PowerTec Automobile Parts OMRG25204 User Manual

PowerTech

4.5 L and 6.8 L

Non-Certified and

Tier 1 Certified

OEM Diesel Engines

OPERATOR’S MANUAL

PowerTech 4.5 L and 6.8 L

Non-Certified and Tier 1 Certified

OEM Diesel Engines

OMRG25204 Issue 02Nov06 (ENGLISH)

CALIFORNIA

Proposition 65 Warning

Diesel engine exhaust and some of its constituents are

known to the State of California to cause cancer, birth

defects, and other reproductive harm.

If this product contains a gasoline engine:

WARNING

The engine exhaust from this product contains chemicals

known to the State of California to cause cancer, birth

defects or other reproductive harm.

The State of California requires the above two warnings.

John Deere Power Systems

LITHO IN U.S.A.

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Introduction

• PE4045TF151

• PE4045HF150

• PE4045HF252

• PE6068DF150

• PE6068TF150

• PE6068TF151

• PE6068TF250

• PE6068HF150

• PE6068HF250

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.

DUBUQUE BUILT TIER 1 CERTIFIED ENGINES

• T04045DF150

• T04045DF151

• T04045DF152

• T04045DF153

• T04045TF150

• T04045TF151

• T04045TF152

• T04045TF250

• T04045TF251

• T04045HF120

• T04045HF150

• T06068DF150

• T06068TF150

• T06068TF151

• T06068TF250

• T06068HF150

• T06068HF250

RIGHT-HAND AND LEFT-HAND sides are determined

by standing at the drive or flywheel end (rear) of the

engine and facing toward the front of the engine.

WRITE ENGINE SERIAL NUMBERS and option codes

in the spaces indicated in the Record Keeping Section.

Accurately record all the numbers. Your dealer also

needs these numbers when you order parts. File the

identification numbers in a secure place off the engine.

SETTING FUEL DELIVERY beyond published factory

specifications or otherwise overpowering will result in

loss of warranty protection for this engine.

CERTAIN ENGINE ACCESSORIES such as radiator,

air cleaner, and instruments are optional equipment on

John Deere OEM Engines. These accessories may be

provided by the equipment manufacturer instead of

John Deere. This operator’s manual applies only to the

engine and those options available through the John

Deere distribution network.

NOTE: Before 2005, all Non-certified and Tier 1

Certified Saran built engines used the following

serial number sequences:

• (CDxxxxD500000) - (CDxxxxD799999)

• (CDxxxxT500000) - (CDxxxxT799999)

• (CDxxxxH500000) - (CDxxxxH799999)

NOTE: This operators manual covers only engines

provided to OEM (Outside Equipment

Manufacturers). For engines in Deere

machines, refer to the machine operators

manual.

Since 2005, non-certified engines have the

seventh digit of the serial number as “B” while

Tier 1 certified engines have the seventh digit

as “C”.

OURGP11,0000004 –19–27OCT06–2/2

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Introduction

Engine Owner

John Deere Engine Owner:

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:

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

Lo identifichi e si informi sulla sua ubicazione. Alla

prima occasione utile lo contatti. Egli desidera fare la

sua conoscenza e capire quali potrebbero essere le

sue necessita`.

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.

Propietario De Equipo John Deere:

Aux Utilisateurs De Moteurs John Deere:

No espere hasta necesitar servicio de garantıa o de

N’attendez pas d’eˆtre oblige´ d’avoir recours a` votre

concessionnaire John Deere ou au point de service le

plus proche pour vous adresser a` lui. Pour enregistrer

votre moteur pour la garantie via Internet, utilisez

l’adresse suivante:

otro tipo para conocer a su Distribuidor de Motores

John Deere o al Concesionario de Servicio. Registre

su motor para la garantıa en la siguiente direccio´n de

internet: http://www.johndeere.com/enginewarranty

http://www.johndeere.com/enginewarranty

Ente´rese de quie´n es, y do´nde esta´ situado. Cuando

tenga un momento, vaya a visitarlo. A e´l le gustara´

Renseignez-vous de`s que possible pour l’identifier et

le localiser. A la premie`re occasion, prenez contact

conocerlo, y saber cua´les podrıan ser sus

necesidades.

avec lui et faites-vous connaıtre. Il sera lui aussi

heureux de faire votre connaissance et de vous

proposer ses services le moment venu.

Till a¨gare av John Deere motorer:

Ta reda pa vem din aterfo¨rsa¨ljare a¨r och beso¨k honom

An Den Besitzer Des John Deere Motors:

sa snart tillfa¨lle ges. Va¨nta inte tills det a¨r dags fo¨r

service eller eventuellt garantiarbete. Din motor

Warten Sie nicht auf einen evt. Reparaturfall, um den

na¨chstgelegenen John Deere Ha¨ndler kennen zu

garantiregistrerar Du via Internet pa

http://www.johndeere.com/enginewarranty

lernen. Zur Registrierung Ihres Motors fur die Garantie

dient folgende Internet-Adresse:

Din aterfo¨rsa¨ljare vill mycket ga¨rna tra¨ffa dig fo¨r att la¨ra

http://www.johndeere.com/enginewarranty

ka¨nna dina behov och hur ba¨st han kan hja¨lpa dig.

Machen Sie sich bei ihm bekannt und nutzen Sie sein

“Service Angebot”.

Proprietario del motore John Deere:

Non aspetti fino al momento di far valere la garanzia o

di chiedere assistenza per fare la conoscenza del

OURGP11,0000251 –19–11OCT06–1/1

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Introduction

POWERTECH 4.5 L Engines With Mechanical Controls (Tier 1 Emission Certified)

4045D Engine

4045T Engine

POWERTECH is a trademark of Deere & Company

RG,RG34710,5501 –19–04JAN02–1/1

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Introduction

POWERTECH 6.8 L Engines With Mechanical Controls (Tier 1 Emission Certified)

6068D Engine

6068T Engine

POWERTECH is a trademark of Deere & Company

RG,RG34710,5503 –19–04JAN02–1/1

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Contents

Page

Record Keeping

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

VDO Instrument (Gauge) Panel (Except

PowerTech Medallion . . . . . . . . . . . . . . . . . . . . . 01-1

Engine Serial Number Plate . . . . . . . . . . . . . . . . 01-1

Record Engine Serial Number . . . . . . . . . . . . . . 01-2

Engine Option Codes . . . . . . . . . . . . . . . . . . . . . 01-3

Record Fuel Injection Pump Model Number . . . . 01-5

North America) . . . . . . . . . . . . . . . . . . . . . . . . 15-4

Engine Break-In Service. . . . . . . . . . . . . . . . . . . 15-6

Auxiliary Gear Drive Limitations . . . . . . . . . . . . . 15-9

Generator Set (Standby) Applications. . . . . . . . . 15-9

Starting the Engine. . . . . . . . . . . . . . . . . . . . . . 15-10

Warming Engine. . . . . . . . . . . . . . . . . . . . . . . . 15-12

Normal Engine Operation . . . . . . . . . . . . . . . . . 15-13

Cold Weather Operation. . . . . . . . . . . . . . . . . . 15-14

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

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

Stopping the Engine. . . . . . . . . . . . . . . . . . . . . 15-16

Using a Booster Battery or Charger . . . . . . . . . 15-17

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-1

Fuels, Lubricants, and Coolant

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

Lubricity of Diesel Fuel. . . . . . . . . . . . . . . . . . . . 10-1

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

Testing Diesel Fuel. . . . . . . . . . . . . . . . . . . . . . . 10-2

Bio-Diesel Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . 10-3

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

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

Minimizing the Effect of Cold Weather on

Diesel Engines . . . . . . . . . . . . . . . . . . . . . . . . 10-5

Diesel Engine Break-In Oil . . . . . . . . . . . . . . . . . 10-6

Diesel Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . 10-7

Extended Diesel Engine Oil Service Intervals. . . 10-8

Mixing of Lubricants . . . . . . . . . . . . . . . . . . . . . . 10-8

OILSCAN and COOLSCAN . . . . . . . . . . . . . . 10-9

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

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

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

Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11

Diesel Engine Coolant . . . . . . . . . . . . . . . . . . . 10-12

Drain Intervals for Diesel Engine Coolant . . . . 10-13

Additional Information About Diesel

Lubrication and Maintenance

Observe Service Intervals. . . . . . . . . . . . . . . . . . 20-1

Use Correct Fuels, Lubricants, and Coolant . . . . 20-1

Lubrication and Maintenance Service

Interval Chart—Standard Industrial Engines . . 20-2

Lubrication and Maintenance Service

Interval Chart—Generator (Standby)

Applications . . . . . . . . . . . . . . . . . . . . . . . . . . 20-4

Lubrication & Maintenance/Daily

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

Lubrication & Maintenance/250 Hour/6 Month

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

Changing Engine Oil and Replacing Filter . . . . . 30-2

Checking Engine Mounts . . . . . . . . . . . . . . . . . . 30-4

Servicing Battery . . . . . . . . . . . . . . . . . . . . . . . . 30-5

Manual Belt Tensioner Adjustment . . . . . . . . . . . 30-7

Manual Belt Tensioner Adjustment Using

Engine Coolants and Supplemental Coolant

Additives . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14

Supplemental Coolant Additives . . . . . . . . . . . . 10-15

Additional Information About Diesel

Belt Tension Tool (Alternate Method

Engine Coolants and Supplemental Coolant

For Engines Without Auxiliary Drive). . . . . . . . 30-8

Additives . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16

Testing Diesel Engine Coolant . . . . . . . . . . . . . 10-17

Operating in Warm Temperature Climates . . . . 10-18

Disposing of Coolant . . . . . . . . . . . . . . . . . . . . 10-18

Lubrication & Maintenance/500 Hour/12 Month

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

Checking Air Intake System . . . . . . . . . . . . . . . . 35-2

Replacing Fuel Filter Element (Single Filter). . . . 35-3

Engine Operating Guidelines

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

Continued on next page

All information, illustrations and specifications in this manual are based on

the latest information available at the time of publication. The right is

reserved to make changes at any time without notice.

DEERE & COMPANY

Moline, Illinois

A John Deere ILLUSTRUCTION Manual

Previous Editions

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Contents

Page

Replacing Fuel Filter Elements (Dual Filters) . . . 35-5

Checking Belt Tensioner Spring Tension

Specifications

General OEM Engine Specifications—4.5 L

and Belt Wear (Automatic Tensioner) . . . . . . . 35-6

Checking Engine Speeds . . . . . . . . . . . . . . . . . . 35-9

Checking Engine Electrical Ground

Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 35-9

Checking Cooling System. . . . . . . . . . . . . . . . . 35-10

Replenishing Supplemental Coolant

Engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-1

General OEM Engine Specifications—6.8 L

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

Engine Power Ratings And Fuel Injection

Pump Specifications . . . . . . . . . . . . . . . . . . . . 60-3

Engine Crankcase Oil Fill Quantities . . . . . . . . 60-11

Unified Inch Bolt and Screw Torque Values . . . 60-15

Metric Bolt and Screw Torque Values. . . . . . . . 60-16

Additives (SCAs) Between Coolant

Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-11

Testing Diesel Engine Coolant . . . . . . . . . . . . . 35-12

Pressure Testing Cooling System. . . . . . . . . . . 35-13

Lubrication and Maintenance Records

Using Lubrication and Maintenance Records . . . 65-1

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

250 Hour/6 Month Service . . . . . . . . . . . . . . . . . 65-2

500 Hour/12 Month Service . . . . . . . . . . . . . . . . 65-3

2000 Hour/24 Month Service . . . . . . . . . . . . . . . 65-4

Service as Required . . . . . . . . . . . . . . . . . . . . . . 65-5

Lubrication & Maint./2000 Hour/24 Month

Adjusting Variable Speed (Droop) on

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

Checking Crankshaft Vibration Damper

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

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

Testing Thermostats Opening Temperature . . . . 40-7

Check and Adjust Valve Clearance . . . . . . . . . 40-10

Emission System Warranty

U.S. EPA Emissions Control Warranty

Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-1

Emissions Control System Certification Label. . . 70-1

Service as Required

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

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

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

Replacing Single Stage Air Cleaner . . . . . . . . . . 45-3

Replacing Axial Seal Air Cleaner Filter

Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-4

Replacing Radial Seal Air Cleaner Filter

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

Replacing Fan and Alternator Belts . . . . . . . . . . 45-8

Checking Fuses In Instrument Panels . . . . . . . . 45-9

Checking Air Compressors . . . . . . . . . . . . . . . . 45-10

Bleeding the Fuel System. . . . . . . . . . . . . . . . . 45-11

Troubleshooting

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

Engine Wiring Diagram Legend

(Standard Instrument Panel For North

America) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-3

Wiring Diagram (Standard Instrument

Panel For North America) . . . . . . . . . . . . . . . . 50-4

Engine Wiring Diagram—VDO

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

Engine Wiring Diagram Legend—VDO

Instrument Panel (Except North America) . . . . 50-6

Engine Troubleshooting . . . . . . . . . . . . . . . . . . . 50-7

Storage

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

Preparing Engine for Long Term Storage . . . . . . 55-2

Removing Engine from Long Term Storage . . . . 55-3

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Record Keeping

POWERTECH Medallion

A medallion is located on the rocker arm cover which

identifies each engine as a John Deere POWERTECH

engine.

POWERTECH is a trademark of Deere & Company.

RG,RG34710,5505 –19–04JAN02–1/1

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:

• “T0” indicates the engine was built in Dubuque, Iowa

• “CD” indicates the engine was built in Saran, France

• “PE” indicates the engine was built in Torreon, Mexico

• “J0” indicates the engine was built in Rosario, Argentina

Your engine’s serial number plate (A) is located on the

right-hand side of cylinder block behind the fuel filter.

13-Digit Engine Serial Number Plate

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Record Keeping

Record Engine Serial Number

Record all of the numbers and letters found on your

engine serial number plate in the spaces provided below.

This information is very important for repair parts or

warranty information.

Engine Serial Number (B)

Dubuque Engine Serial Number Plate

Engine Model Number (C)

Coefficient of Absorption Value (D)

(Saran Engines Only)

Saran Engine Serial Number Plate

Torreon Engine Serial Number Plate

RG,RG34710,5507 –19–04JAN02–1/1

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Record Keeping

Engine Option Codes

A—Engine Base Code

In addition to the serial number plate, OEM engines

have an engine option code label affixed to the rocker

arm cover. These codes indicate which of the engine

options were installed on your engine at the factory.

When in need of parts or service, furnish your

authorized servicing dealer or engine distributor with

these numbers.

The engine option code label includes an engine base

code (A). This base code must also be recorded along

with the option codes.

The first two digits of each code identify a specific

group, such as alternators. The last two digits of each

code identify one specific option provided on your

engine, such as a 12-volt, 55-amp alternator.

NOTE: These option codes are based on the latest

information available at the time of publication.

The right is reserved to make changes at any

time without notice.

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

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Record Keeping

NOTE: Your engine option code label may not contain

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.

