04 52 Sensor Supply 1 Voltage Low 001080 03 49 Fuel Rail Pressure Sensor Supply Voltage High 04 48 Fuel Rail Pressure Sensor Supply Voltage Low 001109 31 Engine Protection Shutdown Warning 001110 31 82 Engine Protection Shutdown 001347 03 79 Pump Return Shorted High 05 7 Pump Control Valve Error 07 78 Fuel Rail Pressure Control Error 001568 02 Torque Curve Selection Invalid 001569 31 Fuel Derate Continued on next page OURGP11 0000088 19 27JUL06 2 3 45 27 080706 PN 221 Troubleshooting SPN Blink Code Description of Fault 002000 Security Violation N A 32 When reading blink codes signifies the start of active codes N A 33 When reading blink codes signifies the start of stored codes N A 88 When reading blink codes signifies that no fault codes are in the buffer OURGP11 0000088 19 27JUL06 3 3 Error Codes Displayed With Early Electronic Panels NOTE The Diagnostic Gauge on the earlier 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 XXXXX EP No Data ACP Err XXXXX BO No Addr No Data ACP Err XXXXX BR BUS EP No Data NOTE Later instrument panels will display text for communication fa
128. e John Deere oil filter alf considering fuel with sulfur content over 0 50 5000 ppm contact your John Deere Dealer dealer to reference DTAC solution Continued on next page OURGP11 0000012 19 27JULO06 2 3 10 8 080706 PN 36 Fuels Lubricants and Coolant 6 8 L a Oil and Filter Service Intervals in Hours of Operation Oil Pan Option Codes a Sulfur Content 1907 1908 19AC ae 1 EE 1944 interval interval Interval Interval Interval 101 129 Less Than 0 05 500 ppm 500 500 500 250 500 35 173 PS 05 0 50 500 5000 0 05 0 50 500 5000 ppm 150 400 150 400 150 400 150 400 150 400 0 50 1 0 5000 10 000 ppm 138 185 ooet asos on sovo poni 1o es Po T sao T iso T aoo T iea on T i oo EO 175 250 1074 500018600 _ Than 0 05 500 ppm 375 375 500 500 250 500 e 235 0 05 0 50 500 5000 ppm 150 0 50 1 0 5000 10 000 ppm 125 175 125 175 125 250 125 250 125 250 T __ 0 05 0 50 500 5000 ppm 2 0 1 0 8000 10 000 pp a 272 0 05 0 50 500 5000 ppm 150 275 150 275 150 275 150 275 150 400 0 50 1 0 5000 10 000 ppm 234 314 Less Than 0 05 500 ppm 250 eee ee ee ee 0 50 1 0 5000 10 000 ppm Use of premium oil also requires use of an approved John Deere oil filter alf considering fuel with sulfur content over 0 50 5000 ppm
129. e eaw goa Goa ee eles 16 16 View active service codes later engines 17 10 View stored service codes earlier engines anaua naaa 16 17 View stored service codes later engines 17 8 E Emissions EPA Statement nanana anaana naaa 65 1 Engine Adjust speed anana anaana aaa 30 21 Break in except 4045DF TF270 19 1 Break in 4045DF TF270 20 2 Changing speed 00 cee eee 19 13 Check electrical ground 30 16 OUI sexes cia cette tt Ge nae nae eet rte ts ea 19 12 20 9 Operation except 4045DF ITF270 19 7 Operation 4045DF TF270 20 1 Option CODES sie cas cae ace ie be hee beeen 4 01 3 Serial number wea oe 6 4 G9 ow Pe ae es 01 1 Starting except 4045DF TF270 engine 19 4 Starting 4045DF TF270 engine 20 4 Stopping except 4045DF TF270 19 16 Stopping 4045DF TF270 20 10 Troubleshooting 0000e eae 45 10 Warming except 4045DF TF270 19 8 Warming 4045DF TF270 20 8 Engine Control Unit ECU serial number 01 5 Engine coolant Disposing Of acc kGrnceae ste ea 10 16 Engine mounts check 0 30 1 Engine oil Break n 2cet bt eceetetweeka tees e249 ea 10 5 Change n n nanana aaa 30 7 Service Intervals anaana anaa 10 7 Engine speed Changing sanaa aaaea 19 13 Engine wiring diagram W electronic instrument panel 45 6 E
130. e 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 Continued on next page OURGP11 0000079 19 27JULO6 2 3 1 9 1 4 080706 PN 112 Engine Operation Except 4 5L 270 Engines 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 loaded return to the center rest position Off To increase the engine speed press and hold upper half of rocker switch E indicated by rabbit symbol to increase or ramp up the engine speed to desired speed Release the rocker switch RG13289 UN 300CT03 od Changing Engine Speed With Basic Panel Press lower half of rocker switch indicated by turtle symbol to decrease or ramp down the engine speed to E High Low Speed Select Rocker Switch desired speed Release the rocker switch The settings will not be stored OURGP11 0000079 19 27JUL06 3 3 1 9 1 5 080706 PN 113 Engine Operation Except 4 5L 270 Engines Stopping The Engine 1 Disengage clutch if equipped controll
131. e ventilator tube Continued on next page DPSG RG41165 137 19 27JULO6 3 5 3 5 1 0 080706 PN 168 Lubrication amp Maint 2000 Hour 24 Month 4 Cylinder Engine NOTE Firing order is 1 3 4 2 1 Using JDE81 4 Timing Pin lock No 1 piston at TDC compression stroke B Adjust valve clearance on No 1 and 3 exhaust valves and No 1 and 2 intake valves Turn crankshaft 360 Lock No 4 piston at TDC compression stroke C RG4776 UN 310CT97 Cylinder Engine Valve Adjustment 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 27JULO06 4 5 6 Cylinder Engine NOTE Firing order is 1 5 3 6 2 4 Lock No 1 piston at TDC compression stroke B Adjust valve clearance on No 1 3 and 5 exhaust valves and No 1 2 and 4 intake valves Turn crankshaft 360 Lock No 6 piston at TDC compression stroke C RG4777 UN 310CT97 Adjust valve clearance on No 2 4 and 6 exhaust a a 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 27JULO6 5 5 35 11 080706 PN 169 Lubrication amp Maint 2000 Hour 24 Month Check and Adjust Valve Clearance 4045HF475 And 6068HF47
132. ed servicing dealer or engine distributor Have authorized servicing dealer or engine distributor check injectors See your authorized servicing dealer or engine distributor See your John Deere distributor or servicing dealer See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor Clean or replace fuel hose See your authorized servicing dealer or engine distributor Add oil Drain fill crankcase with oil of proper viscosity and quality RG RG34710 5608 19 27JUL06 4 8 080706 PN 207 Symptom High oil consumption Engine emits white smoke Engine emits black or gray exhaust smoke Troubleshooting Problem Crankcase oil too light Oil leaks Restricted crankcase vent tube Defective turbocharger Improper type of fuel Low engine temperature Defective thermostat Defective injection nozzles Defective glow plugs 4045HF475 6068HF475 Improper type of fuel Clogged or dirty air cleaner Engine overloaded Injection nozzles dirty Electronic fuel system problem Turbocharger not functioning Continued on next page 45 14 Solution Use proper viscosity oil Check for leaks in lines gaskets and drain plug Clean vent tube See your authorized servicing dealer or engine distributor Use proper fuel Warm up engine to norma
133. ed the Torreon Engine Serial Number Plate aspiration code as follows A for turbocharged with air to water aftercooler D for naturally aspirated H for turbocharged with air to air aftercooler T for turbocharged only On later engines after April 2005 the seventh digit will be as follows B for non certified engines C for Tier 1 Stage engines G for Tier 2 Stage Il engines L for Tier 3 Stage IIIA engines OURGP11 0000070 19 27JULO06 1 1 01 2 080706 PN 12 Record Keeping Engine Option Codes JOHN DEERE NUMBER CD6068H123456 6068HF 275 6 8 L ITIECD 1100 1200 1300 1400 1500 1600 1700 1800 1900 2100 2300 2400 2500 2700 2800 2900 3000 3100 3500 4000 4300 5200 5500 5600 5700 6000 6200 6400 6500 6600 7500 7600 8600 8700 8800 Order 2B0000000 000000 OPTION CODES AIA RG11946 UN O6NOV01 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 l
134. ee eee 10 6 Diesel Engine Oil and Filter Service Intervals 10 7 Mixing of Lubricants 0005 10 9 l FES o24 05 tee adorbeneneadas an anaes 10 10 OILSCAN and COOLSCAN 10 10 Alternative and Synthetic Lubricants 10 11 Lubricant Storage 2 0 00 ee ee 10 11 Grease nuana aaa 10 12 Diesel Engine Coolant 10 13 Drain Intervals for Diesel Engine Coolant 10 14 Supplemental Coolant Additives 10 15 Testing Diesel Engine Coolant 10 15 Operating in Warm Temperature Climates 10 16 Disposing of Coolant 0005 10 16 Instrument Panel Identification Instrument Panels Identification 15 1 Instrument Panel Elect Cont Earlier Engines Instrument Panel 2 0 00 c eee 16 1 Using Diagnostic Gauge to Access Engine Information 0 0 0 00 cee ee eee 16 8 Page Using Touch Switches to Display Information ec ast oes eee ee ee De DS 16 10 Changing Units of Measure English or VVC AG Nie sas ek EE E eve E O a ey ay e NE E Jade aoe Be A 16 12 Viewing Engine Configuration Data 16 14 Viewing Active Engine Service Codes Diagnostic Trouble Codes DTCs 16 16 Viewing Stored Service Codes Diagnostic Trouble Codes DTCs in the Engine ECU 16 17 Instrument Panel Elect Cont Later Engines Instrument Panels 20 0008 17 1 Using Diagnostic Gauge to Access Engine Inform
135. el control Right A Key Start Switch NOTE Engine control unit ECU reads the higher of the B High Low Speed Select Rocker Switch high low speed select rocker switch or the analog C Bump Speed Enable Rocker Switch throttle speed settings D Speed Select Rocker Switch E Analog Throttle Control Optional 7 Check all gauges for normal engine operation If operation is not normal stop the engine and determine the cause For normal gauge pressures and temperatures see BREAK IN SERVICE earlier in this section NOTE Hand throttle may have an analog potentiometer E for changing engine speeds See Changing Engine Speeds later in this section OURGP11 0000076 19 27JUL06 3 3 1 9 6 080706 PN 104 Engine Operation Except 4 5L 270 Engines Normal Engine Operation Observe engine coolant temperature and engine oil remove load and restart the engine pressure Temperatures and pressures will vary Overheating of the turbocharger between engines and with changing operating parts may occur when oil flow is conditions temperatures and loads stopped Normal engine coolant operating temperature range is Stop engine immediately if there are any signs of part 82 94 C 180 202 F If coolant temperature rises failure Symptoms that may be early signs of engine above 112 C 234 F reduce load on engine Unless problems are temperature drops quickly stop engine and determine cause before resu
136. element E Immediately replace secondary element with new element to prevent dust from entering air intake system 5 Install new primary element and tighten wing nut securely Install cover assembly and tighten retaining wing nut securely IMPORTANT Whenever the air cleaner has been serviced or had cover removed ALWAYS fully depress the air restriction indicator reset button if equipped to assure accurate readings 6 If equipped fully depress air restriction indicator reset button and release to reset indicator 40 7 RG4687 UN 20DEC88 RG4686 UN 20DEC88 RG11068 UN 26JUNO0 Retaining Nut and Secondary Element A Wing Nut B Primary Element C Dust Unloader Valve D Retaining Nut E Secondary Element OURGP11 000013A 19 27JUL06 2 2 080706 PN 180 Service as Required Replacing Radial Seal Air Cleaner Filter Element IMPORTANT ALWAYS REPLACE primary air cleaner element when air restriction indicator shows a vacuum of 625 mm 25 in H20 is torn or visibly dirty UN 08SEP00 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 RG11321A 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 3 Pull filter B off outlet tube and out of housing
137. ems 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 OURGP11 0000080 19 27JUL06 1 3 Checking Belt Wear The belt tensioner is designed to operate within the limit of arm movement provided by the cast stops A and B when correct belt length and geometry is used Visually inspect cast stops A and B on belt tensioner assembly a If the tensioner stop on swing arm A is hitting the fixed RG8098 UN 18NOV97 stop B check mounting brackets alternator belt A B tensioner idler pulley etc and the belt length Replace Sie belt as needed see REPLACING FAN AND Belt Tensioner Earlier Engines ALTERNATOR BELTS in Service As Required Section _ v a A Cast Stop B Cast Stop RG13744 UN 11NOV04 Continued on next page OURGP11 0000080 19 27JULO06 2 3 30 14 080706 PN 151 Lubrication amp Maintenance 500 Hour 12 Month Checking Tensioner Spring Tension A belt tension gauge will not give an accurate measure of the belt tension when automatic spring tensioner is used Measure tensioner spring tension using a torque wrench and procedure outlined below NOTE Later engines have a 12 7 mm 1 2 in square hole in tensioner so no socket drive is required 1 Release
138. equence E1 ENGINE BREAK IN OIL During the break in period add John Deere ENGINE BREAK IN OIL as needed to After the break in period use John Deere PLUS 50 maintain the specified oil level or other diesel engine oil as recommended in this manual Change the oil and filter after the first 100 hours of operation of a new or rebuilt engine IMPORTANT Do not use PLUS 50 oil or engine oils meeting any of the following After engine overhaul fill the engine with John Deere during the first 100 hours of ENGINE BREAK IN OIL operation of a new or rebuilt engine If John Deere ENGINE BREAK IN OIL is not available API Cl 4 PLUS API CF use a diesel engine oil meeting one of the following p a pes al during the first 100 hours of operation API CG 4 ACEA E5 API CF 4 ACEA E4 e API Service Classification CE API CF 2 ACEA E3 e API Service Classification CD e API Service Classification CC These oils will not allow the engine e ACEA Oil Sequence E2 to break in properly PLUS 50 is a trademark of Deere amp Company DX ENOIL4 19 19DEC05 1 1 10 5 080706 PN 33 Fuels Lubricants and Coolant Diesel Engine Oil 1220F Use oil viscosity base on the expected air temperature Naor range during the period between oil changes moe 86 F John Deere PLUS 50 oil is preferred ee E sr Oil meeting one of the following specifications are also D Ss So wo t recommended lt u 500F 5 an e ACEA Oil Sequence E7 320F lt lt e AC
139. er CP Coolant Pump 402 mm 15 8 in Fan Height With Freon Compressor RG11952 UN O7NOVO1 OURGP11 000013B 19 27JUL06 1 1 40 10 080706 PN 183 Service as Required Checking Fuses NOTE The instrument panels for later electronically 2 controlled engines as described in Section 17 do not have this fuse D 30 RaW x 140 97 2 we a a ges arian Check fuse A located in fuse holder on face of instrument panel If defective replace with a 5 amp fuse A separate wiring harness fuse 10 amp and a main system fuse 20 amp are shown in the Wiring Diagrams in the Troubleshooting Section RG11938 UN O6NOV01 Early Engines with Electronic Instrument Panel 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 A 5 Amp Fuse NOTE On 4045DF TF 270 engines refer to supplier s instructions and diagrams for fuse location and type OURGP11 000013C 19 27JULO06 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 spli
140. es are at lower left and upper right corners of manifold matching studs A Clean all gasket material from thermostat cover and housing mounting surfaces UN 06NOV97 Using guide studs A to keep gasket in place install a new gasket on cylinder head RG7614A Install thermostat s with jiggle wire facing up in the 12 o clock position Using a screwdriver to hold thermostat s in place install thermostat s and coolant manifold thermostat cover Tighten cover cap screws to 70 Nem 52 lb ft Lubricate new O ring with PT507 Multi Purpose Grease Install seal B in thermostat cover RG7921B UN 13NOV97 A Guide Studs Thermostat Cover Seal B Seal DPSG RG34710 112 19 27JULO6 4 5 Install coolant manifold thermostat cover to coolant pump tube C Tighten clamps If not already done fill cooling system and check for leaks IMPORTANT Air must be expelled from cooling system when filling Loosen temperature sending unit fitting at rear of cylinder head or plug in thermostat housing to allow air to escape when filling system Tighten fitting or plug t when all air has been expelled Cover To Coolant Pump Tube RG8115B UN 15JAN98 C Cover To Coolant Pump Tube DPSG RG34710 112 19 27JULO6 5 5 35 8 080706 PN 166 Lubrication amp Maint 2000 Hour 24 Month Check and Adjust Valve Clearance All Engines Except 4045HF475 And 6068HF475 ER r ry I kai s
141. es total POWER E CH 4 5 liter RG11608 UN 170CT01 POWERIECH 6 8 liter Q O N Z O O O X POWERTECH s a trademark of Deere amp Company OURGP11 0000274 19 04AUG06 1 1 Engine Serial Number Plate Each engine has a 13 digit John Deere engine serial number The first two digits identify the factory that produced the engine CD Saran France PE Torreon Mexico TO Dubuque lowa JO Rosario Argentina RG8007 UN 15JAN99 The engine s serial number plate A is located on the a right hand side of cylinder block behind the fuel filter 13 Digit Engine Serial Number Plate A Serial Number Plate RG RG34710 5506 19 27JUL06 1 1 01 1 080706 PN 11 Record Keeping Record Engine Serial Number JOHN DEERE Engine Serial Number Record all of the numbers and letters found on your engine serial number plate in the spaces provided below CD4045T123456 S O This information is very important for repair parts or warranty information z Engine Serial Number B S O oc Engine Model Number C Coefficient of Absorption Value D Saran Engines Only ed php NOTE Effective in April 2005 engine serial numbers PE4045TF275 g were changed at the 7th digit to show the 0 z Emission Level Previously this digit identified the DEERE amp COMPANY MOLINE ILLINOIS MADE IN MEXICO JS type of aspiration oa On earlier engines the 7th digit show
142. fan or accessories like air compressors 2Engine 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 OURGP11 000008A 19 27JULO06 1 3 55 3 080706 PN 230 Engine Model 4045HF275 4045HF475 4 Valve Head 6068TF275 6068HF275 Fuel System Option Codes 161F 163G 161G 163K 161G 163K 161F 163G 161G 163K 161J 163M 161H 163F 161J 163M 161H 163F 161J 163M 161H 163F 161J 163M 161H 163F 161J 163M 161H 163F 161J 163M 161H 163F 161J 163M 161H 163F 161H 163F 161H 163F 161N 163E 161Q 163J 161N 163E 161Q 163J TOYO usisne TOVE oesie 16YS 162B Electronic Software Option Codes 7201 7222 7230 7202 7223 7231 Specifications System Power Rated Voltage Rating Speed Rated Speed rpm kW hp 12V araia 117 157 ete 1800 24V woe 117 157 1800 24V woe 93 125 sss 2400 TAN uuris 99 133 1500 24V woe 99 133 1500 12V oni 129 173 2400 12y uainn 119 160 2200 12V anun 143 192 1800 12V cetesaacs 120 161 1500 PAN orem 123 165 ss 2400 12V aein 101 135 2200 24V naain 101 135 2200 12 canir 112 150 2200 DAN iustas 112 150 cece 2200 12V eee 104
143. ge High 04 26 Manifold Air Temperature Input Voltage Low 16 66 Manifold Air Temperature Moderately High 000107 00 Air Filter Restricted 000110 00 69 Engine Coolant Temperature Extremely High 03 18 Engine Coolant Temperature Input Voltage High 04 19 Engine Coolant Temperature Input Voltage Low 15 62 Engine Coolant Temperature High Least Severe 16 63 Engine Coolant Temperature Moderately High 000111 00 Loss of Coolant Temperature Extremely High 03 Loss of Coolant Temperature Input Voltage High 04 Loss of Coolant Temperature Input Voltage Low 000158 17 54 ECU Power Down Error 17 84 ECU Power Down Error 000171 03 Ambient Air Temperature Voltage Out of Range High 03 Ambient Air Temperature Voltage Out of Range Low 000174 03 or Fuel Temperature Input Voltage High Continued on next page OURGP11 0000086 19 27JULO6 1 2 45 22 080706 PN 216 SPN 000189 000190 000620 000627 000629 000636 000637 000639 000729 000970 000971 001076 001079 001109 001110 001568 001569 002000 N A N A N A FMI 04 16 00 00 01 16 03 04 04 13 02 08 10 01 02 10 13 03 05 31 31 00 01 03 06 07 10 13 03 04 31 31 04 31 06 13 N A N A N A Blink Codes 38 81 42 42 21 22 28 Troubleshooting Description of Fault Fuel Temperature Input Voltage Low Fuel Temperature High Moderately Severe Engine Speed Derate Engine Overspeed Extreme Engine Speed Below Normal Mos
144. h 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 UN 18MAR92 High Pressure Fuel Lines Only technicians familiar with this type of system can perform repairs See your John Deere dealer IMPORTANT Never steam clean or pour cold water on an injection pump while it is still warm To do so may cause seizure of pump parts 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 RG11953 UN 26NOV01 fi In addition tampering with fuel system Fuel Injection Pump which alters emission related equipment on engines may result in fines or other penalties per EPA regulations or other local emission laws Do not attempt to service injection pump or fuel injectors yourself Special training and special tools are required See your authorized servicing dealer or engine distributor OURGP11 0000083 19 27JUL06 1 1 40 2 080706 PN 175 Service as Required Adding Coolant CAUTION Explosive release of fluids from pressurized cooling system can cause serious burns Shut off engine Only remove filler cap when cool enough to touch with b
145. he coolant standards listed above is available in the geographical area where service is performed If these coolants are unavailable use a coolant concentrate or prediluted coolant with a quality additive package that provides cylinder liner cavitation protection and protects the cooling system metals cast iron aluminum alloys and copper alloys such as brass from corrosion The additive package must be part of one of the following coolant mixtures e ethylene glycol or propylene glycol base prediluted 40 to 60 coolant e ethylene glycol or propylene glycol base coolant concentrate in a 40 to 60 mixture of concentrate with quality water Water quality Continued on next page DX COOL3 19 270CT05 1 2 1 0 1 3 080706 PN 41 Fuels Lubricants and Coolant Water quality is important to the performance of the IMPORTANT Do not mix ethylene glycol and cooling system Distilled deionized or demineralized propylene glycol base coolants water is recommended for mixing with ethylene glycol and propylene glycol base engine coolant concentrate IMPORTANT Do not use cooling system sealing additives or antifreeze that contains sealing additives DX COOL3 19 270CT05 2 2 Drain Intervals for Diesel Engine Coolant Drain the factory fill engine coolant flush the cooling system and refill with new coolant after the first 3 years or 3000 hours of operation Subsequent drain intervals are determined by the coolant
146. he starter If the engine does ea ARNG z not start the first time wait at least 2 ana S minutes before trying again If engine does not start after four attempts see Troubleshooting section Z O N N m O oc 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 Continued on next page OURGP11 0000076 19 27JULO06 2 3 19 5 080706 PN 103 Engine Operation Except 4 5L 270 Engines 5 Turn the key start switch A clockwise to crank the engine When the engine starts release the key switch so that it returns to the ON position IMPORTANT If the key switch is released before the engine starts wait until the starter and the engine stop turning before trying again This will prevent possible damage to the starter and or flywheel 6 After engine starts idle engine at not more than 1200 rom until warm See WARMING ENGINE later in this section Panels with high low speed select rocker switch 5 B only Set rom using bump speed enable switch C with speed select rocker switch D Panels with optional analog throttle E Set either gt high low speed select switch B or analog throttle E T to slow speed and set desired speed with remaining Start And Idle Engine On Earlier Panel Left or Later Pan
147. hours of the engine If engine trouble occurs the gauge will alternately flash from displayed parameter to the message SvrcCode Then the touch switches E and F can be used to access the trouble code see following Continued on next page OURGP11 000027A 19 07AUG06 2 7 16 2 080706 PN 48 Instrument Panel Elect Cont 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 various engine parameters and diagnostic trouble codes See Using Diagnostic Gauge To Access Engine Information on the following pages for instructions Audible Alarm Optional The audible alarm G sounds whenever a low oil pressure high coolant temperature or water in fuel plugged fuel filter condition exists This includes all signals that light up the amber WARNING indicator B or the red STOP ENGINE indicator C Audible Alarm Override Switch Optional The audible alarm override switch H can be pressed to silence the alarm for approximately 2 1 2 minutes Analog Throttle Control Optional The throttle control I is used to control engine speed This control is available only on engines with analog throttle Dimmer Control Optional j The dimmer control J is used to control illumination of 8 the instrument panel gauges ox By 3
148. ic 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 on John Deere provided instrument panels Refer to manufacturer s literature for information on controls not provided by Deere Engine Oil Pressure Gauge The engine oil pressure gauge A indicates engine oil pressure in pounds per square inch psi or kPa An optional audible alarm G warns the operator if engine oil pressure falls below a safe operating pressure Amber Warning Indicator The amber WARNING indicator B signals an abnormal condition such as low oil pressure high coolant temperature water in fuel low battery voltage etc Observe displayed code in window of diagnostic gauge hour meter D for diagnostic trouble code DTC Use the service code menu See USING DIAGNOSTIC GAUGE TO ACCESS ENGINE INFORMATION later in this section Red Stop Engine Indicator The Red STOP ENGINE indicator C signals operator to s stop engine immediately or as soon as safely possible A 8 condition exists that could cause damage to engine ox By i Diagnostic Gauge Hour Meter g The diagnostic gauge hour meter D displays diagnostic E 2 Q o 5 trouble codes DTCs as they are accessed Other ASUR RAR information on the engine can be accessed using the touch switches E and F The hour meter shows the operating
149. iction indicator gauge B check gauge to determine if air cleaner needs to be serviced UN 22JAN99 IMPORTANT Maximum air intake restriction is 6 25 kPa 0 06 bar 1 0 psi 25 in H20 A clogged air cleaner element will cause excessive intake restriction and a a reduced air supply to the engine Dust Unloader Valve and In RG7332A dicator Gauge A Dust Unloader Valve 5 Make a thorough inspection of the engine B Air Restriction Indicator 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 e Radiator for leaks and trash build up e Air intake system hoses and connections for cracks and loose clamps e Fan alternator and accessory drive belts for cracks breaks or other damage e 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 OURGP11 000018F 19 27JUL06 4 5 25 4 080706 PN 136 Lubrication amp Maintenance Daily 6 4 5 L Suffix 270 Earlier Engines Only Turn key
150. ifferent from those shown here Always follow manufacturer s instructions and familiarize yourself with the correct starting procedure A CAUTION Before starting engine in a confined building install proper outlet exhaust ventilation equipment Always use safety approved fuel storage and piping TS220 UN 23AUG88 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 Perform all prestarting checks outlined in Lubrication amp Maintenance Daily Section later in this manual Disengage engine rear driveline if equipped or gen set drive Open the fuel supply shut off valve if equipped Place the speed control lever in the START position if equipped Continued on next page OURGP11 000016A 19 27JULO06 1 2 20 4 080706 PN 119 Engine Operation 4 5 L 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 5 Earlier Engines 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 Later Engines
151. indicator 40 5 UN 06SEP00 RG11319A RG11320 UN 0O7SEPO00 Installation of Single Stage Air Cleaner A Outlet Neck Clamp B Filter to Engine Overlap RG RG34710 5594 19 27JUL06 1 1 080706 PN 178 Service as Required Replacing Axial Seal Air Cleaner Filter Element IMPORTANT ALWAYS REPLACE primary air cleaner element when air restriction indicator A shows a vacuum of 625 mm 25 in H20 is torn or visibly dirty NOTE This procedure applies to John Deere 2 stage axial seal air cleaner kits Refer to manufacturers instructions for servicing air cleaners not supplied by John Deere RG8719B UN O3SEP99 Air restriction Indicator Continued on next page OURGP11 000013A 19 27JULO06 1 2 40 6 080706 PN 179 Service as Required 1 Remove wing nut and remove canister cover shown in small illustration inset 2 Remove wing nut A and remove primary element B from canister 3 Thoroughly clean all dirt from inside canister NOTE Some engines may have a dust unloader valve C on the air cleaner If equipped squeeze valve tio 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 4 To replace secondary element remove retaining nut D and secondary
152. ing This is a read only function 1 Starting at the single or four engine parameter display press the Menu key 45 29 e f 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 e Faulty contact between terminals in connector e 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 OUOD007 0000036 19 27JUL06 1 1 98 1000 RPM LOAD RPM ENG RPM 1800 RPM Fea CooL TEMP Menu Key 57 PSI OIL PRES 14 2 BAT VOLT RG13159 UN 26SEP03 Continued on next page OURGP11 000012B 19 27JULO6 1 4 080706 PN 223 Troubleshooting 2 The main menu will be displayed Use the Arrow key to scroll through the menu until Utilities is highlighted STORED CODES ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT UTILITIES OPE Select Utilities RG13234 UN 220CT03 O
153. ing Drivelines OU0O1004 0000BD8 19 27JUL06 1 1 05 5 080706 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 On self propelled equipment disconnect battery ground cable before making adjustments on electrical systems or welding on machine On towed implements disconnect wiring harnesses from tractor before servicing electrical system components or welding on machine TS218 UN 23AUG88 DX SERV 19 17FEB99 1 1 Work In Ventilated Area Engine exhaust fumes can cause sickness or death If it is necessary to run an engine in an enclosed area remove J the exhaust fumes from the area with an exhaust pipe A NS cs ein a L extension If you do not have an exhaust pipe extension open the doors and get outside air into the area TS220 UN 23AUG88 DX AIR 19 17FEB99 1 1 05 6 080706 PN 21 Safety Avoid High Pressure Fluid
154. ing engine power driveline IMPORTANT Before stopping an engine that has been operating at working load idle engine at least 2 minutes at 1000 1200 rpm to cool hot engine parts Engines in generator set applications where the ECU is locked at a specified speed and no slow idle function is available run engine for at least 2 minutes at fast idle and no load 2 Run engine at 1000 1200 rpm for at least 2 minutes to cool RG13280 UN 3800CT03 Panels with High Low Speed Select Rocker Switch B only Set rom using Bump Speed Enable Switch C with Stopping the Engine On Earlier Panel Left or Later Panel Right Speed Select Rocker Switch D 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 NOTE Engine Control Unit ECU reads the higher of the High Low Speed Select Rocker Switch or the Analog Throttle s Speed settings 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 RG9933 UN 18NOV99 Exhaust Stack Rain Cap 4 Turn key switch A to OFF position to stop the A Key Switch engine Remove ignition key B High Low Speed Select Rocker Switch C Bump Speed Enable Switch IMPORTANT Make sure that exhaust stack rain cap Pea merece noche wien E
155. inking 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 Press down Override Shutdown Switch while turning the ignition switch ON 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 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 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 5 Once complete this sequence will repeat 6 When complete turn ignition OFF 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 l
156. ion E Exhaust Valve I Intake Valve OQUO01089 0000208 19 27JUL06 5 5 080706 PN 172 Lubrication amp 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 A for continuity using a multimeter RG13802 UN 18NOV04 he s ui yna is P Check continuity between glow plug and ground on l aes lugs for Continuity cylinder head If resistance is infinite no current the glow plug is damaged and must be replaced A Glow Plug Install new glow plugs and torque to specifications Specification Glow Plug Torque 12 18 Nem 9 13 lb ft Reinstall rocker arm cover and crankcase ventilator tube OURGP11 0000082 19 27JUL06 1 1 35 15 080706 PN 173 Service as Required Additional Service Information 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 O Lu Q LO Z xt nN t oc Component Technical Manual RG RG34710 5591 19 27JULO6 1 1 40 1 080706 PN 174 Service as Required Do Not Modify Fuel System CAUTION Do not open high pressure fuel system Hig