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

Option Codes

Description

Rocker Arm Cover

Oil Fill Inlet

Crankshaft Pulley

Flywheel Housing

Flywheel

Fuel Injection Pump

Air Inlet

Air Cleaner

Balancer Shafts

Cylinder Block With Liners and Camshaft

Crankshaft and Bearings

Connecting Rods and Pistons

Valve Actuating Mechanism

Oil Pump

Cylinder Head With Valves

Auxiliary Gear Drive

Shipping Stand

Paint Option

Coolant Pump Inlet

Oil Cooler

Add-on Auxiliary Drive Pulley

Alternator Mounting Bracket

Exhaust Elbow

Oil Pan

Coolant Pump

Thermostat Cover

Thermostat

Fan Drive

Fan Belt

Fan

Engine Coolant Heater

Radiator

Exhaust Manifold

Crankcase Ventilator System

Starter Motor

Alternator

Instrument Panel

Tachometer

Turbocharger

Coolant Temperature Switch

Electronic Tachometer Sensor

Crankshaft Rear Damper

Engine Serial Number Plate

Air Conditioning (Freon) Compressor

Air Restriction Indicator

Oil Pressure Switch

Air Compressor

Water Separator

Fan Pulley

Belt Tensioner

Oil Filter

Fuel Filters

Front Plate

Fuel Transfer Pump

Thermostat Housing

Oil Dipstick

Belt-Driven Front Auxiliary Drive

Starting Aid

Special Equipment (Factory Installed)

Special Equipment (Field Installed)

Shipping

Timing Gear Cover With Gears

Service Only Items

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

OURGP11,0000005 –19–24JUN04–2/2

01-4

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Record Keeping

Record Fuel Injection Pump Model Number

Record the fuel injection pump model and serial

information found on the serial number plate (A).

Model No.

RPM

Manufacturer’s No.

Serial No.

A—Serial Number Plate

Record Injection Pump Serial Number

RG,RG34710,5511 –19–20MAY96–1/1

01-5

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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.

DX,ALERT –19–29SEP98–1/1

Understand Signal Words

A signal word—DANGER, WARNING, or CAUTION—is

used with the safety-alert symbol. DANGER identifies the

most serious hazards.

DANGER or WARNING safety signs are located near

specific hazards. General precautions are listed on

CAUTION safety signs. CAUTION also calls attention to

safety messages in this manual.

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.

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

05-1

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Safety

Replace Safety Signs

Replace missing or damaged safety signs. See the

machine operator’s manual for correct safety sign

placement.

DX,SIGNS1 –19–04JUN90–1/1

Prevent Machine Runaway

Avoid possible injury or death from machinery runaway.

Do not start engine by shorting across starter terminals.

Machine will start in gear if normal circuitry is bypassed.

NEVER start engine while standing on ground. Start

engine only from operator’s seat, with transmission in

neutral or park.

DX,BYPAS1 –19–29SEP98–1/1

Handle Fuel Safely—Avoid Fires

Handle fuel with care: it is highly flammable. Do not refuel

the machine while smoking or when near open flame or

sparks.

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.

DX,FIRE1 –19–03MAR93–1/1

05-2

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Safety

Prepare for Emergencies

Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service,

hospital, and fire department near your telephone.

DX,FIRE2 –19–03MAR93–1/1

DX,FIRE3 –19–16APR92–1/1

DX,FLAME –19–29SEP98–1/1

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.

Do not incinerate or puncture a starting fluid container.

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.

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Safety

Service Machines Safely

Tie long hair behind your head. Do not wear a necktie,

scarf, loose clothing, or necklace when you work near

machine tools or moving parts. If these items were to get

caught, severe injury could result.

Remove rings and other jewelry to prevent electrical

shorts and entanglement in moving parts.

DX,LOOSE –19–04JUN90–1/1

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.

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 impairment

or loss of hearing.

Wear a suitable hearing protective device such as

earmuffs or earplugs to protect against objectionable or

uncomfortable loud noises.

DX,NOISE –19–03MAR93–1/1

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Safety

Handle Chemical Products Safely

Direct exposure to hazardous chemicals can cause

serious injury. Potentially hazardous chemicals used with

John Deere equipment include such items as lubricants,

coolants, paints, and adhesives.

A Material Safety Data Sheet (MSDS) provides specific

details on chemical products: physical and health hazards,

safety procedures, and emergency response techniques.

Check the MSDS before you start any job using a

hazardous chemical. That way you will know exactly what

the risks are and how to do the job safely. Then follow

procedures and recommended equipment.

(See your John Deere dealer for MSDS’s on chemical

products used with John Deere equipment.)

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.

Wear close-fitting clothing. Stop the engine and be sure

PTO driveline is stopped before making adjustments,

connections, or performing any type of service on the

engine or PTO-driven equipment.

Rotating Drivelines

OUO1004,0000BD8 –19–11OCT06–1/1

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Safety

Practice Safe Maintenance

Understand service procedure before doing work. Keep

area clean and dry.

Never lubricate, service, or adjust machine while it is

moving. Keep hands, feet , and clothing from

power-driven parts. Disengage all power and operate

controls to relieve pressure. Lower equipment to the

ground. Stop the engine. Remove the key. Allow machine

to cool.

Securely support any machine elements that must be

raised for service work.

Keep all parts in good condition and properly installed. Fix

damage immediately. Replace worn or broken parts.

Remove any buildup of grease, oil, or debris.

On self-propelled equipment, disconnect battery ground

cable (-) before making adjustments on electrical systems

or welding on machine.

On towed implements, disconnect wiring harnesses from

tractor before servicing electrical system components or

welding on machine.

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

the exhaust fumes from the area with an exhaust pipe

extension.

If you do not have an exhaust pipe extension, open the

doors and get outside air into the area

DX,AIR –19–17FEB99–1/1

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Safety

Avoid High-Pressure Fluids

Escaping fluid under pressure can penetrate the skin

causing serious injury.

Avoid the hazard by relieving pressure before

disconnecting hydraulic or other lines. Tighten all

connections before applying pressure.

Search for leaks with a piece of cardboard. Protect hands

and body from high pressure fluids.

If an accident occurs, see a doctor immediately. Any fluid

injected into the skin must be surgically removed within a

few hours or gangrene may result. Doctors unfamiliar with

this type of injury should reference a knowledgeable

medical source. Such information is available from Deere

& Company Medical Department in Moline, Illinois, U.S.A.

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.

DX,TORCH –19–10DEC04–1/1

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Safety

Remove Paint Before Welding or Heating

Avoid potentially toxic fumes and dust.

Hazardous fumes can be generated when paint is heated

by welding, soldering, or using a torch.

Remove paint before heating:

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

to be affected by heating. If paint cannot be removed,

wear an approved respirator before heating or welding.

• If you sand or grind paint, avoid breathing the dust.

Wear an approved respirator.

• If you use solvent or paint stripper, remove stripper with

soap and water before welding. Remove solvent or

paint stripper containers and other flammable material

from area. Allow fumes to disperse at least 15 minutes

before welding or heating.

Do not use a chlorinated solvent in areas where welding

will take place.

Do all work in an area that is well ventilated to carry toxic

fumes and dust away.

Dispose of paint and solvent properly.

DX,PAINT –19–24JUL02–1/1

Service Cooling System Safely

Explosive release of fluids from pressurized cooling

system can cause serious burns.

Shut off engine. Only remove filler cap when cool enough

to touch with bare hands. Slowly loosen cap to first stop

to relieve pressure before removing completely.

DX,RCAP –19–04JUN90–1/1

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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.

Rotating Fan

OUOD006,000009D –19–11OCT06–1/1

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 may reach temperatures as high

as 500°C (932°F) under full load, and naturally aspired

exhaust manifolds may reach 600°C (1112°F) under full

load. This may ignite paper, cloth or wooden materials.

Parts on engines that have been at full load and reduced

to no load idle will maintain approximately 150°C (302°F).

Hot Surface

OUOD006,000009E –19–04DEC02–1/1

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Safety

Avoid Harmful Asbestos Dust

Avoid breathing dust that may be generated when

handling components containing asbestos fibers. Inhaled

asbestos fibers may cause lung cancer.

Components in products that may contain asbestos fibers

are brake pads, brake band and lining assemblies, clutch

plates, and some gaskets. The asbestos used in these

components is usually found in a resin or sealed in some

way. Normal handling is not hazardous as long as

airborne dust containing asbestos is not generated.

Avoid creating dust. Never use compressed air for

cleaning. Avoid brushing or grinding material containing

asbestos. When servicing, wear an approved respirator. A

special vacuum cleaner is recommended to clean

asbestos. If not available, apply a mist of oil or water on

the material containing asbestos.

Keep bystanders away from the area.

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).

DX,SPARKS –19–03MAR93–1/1

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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.

Always remove grounded (—) battery clamp

first and replace it last.

Explosion

CAUTION: Sulfuric acid in battery electrolyte is

poisonous. It is strong enough to burn skin, eat

holes in clothing, and cause blindness if

splashed into eyes.

Avoid the hazard by:

1. Filling batteries in a well-ventilated area.

2. Wearing eye protection and rubber gloves.

3. Avoiding breathing fumes when electrolyte is

added.

4. Avoiding spilling or dripping electrolyte.

5. Using proper jump start procedure.

If you spill acid on yourself:

1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize

the acid.

3. Flush your eyes with water for 15—30

minutes. Get medical attention immediately.

If acid is swallowed:

1. Do not induce vomiting.

2. Drink large amounts of water or milk, but do

not exceed 2 L (2 qt.).

Acid

3. Get medical attention immediately.

WARNING: Battery posts, terminals, and related

accessories contain lead and lead compounds, chemicals

known to the State of California to cause cancer and

reproductive harm. Wash hands after handling.

DPSG,OUO1004,2758 –19–11OCT06–1/1

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Safety

Protect Against High Pressure Spray

Spray from high pressure nozzles can penetrate the skin

and cause serious injury. Keep spray from contacting

hands or body.

If an accident occurs, see a doctor immediately. Any high

pressure spray injected into the skin must be surgically

removed within a few hours or gangrene may result.

Doctors unfamiliar with this type of injury should reference

a knowledgeable medical source. Such information is

available from Deere & Company Medical Department in

Moline, Illinois, U.S.A.

DX,SPRAY –19–16APR92–1/1

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.

DX,LIFT –19–04JUN90–1/1

Use Proper Tools

Use tools appropriate to the work. Makeshift tools and

procedures can create safety hazards.

Use power tools only to loosen threaded parts and

fasteners.

For loosening and tightening hardware, use the correct

size tools. DO NOT use U.S. measurement tools on

metric fasteners. Avoid bodily injury caused by slipping

wrenches.

Use only service parts meeting John Deere specifications.

DX,REPAIR –19–17FEB99–1/1

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Safety

Dispose of Waste Properly

Improperly disposing of waste can threaten the

environment and ecology. Potentially harmful waste used

with John Deere equipment include such items as oil, fuel,

coolant, brake fluid, filters, and batteries.

Use leakproof containers when draining fluids. Do not use

food or beverage containers that may mislead someone

into drinking from them.

Do not pour waste onto the ground, down a drain, or into

any water source.

Air conditioning refrigerants escaping into the air can

damage the Earth’s atmosphere. Government regulations

may require a certified air conditioning service center to

recover and recycle used air conditioning refrigerants.

Inquire on the proper way to recycle or dispose of waste

from your local environmental or recycling center, or from

your John Deere dealer.

DX,DRAIN –19–03MAR93–1/1

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Fuels, Lubricants, and Coolant

Diesel Fuel

Consult your local fuel distributor for properties of the

diesel fuel available in your area.

scar diameter of 0.45 mm as measured by ASTM

D6079 or ISO 12156-1.

In general, diesel fuels are blended to satisfy the low

temperature requirements of the geographical area in

which they are marketed.

Sulfur content:

• Diesel fuel quality and fuel sulfur content must

comply with all existing emissions regulations for the

area in which the engine operates.

• Use of diesel fuel with sulfur content less than

0.10% (1000 ppm) is STRONGLY recommended.

• Use of diesel fuel with sulfur content 0.10% (1000

ppm to 0.50% (5000 ppm) may result in REDUCED

oil and filter change intervals.

• BEFORE using diesel fuel with sulfur content greater

than 0.50% (5000 ppm), contact your John Deere

dealer.

• DO NOT use diesel fuel with sulfur content greater

than 1.0%.

Diesel fuels specified to EN 590 or ASTM D975 are

recommended.

Required fuel properties

In all cases, the fuel shall meet the following

properties:

Cetane number of 45 minimum. Cetane number

greater than 50 is preferred, especially for

temperatures below -20°C (-4°F) or elevations above

1500 m (5000 ft).

IMPORTANT: Do not mix used diesel engine oil or

any other type of lubricating oil with

diesel fuel.

Cold Filter Plugging Point (CFPP) below the

expected low temperature OR Cloud Point at least

5°C (9°F) below the expected low temperature.

IMPORTANT: Improper fuel additive usage may

cause damage on fuel injection

Fuel lubricity should pass a minimum level of 3100

grams as measured by ASTM D6078 or maximum

equipment of diesel engines.

DX,FUEL1 –19–17NOV05–1/1

Lubricity of Diesel Fuel

Most diesel fuels manufactured in the United States,

Canada, and the European Union have adequate

lubricity to ensure proper operation and durability of

fuel injection system components. However, diesel

fuels manufactured in some areas of the world may

lack the necessary lubricity.

Fuel lubricity should pass a minimum load level of

3100 grams as measured by ASTM D6078 or a

maximum scar diameter of 0.45 mm as measured by

ASTM D6079 or ISO 12156-1.

If fuel of low or unknown lubricity is used, add John

Deere PREMIUM DIESEL FUEL CONDITIONER (or

equivalent) at the specified concentration.

IMPORTANT: Make sure the diesel fuel used in

your machine demonstrates good

lubricity characteristics.

DX,FUEL5 –19–27OCT05–1/1

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Fuels, Lubricants, and Coolant

Handling and Storing Diesel Fuel

When using bio-diesel fuel, the fuel filter may require

more frequent replacement due to premature plugging.

CAUTION: Handle fuel carefully. Do not fill

the fuel tank when engine 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

original vented cap.

Keep all storage tanks as full as practicable to

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 & Company

DX,FUEL6 –19–14NOV05–1/1

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Fuels, Lubricants, and Coolant

Bio-Diesel Fuel

Consult your local fuel distributor for properties of the

bio-diesel fuel available in your area.

leaving deposits on injectors and in

the combustion chamber.

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.

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:

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.

• Quality of new fuel

• Water content of the fuel

• Problems due to aging of the fuel

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.

Potential problems resulting from deficiencies in the

above areas when using bio-diesel fuel in

concentrations above 5% may lead to the following

symptoms:

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.

• Power loss and deterioration of performance

• Fuel leakage

• Corrosion of fuel injection equipment

• Coked and/or blocked injector nozzles, resulting in

engine misfire

IMPORTANT: Raw pressed vegetable oils are NOT

acceptable for use as fuel in any

concentration in John Deere

engines.

• Filter plugging

• Lacquering and/or seizure of internal components

• Sludge and sediments

• Reduced service life of engine components

These oils do not burn completely,

and will cause engine failure by

Consult your fuel supplier for additives to improve

storage and performance of bio-diesel fuels.

DX,FUEL7 –19–14NOV05–1/1

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Fuels, Lubricants, and Coolant

Aviation (Jet) Fuels

Aviation (jet) fuels may be used with the following

restrictions.

Type

Comments

Jet A

Lower viscosity and density than base No. 2-D diesel

fuel. Power loss up to 10% can be expected.

Jet A-1

Jet B

Lower viscosity and density than base No. 2-D diesel

fuel. Power loss up to 10% can be expected.

Not Recommended.Lower density and extremely

low viscosity compared to base No. 2-D diesel fuel.

Power loss up to 14% can be expected.

JP-4

Not Recommended.Lower density and extremely

low viscosity compared to base No. 2-D diesel fuel.

Power loss up to 12% can be expected.

JP-5

JP-7

JP-8

Lower viscosity and density than base No. 2-D diesel

fuel. Power loss up to 9% can be expected.

Lower viscosity and density than base No. 2-D diesel

fuel. Power loss up to 10% can be expected.

Lower viscosity and density than base No. 2-D diesel

fuel. Power loss up to 10% can be expected.

OURGP12,000003F –19–07JUL04–1/1

Burner Fuels

Burner fuels, like kerosene, may be used with the

following restrictions.

Type

Comments

No.2

Higher density and specific gravity than base No. 2-D

diesel fuel. Power increase up to 3% can be

expected.

No.1

Lower viscosity than base No. 2-D diesel fuel. Power

loss up to 2% can be expected.

OURGP12,0000040 –19–07JUL04–1/1

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Fuels, Lubricants, and Coolant

Minimizing the Effect of Cold Weather on Diesel Engines

John Deere diesel engines are designed to operate

effectively in cold weather.

CAUTION: Do not use any starting fluid with

an engine equipped with glow plugs

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

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 Winter Grade Fuel

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.)

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.

Diesel Fuel Flow Additive

Cloud point is the temperature at which wax will begin

to form in the fuel and this wax causes fuel filters to

plug. Pour point is the temperature at which fuel

begins to thicken and becomes more resistant to flow

through fuel pumps and lines.

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.

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

IMPORTANT: Treat fuel when outside temperature

drops below 0°C (32°F). For best

results, use with untreated fuel.

Follow all recommended instructions

on label.

performance effects. Check the grade of fuel

being used before troubleshooting for low

power complaints in cold weather operation.

Winterfronts

Air Intake Heater

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.

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.

Continued on next page

DX,FUEL10 –19–16DEC05–1/2

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Fuels, Lubricants, and Coolant

If winterfronts are used, they should never totally close

the time the coolant reaches 93°C (200°F) to prevent

excessive intake manifold temperatures. Manually

controlled systems are not recommended.

off the grill frontal area. Approximately 25% area in the

center of the grill should remain open at all times. At

no time should the air blockage device be applied

directly to the radiator core.

If air-to-air aftercooling is used, the shutters must be

completely open by the time the intake manifold air

temperature reaches the maximum allowable

temperature out of the charge air cooler.

Radiator Shutters

If equipped with a thermostatically controlled radiator

shutter system, this system should be regulated in

such a way that the shutters are completely open by

For more information, see your John Deere dealer.

DX,FUEL10 –19–16DEC05–2/2

Diesel Engine Break-In Oil

New engines are filled at the factory with John Deere

ENGINE BREAK-IN OIL. During the break-in period,

add John Deere ENGINE BREAK-IN OIL as needed to

maintain the specified oil level.

After the break-in period, use John Deere PLUS-50

or other diesel engine oil as recommended in this

manual.

IMPORTANT: Do not use PLUS-50 oil or engine

oils meeting any of the following

Change the oil and filter after the first 100 hours of

operation of a new or rebuilt engine.

during the first 100 hours of

operation of a new or rebuilt engine:

After engine overhaul, fill the engine with John Deere

ENGINE BREAK-IN OIL.

API CJ-4

API CI-4 PLUS

API CI-4

API CH-4

API CG-4

API CF-4

API CF-2

API CF

ACEA E7

ACEA E6

ACEA E5

ACEA E4

ACEA E3

If John Deere ENGINE BREAK-IN OIL is not available,

use a diesel engine oil meeting one of the following

during the first 100 hours of operation:

• API Service Classification CE

• API Service Classification CD

• API Service Classification CC

• ACEA Oil Sequence E2

These oils will not allow the engine

to break-in properly.

• ACEA Oil Sequence E1

PLUS-50 is a trademark of Deere & Company.

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Fuels, Lubricants, and Coolant

Diesel Engine Oil

Use oil viscosity based on the expected air temperature

range during the period between oil changes.

John Deere PLUS-50 oil is preferred.

Oils meeting one of the following specifications are also

recommended:

• ACEA Oil Sequence E7

• ACEA Oil Sequence E6

• ACEA Oil Sequence E5

• ACEA Oil Sequence E4

Extended service intervals may apply when John Deere

PLUS-50, ACEA E7, ACEA E6, ACEA E5, or ACEA E4

engine oils are used. Consult your John Deere dealer for

more information.

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

following:

Oil Viscosities for Air Temperature Ranges

• John Deere TORQ-GARD SUPREME

• API Service Category CJ-4

• API Service Category CI-4 PLUS

• API Service Category CI-4

• API Service Category CH-4

• API Service Category CG-4

• API Service Category CF-4

• ACEA Oil Sequence E3

• ACEA Oil Sequence E2

If oils meeting API CG-4, API CF-4, or ACEA E2 are

used, reduce the service interval by 50%.

Multi-viscosity diesel engine oils are preferred.

Diesel fuel quality and fuel sulfur content must comply

with all existing emissions regulations for the area in

which the engine operates.

If diesel fuel with sulfur content greater than 0.50% (5000

ppm) is used, reduce the service interval by 50%.

PLUS-50 is a trademark of Deere & Company

TORQ-GARD SUPREME is a trademark of Deere & Company

Continued on next page

DX,ENOIL –19–13SEP06–1/2

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Fuels, Lubricants, and Coolant

DO NOT use diesel fuel with sulfur content greater than

1.00% (10 000 ppm).

DX,ENOIL –19–13SEP06–2/2

Extended Diesel Engine Oil Service Intervals

When John Deere PLUS-50 oil is used with the

specified John Deere filter, the service interval for

engine oil and filter changes may be increased by 50%

but not to exceed a maxium of 500 hours.

specified John Deere filter, change the engine oil and

filter at the normal service interval.

If John Deere TORQ-GARD SUPREME , API CJ-4,

API CI-4 PLUS, API CI-4, API CH-4, or ACEA E3 oils

are used, change the engine oil and filter at the normal

service interval.

When ACEA E7, ACEA E6, ACEA E5, or ACEA E4

oils are used with specified John Deere filter, use

engine oil analysis to determine if the service interval

for engine oil and filter changes may be increased by a

maximum of 50% but not to exceed 500 hours.

If API CG-4, API CF-4, or ACEA E2 oils are used,

change the engine oil and filter at 50% of the normal

service interval.

If John Deere PLUS-50 , ACEA E7, ACEA E6, ACEA

E5, or ACEA E4 oils are used with other than the

PLUS-50 is a trademark of Deere & Company

TORQ-GARD SUPREME is a trademark of Deere & Company

DX,ENOIL6 –19–13SEP06–1/1

Mixing of Lubricants

In general, avoid mixing different brands or types of oil.

Oil manufacturers blend additives in their oils to meet

certain specifications and performance requirements.

Consult your John Deere dealer to obtain specific

information and recommendations.

Mixing different oils can interfere with the proper

functioning of these additives and degrade lubricant

performance.

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Fuels, Lubricants, and Coolant

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.

OILSCAN is a registered trademark of Deere & Company.

COOLSCAN is a trademark of Deere & Company.

DX,OILSCAN –19–02DEC02–1/1

Alternative and Synthetic Lubricants

Conditions in certain geographical areas may require

lubricant recommendations different from those printed in

this manual.

Some John Deere brand coolants and lubricants may not

be available in your location.

Consult your John Deere dealer to obtain 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.

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Fuels, Lubricants, and Coolant

Lubricant Storage

Your equipment can operate at top efficiency only

when clean lubricants are used.

Make certain that all containers are properly marked to

identify their contents.

Use clean containers to handle all lubricants.

Properly dispose of all old containers and any residual

lubricant they may contain.

Whenever possible, store lubricants and containers in

an area protected from dust, moisture, and other

contamination. Store containers on their side to avoid

water and dirt accumulation.

DX,LUBST –19–18MAR96–1/1

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

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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 POLYUREA GREASE is preferred.

The following greases are also recommended

• John Deere HD LITHIUM COMPLEX GREASE

• John Deere HD WATER RESISTANT GREASE

• John Deere GREASE-GARD

Other greases may be used if they meet the following:

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

GREASE-GARD is a trademark of Deere & Company

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Fuels, Lubricants, and Coolant

Diesel Engine Coolant

The engine cooling system is filled to provide

Other low silicate ethylene glycol base coolants for

heavy-duty engines may also be used if they meet one

of the following specifications:

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.

• ASTM D4985 ethylene glycol base prediluted (50%)

coolant

John Deere COOL-GARD Prediluted Coolant is

preferred for service.

• ASTM D4985 ethylene glycol base coolant

concentrate in a 40% to 60% mixture of concentrate

with quality water

John Deere COOL-GARD Prediluted Coolant is

available in a concentration of either 50% ethylene

glycol or 55% propylene glycol.

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.

Additional recommended coolants

The following engine coolant is also recommended:

• John Deere COOL-GARD Coolant Concentrate in a

40% to 60% mixture of concentrate with quality

water.

Other coolants

It is possible that neither John Deere COOL-GARD nor

coolants meeting one of the 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.

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:

The additive package must be part of one of the

following coolant mixtures:

• ASTM D6210 prediluted (50%) coolant

• ASTM D6210 coolant concentrate in a 40% to 60%

mixture of concentrate with quality water

• ethylene glycol or propylene glycol base prediluted

(40% to 60%) coolant

• ethylene glycol or propylene glycol base 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.

Water quality

Coolants requiring supplemental coolant additives

COOL-GARD is a trademark of Deere & Company

Continued on next page

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Fuels, Lubricants, and Coolant

Water quality is important to the performance of the

IMPORTANT: Do not mix ethylene glycol and

propylene glycol base coolants.

cooling system. Distilled, deionized, or demineralized

water is recommended for mixing with ethylene glycol

and propylene glycol base engine coolant concentrate.

IMPORTANT: Do not use cooling system sealing

additives or antifreeze that contains

sealing additives.

DX,COOL3 –19–27OCT05–2/2

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

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

If 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 & Company

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Fuels, Lubricants, and Coolant

Additional Information About Diesel Engine Coolants and Supplemental Coolant

Additives

Engine coolants are a combination of three chemical

components: ethylene glycol or propylene glycol

antifreeze, inhibiting coolant additives, and quality

water.

simple mixture of ethylene glycol or propylene glycol

and water will not give adequate protection.

Use of supplemental coolant additives reduces

corrosion, erosion, and pitting. These chemicals

reduce the number of vapor bubbles in the coolant and

help form a protective film on cylinder liner surfaces.

This film acts as a barrier against the harmful effects

of collapsing vapor bubbles.

Coolant specifications

Some products, including John Deere COOL-GARD

Prediluted Coolant, are fully formulated coolants that

contain all three components in their correct

concentrations. Do not add an initial charge of

supplemental coolant additives to these fully

formulated products.

Avoid automotive-type coolants

Never use automotive-type coolants (such as those

meeting ASTM D3306). These coolants do not contain

the correct additives to protect heavy-duty diesel

engines. They often contain a high concentration of

silicates and may damage the engine or cooling

system.

Coolants meeting ASTM D6210 do not require an

initial charge of supplemental coolant additives.

Some coolant concentrates, including John Deere

COOL-GARD Coolant Concentrate, contain both glycol

antifreeze and inhibiting coolant additives. Mix these

products with quality water, but do not add an initial

charge of supplemental coolant additives.

Water quality

Water quality is important to the performance of the

cooling system. Distilled, deionized, or demineralized

water is recommended for mixing with ethylene glycol

and propylene glycol base engine coolant concentrate.

All water used in the cooling system should meet the

following minimum specifications for quality:

Coolants meeting ASTM D4985 require an initial

charge of supplemental coolant additives.

Replenish coolant additives

Chlorides

<40 mg/L

<100 mg/L

<340 mg/L

<170 mg/L

5.5 to 9.0

The concentration of coolant additives is gradually

depleted during engine operation. Periodic

replenishment of inhibitors is required, even when

John Deere COOL-GARD or another fully formulated

coolant is used. Follow the recommendations in this

manual for the use of supplemental coolant additives.

Sulfates

Total dissolved solids

Total hardness

Freeze protection

Why use supplemental coolant additives?

The relative concentrations of glycol and water in the

engine coolant determine its freeze protection limit.

Operating without proper coolant additives will result in

increased corrosion, cylinder liner erosion and pitting,

and other damage to the engine and cooling system. A

COOL-GARD is a trademark of Deere & Company

Continued on next page

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Fuels, Lubricants, and Coolant

Ethylene Glycol

Freeze Protection Limit

DO NOT use a coolant-water mixture greater than

60% ethylene glycol or 60% propylene glycol.

40%

-24°C (-12°F)

-37°C (-34°F)

50%

60%

Propylene Glycol

40%

-52°C (-62°F)

Freeze Protection Limit

-21°C (-6°F)

50%

-33°C (-27°F)

60%

-49°C (-56°F)

DX,COOL7 –19–19DEC03–2/2

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.

If other coolants are used, consult the coolant supplier

and follow the manufacturer’s recommendation for use

of supplemental coolant additives.

The use of non-recommended supplemental coolant

additives may result in additive drop-out and gelation

of the coolant.

John Deere COOLANT CONDITIONER is

recommended as a supplemental coolant additive in

John Deere engines.

Add the manufacturer’s recommended concentration of

supplemental coolant additive. DO NOT add more than

the recommended amount.

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 & Company

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Fuels, Lubricants, and Coolant

Additional Information About Diesel Engine Coolants and Supplemental Coolant

Additives

Engine coolants are a combination of three chemical

components: ethylene glycol or propylene glycol

antifreeze, inhibiting coolant additives, and quality

water.

simple mixture of ethylene glycol or propylene glycol

and water will not give adequate protection.

Use of supplemental coolant additives reduces

corrosion, erosion, and pitting. These chemicals

reduce the number of vapor bubbles in the coolant and

help form a protective film on cylinder liner surfaces.

This film acts as a barrier against the harmful effects

of collapsing vapor bubbles.

Coolant specifications

Some products, including John Deere COOL-GARD

Prediluted Coolant, are fully formulated coolants that

contain all three components in their correct

concentrations. Do not add an initial charge of

supplemental coolant additives to these fully

formulated products.

Avoid automotive-type coolants

Never use automotive-type coolants (such as those

meeting ASTM D3306). These coolants do not contain

the correct additives to protect heavy-duty diesel

engines. They often contain a high concentration of

silicates and may damage the engine or cooling

system.

Coolants meeting ASTM D6210 do not require an

initial charge of supplemental coolant additives.

Some coolant concentrates, including John Deere

COOL-GARD Coolant Concentrate, contain both glycol

antifreeze and inhibiting coolant additives. Mix these

products with quality water, but do not add an initial

charge of supplemental coolant additives.