157. ire sparks or flames DO NOT incinerate or puncture a starting fluid container 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 82 F They will enhance starting performance above these temperatures and may be needed to start applications that have high parasitic loads during cranking and or start acceleration to idle Using correct grade of oil per engine and machine operator s manual is critical to achieving adequate cold weather cranking speed synthetic oils have improved flow at low temperatures especially in arctic conditions Other cold weather starting aids are required at temperatures below 30 C 22 F or at altitudes above 1500 m 5000 ft See Using a Booster Battery or Charger later in this section 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 2 275 Series Engines Without Air Intake Heaters Manually activate ether injectors Continued on next page 19 9 140 130 oo cn oo on Minimum Cranking RPM o i Go 100 100 100 RG11521 we Sindee Handle Starting Fluid with Care Cold Weather Starting Guidelines
158. is allows the operator to monitor engine performance as well as to diagnose any troubles during engine operation All electronic engine controls are optional equipment for John Deere POWERTECH OEM Engines These electronic controls may be provided by the equipment manufacturer instead of purchased from John Deere Refer to your engine application manual for specific guidelines if John Deere sourced controls and instrumentation are not used 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 Analog 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 P Speed Select Rocker Switch Q Fuse Holder 5 Amp Fuse R Tachometer S Power Meter Percent Load Optional T Voltmeter Optional U Engine Coolant Temperature Gauge POWERTECH s a trademark of Deere amp Company 16 1 a D NY Instrument Panel Earlier Electronically Controlled Engines Continued on next page RG11169 UN 01NOVOO OURGP11 000027A 19 07AUGO06 1 7 080706 PN 47 Instrument Panel Elect Cont Earlier Engines IMPORTANT Any time an electr
159. is removed test glow plugs See following procedure 6 Install rocker arm cover and crankcase ventilator tube 7 Reconnect battery terminal RG12169 UN 03JUL02 Continued on next page QUO01089 0000208 19 27JULO6 3 5 35 13 080706 PN 171 Lubrication amp Maint 2000 Hour 24 Month 4 Cylinder Engine NOTE Firing order is 1 3 4 2 1 Using JDG1571 or JDE81 4 Timing Pin lock No 1 piston at TDC compression stroke B Adjust valve clearance on No 1 and 3 exhaust valves and No 1 and 2 intake valves Turn crankshaft 360 Lock No 4 piston at TDC compression stroke C Adjust valve clearance on No 2 and 4 exhaust valves and No 3 and 4 intake valves 6 Cylinder Engine NOTE Firing order is 1 5 3 6 2 4 1 Lock No 1 piston at TDC compression stroke B 2 Adjust valve clearance on No 1 3 and 5 exhaust valves and No 1 2 and 4 intake valves Turn crankshaft 360 Lock No 6 piston at TDC compression stroke C Adjust valve clearance on No 2 4 and 6 exhaust valves and No 3 5 and 6 intake valves 35 14 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 iI Intake Valve OQUO01089 0000208 19 27JUL06 4 5 RG12170 UN 21MAY02 6 Cylinder Valve Adjustment A Front of Engine B No 1 Piston TDC Compression C No 6 Piston TDC Compress
160. is running Check engine oil level daily prior to starting engine A rising oil level may indicate fuel dilution of the engine oil 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 The fuel tank is vented through the filler cap If a new filler cap is required always replace it with an Keep all storage tanks as full as practicable to original vented cap minimize condensation 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 Ensure that all fuel tank caps and covers are installed properly to prevent moisture from entering Monitor water content of the fuel regularly DX FUEL4 19 19DEC03 1 1 Testing Diesel Fuel DIESELSCAN is a John Deere fuel analysis program that can be used to monitor the quality of your fuel The DIESELSCAN analysis verifies fuel type cleanliness water content suitability for cold weather operation and whether the fuel meets specifications Check with your John Deere dealer for availability of DIESELSCAN kits DIESELSCAN is a trademark of Deere amp Company DX FUEL6 19 14NOV05 1 1 10 2 080706 PN 30 Fuels Lubricants and Coolant Bio Diesel Fuel Consult your local fue
161. ith identical grade oh SlJolwfa a o oa o NI OJIN O1 oO NJ SAE Grade 5 5 1 or 5 2 Lubricated Ibin T 5 172 ott at SAE Grade 8 or 8 2 fh lt O pa rm co on re co on oO oO on on on o la o Ro eee secon fe N D olal lalalo o oO olola alinl D o1 a lin olo on OlOo lalo loala ie on rom O OJIN O O Ol oe O O lb oO OO D N NO aN No oO alo D oO fos on O1 N A GQ oO oOo ol aN O o1 CO O O N O l h O1 O o_o D Oo1 O l O oO oO ho oO O NO Ql O 1250 2250 1650 2850 2100 3600 2650 4550 3350 Replace fasteners with the same or higher grade If higher grade fasteners are used tighten these to the strength of the original Make sure fastener threads are clean and that you properly start thread engagement When possible lubricate plain or zinc plated fasteners other than lock nuts wheel bolts or wheel nuts unless different instructions are given for the specific application all N D O o_o O1 CO O HE O O aGrade 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 Lubricated means coated with a lubricant such as engine oil fasteners with phosphate and oil coatings or 7 8 in and larger fasteners with JDM F13C
162. l Continuously Detected 03 Water in Fuel Signal Voltage High 04 Water in Fuel Signal Voltage Low 16 Water in Fuel Detected 000100 01 75 Engine Oil Pressure Extremely Low 03 23 Engine Oil Pressure Input Voltage High 04 24 Engine Oil Pressure Input Voltage Low 18 74 Engine Oil Pressure Moderately Low 000105 00 Manifold Air Temperature Extremely High 03 25 Manifold Air Temperature Input Voltage High 04 26 Manifold Air Temperature Input Voltage Low 16 55 Manifold Air Temperature Moderately High 000107 00 Air Filter Differential Pressure 000110 00 63 Engine Coolant Temperature High Most Severe 03 18 Engine Coolant Temperature Input Voltage High 04 19 Engine Coolant Temperature Input Voltage Low 15 61 Engine Coolant Temperature High Least Severe 16 62 Engine Coolant Temperature High Moderately Severe 000111 01 64 Engine Coolant Level Low 000158 17 54 ECU Power Down Error 000160 02 Wheel Speed Input Noise 000174 00 Fuel Temperature High Most Severe 03 or Fuel Temperature Input Voltage High 04 38 Fuel Temperature Input Voltage Low Continued on next page OURGP11 0000088 19 27JULO6 1 3 45 26 080706 PN 220 Troubleshooting 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
163. l distributor for properties of the bio diesel fuel available in your area Bio diesel fuels may be used ONLY if the bio diesel fuel properties meet the latest edition of ASTM D6751 EN 14214 or equivalent specification It is recommended to purchase bio diesel fuel blended with B100 from a BQ 9000 Accredited Producer or a BQ 9000 Certified Marketer as recommended by the National Bio diesel Board The maximum allowable bio diesel concentration is a 5 blend also known as B5 in petroleum diesel fuel It has been found that bio diesel fuels may improve lubricity in concentrations up to this 5 blend When using a blend of bio diesel fuel the engine oil level must be checked daily when the air temperature is 10 C 14 F or lower If oil becomes diluted with fuel shorten oil change intervals accordingly IMPORTANT Raw pressed vegetable oils are NOT acceptable for use as fuel in any concentration in John Deere engines 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 e Quality of new fuel e Water content of the fuel e Problems due to aging of the fuel Potential problems resulting from deficiencies in the above areas when using bio diesel fuel in concentrati
164. l intake hoses piping for cracks Replace as necessary RG4689 UN 20DEC88 2 Check clamps A on piping which connect the air cleaner engine and if present turbocharger Tighten Check Clamps clamps as necessary This will help prevent dirt from a entering the air intake system through loose f connections causing internal engine damage 3 If engine has a rubber dust unloader valve B inspect the valve on bottom of air cleaner for cracks or plugging Replace as necessary IMPORTANT ALWAYS REPLACE primary air cleaner element when air restriction indicator shows a vacuum of 625 mm 25 in H20 is torn or visibly dirty RG7332B UN 22JAN99 ial 1 jf ae F K l Underloader Valve and Air Restriction Indicator je 4 Test air restriction indicator C for proper operation Replace indicator as necessary A Clamps B Dust Unloader Valve IMPORTANT If not equipped with air restriction C Air Restriction Indicator indicator replace air cleaner elements at 500 Hours or 12 Months whichever occurs first RG RG34710 5575 19 27JULO06 1 1 30 1 1 080706 PN 148 Lubrication amp Maintenance 500 Hour 12 Month Replacing Fuel Filter Elements 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 CAUTION Escaping fluid under pressu
165. l operating temperature Remove and check thermostat See your authorized servicing dealer or engine distributor Test glow plugs See 2000 hour 24 month maintenance section Use proper fuel Service air cleaner Reduce load See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor RG RG34710 5608 19 27JUL06 5 8 080706 PN 208 Symptom Engine overheats High fuel consumption Troubleshooting Problem Engine overloaded Low coolant level Faulty radiator cap Stretched poly vee belt or defective belt tensioner Low engine oil level Cooling system needs flushing Defective thermostat Defective temperature gauge or sender Incorrect grade of fuel Improper type of fuel Clogged or dirty air cleaner Engine overloaded Improper valve clearance Injection nozzles dirty Electronic fuel system problem Defective turbocharger Low engine temperature Continued on next page 45 15 Solution Reduce load Fill radiator to proper level check radiator and hoses for loose connections or leaks Have technician check Check automatic belt tensioner and check belts for stretching Replace as required Check oil level Add oil as required Flush cooling system Remove and check thermostat Check coolant temperature with thermometer and replace
166. le lists engine crankcase oil fill quantities Engine Model Oil Pan Option Crankcase Oil Code s Capacity L qt 4045DF270 8 5 9 0 8 5 9 0 4045TF270 1903 1904 1923 4045TF275 4045HF275 1904 1923 1976 4045HF475 1923 15 0 1976 20 0 6068TF275 6068HF275 6068HF475 1924 1961 19AC 55 6 NOTE Crankcase oil capacity may vary slightly from amount shown ALWAYS fill crankcase to within crosshatch on dipstick DO NOT overfill OURGP11 000008B 19 27JULO6 1 1 080706 PN 233 Specifications Unified Inch Bolt and Screw Torque Values TS1671 UN 01MAY03 SAE Grade 1 SAE Grade 2 Lubricated J lt O J lt O Ag NO s O Ol O ice Oo X N oo k N N w o J Oo N Ol Oo ine O W ol NO NO s O O1 ok O NO co i i E Wm T wW IN ae o S lalo D N N A OlO lo la NO o1 NI NIe N R yl liolalo e on alailo lwala on oO bt ma O Q N O1 D O O o1 oo O Torque values listed are for general use only based on the strength of the bolt or screw DO NOT use these values if a different torque value or tightening procedure is given for a specific application For plastic insert or crimped steel type lock nuts for stainless steel fasteners or for nuts on U bolts see the tightening instructions for the specific application Shear bolts are designed to fail under predetermined loads Always replace shear bolts w
167. lfuric 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 AIDS acaetegntetiereeteeateecaroee etewhre test dcteeden corte aeeeteeesees 640 12 Volt Heavy Duty Starter Cold CT AIT PINS eee E 800 24 Volt Standard Duty Starter Cold Cranking AMPS eee nent ere ee nen een nt eee em ee eee 570 RG RG34710 5568 19 27JUL06 2 2 30 3 080706 PN 140 Lubrication amp Maintenance 500 Hour 12 Month Manual Belt Tensioner Adjustment NOTE Two types of manual tensioners shown NOTE Inspect belts for cracks fraying or stretched out areas Replace if necessary As a reference check twist belt in the middle of a 254 305 mm 10 12 in span with two fingers A properly tensioned belt will turn 75 85 degrees If belt turns more it needs to be tightened If belt turns less it needs to be loosened NOTE If timing gear cover or alternator bracket interfere with installation centering of belt tension gauge A install gauge with face toward engine 1 Install JDG1341 Belt Tension Gauge A on belt halfway between pulleys as shown JDG1341 Belt Tension Gauge available from local John Deere Dealer or Distributor 2 Loosen cap screws B and C 3 Slide alternato
168. llowing during the first 100 hours of operation of a new or rebuilt engine API Cl 4 PLUS ACEA CF API Cl 4 ACEA E7 API CH 4 ACEA E6 API CG 4 ACEA E5 API CF 4 ACEA E4 API CF 2 ACEA E3 These oils will not allow the engine to break in properly DO NOT fill above the crosshatch pattern A or the FULL mark whichever is present Oil levels anywhere within the crosshatch are considered in the acceptable operating range IMPORTANT Specification Engine Oil Pressure at Full Load Rated Speed With Oil Warmed to 115 C 240 F cceeeee 345 103 kPa 3 45 1 03 bar 50 15 psi Minimum Oil Pressure at Slow VOLS SS CO PE E E T Coolant Temperature Range ccceeeeeeeeeeees 105 kPa 1 05 bar 15 psi 82 94 C 180 202 F 19 2 RG8028A Crosshatch Pattern On Dipstick A Crosshatch Pattern On Dipstick Continued on next page OURGP11 0000075 19 27JULO6 2 4 080706 PN 100 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 Before the first 100 hours maximum change engine oil and replace engine oil filter A Gee 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 C
169. low for proper operation of the fuel injection system D Audible Alarm Optional The audible alarm D will sound whenever low oil pressure high coolant temperature or water in fuel conditions exist This includes all signals that light up the amber warning indicator intermittent alarm or the red stop engine indicator steady alarm E Audible Alarm Override Button The optional audible alarm has an override button E that silences the audible alarm for approximately two minutes when pressed F Key Start Switch The three position key start switch F controls the engine electrical system When the key switch is turned clockwise to START the engine will crank When the engine starts the key is released and returns to the ON RUN position G Override Shutdown Rocker Switch Switch will be present but may not be active depending on engine controller ECU options Originally selected If switch is active pressing the upper half of the override shutdown switch G will override an engine shutdown signal The switch must be pressed within 30 seconds to prevent undesired shutdown of engine Pressing this switch will override the engine shutdown for 30 seconds at a time to move vehicle to a safe location H Bump Speed Enable Rocker Switch This is a three position switch H with the center position as OFF locked With this switch in the OFF position the speed select switch
170. ls 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 25 1 UN 16JUNO00 Left Side Oil Filler Cap RG8009A UN 16JUNO00 RG8054A ie A ro a oO O i i i T he j t 4 T a i i i e r l 7 z i d k q i pmm Te i rN D ee y O on f oc Rocker Arm Cover Filler Cap RG8028B UN 15JAN99 Crosshatch on Dipstick Continued on next page OURGP11 000018F 19 27JUL0O6 1 5 080706 PN 133 Lubrication amp Maintenance Daily CAUTION Explosive release of fluids from pressurized cooling system can cause serious burns Only remove filler cap when engine is cold or when cool enough to touch with bare hands Slowly loosen cap to first stop to relieve pressure before removing completely UN 23AUG88 2 Check the coolant level when engine is cold Coolant level should be at bottom of filler neck Fill radiator A with proper coolant solution if level is low See ADDING COOLANT in Service As Required Section Check overall cooling system for leaks TS281 NOTE Refer to your vehicle s operator s manual for recommendations for non John Deere supplied accessories A Fill Radiator tats cate aot be pase O Ww Q 2 gt LO N O or Fill Radiator Continued o