Water quality

Water quality is important to the performance of the

cooling system. Distilled, deionized, or demineralized

water is recommended for mixing with ethylene glycol

and propylene glycol base engine coolant concentrate.

All water used in the cooling system should meet the

following minimum specifications for quality:

Coolants meeting ASTM D4985 require an initial

charge of supplemental coolant additives.

Replenish coolant additives

Chlorides

<40 mg/L

<100 mg/L

<340 mg/L

<170 mg/L

5.5 to 9.0

The concentration of coolant additives is gradually

depleted during engine operation. Periodic

replenishment of inhibitors is required, even when

John Deere COOL-GARD or another fully formulated

coolant is used. Follow the recommendations in this

manual for the use of supplemental coolant additives.

Sulfates

Total dissolved solids

Total hardness

Freeze protection

Why use supplemental coolant additives?

The relative concentrations of glycol and water in the

engine coolant determine its freeze protection limit.

Operating without proper coolant additives will result in

increased corrosion, cylinder liner erosion and pitting,

and other damage to the engine and cooling system. A

COOL-GARD is a trademark of Deere & Company

Continued on next page

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Fuels, Lubricants, and Coolant

Ethylene Glycol

Freeze Protection Limit

DO NOT use a coolant-water mixture greater than

60% ethylene glycol or 60% propylene glycol.

40%

-24°C (-12°F)

-37°C (-34°F)

50%

60%

Propylene Glycol

40%

-52°C (-62°F)

Freeze Protection Limit

-21°C (-6°F)

50%

-33°C (-27°F)

60%

-49°C (-56°F)

DX,COOL7 –19–19DEC03–2/2

Testing Diesel Engine Coolant

method to check the freeze point and additive levels of

your engine coolant.

Maintaining adequate concentrations of glycol and

inhibiting additives in the coolant is critical to protect

the engine and cooling system against freezing,

corrosion, and cylinder liner erosion and pitting.

Compare the results to the supplemental coolant

additive (SCA) chart to determine the amount of

inhibiting additives in your coolant and whether more

John Deere COOLANT CONDITIONER should be

added.

Test the coolant solution at intervals of 12 months or

less and whenever excessive coolant is lost through

leaks or overheating.

COOLSCAN and COOLSCAN PLUS

Coolant test strips

For a more thorough evaluation of your coolant,

perform a COOLSCAN or COOLSCAN PLUS analysis,

where available. See your John Deere dealer for

information.

Coolant test strips are available from your John Deere

dealer. These test strips provide a simple, effective

COOLSCAN is a trademark of Deere & Company

COOLSCAN PLUS is a trademark of Deere & Company

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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.

Recycle Waste

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.

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Engine Operating Guidelines

Instrument (Gauge) Panels

All controls and gauges are optional equipment for John

Deere OEM Engines. They may be provided by the

equipment manufacturer instead of John Deere. The

following information applies only to those controls and

gauges provided by John Deere.

IMPORTANT: Any time an electric gauge or meter

does not register correctly, replace it

with a new one. Do not attempt to repair

it.

Two types of instrument panels are offered on 4.5 L and

6.8 L engines, as shown on this page. See following for

complete information on each type of instrument panel.

North American Instrument Panel

VDO Instrument Panel (Except North America)

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Engine Operating Guidelines

Instrument (Gauge) Panel (North America)

All controls and gauges are optional equipment for John

Deere OEM Engines. They may be provided by the

equipment manufacturer instead of John Deere. The

following information applies only to those controls and

gauges provided by John Deere.

IMPORTANT: Any time an electric gauge or meter

does not register correctly, replace it

with a new one. Do not attempt to repair

it.

Following is a brief description of the components on the

instrument (gauge) panel:

A—Oil Pressure Gauge - This gauge indicates oil

pressure. It also has an adjustable electrical contact which

activates the safety switch when oil pressure goes below

the pressure set point. This will automatically stop the

engine.

North American Instrument Panel

B—Coolant Temperature Gauge - This gauge indicates

coolant temperature. It also has an electrical contact

which activates the safety switch when coolant

temperature goes above the temperature set point. This

will automatically stop the engine.

C—Key Switch - The key switch is used to start and stop

the engine. A key is required to operate the switch so as

to prevent unauthorized operation of the engine.

D—Tachometer - The tachometer indicates engine speed

in hundreds of revolutions per minute (rpm).

E—Safety Switch (Reset Button) - The safety switch

de-energizes the fuel shut-off solenoid or injection rack

puller to stop the engine, if one or more conditions are

met:

Hour Meter And Tachometer Codes

A—Oil Pressure Gauge

B—Coolant Temperature Gauge

C—Key Switch

D—Tachometer

• Low or no oil pressure

E—Reset (Safety) Switch

F—Fuse Holder (14 Amp Fuse)

G—Ammeter

H—Hourmeter

I—Hand Throttle

• High coolant temperature

• Low crankcase oil level (if equipped with engine oil level

switch)

• High crankcase oil level (if equipped with engine oil

level switch)

J—Tachometer Binary Code

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Engine Operating Guidelines

The reset button has to be held in when starting the

engine. The button allows the safety switch to override the

shut-down circuits until safe engine oil pressure is

maintained. Once engine oil pressure is within

specifications, the safety switch will latch and the reset

button can be released.

F—Fuse Holder - Contains 14 amp fuse.

G—Ammeter - The ammeter indicates the rate of charge

(+) or discharge (—) of the battery. When the engine is

first started, the ammeter will usually indicate a charge

rate of approximately 30 amps. After a short period of

operation, the ammeter needle will point slightly to the

right of “0”, indicating the charging system is operating

normally. A problem with the charging system is indicated

if the ammeter needle points to the left of “0” during

engine operation.

H—Hour Meter - The hour meter operates when the

engine is operating, or when the reset button is manually

held in while the key switch is in the ON position. The

accumulated hours are displayed in hours and tenths of

hours. On some panels, the hourmeter may be separate

from the tachometer.

I—Hand Throttle - The hand throttle is used to manually

control engine speed. If the hand throttle is electronic (as

shown), turn the knob clockwise or counterclockwise to

change engine speed. If the hand throttle is mechanical

(not shown), turning the handle, either clockwise or

counterclockwise, will lock the throttle position. Turn the

handle half way between the two lock positions to unlock

the throttle.

J—Tachometer Binary Code - The tachometer is

calibrated to the number of flywheel gear teeth read. The

dip switch to set the binary code is located in back of

tachometer and must be set at “10110011” to operate at

30 pulses per revolution.

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Engine Operating Guidelines

VDO Instrument (Gauge) Panel (Except North

America)

All controls and gauges are optional equipment for John

Deere OEM Engines. They may be provided by the

equipment manufacturer instead of John Deere. The

following information applies only to those controls and

gauges provided by John Deere.

IMPORTANT: Any time an electric gauge or meter

does not register correctly, replace it

with a new one. Do not attempt to repair

it.

VDO Instrument Panel

A—Oil Pressure Gauge

B—Coolant Temperature Gauge

C—Tachometer

Following is a brief description of the components on the

instrument (gauge) panel:

D—Engine Control Light

E—Preheater Light

A—Oil Pressure Gauge - The oil pressure gauge

indicates engine oil pressure.

F—Fuel Level Light

G—Battery Light

H—Oil Pressure Light

I—Coolant Temperature Light

J—Key/Start Switch

K—Hour Meter

B—Coolant Temperature Gauge - The coolant

temperature gauge indicates coolant temperature.

C—Tachometer - The tachometer indicates engine speed

in hundreds of revolutions per minute (rpm).

The engine control system consists of the following:

D—Engine Control Light - The engine control light

illuminates after the engine has started and oil pressure is

up to specification. The light indicates that the engine

protection circuitry is activated.

E—Preheater Light - The preheater light illuminates

when the key is turned to the bulb test position (position

I). It should go off after approximately five seconds. When

the key switch is held in position II, the engine preheater

is energized and the preheater light illuminates.

F—Fuel Level Light - The fuel level light illuminates

when the key is turned to the bulb test position (position

I). It should go off after approximately five seconds. After

the engine is running, if the engine runs out of fuel, the

light will illuminate and protection circuitry will stop the

engine. The fuel level light will remain on indicating the

engine was stopped due to the fuel tank being empty.

Continued on next page

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Engine Operating Guidelines

G—Battery Light - The battery light illuminates when the

key is turned to the bulb test position (position I). It should

go off after approximately five seconds. After the engine is

running, if the alternator stops charging, the light will

illuminate and protection circuitry will stop the engine. The

battery light will remain on indicating the engine was

stopped due to the alternator not charging.

H—Oil Pressure Light - The oil pressure light illuminates

when the key switch is turned to the bulb test position

(position I). The light will remain on until the engine is

started and the specified oil pressure is reached. If oil

pressure is lost during engine operation, the light will

illuminate and protection circuitry will stop the engine. The

oil pressure light will remain on, indicating that the engine

was stopped due to a low oil pressure condition.

I—Coolant Temperature Light - The coolant temperature

light illuminates when the key is turned to the bulb test

position (position I). It should go off after approximately

five seconds. After the engine is running, if the engine

overheats, the light will illuminate and protection circuitry

will stop the engine. The coolant temperature light will

remain on indicating the engine was stopped due to the

engine overheating.

Other components on the instrument panel:

J—Key/Start Switch - The four-position key start switch

controls the electrical system.

K—Hour Meter - The hour meter is an integral part of the

tachometer. It shows the accumulated hours of engine

service. The hour meter operates when the engine is

running and accumulated hours are displayed in hours

and tenths of hours.

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Engine Operating Guidelines

Engine Break-In Service

The engine is ready for normal operation. However, extra

care during the first 250 hours of operation will result in

more satisfactory long-term engine performance and life.

DO NOT exceed 250 hours of operation with break-in oil.

1. This engine is factory-filled with John Deere ENGINE

BREAK-IN OIL. Operate the engine at heavy loads

with minimal idling during the break-in period.

2. If the engine has significant operating time at idle,

constant speeds, and/or light load usage, or makeup

oil is required in the first 250 hour period, a longer

break-in period may be required. In these situations, an

additional 250 hour break-in period is recommended

using a new change of John Deere ENGINE

Check Engine Oil

BREAK-IN OIL and a new John Deere oil filter.

Continued on next page

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Engine Operating Guidelines

RG8028A –UN–15JAN99

IMPORTANT: DO NOT add makeup oil until the oil

level is BELOW the ADD mark on

dipstick. John Deere ENGINE BREAK-IN

OIL (TY22041) should be used to make

up any oil consumed during the

break-in period.

Crosshatch Pattern On Oil Dipstick

A—Crosshatch Pattern On Oil Dipstick

3. Check engine oil level more frequently during engine

break-in period. If oil must be added during this period,

John Deere ENGINE BREAK-IN OIL is preferred. See

ENGINE BREAK-IN OIL, in Fuels, Lubricants, and

Coolant Section.

IMPORTANT: DO NOT use PLUS-50 Engine Oil

during the break-in period of a new

engine or engine that has had a major

overhaul. PLUS-50 oil will not allow a

new or overhauled engine to properly

wear during this break-in period.

DO NOT fill above the crosshatch

pattern (A) or the FULL mark, whichever

is present. Oil levels anywhere within

the crosshatch are considered in the

acceptable operating range.

Specification

Engine¹—Oil Pressure at Full

Load Rated Speed ................................. 345 ± 103 kPa (3.45 ± 1.03 bar)

(50 ± 15 psi)

Minimum Oil Pressure at Rated

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

Minimum Oil Pressure at 850 rpm ................. 105 kPa (1.05 bar) (15 psi)

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

PLUS-50 is a trademark of Deere & Company.

¹At normal operating temperature of 115°C (240°F) sump.

Continued on next page

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Engine Operating Guidelines

4. During the first 20 hours, avoid prolonged periods of

engine idling or sustained maximum load operation. If

engine will idle longer than 5 minutes, stop engine.

5. Before the first 250 hours (maximum), change engine

oil and replace engine oil filter. (See CHANGING

ENGINE OIL AND REPLACING OIL FILTER in

Lubrication and Maintenance/250 Hour/6 Month

Section.) Fill crankcase with the normal seasonal

viscosity grade oil. (See DIESEL ENGINE OIL, in

Fuels, Lubricants, and Coolant Section.)

Changing Oil And Oil Filter Before First 250 Hours

NOTE: Some increase in oil consumption may be

expected when low viscosity oils are used. Check

oil levels more frequently.

If air temperature is below -10°C (14°F), use an

engine block heater.

OURGP12,0000076 –19–09SEP04–3/4

6. Watch coolant temperature gauge (A) closely. If

coolant temperature rises above 112°C (234°F), reduce

load on engine. Unless temperature drops quickly, stop

the engine and determine the cause before resuming

operation.

NOTE: When the coolant temperature gauge reads

approximately 115°C (239°F), the engine will

shutdown automatically, if equipped with safety

controls.

7. Check poly-vee belt for proper alignment and seating

in pulley grooves.

A—Coolant Temperature Gauge

North American (1999— ) Instrument Panel Shown

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Engine Operating Guidelines

Auxiliary Gear Drive Limitations

IMPORTANT: When attaching an air compressor,

hydraulic pump, or other accessory to

be driven by the auxiliary gear drive (A)

(engine timing gear train at front of

engine), power requirements of the

accessory must be limited to values

listed below:

• 30 kW (40 hp) Continuous Operation at 2500 rpm

• 37 kW (50 hp) Intermittent Operation at 2500 rpm

A—Auxiliary Gear Drive

Auxiliary Gear Drive

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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.

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Engine Operating Guidelines

Starting the Engine

The following instructions apply to the optional controls

and instruments available through the John Deere Parts

Distribution Network. The controls and instruments for

your engine may be different from those shown here;

always follow manufacturer’s instructions.

CAUTION: Before starting engine in a confined

building, install proper outlet exhaust

ventilation equipment. Always use safety

approved fuel storage and piping.

Use Proper Ventilation

NOTE: If temperature is below 0°C (32°F), it may be

necessary to use cold weather starting aids (See

COLD WEATHER OPERATION, later in this

section).

1. Perform all prestarting checks outlined in Lubrication &

Maintenance/Daily Section later in this manual.

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

3. Disengage clutch (if equipped) controlling any engine

drivelines.

Continued on next page

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Engine Operating Guidelines

NOTE: Electronically controlled governor applications may

be equipped with a rotary speed potentiometer on

the throttle (A) on the instrument panel.

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

pull hand throttle (A) 1/3 of the way out. Turn the handle

in either direction to lock it in place.

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

starting.

IMPORTANT: Do not operate the starter for more than

30 seconds at a time. To do so may

overheat the starter. If the engine does

not start the first time, wait at least 2

minutes before trying again. If engine

does not start after four attempts, see

Troubleshooting Section.

North American Standard Instrument Panel (1999— ) Shown

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

When the engine starts, release the key so that it returns

to the "ON" position.

IMPORTANT: If the key switch is released before the

engine starts, wait until the starter and

the engine stop turning before trying

again. This will prevent possible

VDO Standard Instrument Panel (Except North America)

A—Hand Throttle

B—Reset Button

damage to the starter and/or flywheel.

C—Key Start Switch

D—Oil Pressure Gauge

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

in until the oil pressure gauge (D) reads at least 105 kPa

(1.05 bar) (15 psi). The safety controls will not allow the

engine to run at a lower oil pressure unless the reset

button is held in.

IMPORTANT: Should the engine die when operating

under load, immediately disengage PTO

clutch and restart the engine.

Overheating of turbocharger parts may

occur when oil flow is stopped.

8. Check all gauges for normal engine operation. If

operation is not normal, stop the engine and determine

the cause.

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Engine Operating Guidelines

Warming Engine

IMPORTANT: To assure proper lubrication, operate

engine at or below 1200 rpm with no

load for 1–2 minutes. Extend this period

2–4 minutes when operating at

temperatures below freezing.

Engines used in generator set

applications where the governor is

locked at a specified speed may not

have a slow idle function. Operate these

engines at high idle for 1 to 2 minutes

before applying the load. This

procedure does not apply to standby

generator sets where the engine is

loaded immediately upon reaching rated

speed.

Standard North American Instrument Panel

1. Check oil pressure gauge (A) as soon as engine starts.

If gauge needle does not rise above minimum oil

pressure specification of 105 kPa (1.05 bar) (15.0 psi)

within 5 seconds, stop the engine and determine the

cause. Normal engine oil pressure is 345 kPa (3.45

bar) (50 psi) at rated full load speed (1800–2500 rpm)

with oil at normal operating temperature of 115°C

(240°F).

Standard VDO Instrument Panel (Except North America)

A—Oil Pressure Gauge

B—Coolant Temperature Gauge

NOTE: On certain engines, the oil pressure and coolant

temperature gauges are replaced by indicator

warning lights. The lights must be "OFF" when

engine is running.

2. Watch coolant temperature gauge (B). Do not place

engine under full load until it is properly warmed up.

The normal engine coolant temperature range is 82°—

94°C (180°—202°F).

NOTE: It is a good practice to operate the engine under a

lighter load and at lower speeds than normal for

the first few minutes after start-up.

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Engine Operating Guidelines

Normal Engine Operation

Observe engine coolant temperature and engine oil

pressure. Temperatures and pressures will vary

between engines and with changing operating

conditions, temperatures, and loads.

remove load and restart the engine.

Overheating of the turbocharger

parts may occur when oil flow is

stopped.

Normal engine coolant operating temperature range is

82°—94°C (180°—202°F). If coolant temperature rises

above 112°C (234°F), reduce load on engine. Unless

temperature drops quickly, stop engine and determine

cause before resuming operation.

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

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

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Engine Operating Guidelines

Cold Weather Operation

CAUTION: Ether injector starting fluid is highly

flammable. DO NOT use starting fluid on

engines equipped with air intake heaters.

DO NOT use starting fluid near fire, sparks, or

flames. DO NOT incinerate or puncture a

starting fluid container.

Engines may be equipped with intake air heaters, coolant

heaters, or ether injectors as a cold weather starting aid.

Handle Starting Fluid with Care

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

enhance starting performance above these temperatures

and may be needed to start applications that have high

parasitic loads during cranking and/or start acceleration to

idle.

Using correct grade of oil (per engine and machine

operator’s manual) is critical to achieving adequate cold

weather cranking speed.

Other cold weather starting aids are required at

temperatures below -22°F (-30°C) or at altitudes above

1500 m (5000 ft).

1. Follow steps 1—4 as listed under , then proceed as

follows according to the instrument (gauge) panel on

your engine.

2. Switch on the air intake heater for 30 seconds or

activate ether injector by following suppliers

instructions.

Cold Weather Starting Guidelines

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

this section.

Additional information on cold weather operation is

available from your authorized servicing dealer.

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Engine Operating Guidelines

Changing Engine Speed

To increase engine speed, turn throttle handle (A), if

equipped, to the horizontal position and pull out until

desired engine speed is obtained. Turn the handle in

either direction to lock throttle position. The handle is

pushed inward to decrease engine speed.

NOTE: On engines without handle, use throttle lever to

control engine speed.

A—Throttle Handle

North American Standard Instrument Panel Shown

RG,RG34710,5561 –19–07JAN02–1/1

Avoid Excessive Engine Idling

Prolonged idling may cause the engine coolant

temperature to fall below its normal range. This, in

turn, causes crankcase oil dilution, due to incomplete

fuel combustion, and permits formation of gummy

deposits on valves, pistons, and piston rings. It also

promotes rapid accumulation of engine sludge and

unburned fuel in the exhaust system.

speed. Slow idle speed for this engine is 850 rpm at

factory. If an engine will be idling for more than 5

minutes, stop and restart later.

NOTE: Generator set applications where the governor

is locked at a specified speed may not have a

slow idle function. These engines will idle at no

load governed speed (high idle).

Once an engine is warmed to normal operating

temperatures, engine should be idled at slow idle

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Engine Operating Guidelines

Stopping the Engine

1. Disengage clutch (if equipped) controlling engine

drivelines.

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

(mechanical) governor engines.

IMPORTANT: Before stopping an engine that has

been operating at working load, idle

engine at least 2 minutes at 1000–1200

rpm to cool hot engine parts.

For engines in generator set

applications, where the governor is

locked at a specified speed and no slow

idle function is available, run engine for

at least 2 minutes at fast idle and no

load.

North American Standard Instrument Panel Shown

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

engine. Remove ignition key.

IMPORTANT: Make sure that exhaust stack cap (rain

cap) is installed when engine is not

running. This will prevent water and dirt

from entering engine.

A—Throttle

B—Key Switch

Exhaust Stack Rain Cap

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Engine Operating Guidelines

Using a Booster Battery or Charger

A 12-volt booster battery can be connected in parallel with

battery (ies) on the unit to aid in cold weather starting.

ALWAYS use heavy duty jumper cables.

CAUTION: Gas given off by battery is explosive.

Keep sparks and flames away from battery.

Before connecting or disconnecting a battery

charger, turn charger off. Make last connection

and first disconnection at a point away from

battery. Always connect NEGATIVE (–) cable

last and disconnect this cable first.

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.

IMPORTANT: Be sure polarity is correct before

making connections. Reversed polarity

will damage electrical system. Always

connect positive to positive and

12-Volt System

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.

1. Connect booster battery or batteries to produce the

required system voltage for your engine application.

NOTE: To avoid sparks, DO NOT allow the free ends of

jumper cables to touch the engine.

2. Connect one end of jumper cable to the POSITIVE (+)

post of the booster battery.

3. Connect the other end of the jumper cable to the

POSITIVE (+) post of battery connected to starter.

24-Volt System

A—12-Volt Machine Battery (ies)

B—12-Volt Booster Battery (ies)

C—Booster Cable

4. Connect one end of the other jumper cable to the

NEGATIVE (–) post of the booster battery.

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

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Engine Operating Guidelines

6. Start the engine. Disconnect jumper cables

immediately after engine starts. Disconnect NEGATIVE

(–) cable first.

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Lubrication and Maintenance

Observe Service Intervals

Using hour meter (A) as guide, perform all services at the

hourly intervals indicated on following pages. At each

scheduled maintenance interval, perform all previous

maintenance operations in addition to the ones specified.

Keep a record of hourly intervals and services performed

using charts provided in Lubrication and Maintenance

Records Section.

IMPORTANT: Recommended service intervals are for

normal operating conditions. Service

MORE OFTEN if engine is operated

under adverse conditions. Neglecting

maintenance can result in failures or

permanent damage to the engine.

A—Hour Meter

North American Instrument Panel Hour Meter Shown

DPSG,OUOE003,20 –19–07JAN02–1/1

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.

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.

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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

250 Hour/

6 Month

500 Hour/

12 Month

2000 Hour/

24 Month

Item

Check Engine Oil and Coolant Level

Check Fuel Filter(s)/Water Separator Bowl

Check Air Cleaner Dust Unloader Valve & Indicator^a

Perform Visual Walkaround Inspection

Service Fire Extinguisher

Daily

As Required

•

Change Engine Oil And Replace Oil Filter^b

Check Engine Mounts

Service Battery

Check Manual Belt Tensioner and Belt Wear

Clean Crankcase Vent Tube

•

Check Air Intake Hoses, Connections, & System

Replace Single or Dual Fuel Filter Elements

Check Automatic Belt Tensioner and Belt Wear

Check Engine Speeds

Check Engine Electrical Ground Connection

Check Cooling System

Coolant Solution Analysis-Add SCAs as required

Pressure Test Cooling System

Check Crankshaft Vibration Damper (6.8 L Engines)^c

Flush Cooling System^d

•

Test Thermostats

Check and Adjust Engine Valve Clearance

Add Coolant

•

Replace Air Cleaner Elements

Replace Poly-Vee Belt

Check Fuses

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

^bChange the oil for the first time after 100 hours maximum of break-in operation. For subsequent oil and filter intervals, see recommendations

in section 10.

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

^dIf John Deere COOL-GARD is used, the flushing interval may be extended to 3000 hours or 36 months. If John Deere COOL-GARD is used

and the coolant is tested annually AND additives are replenished as needed by adding a supplemental coolant additive, the flushing interval

may be extended to 5000 hours or 60 months, whichever occurs first.

Continued on next page

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Lubrication and Maintenance

Lubrication and Maintenance Service Intervals

250 Hour/

6 Month

500 Hour/

12 Month

2000 Hour/

24 Month

Item

Check Air Compressor (If Equipped)

Bleed Fuel System

Daily

As Required

•

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Lubrication and Maintenance

Lubrication and Maintenance Service Interval

Chart—Generator (Standby) Applications

NOTE: Use service intervals listed below for generator

(standby) applications. Match service items below

to titles in Lubrication and Maintenance Sections

for procedures.

Lubrication and Maintenance Service Intervals

Every 2

250 Hours or 500 Hours or

2000 Hours

Item

Weeks

12 Months

or 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(s)/Water Separator Bowl

Check Air Cleaner Dust Unloader Valve & Indicator^a

Perform Visual Walkaround Inspection

Service Fire Extinguisher

•

Change Engine Oil and Replace Oil Filter^b

Check Engine Mounts

Service Battery

Clean Crankcase Vent Tube

•

Check Air Intake Hoses, Connections, & System

Replace Single or Dual Fuel Filter Elements

Check Belt Tensioner and Belt Wear

Check Engine Speeds

Check Engine Electrical Ground Connection

Check Cooling System

Coolant Solution Analysis-Add SCAs as required

Pressure Test Cooling System

Check Variable Speed (Droop) (Gen-Sets)

Check Crankshaft Vibration Damper (6.8 L Engines)^c

Flush Cooling System^d

•

Test Thermostats

Check and Adjust Engine Valve Clearance

Add Coolant

Replace Air Cleaner Elements

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

^bChange the oil for the first time after 100 hours maximum of break-in operation. For subsequent oil and filter intervals, see recommendations

in section 10.

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

^dIf John Deere COOL-GARD is used, the flushing interval may be extended to 3000 hours or 36 months. If John Deere COOL-GARD is used

and the coolant is tested annually AND additives are replenished as needed by adding a supplemental coolant additive, the flushing interval

may be extended to 5000 hours or 60 months, whichever occurs first.

Continued on next page

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Lubrication and Maintenance

Lubrication and Maintenance Service Intervals

Every 2

Weeks

250 Hours or 500 Hours or

12 Months 12 Months

2000 Hours

or 24 Months As Required

Item

Replace Poly-Vee Belt

Check Fuses

•

Check Air Compressor (If Equipped)

Bleed Fuel System

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Lubrication & Maintenance/Daily

Daily Prestarting Checks

Do the following BEFORE STARTING THE ENGINE for

the first time each day:

IMPORTANT: DO NOT add makeup oil until the oil

level is BELOW the add mark.

1. Check engine oil level on dipstick. Add as required,

using seasonal viscosity grade oil. (See DIESEL

ENGINE OIL in Fuels, Lubricants, and Coolant Section

for oil specifications.)

Left Side Oil Filler Cap

Right Side Oil Filler Cap

Rocker Arm Cover Filler Cap

Depending on application, oil may be added at left (A)

or right (B) side oil filler cap and rocker arm cover filler

cap (C) locations.

IMPORTANT: DO NOT fill above the top mark on the

dipstick. Oil levels anywhere within

crosshatch (D) are considered in the

acceptable operating range.

A—Left Side Oil Filler Cap

B—Right Side Oil Filler Cap

C—Cover Oil Filler Cap

D—Crosshatch On Dipstick

RG8028B –UN–15JAN99

Crosshatch on Dipstick

Continued on next page

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Lubrication & 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.

2. Check the coolant level when engine is cold. Coolant

level should be at bottom of filler neck. Fill radiator (A)

with proper coolant solution if level is low. (See

ADDING COOLANT in Service As Required Section.)

Check overall cooling system for leaks.

High-Pressure Fluids

NOTE: Refer to your vehicle’s operator’s manual for

recommendations for non-John Deere supplied

accessories.

A—Fill Radiator

Fill Radiator

Continued on next page

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Lubrication & Maintenance/Daily

3. Check the single or dual fuel filters for water or debris.

If filter is fitted with a see-through water separator

bowl, drain as needed based on a daily visual

inspection.

IMPORTANT: Drain water into a suitable container

and dispose of properly.

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

or bowl, if equipped, two or three turns.

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

filter mountings and drain water from bottom until

fuel starts to drain out.

Drain Fuel Filters (Dual Filters Shown)

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

securely.

After draining water from the fuel filter, the filter must

be primed by bleeding all air from the fuel system.

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

until fuel flow is free from air bubbles.

b. Tighten bleed plugs securely, and continue

operating hand primer until pumping action is not

felt. Primer lever is spring-loaded, and will return to

normal position.

Priming At Fuel Supply Pump

A—Air Bleed Plugs

B—Drain Plugs

C—Fuel Supply Pump Primer Lever

If the fuel system needs further bleeding of air, see

BLEEDING FUEL SYSTEM in Service As Required

Section, later in this manual.

Continued on next page

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Lubrication & Maintenance/Daily

4. If the air cleaner has an automatic dust unloader valve

(A), squeeze the unloader valve on air cleaner

assembly to clear away any dust buildup.

If equipped with air intake restriction indicator gauge

(B), check gauge to determine if air cleaner needs to

be serviced.

IMPORTANT: Maximum air intake restriction is 6.25

kPa (0.06 bar) (1.0 psi) (25 in. H²O). A

clogged air cleaner element will cause

excessive intake restriction and a

Dust Unloader Valve and Indicator Gauge

reduced air supply to the engine.

A—Dust Unloader Valve

B—Air Restriction Indicator

5. Make a thorough inspection of the engine

compartment. Look for oil or coolant leaks, worn fan

and accessory drive belts, loose connections and trash

build-up. Remove trash buildup and have repairs made

as needed if leaks are found.

NOTE: Wipe all fittings, caps, and plugs before

performing any maintenance to reduce the chance

of system contamination.

Inspect:

• Radiator for leaks and trash build-up.

• Air intake system hoses and connections for cracks

and loose clamps.

• Fan, alternator, and accessory drive belts for cracks,

breaks or other damage.

• Water pump for coolant leaks.

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

as the engine cools down and parts contract.

Excessive coolant leakage may indicate the need

to replace the water pump seal. Contact your

engine distributor or servicing dealer for repairs.