171. m system 4 Run engine until it reaches operating temperature OURGP11 0000222 19 27JUL06 2 2 40 4 080706 PN 177 Service as Required Replacing Single Stage Air Cleaner IMPORTANT ALWAYS REPLACE air cleaner when air restriction indicator shows a vacuum of 625 mm 25 in H20 is torn or visibly dirty NOTE This procedure applies to John Deere single stage air cleaner kits Refer to manufacturers instructions for servicing air cleaners not supplied by John Deere 1 If equipped loosen body clamp 2 Loosen clamp around outlet neck A 3 Remove air cleaner 4 Install new filter so that overlap B of air cleaner outlet neck and engine intake pipe is to specification below Specification Air Cleaner Neck to Engine INtAKE OVErlAD cc cceeeeeeceececceessseeeeececeeessseeeeesssneasseeeeess 38 mm 1 5 in 5 Tighten neck clamp A to specification below Specification Air Cleaner Neck Clamp Torque ceeeeeeeeees 6 8 Nem 60 lb in IMPORTANT Do NOT overtighten body clamp Overtightening may cause crushing of air cleaner body Tighten body clamp only until snug 6 If equipped tighten body clamp until snug IMPORTANT Whenever the air cleaner has been serviced or removed ALWAYS fully depress the air restriction indicator reset button if equipped to assure accurate readings 7 lf equipped fully depress air restriction indicator reset button and release to reset
172. ming operation 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 Engine oil pressure should be at least 103 kPa 1 03 bar 15 psi at slow idle and should reach at least 241 kPa 2 41 bar 85 psi at rated speed under full load 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 OURGP11 0000077 19 27JUL06 1 1 19 7 080706 PN 105 Engine Operation Except 4 5L 270 Engines Warming Engine The electronically controlled engines will operate at an accelerated slow idle of 1050 rom until the engine coolant warms up to 20 C 68 F 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 A Engines used in generator set A E a 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 Oil Pressure and Coolant Temperature G
173. mpairment or loss of hearing Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises TS207 UN 23AUG88 DX NOISE 19 03MAR93 1 1 05 4 080706 PN 19 Safety Handle Chemical Products Safely Direct exposure to hazardous chemicals can cause serious injury Potentially hazardous chemicals used with John Deere equipment include such items as lubricants coolants paints and adhesives A Material Safety Data Sheet MSDS provides specific details on chemical products physical and health hazards safety procedures and emergency response techniques TS1132 UN 26NOV90 Check the MSDS before you start any job using a hazardous chemical That way you will know exactly what the risks are and how to do the job safely Then follow procedures and recommended equipment See your John Deere dealer for MSDS s on chemical products used with John Deere equipment DX MSDS NA_ 19 03MAR93 1 1 Stay Clear of Rotating Drivelines Entanglement in rotating driveline can cause serious injury or death Keep master shield and driveline shields in place at all times Make sure rotating shields turn freely aa Wear close fitting clothing Stop the engine and be sure Ba PTO driveline is stopped before making adjustments connections or performing any type of service on the engine or PTO driven equipment hY TS1644 UN 22AUG95 Rotat
174. mperature gauge U indicates engine coolant temperature in degrees Celsius or Fahrenheit An optional audible alarm G warns the operator if coolant temperature rises above the preset safe operating temperature Cruise Control Engine ECUs are available with the cruise control function The cruise control is an off road type that maintains a constant engine rom under varying load conditions The cruise cancel resume function is a one button cancel then resume function The first time contact is made with the 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 Q D NY o RaW x 140 ariana a RG11169 UN 01NOVOO Instrument Panel For Earlier Engines Continued on next page 16 6 OURGP11 000027A 19 07AUG06 6 7 080706 PN 52 Instrument Panel Elect Cont Earlier Engines 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 read
175. 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 amp 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 e After fuel filter changes e After pump or nozzle replacement e Anytime fuel lines have been disconnected e After engine has run out of fuel Continued on next page OURGP11 0000010 19 27JULO6 1 5 40 19 080706 PN 192 Service as Required 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 A Vent Screw RG7947 UN 13NOV97 Air Bleed Vent Screw OURGP11 0000010 19 27JUL06 2 5 Operate supply pump primer lever B until fuel flow is free from air bubbles 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 Start engine and check for leaks UN 15JAN99 If engine will not start it may be necessary to bleed air from fuel system at fuel injectio
176. n 001078 07 95 ECU Pump Timing Moderately Out of Sync 11 87 ECU Pump Speed Out of Sync 31 94 ECU Pump Timing Extremely Out of Sync 001079 03 21 Sensor Supply 1 Voltage High 04 22 Sensor Supply 1 Voltage Low 001080 03 51 Sensor Supply 2 Voltage High 04 52 Sensor Supply 2 Voltage Low 001109 31 Engine Shutdown Warning 001110 31 82 Engine Shutdown 001485 02 89 Pump Power Relay Fault 001569 31 47 Fuel Derate 002000 13 Security Violation OURGP11 0000087 19 27JUL06 2 2 45 25 080706 PN 219 Troubleshooting 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 in Ascending SPN FMI Codes SPN FMI Blink Code Description of Fault 000028 03 15 Analog Throttle B Voltage High 04 Analog Throttle B Voltage Low 000029 03 13 Analog Throttle A Voltage High 04 Analog Throttle A Voltage Low 000084 31 Vehicle Speed Mismatch 000091 03 11 Multi state Throttle Voltage High 04 12 Multi state Throttle Voltage Low 09 Throttle Invalid 000094 03 ar Fuel Rail Pressure Input Voltage High 04 28 Fuel Rail Pressure Input Voltage Low 10 86 Fuel Rail Pressure Loss Detected 13 Fuel Rail Pressure Higher Than Expected 17 85 Fuel Rail Pressure Not Developed 000097 00 Water in Fue
177. n next page 16 14 To exit the E Config Display sub menu Press BOTH keys at ANY time RG10019 19 280CT99 DPSG OUOD007 2842 19 27JUL06 1 2 080706 PN 60 Instrument Panel Elect Cont Earlier Engines The diagnostic gauge can display the engine E Config Then press BOTH the UP and DOWN configuration data stored in the engine control unit switches at the same time to select the Engine ECU To select the Engine Configuration Sub Menu Configuration Sub Menu The diagnostic gauge will see diagram on previous page press the UP or display the engine configuration data as shown in the DOWN switch until the top line of the display reads diagram DPSG QUOD007 2842 19 27JUL06 2 2 16 15 080706 PN 61 Instrument Panel Elect Cont Earlier Engines Viewing Active Engine Service Codes Diagnostic Trouble Codes DTCs SERVICE CODE SUB MENU Enter SrvcCodes First SPN FMI combination User may exit the Service Code Display routine by pressing BOTH keys at any time Exit SrvcCodes FMI n Aly fal Viewing Active Service Codes Diagnostic Trouble Codes DTCs The diagnostic gauge continuously monitors all DTC Sub Menu The diagnostic gauge has the ability messages broadcast over the Control Area Network to display all active service codes DTCs received CAN and displays all active service codes diagnostic The diagram above titled Service Code DTC trouble codes DTCs
178. n next page OURGP11 00000AF 19 27JULO6 4 6 17 16 080706 PN 79 RG13186 UN 29SEP03 Instrument Panel Elect Cont Later Engines 5 Press the Menu key to return to the main menu ADJUST CONTRAST RG13187 UN 26SEP03 Return To Main Menu OURGP11 00000AF 19 27JULO6 5 6 6 Press the Menu key to exit the main menu and return 98 to the engine parameter display eLA Se 1800 RPM EXeGGI coo TEMP aly a Exit Main Menu RG13159 UN 26SEP03 OURGP11 00000AF 19 27JULO6 6 6 Selecting Units Of Measurement 98 1000 RPM LOAD RPM ENG RPM 1 Turn the key switch to the ON position Starting at the 1800 RPM single or four engine parameter display press the HTE coo TEMP oe ft Menu key Menu Key RG13159 UN 26SEP03 Continued on next page OURGP11 00000BO 19 27JULO6 1 7 17 17 080706 PN 80 Instrument Panel Elect Cont Later Engines 2 The main menu will be displayed Use the Arrow keys fgg TO 1 UP DISPLAY to scroll through the menu until Select Units is STORED CODES highlighted ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT OGO Select Units RG13188 UN 02OCT03 OURGP11 00000B0 19 27JUL06 2 7 3 Once the Select Units menu item has been GO TO 1 UP DISPLAY highlighted press the Enter key to access the Select STORED CODES Units function ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPL
179. n next page OURGP11 000018F 19 27JULO06 2 5 25 2 080706 PN 134 Lubrication amp 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 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 IMPORTANT Drain water into a suitable container and dispose of properly RG12222 UN 24MAY02 Loosen drain plugs A at bottom of fuel filters or bowls if equipped two or three turns Loosen air bleed plug B two full turns on fuel filter mounting and drain water from bottom until fuel Starts to drain out When fuel starts to drain out tighten drain plugs D E t A securely ETEN d ii f After draining water from the fuel filters the filters must sR be primed by bleeding all air from the fuel system See id BLEEDING FUEL SYSTEM in Service As Required Section later in this manual aar waren et RG11955 UN 05DECo1 A Drain Plug B Air Bleed Plug Continued on next page OURGP11 000018F 19 27JUL06 3 5 25 3 080706 PN 135 Lubrication amp Maintenance Daily 4 lf the air cleaner has an automatic dust unloader valve A squeeze the unloader valve on air cleaner x assembly to clear away any dust buildup If equipped with air intake restr
180. n pump or injection nozzles as explained next RG8013A Fuel Supply Pump Primer Lever B Fuel Supply Pump Primer Lever Continued on next page OURGP11 0000010 19 27JULO6 3 5 40 20 080706 PN 193 Service as Required At Fuel Injection Pump 1 Slightly loosen fuel return line connector A at fuel injection pump Operate fuel supply pump primer lever until fuel without air bubbles flows from fuel return line connection Tighten return line connector to 27 Nem 20 lb ft RG6264 UN 03NOV97 Primer lever is spring loaded and will return to normal position Stanadyne Rotary Fuel Injection Pump A Fuel Return Line Connector OURGP11 0000010 19 27JUL06 4 5 At Fuel Injection Nozzles 1 Move the engine speed control lever to half throttle position On engines equipped with electronic fuel shut off solenoid energize solenoid Using two open end wrenches loosen fuel line connection at injection nozzle as shown Crank engine over with starter motor but do not start engine until fuel free from bubbles flows out of loosened connection RG7725 UN O8JAN97 Fuel Line Connection Retighten connection to 23 Nem 17 lb ft 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 OURGP11 0000010 19 27JUL06 5 5
181. n the high pressure fuel pump and nozzles on engines with High Pressure Common Rail HPCR fuel system Only technicians familiar High Pressure Fuel Lines with this type of system can perform repairs See your John Deere dealer TS1343 UN 18MAR92 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 X9811 UN 23AUG88 If an accident occurs see a doctor immediately Any fluid injected into the skin must be High Pressure Fluids surgically removed within a few hours or gangrene may result Doctors unfamiliar with this type of injury may call the Deere amp Company Medical Department in Moline Illinois or other knowledgeable medical source 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 OURGP11 000000F 19 27JUL06 1 3 40 17 080706 PN 190 Service as Required 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 a L 475 model engines with Denso HP3 pumps i and High Pressure Common Rail HPCR fuel a systems dec
182. naana terete ie 30 20 Pressure test radiator cap 30 20 ACI he eae were ot nen ee a Oe pape 35 3 Crankcase vent system check 30 9 Crankshaft vibration damper 35 2 D Damper checking 04 35 2 Diagnostic gauge Software version later engines 45 29 Diagnostic Procedure 045 45 20 Diagnostic procedure Using diagnostic gauge earlier engines 16 8 Using diagnostic gauge later engines 17 4 Diagnostic trouble codes Dlink CO eS aeeseqaqueqeqeeu sede ee 45 18 Diagnostic trouble codes DTCs Active engine service codes viewing earlier SNINE 4 4 6 4 s a a 4 ee ee ow eg oes 16 16 Active engine service codes viewing later CHONG Sue eee oe ee ans dnt dk 8 17 10 Electronic systems and Bosch VP44 45 24 Diagnostic Trouble Codes DTCs Electronic systems and Denso High Pressure Common Rail 000000 00e 45 26 Diagnostic trouble codes DTCs Electronic systems and Stanadyne DE10 45 22 Diagnostic trouble codes DTC s Instrument panel 20008 45 20 080706 PN 1 Index Page Diagnostic trouble codes DTCs Stored service codes viewing earlier CNOWINCS essre resset NSE eee eee 16 17 Stored service codes viewing later CNOINGS ncn cee ses oo eee ee ee 17 8 Diesel fuel 0 0 0000 10 1 10 3 DTCs Diagnostic Trouble Codes View active service codes earlier CNOINGS ccae ee s w
183. ne temperature Troubleshooting Problem Low coolant temperature Clogged fuel filter Water dirt or air in fuel system Dirty or faulty injection nozzles Electronic fuel system problem Defective thermostat Defective temperature gauge or sender Continued on next page 45 12 Solution Remove and check thermostat Replace fuel filter element Drain flush fill and bleed system Have authorized servicing dealer or engine distributor check injectors See your John Deere distributor or servicing dealer Remove and check thermostat Check gauge sender and connections RG RG34710 5608 19 27JUL06 3 8 080706 PN 206 Symptom Lack of power Low oil pressure Troubleshooting Problem Engine overloaded Intake air restriction Clogged fuel filter Improper type of fuel Overheated engine Below normal engine temperature Improper valve clearance Dirty or faulty injection nozzles Injection pump out of time Electronic fuel system problem Turbocharger not functioning Turbocharger engines only Leaking exhaust manifold gasket Defective aneroid control line Restricted fuel hose Low fast idle speed Low oil level Improper type of oil Continued on next page 45 13 Solution Reduce load Service air cleaner Replace filter elements Use proper fuel See Engine Overheats Remove and check thermostat See your authoriz
184. ne driven by the auxiliary drive of the engine but has loaded and unloaded operating modes This is controlled by the vehicle s air system refer to vehicle technical manual for complete air system checks and services see your John Deere engine distributor or servicing dealer for diagnostic and troubleshooting information If diagnosis leads to an internal fault in the compressor replace the complete compressor as a new or remanufactured unit RG12836 UN 27FEB03 Air Compressor Optional OURGP12 00001E0 19 27JUL06 1 1 40 11 080706 PN 184 Service as Required Bleeding the Fuel System Engines With Electronic Fuel Systems And Bosch VP44 Pump 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 X9811 UN 23AUG88 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 amp Company Medical Department in Moline Illinois or other knowledgeable medical source Bleed the fuel system anytime the fuel system
185. ne the total system capacity and premix with 3 John Deere Coolant Conditioner Through time and use the concentration of coolant additives is gradually depleted during engine operation Periodic replenishment of inhibitors is required even when John Deere COOL GARD is used The cooling system Radiator Conlant Check must be recharged with additional supplemental coolant additives available in the form of liquid coolant conditioner RG6261 UN O8DEC97 Maintaining the correct coolant conditioner concentration SCAs and freeze point is essential in your cooling yes system to protect against rust liner pitting and corrosion and freeze ups due to incorrect coolant dilution John Deere LIQUID COOLANT CONDITIONER is recommended as a supplemental coolant additive in John Deere engines DO NOT mix one brand of SCA with a different brand i Test the coolant solution at 500 hours or 12 months of operation using either John Deere coolant test strips or a y COOLSCAN or COOLSCAN PLUS analysis If a ae COOLSCAN or COOLSCAN PLUS analysis is not JT07298 Coolant Battery Tester available recharge the system per instructions printed on label of John Deere Liquid Coolant Conditioner COOL GARD is a trademark of Deere amp Company COOLSCAN is a trademark of Deere amp Company COOLSCAN PLUS is a trademark of Deere amp Company Continued on next page DPSG OUOD002 1921 19 27JUL06 1 2 30 17 080706 PN 154