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Lubrication & Maintenance/250 Hour/6 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 250

hours of engine operation or once a month. Once

extinguisher is operated, no matter how long, it must be

recharged. Keep record of inspections on the tag which

comes with the extinguisher instruction booklet.

Fire Extinguisher

A—Fire Extinguisher

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Lubrication & Maintenance/250 Hour/6 Month

Changing Engine Oil and Replacing Filter

NOTE: Change engine oil and oil filter for the first time

after 100 hours maximum of operation, then every

250 hours thereafter.

If John Deere PLUS-50 or ACEA E4 or E5 engine oil and

a John Deere oil filter are used, the oil and filter change

interval may be extended by 50 percent.

OILSCAN or OILSCAN PLUS is a John Deere sampling

program to help you monitor machine performance and

identify potential problems before they cause serious

damage. OILSCAN and OILSCAN PLUS kits are

available from your John Deere engine distributor or

servicing dealer. Oil samples should be taken prior to the

oil change. Refer to instructions provided with kit.

Oil Filter

To change engine oil and oil filter:

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

Shut engine off.

2. Remove oil pan drain plug (arrow).

3. Drain crankcase oil from engine while warm.

Oil Pan Drain Plug

A—Oil Filter Element

NOTE: Drain plug location may vary, depending on the

application.

PLUS-50 is a trademark of Deere & Company.

OILSCAN is a trademark of Deere & Company.

OILSCAN PLUS is a trademark of Deere & Company.

Continued on next page

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Lubrication & Maintenance/250 Hour/6 Month

4. Turn filter element (A) counterclockwise using a

suitable filter wrench to remove. Discard oil filter

element.

NOTE: Depending on engine application, oil filter may be

located on either side of the engine.

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

IMPORTANT: Filtration of oils is critical to proper

lubrication. Always change filter

regularly. Use filter meeting John Deere

performance specifications.

Removing Oil Filter Element

A—Oil Filter Element

6. Oil new packing and install new filter element. Hand

tighten element according to values printed on filter

element. If values are not provided, tighten element

approximately 3/4 — 1-1/4 turn after packing contacts

filter housing. DO NOT overtighten filter element.

7. Install oil pan drain plug with O-ring or copper washer.

If copper washer is used, install with raised center

against plug. If O-ring or washer is damaged, replace

it.

8. Tighten drain plug to specifications.

Specification

Oil Pan Drain Plug With Copper

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

Oil Pan Drain Plug With O-Ring—

Torque ............................................................................. 50 N•m (37 lb ft)

Continued on next page

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9. Fill engine crankcase with correct John Deere engine

oil through rocker arm cover opening (B) or either side

oil filler (C) depending on engine application. (See

DIESEL ENGINE OIL in Fuels, Lubricants, and Coolant

Section for determining correct engine oil.)

To determine the correct oil fill quantity for your engine,

see ENGINE CRANKCASE OIL FILL QUANTITIES in

the Specifications Section of this manual.

IMPORTANT: Immediately after completing any oil

change, crank engine for 30 seconds

without permitting engine to start. This

will help insure adequate lubrication to

engine components before engine

starts.

Rocker Arm Cover Oil Filler

NOTE: Crankcase oil capacity may vary slightly.

ALWAYS fill crankcase to full mark or within

crosshatch on dipstick, whichever is present. DO

NOT overfill.

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

11. Stop engine and check oil level after 10 minutes. Oil

level reading should be within crosshatch of dipstick.

Side Oil Filler

B—Rocker Arm Cover Oil Filler

C—Side Oil Filler

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Checking Engine Mounts

Engine mounting is the responsibility of the vehicle or

generator manufacturer. Follow manufacturer’s guidelines

for mounting specifications.

IMPORTANT: Use only Grade SAE 8 or higher grade

of hardware for engine mounting.

1. Check the engine mounting bracket, vibration isolators,

and mounting bolts on support frame and engine block

for tightness. Tighten as necessary.

2. Inspect overall condition of vibration isolators, if

equipped. Replace isolators if rubber has deteriorated

or mounts have collapsed, as necessary.

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Servicing Battery

CAUTION: Battery gas can explode. Keep

sparks and flames away from batteries. Use a

flashlight to check battery electrolyte level.

Never check battery charge by placing a metal

object across the posts. Use a voltmeter or

hydrometer.

Always remove grounded NEGATIVE (–) battery

clamp first and replace it last.

Exploding Battery

WARNING: Battery posts, terminals, and related

accessories contain lead and lead compounds, chemicals

known to the State of California to cause cancer and

reproductive harm. Wash hands after handling.

1. On regular batteries, check electrolyte level. Fill each

cell to bottom of filler neck with distilled water.

NOTE: Low-maintenance or maintenance-free batteries

should require little additional service. However,

electrolyte level can be checked by cutting the

center section of decal on dash-line, and

removing cell plugs. If necessary, add clean, soft

water to bring level to bottom of filler neck.

2. Keep batteries clean by wiping them with a damp cloth.

Keep all connections clean and tight. Remove any

corrosion, and wash terminals with a solution of 1 part

baking soda and 4 parts water. Tighten all connections

securely.

NOTE: Coat battery terminals and connectors with a

mixture of petroleum jelly and baking soda to

retard corrosion.

3. Keep battery fully charged, especially during cold

weather. If a battery charger is used, turn charger off

before connecting charger to battery(ies). Attach

POSITIVE (+) battery charger lead to POSITIVE (+)

battery post. Then attach NEGATIVE (–) battery

charger lead to a good ground.

Continued on next page

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CAUTION: Sulfuric acid in battery electrolyte is

poisonous. It is strong enough to burn skin, eat

holes in clothing, and cause blindness if

splashed into eyes.

Avoid the hazard by:

1. Filling batteries in a well-ventilated area.

2. Wearing eye protection and rubber gloves.

3. Avoiding breathing fumes when electrolyte is

added.

4. Avoiding spilling or dripping electrolyte.

5. Use proper jump start procedure.

If you spill acid on yourself:

1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize

the acid.

3. Flush your eyes with water for 10–15

minutes. Get medical attention immediately.

If acid is swallowed:

1. Drink large amounts of water or milk.

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

vegetable oil.

Sulfuric Acid

3. Get medical attention immediately.

In freezing weather, run engine at least 30 minutes to

assure thorough mixing after adding water to battery.

If necessary to replace battery(ies), replacements must

meet or exceed the following recommended capacities at

-18°C (0°F):

Specification

12 Volt Standard Duty Starter—

Cold Cranking Amps ............................................................................ 640

12 Volt Heavy Duty Starter—Cold

Cranking Amps..................................................................................... 800

24 Volt Standard Duty Starter—

Cold Cranking Amps ............................................................................ 570

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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.

Check Belt Tension

NOTE: If timing gear cover or alternator bracket interfere

with installation/centering of belt tension gauge

(A), install gauge with face toward engine.

1. Install JDG1341 Belt Tension Gauge (A) on belt,

halfway between pulleys as shown. (JDG1341 Belt

Tension Gauge available from local John Deere Dealer

or Distributor.)

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

3. Slide alternator or tensioner bracket (D) in slot by hand

to remove all excess slack in belt.

Adjust Belt Tension

A—Belt Tension Gauge

IMPORTANT: Do not pry against alternator rear frame.

B—Cap Screw

C—Cap Screw

D—Tensioner Bracket

4. Stretch belt by prying outward on alternator front frame

or tensioner bracket. Observing tension gauge, stretch

the belt until specified tension is achieved.

Specification

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

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

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

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

used. Belt tension must then be rechecked per

used belt specifications.

6. Run engine for ten minutes and immediately re-check

belt tension per used belt specification above.

7. Reset belt tension as necessary.

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Manual Belt Tensioner Adjustment Using

Belt Tension Tool (Alternate Method For

Engines Without Auxiliary Drive)

NOTE: The JDG1520 Belt Tension Tool may not be

compatible with all alternators. In that case, use

the preceding method for belt tensioning.

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

areas. Replace if necessary.

As a reference check, twist belt in the middle of a

254—305 mm (10—12 in.) span with two fingers.

A properly tensioned belt will turn 75—85

degrees. If belt turns more, it needs to be

tightened. If belt turns less, it needs to be

loosened.

Alternator Bracket and Cap Screws

1. Loosen upper (A) and lower (B) alternator bracket cap

screws. Lower cap screw must remain tight enough to

prevent excessive alternator play but allow alternator to

pivot by hand.

2. Insert JDG1520 Belt Tension Tool (C) behind belt (D)

and over alternator mounting screw.

Belt Tension Tool

A—Upper Alternator Bracket Cap Screw

B—Lower Alternator Bracket Cap Screw

C—JDG1520 Belt Tension Tool

D—Belt

Continued on next page

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3. Place torque wrench (C) on belt tensioning tool (B) at

90° to tool. Pivot alternator (A) until desired torque is

achieved according to specification using the following

table.

Specification

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

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

JDG1520 Belt Tensioning Tool Torque Table

Desired Belt Tension

N (lb-force)

Applied Torque On Tool

N•m (lb-ft)

445 (100)

489 (110)

534 (120)

623 (140)

108 (90)

115 (85)

122 (90)

135 (100)

Belt Tension Tool and Torque Wrench

4. While holding tension with torque wrench (B), scribe a

reference mark (D) on alternator in line with notch (E)

on upper alternator bracket.

5. Continue to hold tension with torque wrench and

tighten upper alternator bracket cap screw.

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

Scribe Reference Mark

D—Reference Mark

E—Alternator Upper Bracket Notch

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Cleaning Crankcase Vent Tube

If you operate the engine in dusty conditions, clean the

tube at shorter intervals.

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

2. Install the vent tube. Be sure the O-ring fits correctly in

the rocker arm cover for elbow adapter. Tighten hose

clamp securely.

A—Crankcase Vent Tube

Crankcase Vent Tube

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Checking Air Intake System

IMPORTANT: The air intake system must not leak.

Any leak, no matter how small, may

result in internal engine damage due to

abrasive dirt and dust entering the

intake system.

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

necessary.

2. Check clamps (A) on piping which connect the air

cleaner, engine and, if present, turbocharger. Tighten

clamps as necessary. This will help prevent dirt from

entering the air intake system through loose

Check Clamps

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.)

H₂O, is torn, or visibly dirty.

Unloader Valve and Air Restriction Indicator

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

Replace indicator as necessary.

A—Clamps

B—Dust Unloader Valve

C—Air Restriction Indicator

IMPORTANT: If not equipped with air restriction

indicator, replace air cleaner elements

at 500 Hours or 12 Months, whichever

occurs first.

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Replacing Fuel Filter Element (Single Filter)

CAUTION: Escaping fluid under pressure can

penetrate the skin causing serious injury.

Relieve pressure before disconnecting fuel or

other lines. Tighten all connections before

applying pressure. Keep hands and body away

from pinholes and nozzles which eject fluids

under high pressure. Use a piece of cardboard

or paper to search for leaks. Do not use your

hand.

High-Pressure Fluids

If any fluid is injected into the skin, it must be

surgically removed within a few hours by a

doctor familiar with this type injury or gangrene

may result. Doctors unfamiliar with this type of

injury may call the Deere & Company Medical

Department in Moline, Illinois, or other

knowledgeable medical source.

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

2. Thoroughly clean fuel filter assembly and surrounding

area.

Fuel Filter

A—Retaining Ring

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

container.

B—Filter Element

C—Drain Plug

D—Bleed Plug

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

get it past raised locators.

4. Firmly grasp the retaining ring (A) and rotate it

clockwise 1/4 turn (when viewed from top). Remove

ring with filter element (B).

5. Inspect filter mounting base for cleanliness. Clean as

required.

NOTE: Raised locators on fuel filter canister must be

indexed properly with slots in mounting base for

correct installation.

6. Install new filter element onto mounting base. Be sure

element is properly indexed and firmly seated on base.

It may be necessary to rotate filter for correct

alignment.

Continued on next page

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

8. Install retaining ring onto mounting base making certain

dust seal is in place on filter base. Hand tighten ring

(about 1/3 turn) until it “snaps” into the detent. DO

NOT overtighten retaining ring.

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

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

A plug is provided with the new element for

plugging the used element.

9. Open fuel shut-off valve and bleed the fuel system.

(See BLEEDING FUEL SYSTEM in Service As

Required Section.) Tighten bleed plug (D).

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Replacing Fuel Filter Elements (Dual Filters)

CAUTION: Escaping fluid under pressure can

penetrate the skin causing serious injury.

Relieve pressure before disconnecting fuel or

other lines. Tighten all connections before

applying pressure. Keep hands and body away

from pinholes and nozzles which eject fluids

under high pressure. Use a piece of cardboard

or paper to search for leaks. Do not use your

hand.

High-Pressure Fluids

If any fluid is injected into the skin, it must be

surgically removed within a few hours by a

doctor familiar with this type injury or gangrene

may result. Doctors unfamiliar with this type of

injury may call the Deere & Company Medical

Department in Moline, Illinois, or other

knowledgeable medical source.

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

2. Thoroughly clean fuel filter assemblies and surrounding

area.

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

Right)

NOTE: Perform the following steps on each fuel filter.

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

container.

A—Retaining Ring

B—Filter Element

C—Drain Plug

D—Bleed Plug

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

get it past raised locators.

4. Firmly grasp the retaining ring (A) and rotate it

clockwise 1/4 turn (when viewed from top). Remove

ring with filter element (B).

5. Inspect filter mounting base for cleanliness. Clean as

required.

6. On primary filter with water separator, remove filter

element from water separator bowl. Drain and clean

separator bowl. Dry with compressed air. Install water

separator bowl onto new element. Tighten securely.

Continued on next page

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NOTE: Raised locators on fuel filter canister must be

indexed properly with slots in mounting base for

correct installation.

7. Install new filter element onto mounting base. Be sure

element is properly indexed and firmly seated on base.

It may be necessary to rotate filter for correct

alignment.

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

9. Install retaining ring onto mounting base making certain

dust seal is in place on filter base. Hand tighten ring

(about 1/3 turn) until it “snaps” into the detent. DO

NOT overtighten retaining ring.

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

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

A plug is provided with the new element for

plugging the used element.

10. Open fuel shut-off valve and bleed the fuel system.

(See BLEEDING FUEL SYSTEM in Service As

Required Section.) Tighten bleed plug (D).

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Checking Belt Tensioner Spring Tension and

Belt Wear (Automatic Tensioner)

Belt drive systems equipped with automatic (spring) belt

tensioners cannot be adjusted or repaired. The automatic

belt tensioner is designed to maintain proper belt tension

over the life of the belt. If tensioner spring tension is not

within specification, replace tensioner assembly.

Continued on next page

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Checking Belt Wear

The belt tensioner is designed to operate within the limit

of arm movement provided by the cast stops (A and B)

when correct belt length and geometry is used.

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

assembly.

If the tensioner stop on swing arm (A) is hitting the fixed

stop (B), check mounting brackets (alternator, belt

tensioner, idler pulley, etc.) and the belt length. Replace

belt as needed (see REPLACING FAN AND

Cast Stops

ALTERNATOR BELTS in Service As Required Section).

A—Cast Stops

B—Cast Stop

Continued on next page

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Checking Tensioner Spring Tension

A belt tension gauge will not give an accurate measure of

the belt tension when automatic spring tensioner is used.