186. nection of the NEGATIVE cable to a good ground on the engine frame and away from the battery ies Continued on next page RG RG34710 5564 19 27JULO06 1 2 19 11 080706 PN 109 Engine Operation Except 4 5L 270 Engines 6 Start the engine Disconnect jumper cables immediately after engine starts Disconnect NEGATIVE cable first 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 RG RG34710 5564 19 27JUL06 2 2 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 soeed may not have a slow idle function These engines will idle at no load governed speed high idle RG RG34710 5562 19 27JUL06 1 1 19 12 080706 PN 110 Engine Operation Except 4 5L 270 Engines Changing Engine Speed NOTE Earlier engines have a 2 position rabbit turtle throttle switch which is not adjustable These throttles allows
187. ner threads are clean and that you properly start thread engagement When possible lubricate plain or zinc plated fasteners other than lock nuts wheel bolts or wheel nuts unless different instructions are given for the specific application N O O 00 O1 oO oO Ol O NO oO oO oO a N NO D gt O _ O N O1 NO oy NO O1 NO oO O _s Ql O1 oO oO gig O1 oO oO oh O O1 O Oo ook ol O Lubricated means coated with a lubricant such as engine oil fasteners with phosphate and oil coatings or M20 and larger fasteners with JDM F13C zinc flake coating Dry means plain or zinc plated without any lubrication or M6 to M18 fasteners with JDM F13B zinc flake coating 55 8 DX TORQ2 19 24APR03 1 1 080706 PN 235 Lubrication and Maintenance Records Using Lubrication and Maintenance Records Refer to specific Lubrication and Maintenance Section complete listing of all items to be performed and the for detailed service procedures service intervals required refer to the quick reference chart near the front of the 1 Keep a record of the number of hours you operate Lubrication and Maintenance Section your engine by regular observation of hour meter IMPORTANT The service recommendations Check your record regularly to learn when your covered in this manual are for the engine needs service accessories that are provided by John Deere Follow manufa
188. nes 17 17 080706 PN 2 Page Page Component function earlier engines 16 1 Filler IOCANONS 2446 oeeae awe eens ee 25 1 Component function later engines 17 1 Oil filter change 2 2 ee ee 30 7 identification s2226 0044655 54 5 neous sees 15 1 Oil TINCT Ss oa oe eae ee ocho E 10 10 Main menu navigation later engines 17 5 Operating engine Setup 1 up display later engines 17 20 Break in except 4045DF TF270 19 1 Setup 4 up display later engines 17 26 Break in 4045DF TF270 20 2 Shutdown codes later engines 17 12 Cold weather except 4045DF TF270 19 9 Touch switches earlier engines 16 10 Cold weather 4045DF TF270 20 6 Using diagnostic gauge earlier engines 16 8 Normal operation except 4045DF TF270 19 7 Using diagnostic gauge later engines 17 4 Normal operation 4045DF TF270 20 1 Viewing active service codes earlier Option codes oan edawawasewedacieus esas ed 01 3 engines anaua Ssh Hy rh Soy 9 Re He 16 16 Viewing active service codes later CNOINCS 5 4 4 6 0 4 0 6 0 eee oe ee oe eee 17 10 Viewing configuration data earlier P En e EEE EE E E 16 14 Viewing configuration data later engines 17 6 Poly vee belts Viewing stored service codes earlier Replace 6 9 OE Ee OS OS SE ee ew ead am we SG 40 10 engines cece eee eee eeeeeee 16 17 Power VAUNOS ca uttdagaededadeu
189. ngine wiring layout With Bosch VP44 pump 45 45 4 Page With Denso High Pressure Common Rail 45 5 With Stanadyne DE10 pump 45 3 Error GO0CG ses hehe Oe hore eee ees 45 28 F Fan belts udu 36 be naaa aaa 40 10 Filter replace FUG aree eea oes eee be Geee 30 12 Macc cadre eee eee eae Gh eG oe ee be A 30 7 Fire extinguisher service 4 30 1 Fuel DIGGS ae oes oe oe oe oe cs 10 1 10 3 Handling and storing anaana naana 10 2 LUDNICI een ee ansaa aaraa ae 10 1 Fuel filter Oae e EEEE EEEE EE E EESE 25 1 Draining water a na aaa eaaa 25 1 Replace nananana nanana 30 12 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 Fuses COCCI cw ersten testers petal nee 2 4 40 11 G Gauges Except 4045DF TF270 19 8 AQIS DFE C10 osceae4 hae Sh hee ew ees 20 8 Generator Standby Applications 21 4 Glow plugs Test 475 engineS 200 20 e 35 15 Grease Extreme pressure and multipurpose 10 12 Idling engine nananana naaa 19 12 20 9 Instrument panels Adjust backlighting later engines 17 13 Adjust contrast later engines 17 15 Changing units of measure earlier CONN S ic 5 5 2 eee ae ee 16 12 Changing units of measure later engi
190. nor U Blink Code Diagnostic Z Starter Relay Connections Sensor Select Connector Connector AA Power and Ground G Fuel Injection Pump O Transient Voltage V Secondary Analog Throttle Battery Connections Connector Protection TVP Module Connector BB Optional Wire Extensions H Alternator Ignition P Main System Fuse 20 Connector Amp OURGP11 0000277 19 27JUL06 1 1 45 4 080706 PN 198 Troubleshooting Engine Wiring Layout Electronic Fuel System With Denso High Pressure Common Rail 4045HF475 6068HF475 O 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 Panel Connections L Pump Control Valve B Electronic Injector Earlier Version Shown I Fuel Rail Pressure Sensor Solenoid Connector F Engine Wiring Harness J Crankshaft Position Sensor M Fuel Temperature Sensor C Manifold Air Temperature G Engine Oil Pressure MAT Sensor Sensor Connector OURGP11 0000278 19 27JUL06 1 1 45 5 080706 PN 199 Troubleshooting Engine Wiring Diagram With Earlier Electronic Instrument Panel 464 SENSOR RETURN 2 020 CAN SHIELD 904 CAN H 905 CAN L X1 012 IGN 12V OR 24V Oa 412 ACC ee pg eas S S5 2 Bt ANALOG THROTTLE EMULATOR Lore OVERRIDE OFF lt SHUTDOWN B Je B ne z TO ECU 022 I s3 A10AB BUMP i core a woa ar
191. nsor Connector H Oil Pressure Sensor Connector S Fuel Heater Connector B Fuel Temperature Sensor Connector N CAN Network Diagnostic T Manifold Air Temperature Connector I Main System Fuse 10 amp Connector MAT Sensor Connector C Injection Pump Solenoid J Power and Ground Battery O lInstrument Panel U Alternator Ignition Connector Connections Connector Harness Connector D SAE 1939 CAN Connector K Fuse Holder P 23 pin Optional Feature V Optional Instrument Panel E Crankshaft Position Sensor L Transient Voltage Connector Extended Earlier Version Shown Connector Protection TVP Module feature ECU only F ECU Connector Connector Q 21 pin Instrument Panel Connector OURGP11 0000276 19 27JUL06 1 1 45 3 080706 PN 197 Troubleshooting Engine Wiring Layout Electronic Fuel System With Bosch VP44 Injection Pump UN 05JUNO02 RG11939A 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 Fuel Transfer Pump S System Ground ECU must X Instrument Panel D Crankshaft Position Sensor K Fuel Heater also be grounded to frame Connector E Fuel Injection Pump Event L Fuel Temperature Sensor T CAN Network Diagnostic Y Optional Instrument Panel Sensor M Network CAN Connector Connector Earlier Version Shown F Coolant Temperature N Isochronous Gover
192. nts Also see precautions in Troubleshooting Section when welding on engine or machine OUOD002 0000169 19 27JUL06 1 1 Checking Cooling System CAUTION Explosive release of fluids from pressurized cooling system can cause serious burns Shut off engine Only remove filler cap when cool enough to touch with bare hands Slowly loosen cap to first stop to relieve pressure before removing completely TS281 UN 23AUG88 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 High Pressure Fluids Visually check entire cooling system for leaks Tighten all clamps securely Thoroughly inspect all cooling system hoses for hard flimsy or cracked condition Replace hoses if any of the above conditions are found Inspect the coolant pump for wear or leakage OURGP11 0000151 19 27JULO6 1 1 3 0 1 6 080706 PN 153 Lubrication amp 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 NOTE If system is to be filled with coolant that does not contain SCAs the coolant must be precharged Determi
193. nu must be selected To select the Units Sub Menu press the UP or DOWN switch until the top line of the display reads Units 2 Then press BOTH the UP and DOWN switches at the same time to select the Units Sub Menu The above 16 12 SUB MENU for ENGLISH METRIC UNITS Enter Units designation Units NewUnits Engl sh English Aly laly A VI Units E New Eng Units New Met Current Units Screen displays the current units Press BOTH keys to select current units and exit sub menu NewUnits Metric NewUnits English RG10018 19 280CT99 Changing Units Of Measure 1 diagram shows the steps for selecting the desired units of measure Two options are available Press both the switches to retain the current units designation Press either UP or DOWN switch to toggle the units selection then press both switches to select the desired unit of measure DPSG QUOD007 2842 19 27JUL06 1 1 080706 PN 58 Instrument Panel Elect Cont Earlier Engines 16 13 080706 PN 59 Instrument Panel Elect Cont Earlier Engines Viewing Engine Configuration Data ENGINE CONFIGURATION SUB MENU Enter E Config Speed 1 Torque 5 Hi Limit ae aes RPM avlem amam amta Torque 1 Speed 6 TE RPM Aly T aE Speed 2 Speed 3 awT a Speed 5 ANY laly am aE Ref Torq amia Hi Limit Lo Limit Viewing Engine Configuration Data Continued o
194. o 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 0 5 1 3 080706 PN 28 Fuels Lubricants and Coolant Diesel Fuel Consult your local fuel distributor for properties of the scar diameter of 0 45 mm as measured by ASTM diesel fuel available in your area D6079 or ISO 12156 1 In general diesel fuels are blended to satisfy the low Sulfur content temperature requirements of the geographical area in which they are marketed Diesel fuel quality and fuel sulfur content must comply with all existing emissions regulations for the Diesel fuels specified to EN 590 or ASTM D975 are area in which the engine operates recommended Use of diesel fuel with sulfur content less than 0 10 1000 ppm is STRONGLY recommended Required fuel properties Use of diesel fuel with sulfur content 0 10 1000 pom to 0 50 5000 ppm may result in REDUCED In all cases the fuel shall meet the following oil and filter change intervals properties BEFORE using diesel fuel with sulfur content greater than 0 50 5000 ppm contact your John Deere Cetane number of 45 minimum Cetane number dealer greater than 50 is preferred especially for DO NOT use diesel fuel with sulfur content greater temperatures below 20 C 4 F or elevations above than 1 0 1500 m 5000 ft IMPORTANT
195. o de garant a o de otro tipo para conocer a su Distribuidor de Motores John Deere o al Concesionario de Servicio Registre su motor para la garant a en la siguiente direcci n de internet http www johndeere com enginewarranty Ent rese de qui n es y donde esta situado Cuando tenga un momento vaya a visitarlo A l le gustar conocerlo y saber cuales podrian ser sus necesidades Till agare av John Deere motorer Ta reda pa vem din terf rs ljare ar och bes k honom s snart tillf lle ges V nta inte tills det ar dags f r service eller eventuellt garantiarbete Din motor garantiregistrerar Du via Internet p http www johndeere com enginewarranty Din terf rs ljare vill mycket g rna tr ffa dig f r att lara k nna dina behov och hur bast han kan hj lpa dig OURGP11 0000251 19 27JUL06 1 1 080706 PN 5 Introduction POWERTECH 4 5 L Engines With Electronic Fuel Systems Tier 2 Emission Certified Two Valve Cylinder Head Models Aj l Yj hy i v RG11932 UN O6NOV01 4045 Engine amp gt O Z Co 1 Z 5 i Oo O X 4045 Engine Stanadyne DE10 Injection Pump Shown POWERTECH s a trademark of Deere amp Company OUOD002 0000162 19 04AUG06 1 1 080706 PN 6 Introduction POWERTECH 6 8 L Engines With Electronic Fuel Systems Tier 2 Emission Certified Two Valve Cylinder Head Models z 5 Q Q O O lt i Zz Zz i 7 fap t op
196. of PSI Exit Main Menu RG13159 UN 26SEP03 OURGP11 00000AC 19 27JULO6 6 6 Accessing Active Trouble Codes 98 1000 RPM LOAD RPM ENG RPM NOTE The engine does not need to be running to 1800 RPM navigate the diagnostic gauge screens If engine 14 2 57 PSI start up is desired See Starting The Engine All of _ A e imal Normal Operation RG13172 UN 26SEP03 For description of trouble codes see chart in Troubleshooting Section 1 During normal operation the single or four parameter screen will be displayed OURGP11 00000AD 19 27JUL06 1 7 2 When the diagnostic gauge receives a trouble code aes WARNING from an engine control unit the single or four SPN 94 FMI 18 parameter screen will be replaced with the Warning PTA message The SPN and FMI number will be displayed EVEEK DELNEM ERESe Une along with a description of the problem and the E corrective action needed lt NEXT gt HIDE IMPORTANT Ignoring active trouble codes can result Active Trouble Codes Displayed RG13240 UN 30SEP03 Continued on next page OURGP11 00000AD 19 27JUL06 2 7 17 10 080706 PN 73 Instrument Panel Elect Cont Later Engines 3 If the word Next appears above the arrow keys there are more trouble codes that can be viewed by using the arrow keys to scroll to the next trouble code IMPORTANT Ignoring active trouble codes can result in severe engine damage 4 To acknowledge and hide the
197. on 4 Pour three 3 ounces of rust preventive oil into the turbocharger intake It may be necessary to temporarily install a short intake elbow on the turbocharger inlet to receive the oil 5 Prepare a tank with a solution of diesel fuel and rust preventive oil at ten 10 ounces of rust preventive oil per gallon of diesel fuel 6 Remove existing lines plugs as required and run a temporary line from the tank to the engine fuel intake and another temporary line from the fuel return manifold to the tank so rust preventive oil solution is circulated through the injection system during cranking 7 Crank the engine several revolutions with starter do not allow the engine to start This will allow rust preventive oil solution to circulate 8 Remove temporary lines installed in Step 6 above and replace any lines plugs previously removed NOTE One gallon of fuel oil solution can be used to treat 100 engines two gallons to treat 200 engines etc The oil could then be replenished by adding an additional five 5 ounces of rust preventive oil per gallon of solution However Starting over with a new solution is recommended to dispose of any water or other impurities 9 Loosen or remove and store fan alternator poly vee belt 10 Remove and clean batteries Store them in a cool dry place and keep them fully charged 11 Disengage the clutch for any driveline 12 Clean the exterior of the engine with salt free wa
198. one shown signifies that the engine has been certified with the EPA and or CARB The EPA and CARB warranties only apply to new Equipment moved at least once every 12 months 65 2 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 DPSG RG41165 133 19 27JULO6 1 1 080706 PN 241 John Deere Service Literature Available Technical Information 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 are many ways to order Contact your John Deere dealer Call 1 800 522 7448 to order using a credit card Search online from http www JohnDeere com Please have available the model number serial number and name of the product Available information includes e 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
199. oner 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 Checking Crankcase Vent System 30 9 Checking Air Intake System 30 11 Replacing Fuel Filter Elements 30 12 Checking Belt Tensioner Spring Tension and Belt Wear Automatic Tensioner 30 14 Checking Engine Electrical Ground Connections 0 0 0 eee ee eee 30 16 Checking Cooling System 30 16 Replenishing Supplemental Coolant Additives SCAs Between Coolant ChangeS 2 ccc ee ee 30 17 Testing Diesel Engine Coolant 30 19 Pressure Testing Cooling System 30 20 Checking and Adjusting Engine Speeds 30 21 Lubrication amp Maint 2000 Hour 24 Month Adjusting Variable Speed Droop 4 5 L 270 Generator Set Engines Only 35 1 Page 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 6GO68HF475 00 es 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 Inform
200. ong pause flash three times short pause flash three times long pause flash five times short pause flash three times OURGP11 0000085 19 27JUL06 1 1 4 5 z 1 T 080706 PN 211 Troubleshooting Blink Code Method for Retrieving Diagnostic Trouble Codes Early VP44 Pump Engines Only 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 UN 13JUL01 NOTE The ECU blinks the codes in 2 digit codes only See LISTING OF DIAGNOSTIC TROUBLE CODES DTCS later in this Group RG11754A 1 Locate and uncap the 4 way METRI PACK diagnostic blink code connector A Diagnostic Blink Code Connector A Diagnostic Blink Code Connector 2 Using a short piece of wire jump terminals A and B in B Diagnostic Connector the diagnostic blink code connector together C ECU 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
201. ons 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 Consult your fuel supplier for additives to improve storage and performance of bio diesel fuels DX FUEL7 19 14NOV05 1 1 080706 PN 31 Fuels Lubricants and Coolant Minimizing the Effect of Cold Weather on Diesel Engines John Deere diesel engines are designed to operate effectively in cold weather However for effective starting and cold weather operation a little extra care is necessary The information below outlines steps that can minimize the effect that cold weather may have on starting and operation of your engine See your John Deere dealer for additional information and local availability of cold weather aids Use Winter Grade Fuel When temperatures fall below 5 C 40 F winter grade fuel Grade No 1 D fuel in North America is best suited for cold weather operation Winter grade fuel has a lower cloud point and a lower pour point Cloud point is the temperature at which wax 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 pump
202. oolant Section RG11616 UN 240CT01 NOTE Some increase in oil consumption may be Engine Oil Filter expected when low viscosity oils are used Check A Engine Oil Filter oil levels more frequently If air temperature is below 10 C 14 F use an engine block heater OURGP11 0000075 19 27JUL06 3 4 Watch oil pressure gauge A Pressure at slow idle should be at least 103 kPa 1 03 bar 15 psi once engine is warmed up and shouild rise to at least 241 Ey rages kPa 2 41 bar 35 psi at rated speed under full load Oi es Watch coolant temperature gauge B closely If ON Oe i 0 fo ax coolant temperature rises above 112 C 234 F reduce ay load on engine Unless temperature drops quickly stop the engine and determine the cause before resuming ary operation O A NOTE When the coolant temperature gauge reads ION v j SD EX approximately 115 C 239 F the engine will A shutdown automatically if equipped with safety E eS controls eee 2 O 8 Check poly vee belt for proper alignment and seating 4 in pulley grooves RG13281 UN 300CT03 A Engine Oil Pressure Gauge B Engine Coolant Temperature Gauge Watch Coolant Temperature and Oil Pressure On Earlier Panel Left or Later Panel Right OURGP11 0000075 19 27JUL06 4 4 1 9 3 080706 PN 101 Engine Operation Except 4 5L 270 Engines Starting the Engine
203. operating temperature the engine will shut down E Pre Heat Button Press button to activate the preheater for cold weather starting F Reset Safety Switch Reset button will pop out and shut down the engine if the coolant temperature is too high or oil pressure is too low Press in and hold while starting engine until oil pressure is at a safe operating level G Fuse Holder Contains 14 amp fuse 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 Button F Reset Safety Switch G Fuse Holder H Key Switch I Throttle Optional J Hourmeter Optional RG13360 UN O6FEB04 OURGP11 0000160 19 27JUL06 1 2 Continued on next page 1 8 3 080706 PN 97 Instrument Panel Mech Cont 270 Engines 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 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 OURGP11 0000160 19 27JUL06 2 2 18 4 080706 PN 98 Engine Operation Except 4 5L 270 Engines Engine Break In Servi
204. 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 If equipped e For slow speed press lower half of switch indicated by turtle symbol e For fast speed press upper half of switch indicated by rabbit symbol 5 NOTE To adjust preset fast or slow speeds for High Low 5 Speed Select Rocker Switch o 1 Select fast rabbit or slow turtle position on g High Low Speed Select Rocker Switch A Changing Engine Speed On Earlier Panel Left or Later Panel 2 Press and hold top or bottom half of Bump Right Speed Enable Rocker Switch B while using A Highdow Speed Select Rocker Switch Speed Select Rocker Switch C B Bump Speed Enable Rocker Switch 3 Use Speed Select Rocker Switch C to bump C Speed Select Rocker Switch engine speed up or down D Analog Throttle Control 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 soeed 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 If equipped Later engine panels shown at right have an adjusta
205. ower portion of the bump speed enable switch O to unlock the high or low setting The bump speed enable must be held down as the speed select switch P is used to change the high or low setting by pressing to increase speed or to decrease speed Once the slow idle speed has been set the bump speed enable switch must be pressed and released three 2 times within two seconds to commit the new 8 operating speed to memory If not done the engine s ee 5 3 new speed will only be effective until the key switch is By 7 shut off Then the speed will revert back to the previous 2 setting f 0 N M 5 Instrument Panel For Earlier Engines The fast idle speed cannot be locked into memory It will always go back to the factory preset fast idle speed Fuse Holder The fuse holder Q contains a 5 amp fuse for power to the instrument panel Continued on next page OURGP11 000027A 19 07AUG06 5 7 16 5 080706 PN 51 Instrument Panel Elect Cont 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 Voltmeter 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 The coolant te
206. play Options parameters available for scrolling in the 1 Up Display Automatic Scan Selecting the scan function will allow the 1 Up Display to scroll through the selected set of parameters one at a time momentarily pausing at each OURGP11 00000B1 19 27JUL06 4 18 5 Use Defaults To select Use Defaults use the Arrow aa n Bp USE DEFAULTS keys to scroll to and highlight Use Defaults in the CUSTOM SETUP menu display AUTOMATIC SCAN OFF RG13195 UN 26SEP03 Select Defaults Continued on next page OURGP11 00000B1 19 27JULO6 5 18 1 1 2 1 080706 PN 84 Instrument Panel Elect Cont Later Engines 6 Press the Enter key to activate the Use Defaults USE DEFAULTS function CUSTOM SETUP AUTOMATIC SCAN OFF RG13197 UN 29SEP03 Defaults Selected OURGP11 00000B1 19 27JUL06 6 18 7 The display parameters are reset to the factory defaults then the display will return to the Setup 1 Up Display menu RESTORED TO DEFAULTS Restored To Defaults RG13149 UN 24SEP03 OURGP11 00000B1 19 27JUL06 7 18 8 Custom Setup To perform a custom setup of the USE DEFAULTS 1 Up Display use the arrow buttons to scroll to and CUSTOM SETUP highlight Custom Setup on the display AUTOMATIC SCAN OFF RG13198 UN 26SEP03 OGPO Select Custom Setup Continued on next page OURGP11 00000B1 19 27JUL06 8 18 17 22 080706 PN 85 Instrument Panel Elect Cont Later Engines 9
207. r without thermostats using old gasket and tighten cap screws to 47 Nem 35 lb ft RG12223 UN 11JUNO2 6 Test thermostat opening temperature See Inspecting Thermostats And Testing Opening Temperature in Service As Required Section A Engine Block Drain Valve 7 Close all drain valves after coolant has drained B Engine Block Drain Plug C Engine Block Drain Plug A CAUTION Do not run engine longer than 10 minutes Doing so may cause engine to overheat which may cause burns when radiator water is draining 8 Fill the cooling system with clean water Run the engine about 10 minutes to stir up possible rust or sediment 9 Stop engine pull off lower radiator hose and remove radiator cap Immediately drain the water from system before rust and sediment settle Continued on next page OURGP11 0000081 19 27JULO6 2 4 35 4 080706 PN 162 Lubrication amp Maint 2000 Hour 24 Month 10 After draining water close drain valves Reinstall radiator cap and radiator hose and clamp Fill the cooling system with clean water and a heavy duty cooling system cleaner such as Fleetguard RESTORE and RESTORE PLUS Follow manufacturer s directions on label 11 After cleaning the cooling system drain cleaner and fill with water to flush the system Run the engine about 10 minutes remove radiator cap and pull off lower radiator hose to drain out flushing water 12 Close all drain valves on engine and ra
208. r level will affect engine oil and filter service intervals Higher fuel sulfur levels reduce oil and filter service intervals as shown in the table e Use of diesel fuel with sulfur content less than 0 05 500 ppm is strongly recommended e Use of diesel fuel with sulfur content 0 05 500 ppm to 0 50 5000 ppm may result in REDUCED oil and filter change intervals as shown in the table e BEFORE using diesel fuel with sulfur content greater than 0 50 5000 ppm contact your John Deere dealer Oil types premium or standard in the tables include e Premium Oils include John Deere PLUS 50 ACEA E7 ACEA E6 ACEA E5 or ACEA E4 oils e Standard Oils include John Deere TORQ GARD SUPREME API Cl 4 PLUS API Cl 4 API CH4 or ACEA E3 oils NOTE The 500 hour extended oil and filter change interval is allowed only if ALL the following conditions are met e Engine equipped with an oil pan that allows capacity for this extended drain interval e Use of premium oil John Deere PLUS 50 ACEA E7 ACEA E6 ACEA E5 or ACEA E4 e Use of an approved John Deere oil filter e Use of diesel fuel with sulfur content less than 0 05 500 ppm PLUS 50 is a trademark of Deere amp Company TORQ GARD SUPREME is a trademark of Deere amp Company Refer to the charts on the following pages to find the proper oil and filter service interval for your engine Using Charts to Find Oil and Filter Service Interval 1 Determine
209. r or tensioner bracket D in slot by hand to remove all excess slack in belt IMPORTANT Do not pry against alternator rear frame 4 Stretch belt by prying outward on alternator front frame or tensioner bracket Observing tension gauge stretch the belt until specified tension is achieved Specification New Belt Tension c ceecceeeeeeeees 470 650 N 105 145 Ib force Used Belt Tension sseeeeeeeeees 400 580 N 90 130 Ib 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 30 4 A Belt Tension Gauge B Cap Screw C Cap Screw D Tensioner Bracket Adjust Belt Tension RG10556 UN 21DEC99 RG10557 UN 21DEC99 DPSG RG41165 128 19 27JULO06 1 1 080706 PN 141 Lubrication amp Maintenance 500 Hour 12 Month Manual Belt Tensioner Adjustment Using Belt Tension Tool Alternate Method For Engines Without Auxiliary Drive NOTE The JD1520 Belt Tension Tool may not be compatible with all alternators In that case use the preceding method for belt tensioning Inspect belts for cracks fraying or stretched out areas Replace if necessary As a reference check twist belt in the middle of a 254
210. rations of glycol and inhibiting additives in the coolant is critical to protect the engine and cooling system against freezing corrosion and cylinder liner erosion and pitting Test the coolant solution at intervals of 12 months or less and whenever excessive coolant is lost through leaks or overheating Coolant test strips Coolant test strips are available from your John Deere dealer These test strips provide a simple effective COOLSCAN is a trademark of Deere amp Company COOLSCAN PLUS is a trademark of Deere amp Company 10 15 If other coolants are used consult the coolant supplier and follow the manufacturers 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 manufacturers recommended concentration of supplemental coolant additive DO NOT add more than the recommended amount DX COOL4 19 07NOV03 1 1 method to check the freeze point and additive levels of your engine coolant Compare the results to the supplemental coolant additive SCA chart to determine the amount of inhibiting additives in your coolant and whether more John Deere COOLANT CONDITIONER should be added COOLSCAN and COOLSCAN PLUS For a more thorough evaluation of your coolant perform a COOLSCAN or COOLSCAN PLUS analysis where available See your John Deere dealer for information DX COOL9 19
211. re 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 High Pressure Fluids 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 X9811 UN 23AUG88 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 amp Company Medical Department in Moline Illinois or other knowledgeable medical source RG7721 UN 15JAN99 1 Close fuel shut off valve if equipped 2 Thoroughly clean fuel filter assemblies and surrounding areas 3 Disconnect water sensor wiring if equipped 4 Loosen drain plugs C and drain fuel into a suitable container NOTE Lifting up on retaining ring A as it is rotated 3 helps to get it past raised locators A 5 Firmly grasp the retaining ring A and rotate it K T clockwise 1 4 turn when viewed from the top 7 S 5 Remove ring with filter element B c amp A 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 OURGP11 000021F
212. 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 Q0U01004 2758 19 27JUL06 1 1 0 5 z 1 2 080706 PN 27 Safety Protect Against High Pressure Spray Spray from high pressure nozzles can penetrate the skin and cause serious injury Keep spray from contacting hands or body If an accident occurs see a doctor immediately Any high pressure spray injected into the skin must be surgically removed within a few hours or gangrene may result Doctors unfamiliar with this type of injury should reference a knowledgeable medical source Such information is available from Deere amp Company Medical Department in Moline Illinois U S A TS1343 UN 18MAR92 DX SPRAY 19 16APR92 1 1 Dispose of Waste Properly Improperly disposing of waste can threaten the environment and ecology Potentially harmful waste used with John Deere equipment include such items as oil fuel coolant brake fluid filters and batteries Use leakproof containers when draining fluids Do not use food or beverage containers that may mislead someone into drinking from them TS1133 UN 26NOV90 Do not pour waste onto the ground down a drain or into any water source Air conditioning refrigerants escaping into the air can damage the Earth s atmosphere Government regulations may require a certified air conditioning service center t
213. rt up is desired See Starting The Engine All of ana 1 Turn the key switch to the ON position Starting at the Menu Key single or four engine parameter display press the Menu key RG13159 UN 26SEP03 OURGP11 00000A9 19 27JUL06 1 5 2 The first seven items of the Main Menu will be GO TO 1 UP DISPLAY displayed STORED CODES ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT Menu Display RG13160 UN 020CT03 OURGP11 00000A9 19 27JUL06 2 5 3 Pressing the Arrow keys will scroll through the menu GO TO 1 UP DISPLAY selections STORED CODES ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT RG13161 UN 020CT03 Main Menu Items Continued on next page OURGP11 00000A9_ 19 27JULO06 3 5 17 5 080706 PN 68 Instrument Panel Elect Cont Later Engines 4 Pressing the right arrow key Wik scroll down to reveal ADJUST CONTRAST the last items of Main Menu screen highlighting the UTILITIES next item down Last Items On Main Menu RG13162 UN 26SEP03 OURGP11 00000A9 19 27JUL06 4 5 5 Use the arrow keys to scroll to the desired menu item GO TO 1 UP DISPLAY 98 1000 RPM or press the Menu Button to exit the main menu and LOAD RPM ENG RPM SETUP 1 UP DISPLAY return to the engine parameter display SETUP 4 UP DISPLAY SELECT UNITS 14 2 57 PSI ADJUST BACKLIGHT BAT VOLT OIL PRES Use Arrow Bu
214. s 2000 Hour 24 Month Service e Check crankshaft vibration damper 6 cylinder only e Check and adjust valve clearance e Flush and refill cooling system e Test glow plugs 4045HF475 6068HF475 e Test thermostats lf 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 27JULO06 1 1 60 3 080706 PN 238 Lubrication and Maintenance Records Service as Required e Add coolant e Check fuses e Service air cleaner e Check air compressor if equipped e Replace poly vee belts e Bleed fuel system RG RG34710 5627 19 27JULO6 1 1 60 4 080706 PN 239 Emission System Warranty U S EPA Emissions Control Warranty Statement Emissions control related parts and components are Warranties stated in this manual refer only to warranted by John Deere for five years or 3000 hours emissions related parts and components of your of operation whichever occurs first John Deere further engine The complete engine warranty less warrants that the engine covered by this warranty was emissions related parts and components is provided designed built and equipped so as to conform at the separately as the John Deere New Off High