Measure tensioner spring tension using a torque wrench

and procedure outlined below:

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

drive hole in tensioner, so no socket drive is

required.

1. Release tension on belt using a breaker bar and

socket (if required) on tension arm. Remove belt from

pulleys.

Marks on Tensioner

2. Release tension on tension arm and remove breaker

bar.

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

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

on tensioner mounting base.

5. Install torque wrench (C) so that it is aligned with

center of pulley and tensioner. Rotate the swing arm

with the torque wrench until marks (A and B) are

aligned.

Align Marks

6. Record torque wrench measurement and compare with

specification below. Replace tensioner assembly as

required.

Specification

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

NOTE: Threads on earlier belt tensioner roller cap screw

are LEFT-HAND threads.

Align Torque Wrench With Pulley And Tensioner

A—Mark On Swing Arm

B—Mark On Tensioner Mounting Base

C—Torque Wrench

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Checking Engine Speeds

Observe tachometer (A) reading on the instrument panel

to verify engine speeds while running engine. (Refer to

Specifications section later in this manual for engine

speed specifications.) If engine speeds need adjustment,

contact your engine dealer or distributor.

A—Tachometer

Check Engine Speed On Tachometer

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Checking Engine Electrical Ground

Connections

Keep all engine ground connections clean and tight to

prevent electrical arcing which can damage electronic

components.

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Checking Cooling System

CAUTION: Explosive release of fluids from

pressurized cooling system can cause serious

burns.

Shut off engine. Only remove filler cap when

cool enough to touch with bare hands. Slowly

loosen cap to first stop to relieve pressure

before removing completely.

IMPORTANT: Air must be expelled from cooling

system when system is refilled. Loosen

temperature sending unit fitting at rear

of cylinder head or plug in thermostat

housing to allow air to escape when

filling system. Retighten fitting or plug

when all the air has been expelled.

High-Pressure Fluids

1. Visually check entire cooling system for leaks. Tighten

all clamps securely.

2. Thoroughly inspect all cooling system hoses for hard,

flimsy, or cracked condition. Replace hoses if any of

the above conditions are found.

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Replenishing Supplemental Coolant Additives (SCAs) Between Coolant Changes

Radiator Coolant Check

JT07298 Coolant/Battery Tester

IMPORTANT: Do not add supplemental coolant

additives when the cooling system is

drained and refilled with John Deere

COOL-GARD

your cooling system to protect against rust, liner pitting

and corrosion, and freeze-ups due to incorrect coolant

dilution.

John Deere LIQUID COOLANT CONDITIONER is

recommended as a supplemental coolant additive

in John Deere engines.

NOTE: If system is to be filled with coolant that does

not contain SCAs, the coolant must be

precharged. Determine the total system

capacity and premix with 3% John Deere

Coolant Conditioner.

DO NOT mix one brand of SCA with a different

brand.

Through time and use, the concentration of coolant

additives is gradually depleted during engine operation.

Periodic replenishment of inhibitors is required, even

when John Deere COOL-GARD is used. The cooling

system must be recharged with additional

Test the coolant solution every 500 hours or 12

months of operation using either John Deere coolant

test strips or a COOLSCAN analysis. If a

COOLSCAN analysis is not available, recharge the

system per instructions printed on label of John Deere

Liquid Coolant Conditioner.

supplemental coolant additives available in the form of

liquid coolant conditioner.

Maintaining the correct coolant conditioner

concentration (SCAs) and freeze point is essential in

COOL-GARD is a registered trademark of Deere & Company

COOLSCAN is a registered trademark of Deere & Company

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IMPORTANT: ALWAYS maintain coolant at correct

The use of non-recommended supplemental coolant

additives may result in additive drop-out and gelation

of the coolant.

level and concentration. DO NOT

operate engine without coolant even

for a few minutes.

If other coolants are used, consult the coolant supplier

and follow the manufacturer’s recommendation for use

of supplemental coolant additives.

If frequent coolant makeup is

required, the glycol concentration

should be checked with JTO7298

Coolant/Battery Tester to ensure that

the desired freeze point is

See DIESEL ENGINE COOLANTS AND

SUPPLEMENTAL ADDITIVE INFORMATION for

proper mixing of coolant ingredients before adding to

the cooling system.

maintained. Follow manufacturer’s

instructions provided with

Coolant/Battery Tester.

Add the manufacturer’s recommended concentration of

supplemental coolant additive. DO NOT add more than

the recommended amount.

DPSG,OUOD002,1921 –19–07JAN02–2/2

Testing Diesel Engine Coolant

method to check the freeze point and additive levels of

your engine coolant.

Maintaining adequate concentrations of glycol and

inhibiting additives in the coolant is critical to protect

the engine and cooling system against freezing,

corrosion, and cylinder liner erosion and pitting.

Compare the results to the supplemental coolant

additive (SCA) chart to determine the amount of

inhibiting additives in your coolant and whether more

John Deere COOLANT CONDITIONER should be

added.

Test the coolant solution at intervals of 12 months or

less and whenever excessive coolant is lost through

leaks or overheating.

COOLSCAN and COOLSCAN PLUS

Coolant test strips

For a more thorough evaluation of your coolant,

perform a COOLSCAN or COOLSCAN PLUS analysis,

where available. See your John Deere dealer for

information.

Coolant test strips are available from your John Deere

dealer. These test strips provide a simple, effective

COOLSCAN is a trademark of Deere & Company

COOLSCAN PLUS is a trademark of Deere & Company

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Pressure Testing Cooling System

Test Radiator Cap

Test Cooling System

1. Allow engine to cool, then carefully remove radiator

cap.

CAUTION: Explosive release of fluids from

pressurized cooling system can cause

serious burns.

2. Fill radiator with coolant to the normal operating

level.

Shut off engine. Only remove filler cap when

cool enough to touch with bare hands.

Slowly loosen cap to first stop to relieve

pressure before removing completely.

IMPORTANT: DO NOT apply excessive pressure to

cooling system, doing so may

damage radiator and hoses.

Test Radiator Cap

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.

4. With pressure applied, check all cooling system

hose connections, radiator, and overall engine for

leaks.

2. Pressurize cap to specification listed. Gauge should

hold pressure for 10 seconds within the normal

range if cap is acceptable.

If leakage is detected, correct as necessary and

pressure test system again.

If gauge does not hold pressure, replace radiator

cap.

If no leakage is detected, but the gauge indicated a

drop in pressure, coolant may be leaking internally

within the system or at the block-to-head gasket.

Have your engine distributor or servicing dealer

correct this problem immediately.

Specification

Radiator Cap Holding Pressure

(Not Opening For 10

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

minimum

3. Remove the cap from gauge, turn it 180°, and

retest cap. This will verify that the first

measurement was accurate.

Test Cooling System

NOTE: Engine should be warmed up to test overall

cooling system.

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Lubrication & Maint./2000 Hour/24 Month

Adjusting Variable Speed (Droop) on

Generator Set Engines

Stanadyne Mechanical Injection Pumps Only

1. Warm engine to normal operating temperature.

2. When necessary, disconnect throttle linkage or cable.

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

when necessary.

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

rated speed.

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

6. Remove load from engine.

Droop Adjustment Screw

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

A—Adjustment Screw

B—Fast Idle Adjustment

C—Slow Idle Adjustment

turned.

8. Repeat procedure until both the engine power and the

fast idle speed are correct.

9. Reinstall throttle linkage if previously removed.

Continued on next page

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Lubrication & Maint./2000 Hour/24 Month

DENSO In-Line Injection Pumps Only

1. Check for specified no-load (frequency). If governor

regulation is within 5–7% range, no adjustment is

necessary.

2. If governor regulation is above 7% or below 5%, stop

engine and remove cap nuts from adjusting screws

before making adjustments.

3. Remove droop adjusting screw access plug (B, shown

removed) from top of governor housing.

4. Back out slow idle (adjusting) screw (D) and bumper

screw. Pull back on throttle lever (F, toward rear of

governor housing) by hand until the droop adjusting

screw (C) inside housing can be adjusted through the

access plug hole.

5. Screw the droop screw in (clockwise), counting the

turns until screw bottoms out. Then, return screw to

original setting.

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

droop adjusting screw. One click clockwise will

increase no-load speed approximately 10 rpm,

counterclockwise will reduce speed by 10 rpm.

DENSO In-Line Injection Pump

A—Fast Idle (Stop) Screw

B—Droop Adjusting Screw Access Plug Location

C—Droop Adjusting Screw

6. Screw in the droop screw (clockwise) no more than 1/2

turn (two clicks) at a time to reduce governor droop.

Turn counterclockwise no more than two clicks at a

time to increase governor droop (to reduce governor

sensitivity).

D—Slow Idle (Adjusting) Screw

E—Idle (Bumper) Spring

F—Throttle Lever

G—Mechanical Shutoff Lever

7. Replace access plug in top of governor housing. Start

engine, apply full (100%) load, and readjust high idle

adjusting screw until 1500 rpm is obtained at the

specified power.

8. Screw in idle (bumper) spring until engine speed

increases 5–10 rpm.

9. Repeat steps 4 through 7 until governor regulation is

within the 5–7% range.

10. Replace all cap nuts onto adjusting screws and

tighten lock nuts securely.

Continued on next page

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Lubrication & Maint./2000 Hour/24 Month

Delphi (Lucas) Injection Pumps Only

See your authorized Delphi (Lucas) Repair Station for

speed droop adjustment. This service requires that an

internal pump adjustment be made.

RG,RG34710,5583 –19–28JAN02–3/3

Checking Crankshaft Vibration Damper

(6-Cylinder Engine Only)

1. Remove belts (shown removed).

2. Grasp vibration damper with both hands and attempt to

turn it in both directions. If rotation is felt, damper is

defective and should be replaced.

IMPORTANT: The vibration damper assembly is not

repairable and should be replaced every

4500 hours or 60 months, whichever

occurs first.

Grasp Vibration Damper

3. Check vibration damper radial runout by positioning a

dial indicator (A) so probe contacts damper outer

diameter.

4. With engine at operating temperature, rotate crankshaft

using either JDE83 or JD81-1 Flywheel Turning Tool.

5. Note dial indicator reading. If runout exceeds

specifications given below, replace vibration damper.

Specification

Vibration Damper—Maximum

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

Check Runout

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Lubrication & 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

High-Pressure Fluids

replenished, as needed, by adding a

supplemental coolant additive (SCA).

If COOL-GARD is not used, the flushing interval is

2000 hours or 24 months of operation.

Drain old coolant, flush the entire cooling system, test

thermostats, and fill with recommended clean coolant per

the following procedure.

1. Pressure test entire cooling system and pressure cap if

not previously done. (See PRESSURE TESTING

COOLING SYSTEM, in the Lubrication and

Maintenance/500 Hour/12 Month Section.)

2. Slowly open the engine cooling system filler cap or

radiator cap (A) to relieve pressure and allow coolant

to drain faster.

Radiator Cap

Continued on next page

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Lubrication & Maint./2000 Hour/24 Month

3. Open engine block drain valve (A) on left side of

engine. Drain all coolant from engine block.

NOTE: These engines use several different oil filter

adapters. Use either drain plug (B) or (C) to drain

coolant, whichever is more accessible for the oil

filter adapter on your engine.

4. Open radiator drain valve. Drain all coolant from

radiator.

5. Remove thermostats at this time, if not previously

done. Install cover (without thermostats) using old

gasket and tighten cap screws to 47 N•m (35 lb-ft).

Engine Block Drain Valve

A—Engine Block Drain Valve

B—Engine Block Drain Plug

C—Engine Block Drain Plug

6. Test thermostat opening temperature. (See Inspecting

Thermostats And Testing Opening Temperature in

Service As Required Section.)

7. Close all drain valves after coolant has drained.

CAUTION: Do not run engine longer than 10

minutes. Doing so may cause engine to

overheat which may cause burns when radiator

water is draining.

8. Fill the cooling system with clean water. Run the

engine about 10 minutes to stir up possible rust or

sediment.

9. Stop engine, pull off lower radiator hose and remove

radiator cap. Immediately drain the water from system

before rust and sediment settle.

10. After draining water, close drain valves. Reinstall

radiator cap and radiator hose and clamp. Fill the

cooling system with clean water and a heavy duty

cooling system cleaner such as Fleetguard

RESTORE and RESTORE PLUS . Follow

manufacturer’s directions on label.

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

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Lubrication & Maint./2000 Hour/24 Month

11. After cleaning the cooling system, drain cleaner and

fill with water to flush the system. Run the engine

about 10 minutes, remove radiator cap and pull off

lower radiator hose to drain out flushing water.

12. Close all drain valves on engine and radiator.

Reinstall radiator hose and tighten clamps securely.

Install thermostats using a new gasket. (See

TESTING THERMOSTATS OPENING

TEMPERATURE later in this section.)

IMPORTANT: Air must be expelled from cooling

system when system is refilled. Loosen

temperature sending unit fitting at rear

of cylinder head or plug in thermostat

housing to allow air to escape when

filling system. Retighten fitting or plug

after filling cooling system.

NOTE: Coolant capacity may vary depending on

application.

13. Add coolant to radiator until coolant touches bottom of

filler neck. (See specification for capacity.) Install

radiator cap.

Specification

4.5 L Engine— Coolant Capacity............................................. 8.5 L (9 qt)

6.8 L Engine—Coolant Capacity.......................................... 11.3 L (12 qt)

14. Run engine until it reaches operating temperature.

This mixes the solution uniformly and circulates it

through the entire system. The normal engine coolant

temperature range is 82°—94°C (180° — 202°F).

15. After running engine, check coolant level and entire

cooling system for leaks.

16. Inspect the fan belt for wear and check belt tension.

(See Checking Belt Tensioner Spring Tension and

Belt Wear in Lubrication and Maintenance 500

Hour/12 Month section.

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Lubrication & Maint./2000 Hour/24 Month

Testing Thermostats Opening Temperature

To Remove Thermostat(s)

NOTE: On some engines, the coolant manifold/thermostat

housing is an integral part of the cylinder head.

CAUTION: Explosive release of fluids from

pressurized cooling system can cause serious

burns. DO NOT drain coolant until it has cooled

below operating temperature. Always loosen

radiator pressure cap or drain valve slowly to

relieve pressure.

High Pressure Fluids

1. Visually inspect area around thermostat housing for

leaks.

2. Remove radiator pressure cap and partially drain

cooling system.

3. Remove thermostat cover-to-water pump tube (A) and

seal.

A—Cover-To-Coolant Pump Tube

Thermostat Cover-to-Water Pump Tube

DPSG,RG34710,112 –19–07JAN02–1/5

4. Remove thermostat cover (B) with gasket.

5. Remove thermostat(s)

6. Remove and discard all gasket material. Clean gasket

surfaces.

7. Clean and check cover for cracks or damage.

B—Thermostat Cover

Thermostat Cover

Continued on next page

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Lubrication & Maint./2000 Hour/24 Month

Testing Thermostats Opening Temperature

1. Remove thermostat(s).

2. Visually inspect thermostat(s) for corrosion or damage.

If dual thermostats, replace as a matched set as

necessary.