215. s Escaping fluid under pressure can penetrate the skin Causing serious injury Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines Tighten all connections before applying pressure search for leaks with a piece of cardboard Protect hands and body from high pressure fluids X9811 UN 23AUG88 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 amp Company Medical Department in Moline Illinois U S A DX FLUID 19 03MAR93 1 1 Avoid Heating Near Pressurized Fluid Lines Flammable spray can be generated by heating near pressurized fluid lines resulting in severe burns to yourself and bystanders Do not heat by welding soldering or using a torch near pressurized fluid lines or other flammable materials Pressurized lines can accidentally burst when heat goes beyond the immediate flame area TS953 UN 15MAY90 DX TORCH 19 10DEC04 1 1 Do Not Open High Pressure Fuel System High pressure fluid remaining in fuel lines can cause serious injury Do not disconnect or attempt repair of fuel lines sensors or any other components between the high pressure fuel pump and nozzles on engines with High Pressure Common Rail HPCR fuel system Only technicians
216. s 1870 800 nann 2700 600 eee 2700 800 oo eee 2700 800 oo eres 2700 BOO iruren 2600 1400 scn 1575 1400 iurien 1575 D50 pees 2600 B50 sitecceenes 2600 800 naaa 2600 850 naasen 2600 Seyi Gta ieee eeniesat 2400 AES nesses 2400 O50 E 2600 G5 consseceeescn 2600 BOO riisiin 2400 BOQ totes 2400 850 nacen 2600 850 nanesen 2600 800 nann 2400 800 naan 2400 BOO oiite 2100 GOO sorratniidni 2100 800 nann 2100 800 naen 2100 1150 ssas 1870 1150 sectccnsceee 1870 TISO sissien 1870 TISO centini 1870 TISO hece 1870 OURGP11 000008A 19 27JUL06 2 3 080706 PN 231 Specifications 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 210 282 138 185 1500 185 175 235 1500 175 235 1500 6068HF475 205 275 2400 4 Valve 205 275 2400 Head 250 187 250 2200 234 314 1800 234 314 1800 207 278 1500 207 278 1500 OURGP11 000008A 19 27JUL06 3 3 55 5 080706 PN 232 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 The following tab
217. s and lines NOTE On an average winter grade fuel has a lower BTU heat content rating Using winter grade fuel may reduce power and fuel efficiency but should not cause any other engine performance effects Check the grade of fuel being used before troubleshooting for low power complaints in cold weather operation Air Intake Heater An air intake heater is an available option to aid cold weather starting CAUTION Do not use any starting fluid with an air intake heater Starting Fluid A starting fluid port on the intake is available to aid cold weather starting CAUTION Do not use any starting fluid with an engine equipped with glow plugs Coolant Heater An engine block heater coolant heater is an available option to aid cold weather starting Seasonal Viscosity Oil and Proper Coolant Concentration Use seasonal grade viscosity engine oil based ion the expected air temperature range between oil changes and proper concentration of low silicate antifreeze as recommended See DIESEL ENGINE OIL and ENGINE COOLANT requirements this section Diesel Fuel Flow Additive Use John Deere Premium Diesel Fuel Conditioner Winter or equivalent to treat fuel during the cold weather season This winter formulation is a combination diesel fuel conditioner and anti gel additive IMPORTANT Treat fuel when outside temperature drops below 0 C 32 F For best results use with untreated fuel Follow all recommended instru
218. s either customary English or metric units NOTE Engine parameters which can be accessed will vary with the engine application The following menu of engine parameters can be displayed on the diagnostic gauge window Accelerator pedal position Percentage load 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 delivery pressure Engine oil level Engine oil pressure Coolant pressure Coolant level Wheel base vehicle speed Fuel rate Barometric pressure Air inlet temperature Boost pressure Intake manifold temperature Air filter differential pressure Exhaust gas temperature Continued on next page 16 8 A Diagnostic Gauge B Touch Switches RG10031 UN 280CT99 Diagnostic Gauge Earlier Engines OURGP11 0000072 19 27JUL06 1 2 080706 PN 54 Instrument Panel Elect Cont Earlier Engines 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 service diagnostic codes Stored service diagnostic codes The diagnostic gauge includes a two line by eight character backlit Liquid Crystal Display LCD The top line displays the data la
219. safe operating level Warm up engine for at least 5 minutes before applying a load See WARMING ENGINE later in this section OURGP11 000007B 19 27JUL06 2 2 20 7 080706 PN 122 Engine Operation 4 5 L 270 Engines Warming Engine IMPORTANT To assure proper lubrication operate engine at or below 1200 rpm with no load for 1 2 minutes Extend this period 2 4 minutes when operating at temperatures below freezing Engines used in generator set applications where the governor is locked at a specified speed may not have a slow idle function Operate these engines at high idle for 1 to 2 minutes before applying the load This procedure does not apply to standby generator sets where the engine is loaded immediately upon reaching rated speed RG6574 UN 17FEB03 1 Check oil pressure gauge A as soon as engine starts If gauge needle does not rise above minimum oil pressure specification of 103 kPa 1 03 bar 15 0 psi within 5 seconds stop the engine and determine the Wily cause Normal engine oil pressure is 345 103 kPa M15 wW 2 3 45 1 03 bar 50 15 psi at rated full load speed Oil Pressure and Coolant Temperature Gauges Later Engines 1800 2500 rpm with oil at normal operating temperature of 115 C 240 F Engine oil pressure at A Oil Pressure Gauge rated speed can as high as 586 kPa 5 86 bar 85 a Temberatlhe sage psi This not detrimental to the engine PREHEAT RG13361
220. sceseeads as 90 3 Viewing stored service codes later Precautions for welding on engines equipped engines Di Ak ee 17 8 WEU oeeuuseeeeuue casgegeasuceweara 45 2 Intermittent fault diagnostics 45 29 R L Radiator cap testing 6 scm oe eee eee anaes 30 20 Listing of DTCs 45 22 45 24 45 26 Recordkeeping Lubricant Engine Control Unit ECU serial number 01 5 WIDAING 266s eee ho ee ee 2 ee ee ee ee ee ee 10 9 Engine option codes 01 3 StOrage ee ee 10 11 Engine serial number 01 1 Lubrication and Maintenance Injection pump model number 01 5 Service Interval Chart 21 2 21 4 Lubricity of diesel fuel 10 1 S M Serial number ENON verp sen SREP rA RAAE EE nN 01 1 Maintenance interval chart Engine Control Unit ECU 01 5 Generator Standby applications 21 4 Fuel injection pump 2 22 22 ee eee 01 5 Standard industrial applications 21 2 Service Manual belt tensioner 04 30 4 Battery 1 eee ee 30 2 Manual belt tensioner using belt tension tool 30 5 Fire extinguisher 6 20 serene 30 1 Mixing lubricants 000 0000 0 eee 10 9 Intervals 16 eee 21 2 21 4 Service intervals Engine oil and filter 10 7 General information n n anaoa aaaea 21 1 O Specifications Battery capabilities 0 30 2 Oil Belt tensioner
221. switch to ON position and check lamps WATER lamp should be off while OIL and CHG lamps should be lit Replace lamps as needed If this does not solve any problems see your John Deere dealer or distributor m O Z lt O X Z l 0 0 N LO O oc Key Switch in ON Position 4 5 L 270 Engines OURGP11 000018F 19 27JULO6 5 5 25 5 080706 PN 137 Lubrication amp Maintenance 500 Hour 12 Month Servicing Fire Extinguisher A fire extinguisher A is available from your authorized servicing dealer or engine distributor Read and follow the instructions which are packaged with it The extinguisher should be inspected at least every 500 hours of engine operation or every 6 months 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 RW4918 UN 15DEC88 Fire Extinguisher A Fire Extinguisher OURGP11 000015F 19 27JULO6 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 Check the engine mounting brackets A vibration isolators and mounting bolts on support frame and engine block for tightness Tighten as necessary is a Engine Mounting
222. t Severe 15 53 Fuel Temperature High Least Severe 16 71 Fuel Temperature High Moderately Severe 31 98 Fuel Temperature Sensor Faulty 000189 00 Engine Speed Derate 31 48 Engine Speed Derate 000190 00 42 Engine Overspeed Extreme 16 42 Engine Overspeed Moderate 000620 03 21 Sensor Supply Voltage High Continued on next page OURGP11 0000087 19 27JULO6 1 2 45 24 080706 PN 218 Troubleshooting 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 Position Input Missing 10 44 Pump Position Input Pattern Error 000637 02 39 Crank Position Input Noise 08 38 Crank Position Input Missing 10 39 Crank Position Input Pattern Error 000729 03 Inlet Air Heater Signal High 05 Inlet Air Heater Signal Low 000810 02 92 Calculated Vehicle Speed Input Noise 000898 09 77 Vehicle Speed Invalid Missing 000970 02 Auxiliary Engine Shutdown Switch Signal Invalid 31 83 Auxiliary Engine Shutdown Switch Active 000971 31 84 External Engine Derate Switch Active 001069 02 93 Tire Size Error 001076 02 66 Pump Detected Defect 001077 07 35 Attempting to Fuel Without Command 11 68 Pump Supply Voltage Out of Range 12 97 Pump Self Test Error 19 96 Pump Detected Communication Error 31 36 Pump Initiated Engine Protectio
223. t Severe Engine Overspeed Moderate Sensor Supply Voltage High Sensor Supply Voltage Low ECU Unswitched Power Missing ECU Error Engine Position Sensor Noise Detected Engine Position Sensor Signal Missing Engine Position Sensor Pattern Error Detected Timing Crank Sensor Signal Pattern Error Crank Position Input Noise Crank Position Input Pattern Error CAN Bus Error Inlet Air Heater Signal High Inlet Air Heater Signal Low Auxiliary Engine Shutdown Switch Active External Engine Derate Switch Active 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 Selection Input 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 OURGP11 0000086 19 27JUL06 2 2 45 23 080706 PN 217 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
224. tension on belt using a breaker bar and socket if required on tension arm Remove belt from pulleys NOTE While belt is removed inspect pulleys and bearings Rotate and feel for hard turning or any unusual sounds If pulleys or bearings need replacement see your John Deere dealer 2 Release tension on tension arm and remove breaker bar 3 Put a mark A on swing arm of tensioner as shown 4 Measure 21 mm 0 83 in from A and put a mark B on tensioner mounting base 5 Install torque wrench C so that it is aligned with centers of pulley and tensioner Rotate the swing arm using a torque wrench until marks A and B are aligned 6 Record torque wrench measurement and compare with specification below Replace tensioner assembly as required Specification Spring Tension Torque ccceceeeeeeeeeeeeees 18 22 Nem 13 16 lb ft NOTE Threads on belt tensioner roller cap screw are LEFT HAND threads 30 15 Align Marks RG7977 UN 14NOV97 UN 11SEP00 RG8037C RG12065 UN 28JAN02 Align Torque Wrench With Pulley and Tensioner A Mark On Swing Arm B Mark On Tensioner Mounting Base C Torque Wrench OURGP11 0000080 19 27JUL06 3 3 080706 PN 152 Lubrication amp 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 compone
225. ter and touch up any scratched or chipped painted surfaces with a good quality paint 13 Coat all exposed machined metal surfaces with grease or corrosion inhibitor if not feasible to paint 14 Seal all openings on engine with plastic bags and tape Continued on next page OURGP11 000006C 19 27JULO6 1 2 50 2 080706 PN 226 Storage 15 Store the engine in a dry protected place If engine must be stored outside cover it with a 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 1 Remove all protective coverings from engine Unseal all openings in engine and remove covering from electrical systems Remove the batteries from storage Install batteries fully charged and connect the terminals Install fan alternator poly vee belt if removed Fill fuel tank Perform all appropriate prestarting checks See DAILY PRESTARTING CHECKS in Lubrication and Maintenance Daily Section waterproof canvas or other suitable protective material and use a strong waterproof tape OURGP11 000006C 19 27JUL06 2 2 IMPORTANT DO NOT operate starter more than 90 3 30 seconds at a time Wait at least 2 minutes for starter to cool before trying again Crank engine for 20 seconds with starter do not allow the engine to start
226. terval is 2000 hours or 24 months of operation Drain old coolant flush the entire cooling system test thermostats and fill with recommended clean coolant per the following procedure 1 Pressure test entire cooling system and pressure cap if not previously done See PRESSURE TESTING COOLING SYSTEM in the Lubrication and Maintenance 500 Hour 12 Month Section 2 Slowly open the engine cooling system filler cap or radiator cap A to relieve pressure and allow coolant to drain faster Radiator Cap Continued on next page 35 3 TS281 UN 23AUG88 RG12833 UN 13FEB03 OURGP11 0000081 19 27JUL06 1 4 080706 PN 161 Lubrication amp 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 NOTE On earlier 475 engines the engine block drain valve is located behind the fuel rail and is not easily accessible UN 19JUNO0 4045HF475 and 6068HF475 Engines Open drain plug B or C on oil cooler housing Drain all coolant from engine block RG8019A NOTE These engines use several different oil filter adapters Use either drain plug B or C to drain coolant whichever is more accessible for the oil filter adapter on your engine 4 Open radiator drain valve Drain all coolant from radiator 5 Remove thermostats at this time if not previously done Install cove
227. the 1800 RPM single engine parameter display press the Menu key COOL TEMP 14 2 S Menu Key RG13159 UN 26SEP03 OURGP11 00000B1 19 27JULO06 1 18 2 Use the Arrow keys to scroll through the menu until GO TO 1 UP DISPLAY Setup 1 Up Display is highlighted STORED CODES ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITSD ADJUST BACKLIGHT Setup 1 Up Display oe e O O A I Z oe on z O oa OURGP11 00000B1 19 27JUL06 2 18 3 Once Setup 1 Up Display menu item has been GO TO 7 UP DISPLAY highlighted press the Enter key to access the Setup STORED CODES S 1 Up Display function ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITSD ADJUST BACKLIGHT Oo Press Enter Key Continued on next page OURGP11 00000B1 19 27JUL06 3 18 RG13194 UN 02O0CT03 17 20 080706 PN 83 Instrument Panel Elect Cont Later Engines 4 Three options are available for modification of the 1 Up USE DEFAULTS Display CUSTOM SETUP AUTOMATIC SCAN OFF a Use Defaults This option contains the following engine parameters for display Engine Hours Engine Speed Battery Voltage Load Coolant Temperature and Oil Pressure RG13196 UN 26SEP03 Custom Setup This option contains a list of f engine parameters Engine parameters from this list gt i can be selected to replace any or all of the default parameters This option can be used to add 1 Up Dis
228. the fuel system has been opened up This includes e After fuel filter changes e After pump or nozzle replacement e Anytime fuel lines have been disconnected e 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 OQUOD002 000016F 19 27JUL06 1 5 40 14 080706 PN 187 Service as Required 1 Loosen the air bleed vent screw A two full turns by hand on fuel filter base A Bleed Vent Screw RG11805 UN 250CTO01 Final Fuel Filter Bleed Vent Screw OUOD002 000016F 19 27JUL06 2 5 2 Operate fuel supply pump primer lever B or primer button on fuel filter base if equipped WN DEEN Tighten bleed plug securely continue operating primer until pumping action is not felt Start engine and check for leaks If engine will not start it may be necessary to bleed air from fuel system at fuel injection pump or injection nozzles as explained next RG11806 UN 250CT01 e B Primer Lever Continued on next page OQUOD002 000016F 19 27JUL06 3 5 40 15 080706 PN 188 Service as Required 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 As soon as fuel flow is free from air bubbles tighten fuel return line to specifications Primer le
229. til the trouble code condition is LOAD RPN Aah corrected 1800 RPM 14 2 57 PSI ENG RPM COOL TEMP l BAT VOLT OIL PRES Active Trouble Code Condition RG13243 UN 010CT03 OURGP11 00000AD 19 27JULO06 7 7 Engine Shutdown Codes 98 1000 RPM 1 During normal operation the single or four parameter 1800 RPM screen will be displayed 57 PSI BAT VOLT OIL PRES Normal Operation RG13172 UN 26SEP03 OURGP11 00000AE 19 27JUL06 1 6 When the diagnostic gauge receives a severe trouble SHUTDOWN 1 of x code from an engine control unit the single or four parameter screen will be replaced with the Shutdown ae 199 EM message The SPN and FMI number will be displayed ENGINE OIL PRESSURE LOW along with a description of the problem and the AAV corrective action needed ER ae 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 RG13238 UN 29SEP03 Shutdown Message OURGP11 00000AE 19 27JUL06 2 6 To acknowledge and hide the trouble code and return rr SHUTDOWN to the single or four parameter display press the SPN 100 EMI 4 Enter key Sia ENGINE OIL PRESSURE LOW CORRECTIVE ACTION o 0 Ge H E7 IMPORTANT Ignoring the shutdown message can result in severe engine damage esas HIDE ar Hide Trouble Code Continued on next page OURGP11 00000AE 19 27JUL06 3 6 17 12 0
230. ting 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 18 1 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 Indicator Lamp F Oil Pressure Indicator Lamp G Coolant Temperature Indicator Lamp H Key Switch UN 07JANO03 RG6574A OURGP11 000018E 19 27JUL06 1 2 080706 PN 95 Instrument Panel Mech Cont 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 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 UN 07JANO03 RG6574A H Key Switch The key switch controls
231. tion Indicator ee ee ee Gauge Check Lamps 4045DFTF270 ooo d e o S S Service Fire Extinguisher ooo d S e S S o Check Engine Mounts ooo S S e S S Service Batey ooo d S e S S o Check Manual Belt Tensioner and Bet Wear oo e o S o Change Engine Oil And Replace Oi Fites o ooo o e o S o Check Crankcase Vent System ooo do o e o S o Check Air Intake Hoses Connections amp System o Jo e To ooo So Replace Fuel Fiter Elements ooo o S e S S o Check Automatic Belt Tensioner and Bet Wear J o o ooo oo e o S o Check Engine Electrical Ground Connection o J e o o o Check Cooling System ooo S S e S S Coolant Solution Analysis Add SCAs as required Pressure Test Cooling System oS o o e o S Check Engine Speeds ooo d S e S S Adjust Variable Speed Droop 4 5 L 270 Engines e ee Check Crankshaft Vibration Damper 6 8 L Engines Jo o o oo ooo e o Flush and Refill Cooling System rs ee ee ee ee Test Thermostats oo o o l e S aReplace primary air cleaner element when restriction indicator shows a vacuum of 625 mm 25 in H2O During engine break in change the oil and filter for the first time before 100 hours of operation lf the recommended engine oils John Deere PLUS 50 or ACEA E7 ACEA E6 ACEA E5 or ACEA E4 are not used the oil and filter change interval is reduced see DIESEL ENGINE OIL AND FILTER INTERVALS chart If diesel fuel with a sulfur content greater than 0 05 is used the oil and filter change interval is also redu
232. tion of 1 part baking soda and 4 parts water Tighten all connections securely NOTE Coat battery terminals and connectors with a mixture of petroleum jelly and baking soda to retard corrosion 3 Keep battery fully charged especially during cold weather If a battery charger is used turn charger off before connecting charger to battery ies Attach POSITIVE battery charger lead to POSITIVE battery post Then attach NEGATIVE battery charger lead to a good ground Continued on next page RG RG34710 5568 19 27JULO06 1 2 30 2 080706 PN 139 Lubrication amp 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 a Flush your skin with water 2 Apply baking soda or lime to help neutralize the acid 3 Flush your eyes with water for 10 15 minutes Get medical attention immediately If acid is swallowed 1 Drink large amounts of water or milk 2 Then drink milk of magnesia beaten eggs or vegetable oil 3 Get medical attention immediately TS203 UN 23AUG88 Su
233. tions If rotation is felt damper is defective and should be replaced IMPORTANT The vibration damper assembly is not repairable and should be replaced every 4500 hours or 60 months whichever occurs first RG8018 UN 15JAN99 Check vibration damper radial runout by positioning a dial indicator A so probe contacts damper outer diameter With engine at operating temperature rotate crankshaft using either JD281A JDE81 4 or JDE83 Flywheel Turning Tool Note dial indicator reading If runout exceeds specifications given below replace vibration damper RG7508 UN 23NOV97 ifi n l _ Specificatio Check Runout Vibration Damper Maximum Radial Runout 1 50 mm 0 060 in RG RG34710 5585 19 27JULO6 1 1 35 2 080706 PN 160 Lubrication amp Maint 2000 Hour 24 Month Flushing and Refilling Cooling System CAUTION Explosive release of fluids from pressurized cooling system can cause serious burns Shut off engine Only remove filler cap when cool enough to touch with bare hands Slowly loosen cap to first stop to relieve pressure before removing completely NOTE When John Deere COOL GARD is used the drain interval is 3000 hours or 36 months The drain interval may be extended to 5000 hours or 60 months of operation provided that the coolant is tested annually AND additives are replenished as needed by adding a supplemental coolant additive SCA If COOL GARD is not used the flushing in
234. 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 RG12607 UN 240CT02 Using Tachometer to Check Engine Speeds OURGP12 00001DB 19 27JULO6 1 1 30 21 080706 PN 158 Lubrication amp Maint 2000 Hour 24 Month Adjusting Variable Speed Droop 4 5 L 270 Generator Set Engines Only Warm engine to normal operating temperature When necessary disconnect throttle linkage or cable Adjust slow idle C and adjust fast idle B speed when necessary Run engine at fast idle then apply load until reaching rated speed Check power Adjust with the screw A if needed Remove load from engine RG12066 UN 29JAN02 Again check and adjust fast idle if screw A has been turned Droop Adjustment Screw A Adjustment Screw Repeat procedure until both the engine power and the B Fast Idle Adjustment fast idle speed are correct C Slow Idle Adjustment Reinstall throttle linkage if previously removed OURGP12 00001ED 19 27JULO6 1 1 35 1 080706 PN 159 Lubrication amp Maint 2000 Hour 24 Month Checking Crankshaft Vibration Damper 6 Cylinder Engine Only 1 Remove belts shown removed 2 Grasp vibration damper with both hands and attempt to turn it in both direc
235. to Ground 000620 03 21 Sensor Supply 2 Voltage High 04 22 Sensor Supply 2 Voltage Low 000627 01 97 Electronic Injector Supply Voltage Problem 000629 13 ECU Error 000636 02 44 Pump Position Sensor Input Noise 08 43 Pump Position Sensor Input Missing 10 44 Pump Position Sensor Input Pattern Error 000637 02 39 Crank Position Input Noise 07 45 Crank Pump Timing Moderately Out of Sync 08 41 Crank Position Input Missing 10 39 Crank Position Input Pattern Error 000639 13 CAN Bus Error 000651 05 31 Cylinder 1 El Circuit Open 06 91 Cylinder 1 El Circuit Shorted 07 65 Cylinder 1 El Delivery Failure 000652 05 29 Cylinder 2 El Circuit Open 06 92 Cylinder 2 El Circuit Shorted 07 66 Cylinder 2 El Delivery Failure 000653 05 17 Cylinder 3 El Circuit Open 06 93 Cylinder 3 El Circuit Shorted 07 59 Cylinder 3 El Delivery Failure 000654 05 34 Cylinder 4 El Circuit Open 06 94 Cylinder 4 El Circuit Shorted 07 67 Cylinder 4 El Delivery Failure 000655 05 35 Cylinder 5 El Circuit Open 06 95 Cylinder 5 El Circuit Shorted 07 56 Cylinder 5 El Delivery Failure 000656 05 36 Cylinder 6 El Circuit Open 06 96 Cylinder 6 El Circuit Shorted 07 68 Cylinder 6 El Delivery Failure 000676 03 Glow Plug Relay Voltage High 05 Glow Plug Relay Voltage Low 000898 09 Vehicle Speed or Torque Message Invalid 000970 31 83 Engine Shutdown Auxiliary Request 000971 31 84 External Fuel Derate Switch Active 001069 09 Tire Size Invalid 31 Tire Siz
236. to No 1 TDC compression Continued on next page QUO01089 0000208 19 27JULO06 1 5 35 12 080706 PN 170 Lubrication amp 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 QU01089 0000208 19 27JUL06 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 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 Aa eed Si Clearance 0 46 mm 0 018 in Adjusting Valves Rocker Arm Adjusting Screw Jam Nut Torque 27 Nem 20 lb ft A Adjusting Screw Jam Nut NOTE While rocker arm cover
237. ttons To Scroll Quadrant Display ae e O O A T Z 7 op op O ao OURGP11 00000A9 19 27JUL06 5 5 Engine Configuration Data 98 1000 RPM LOAD RPM _ ENG RPM NOTE The engine configuration data is a read only 1800 RPM function ENG CooL TEMP oe eS NOTE The engine does not need to be running to navigate the diagnostic gauge screens If engine Q start up is desired See Starting The Engine All of the engine values illustrated on the diagnostic Menu Key gauge indicate the engine is running RG13159 UN 26SEP03 1 Turn the key switch to the ON position Starting at the single or four engine parameter display press the Menu key Continued on next page OURGP11 00000AB 19 27JUL06 1 6 17 6 080706 PN 69 Instrument Panel Elect Cont Later Engines 2 The main menu will be displayed Use the Arrow keys GO TO 1 UP DISPLAY to scroll through the menu until Engine Config is highlighted ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT OORO Select Engine Configuration OURGP11 00000AB_ 19 27JUL06 2 6 3 Once Engine Config menu item has been highlighted GO TO 1 UP DISPLAY press the Enter key to view the engine configuration data ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT RG13164 UN 070CT03 O Enter Key RG13165 UN 020CT03 OURGP11 00000AB 19 27JUL06 3 6 4
238. ults such as CAN BUS FAILURE OURGP11 0000152 19 27JUL06 1 1 45 28 080706 PN 222 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 conneciors 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 Suggestions for diagnosing intermittent faults Displaying Diagnostic Gauge Software Later Engines NOTE The following steps can be used to display the software version of the diagnostic gauge if needed by your dealer for troubleshoot
239. ure if overheated 3 Suspend thermostat and a thermometer in a container of water 4 Stir the water as it heats Observe opening action of thermostat and compare temperatures with the specification given in chart below NOTE Due to varying tolerances of different suppliers initial opening and full open temperatures may vary slightly from specified temperatures THERMOSTAT TEST SPECIFICATIONS Rating Initial Opening Range Full Open Nominal 71 C 160 F 69 72 C 156 162 F 84 C 182 F 77 C 170 F 74 78 C 166 1 72 F 89 C 192 F 82 C 180 F 80 84 C 175 182 F 94 C 202 F 89 C 192 F 86 90 C 187 194 F 101 C 214 F 90 C 195 F 89 93 C 192 199 F 103 C 218 F 92 C 197 F 89 93 C 193 200 F 105 C 221 F 96 C 205 F 94 97 C 201 207 F 100 C 213 F 99 C 210 F 96 100 C 205 212 F 111 C 232 F 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 RG5971 UN 23NOV97 Testing Thermostat Opening Temperature DPSG RG34710 112 19 27JUL06 3 5 080706 PN 165 Lubrication amp Maint 2000 Hour 24 Month To Install Thermostats IMPORTANT Install manifold gasket so that smaller round hol
240. urface On Header F Dust Seal RG11618 UN 240CT01 Continued on next page OURGP11 000008C 19 27JULO6 3 4 30 8 080706 PN 145 Lubrication amp Maintenance 500 Hour 12 Month 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 To determine the correct oil fill quantity for your engine see ENGINE CRANKCASE OIL FILL QUANTITIES in the Specifications Section of this manual IMPORTANT Immediately after completing any oil change crank engine for 30 seconds without permitting engine to start This will help insure adequate lubrication to engine components before engine starts RG11619 UN 240CT01 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 11 Stop engine and check oil level after 10 minutes Oil level reading should be within crosshatch of dipstick i RG11942 UN 240CT01 Oil Filler At Side Of Engine A Rocker Arm Cover Oil Filler Opening B Oil Filler At Side Of Engine OURGP11 000008C 19 27JULO06 4 4 Checking Crankcase Vent System Crankcase Vent Tube If Equipped If you operate the engine in dusty conditions check the system at shorter interv
241. used for service At each interval drain the coolant flush the cooling system and refill with new coolant 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 If John Deere COOL GARD is used but the coolant is not tested OR additives are not replenished by adding a supplemental coolant additive the drain interval is 3 years or 3000 hours of operation lf COOL GARD is not used the drain interval is reduced to 2 years or 2000 hours of operation COOL GARD is a trademark of Deere amp Company DX COOL11 19 19DEC03 1 1 10 14 080706 PN 42 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 Do not add a supplemental coolant additive when the cooling system is drained and refilled with John DeereCOOL GARD COOL GARD is a trademark of Deere amp Company Testing Diesel Engine Coolant Testing Diesel Engine Coolant Maintaining adequate concent
242. ver is spring loaded and will return to normal position RG11807 UN 250CT01 Specification i Ta Fuel Injection Pump Return Fuel Injection Pump Return Line Line Torque 27 Nem 20 lb ft A Fuel Return Line OUOD002 000016F 19 27JULO06 4 5 At Fuel Injection Nozzles IMPORTANT Always use a backup wrench when loosening or tightening fuel lines at nozzles and or injection pump to avoid damage Using two open end wrenches loosen two fuel line connections at injection nozzles 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 Nozzle Fuel Pressure Line to specifications oO H O O Yo i Z gt l 00 O am Specification Fuel Injection Nozzle Delivery Lines Torque 27 Nem 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 OQUOD002 000016F 19 27JULO6 5 5 40 16 080706 PN 189 Service as Required Bleed the Fuel System Engines with Electronic Fuel Systems and Denso High Pressure Common Rail 4045HF475 6068HF475 NO CAUTION High pressure fluid remaining in fuel NY lines can cause serious injury Do not disconnect or attempt repair of fuel lines sensors or any other components betwee
243. way time of sale with all U S emissions standards at the Engine Warranty 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 RG RG34710 7629 19 27JULO06 1 1 65 1 080706 PN 240 Emission System Warranty Emissions Control System Certification Label R JOHNDEERE S RTANT ENGINE INFORMATION DEERE amp COMPANY This engine fs certified to run on Diesel Fuel This engine conforms to 2001 Model U S EPA and California regulations for large n Famity No 1JDXL06 8038 e FEL 6 4 g kW hr NOx Engine Model S063HF275C EU No off Displacement 6 84 Power 168 kW 2400 mpm on road compresskwrignition engines Q7IBSEAOQMDOGXX O12 1 00 1509001 Registered For Engine Service and Parts Call 1 800 JD ENGINE RG11947 UN O6NOV01 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 transportable equipment The presence of an emissions label like the
244. y to resume field operations the operator brings the engine speed above 1300 rom and activates the cancel resume function again to resume cruise speed An internal timer gives the operator one minute to complete the turnaround maneuver 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 Use 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 rom changes until the engine reaches either full soeed or idle The cruise control cannot operate beyond the normal min max engine speeds 16 7 OURGP11 000027A 19 07AUG06 7 7 080706 PN 53 Instrument Panel Elect Cont Earlier Engines Using Diagnostic Gauge to Access Engine Information 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 a
245. your engine model and power rating and find it in the left column of 4 5 L or 6 8 L chart 2 Locate your engine oil pan option code 19 _ on engine label 3 In the chart column under your oil pan code select whether you use premium oil PLUS 50 or equivalent or standard grade oll 4 Determine the sulfur content of your diesel fuel 5 Now you can find the proper oil and filter change interval by lining up your power level and fuel sulfur content with oil pan oil type column The number indicates how frequent your oil and filter should be changed example every 500 hours of operation Continued on next page OURGP11 0000012 19 27JULO6 1 3 10 7 080706 PN 35 Fuels Lubricants and Coolant 4 5 L Engine Oil and Filter Service Intervals in Hours of Operation p Oil Pan Option Codes Power Fuel Sulfur Content 2 1901 1902 1976 Rating P Interval Interval Interval Interval Interval Std Prem Std Oil Prem Std Prem Std Oil Prem Std Oil Prem Oil Oil Oil Oil Oil Oil Oil n 0 05 0 50 500 5000 ppm 150 0 50 1 0 5000 10 000 ppm 63 86 Less Than 0 05 500 ppm 84 115 295 0 50 600 5000 pem 93 125 3 125 Less Than 0 05 500 ppm o 0 05 0 50 500 5000 ppm 99 108 Less Than 0 05 500 133 145 o 0 05 0 50 500 5000 ppm 117 143 Less Than 0 05 500 sor 157 192 o 0 05 0 50 500 5000 ppm Use of premium oil also requires use of an e

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