CAUTION: DO NOT allow thermostat or

thermometer to rest against the side or bottom

of container when heating water. Either may

rupture if overheated.

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.

Testing Thermostat Opening Temperature

THERMOSTAT TEST SPECIFICATIONS

Rating

Initial Opening (Range)

Full Open

(Nominal)

71°C (160°F)

77°C (170°F)

82°C (180°F)

89°C (192°F)

90°C (195°F)

92°C (197°F)

96°C (205°F)

99°C (210°F)

69—72°C (156—162°F)

74—78°C (166—172°F)

80—84°C (175—182°F)

86—90°C (187—194°F)

89—93°C (192—199°F)

89—93°C (193—200°F)

94—97°C (201—207°F)

96—100°C (205—212°F)

84°C (182°F)

89°C (192°F)

94°C (202°F)

101°C (214°F)

103°C (218°F)

105°C (221°F)

100°C (213°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

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Lubrication & Maint./2000 Hour/24 Month

To Install Thermostats

IMPORTANT: Install manifold gasket so that smaller

(round) holes are at lower left and

upper right corners of manifold

(matching studs A).

1. Clean all gasket material from thermostat cover and

housing mounting surfaces.

2. Using guide studs (A) to keep gasket in place, install a

new gasket on cylinder head.

Installing Thermostat Cover

3. Install thermostat(s) with jiggle wire facing up in the 12

o’clock position.

4. Using a screwdriver to hold thermostat(s) in place,

install thermostat(s) and water manifold/thermostat

cover.

5. Tighten cover cap screws to 70 N•m (52 lb-ft).

6. Lubricate new O-ring with PT507 Multi-Purpose

Grease. Install seal (B) in thermostat cover.

A—Guide Studs

B—Seal

Thermostat Cover Seal

DPSG,RG34710,112 –19–07JAN02–4/5

7. Install coolant manifold/thermostat cover-to-coolant

pump tube (C). Tighten clamps.

8. If not already done, fill cooling system and check for

leaks.

IMPORTANT: Air must be expelled from cooling

system when filling. Loosen

temperature sending unit fitting at rear

of cylinder head or plug in thermostat

housing to allow air to escape when

filling system. Tighten fitting or plug

when all air has been expelled.

Cover-To-Coolant Pump Tube

C—Cover-To-Coolant Pump Tube

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Lubrication & Maint./2000 Hour/24 Month

Check and Adjust Valve Clearance

CAUTION: To prevent accidental starting of

engine while performing valve adjustments,

always disconnect NEGATIVE (—) battery

terminal.

IMPORTANT: Valve clearance MUST BE checked and

adjusted with engine COLD.

1. Remove rocker arm cover and crankcase ventilator

tube.

Flywheel Housing Timing Holes

IMPORTANT: Visually inspect contact surfaces of

valve tips and rocker arm wear pads.

Check all parts for excessive wear,

breakage, or cracks. Replace parts that

show visible damage.

A—Timing/Rotation Hole

B—Timing Pin Hole

Rocker arms that exhibit excessive

valve clearance should be inspected

more thoroughly to identify damaged

parts.

2. Remove plastic plugs or cover plate from engine

timing/rotation hole (A) and timing pin hole (B).

NOTE: Some engines are equipped with flywheel

housings which do not allow use of an engine

flywheel rotation tool. These engines may be

rotated from front nose of engine, using JDG966

Crankshaft Front/Rear Rotation Adapter.

3. Using JDE83 or JD81-1 Flywheel Turning Tool, rotate

engine flywheel in running direction (clockwise viewed

from front) until No. 1 cylinder is at TDC compression

stroke. Insert JDG1571 or JDE81-4 Timing Pin in

flywheel.

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

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Lubrication & Maint./2000 Hour/24 Month

4. With engine lock-pinned at TDC of No. 1 piston’s

compression stroke, check valve clearance to following

specifications. (Use sequence for 4-cylinder or

6-cylinder engines as outlined on next page.)

Specification

Intake Valve Clearance For

Checking (Rocker Arm-to-Valve

Tip) (Engine Cold)—Clearance ......................................... 0.31—0.38 mm

(0.012—0.015 in.)

Exhaust Valve Clearance For

Checking (Rocker Arm-to-Valve

Tip) (Engine Cold)—Clearance ......................................... 0.41—0.48 mm

(0.016—0.019 in.)

DPSG,RG41165,137 –19–16JAN02–2/5

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 For

Adjusting (Rocker Arm-to-Valve

Tip) (Engine Cold)—Clearance .................................. 0.36 mm (0.014 in.)

Exhaust Valve Clearance For

Adjusting Valves

A—Adjusting Screw Jam Nut

Adjusting (Rocker Arm-to-Valve

Tip) (Engine Cold)—Clearance .................................. 0.46 mm (0.018 in.)

Rocker Arm Adjusting Screw Jam

Nut—Torque .................................................................... 27 N•m (20 lb-ft)

6. Replace rocker arm cover and crankcase ventilator

tube.

Continued on next page

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Lubrication & 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).

2. Adjust valve clearance on No. 1 and 3 exhaust valves

and No. 1 and 2 intake valves.

3. Turn crankshaft 360°. Lock No. 4 piston at TDC

compression stroke (C).

4-Cylinder Engine Valve Adjustment

4. Adjust valve clearance on No. 2 and 4 exhaust valves

and No. 3 and 4 intake valves.

A—Front of Engine

B—No. 1 Piston TDC Compression

C—No. 4 Piston TDC Compression

E—Exhaust Valve

I—Intake Valve

DPSG,RG41165,137 –19–16JAN02–4/5

6-Cylinder Engine:

NOTE: Firing order is 1-5-3-6-2-4.

1. Lock No. 1 piston at TDC compression stroke (B).

2. Adjust valve clearance on No. 1, 3 and 5 exhaust

valves and No. 1, 2, and 4 intake valves.

3. Turn crankshaft 360°. Lock No. 6 piston at TDC

compression stroke (C).

6-Cylinder Engine Valve Adjustment

A—Front of Engine

4. Adjust valve clearance on No. 2, 4 and 6 exhaust

valves and No. 3, 5, and 6 intake valves.

B—No. 1 Piston TDC Compression

C—No. 6 Piston TDC Compression

E—Exhaust Valve

I—Intake Valve

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Service as Required

Additional Service Information

This is not a detailed service manual. If you want more

detailed service information, use the form in the back of

this manual to order a component technical manual.

Component Technical Manual

RG,RG34710,5591 –19–20MAY96–1/1

Do Not Modify Fuel System

IMPORTANT: Modification or alteration of the

injection pump (arrow), the injection

pump timing, or the fuel injectors in

ways not recommended by the

manufacturer will terminate the

warranty obligation to the purchaser.

In addition, tampering with fuel system

which alters emission-related

equipment on engines may result in

fines or other penalties, per EPA

regulations or other local emission

laws.

Fuel Injection Pump

Do not attempt to service injection

pump or fuel injectors yourself. Special

training and special tools are required.

(See your authorized servicing dealer or

engine distributor.)

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.

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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 bare hands. Slowly

loosen cap to first stop to relieve pressure

before removing completely.

IMPORTANT: Never pour cold liquid into a hot

engine, as it may crack cylinder head or

block. DO NOT operate engine without

coolant for even a few minutes.

High-Pressure Fluids

John Deere TY15161 Cooling System

Sealer may be added to the radiator to

stop leaks. DO NOT use any other

stop-leak additives in the system.

Air must be expelled from cooling

system when coolant is added.

1. Loosen temperature sending unit fitting at rear of

cylinder head or plug in side of thermostat housing to

allow air to escape when filling system.

IMPORTANT: When adding coolant to the system, use

the appropriate coolant solution. ( See

ENGINE COOLANT SPECIFICATIONS in

Fuels, Lubricants, and Coolant Section

for mixing of coolant ingredients before

adding to cooling system.)

Radiator Filler Cap

A—Radiator Filler Cap

Do not overfill cooling system. A

pressurized system needs space for

heat expansion without overflowing at

top of radiator.

2. Remove radiator cap (A) and fill until coolant level

touches bottom of radiator filler neck.

3. Tighten plugs and fittings when air has been expelled

from system.

4. Run engine until it reaches operating temperature.

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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.) H₂O, 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.

Single Stage Air Filter

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—Overlap.................................................................. 38 mm (1.5 in)

5. Tighten neck clamp (A) to specification below.

Installation of Single Stage Air Cleaner

Specification

Air Cleaner Neck Clamp—Torque................................. 6.8 N•m (60 lb-in.)

A—Outlet Neck Clamp

B—Filter to Engine Overlap

IMPORTANT: Do NOT overtighten body clamp.

Overtightening may cause crushing of

air cleaner body. Tighten body clamp

only until snug.

6. If equipped, tighten body clamp until snug.

IMPORTANT: Whenever the air cleaner has been

serviced or removed, ALWAYS fully

depress the air restriction indicator

reset button (if equipped) to assure

accurate readings.

7. If equipped, fully depress air restriction indicator reset

button and release to reset indicator.

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Service as Required

Replacing Axial Seal Air Cleaner Filter

Element

IMPORTANT: ALWAYS REPLACE primary air cleaner

element when air restriction indicator

shows a vacuum of 625 mm (25 in.)

H₂O, 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.

Wing Nut and Primary Element

1. Remove wing nut and remove canister cover shown in

small illustration inset.

2. Remove wing nut (A) and remove primary element (B)

from canister.

3. Thoroughly clean all dirt from inside canister.

NOTE: Some engines may have a dust unloader valve

tip to release any trapped dirt particles.

IMPORTANT: Remove secondary (safety) element (E)

ONLY for replacement. DO NOT attempt

to clean, wash, or reuse secondary

Dust Unloader Valve

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 element (E). Immediately replace

secondary element with new element to prevent dust

from entering air intake system.

5. Install new primary element and tighten wing nut

securely. Install cover assembly and tighten retaining

wing nut securely.

Retaining Nut and Secondary Element

A—Wing Nut

B—Primary Element

C—Dust Unloader Valve

D—Retaining Nut

E—Secondary Element

Continued on next page

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Service as Required

IMPORTANT: Whenever the air cleaner has been

serviced or had cover removed,

ALWAYS fully depress the air

restriction indicator reset button (if

equipped) to assure accurate readings.

6. If equipped, fully depress air restriction indicator reset

button and release to reset indicator.

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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.)

H₂O, is torn, or visibly dirty.

NOTE: This procedure applies to John Deere 2-stage

radial seal air cleaner kits. Refer to manufacturers’

instructions for servicing air cleaners not supplied

by John Deere.

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.

4. Thoroughly clean all dirt from inside housing and from

outlet bore.

IMPORTANT: Remove secondary (safety) element (C)

ONLY for replacement. DO NOT attempt

to clean, wash, or reuse secondary

Primary Filter Element

element. Replacement of secondary

element is usually necessary ONLY

when primary element has a hole in it.

5. To replace secondary element (C), pull filter element

out gently. Immediately replace secondary element

with new element to prevent dust from entering air

intake system.

6. Install new primary filter element. Apply pressure by

hand at outer rim of filter.

IMPORTANT: Do NOT use latches on cover to force

filter into air cleaner. Using cover to

Secondary Filter Element

A—Dust Cap/Cover

force filter will damage cleaner housing.

B—Primary Filter Element

C—Secondary Filter Element

7. Close housing with dust unloader valve aimed down

and latch latches.

Continued on next page

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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.

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Service as Required

Replacing Fan and Alternator Belts

Refer to CHECKING BELT TENSIONER SPRING

TENSION AND BELT WEAR in Lubrication and

Maintenance/250 Hour/6 Month Section for additional

information on the belt tensioner.

1. Inspect belts for cracks, fraying, or stretched out areas.

Replace if necessary.

2. To replace belt with automatic tensioner, release

tension on belt using a breaker bar and socket (if

required) on tension arm.

290 mm (11.4 in.) Fan Height and Lower*

To replace belt with manual tensioner, release tension

at belt tensioner (See MANUAL BELT TENSIONER

ADJUSTMENT in Lubrication and Maintenance/250

Hour/6 Month Section.)

3. Remove poly-vee belt from pulleys and discard belt.

4. Install new belt, making sure belt is correctly seated in

all pulley grooves. Refer to belt routing at right for your

application.

5. Apply tension to belt with tensioner. Remove socket.

6. Start engine and check belt alignment.

338 mm (13.3 in.) Fan Height and Higher Without Freon

Compressor*

*Measured from crank centerline to fan drive center.

A—Alternator

CSP—Crankshaft Pulley

FC—Freon (A/C) Compressor

FD—Fan Drive

I—Idler Pulley

T—Tensioner

CP—Coolant Pump

402 mm (15.8 in.) Fan Height With Freon Compressor*

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Service as Required

Checking Fuses In Instrument Panels

The following instructions apply to engines equipped with

John Deere instrument panels.

1. On Engines With The North American Standard

Instrument Panel ( —1998), check the fuse (A)

between the ammeter (B) and key switch (C) located

on back side of instrument panel. If defective, replace

with an equivalent 25-amp fuse.

Also check the fuse (D) mounted on the bottom of the

magnetic safety switch. If defective, install an

equivalent 14-amp fuse.

North American ( —1998) Standard Instrument Panel Shown

2. On later (1999— ) North American Standard

Instrument Panels, check the fuse in fuse holder (E)

on front face of instrument panel. Replace as

necessary with an equivalent 14-amp fuse.

3. For VDO Instrument Panels, the fuse is located on

the electronic control card inside the panel’s rear

access cover. Remove cover and check fuse (F). If

defective, replace with a 10-amp fuse. There is a spare

fuse (G) available on the card in the “SPARE” terminal.

North American ( —1998) Standard Instrument Panel Shown

NOTE: For main electrical system fuses, see engine

wiring diagrams later in this manual in

Troubleshooting Section.

A—25 Amp Fuse

B—Ammeter

C—Key Switch

D—14 Amp Fuse

E—Fuse Holder

F—10 Amp Fuse

G—Spare Fuse

North American (1999— ) Instrument Panel Shown

VDO Instrument Panel

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Service as Required

Checking Air Compressor (If Equipped)

Air compressors are offered as options with John Deere

OEM engines to provide compressed air to operate

air-powered devices like vehicle air brakes.

Air compressors are engine-driven piston types. They are

either air cooled or cooled with engine coolant. The

compressors are lubricated with engine oil. The

compressor runs continuously as gear or spline driven by

the auxiliary drive of the engine but has “loaded” and

“unloaded” operating modes. This is controlled by the

vehicle’s air system (refer to vehicle technical manual for

complete air system checks and services).

See your John Deere engine distributor or servicing dealer

for diagnostic and troubleshooting information. If diagnosis

leads to an internal fault in the compressor, replace the

complete compressor as a new or remanufactured unit.

Air Compressor (Optional)

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Service as Required

Bleeding the Fuel System

CAUTION: Escaping fluid under pressure can

penetrate the skin causing serious injury.

Relieve pressure before disconnecting fuel or

other lines. Tighten all connections before

applying pressure. Keep hands and body away

from pinholes and nozzles which eject fluids

under high pressure. Use a piece of cardboard

or paper to search for leaks. Do not use your

hand.

High-Pressure Fluids

If ANY fluid is injected into the skin, it must be

surgically removed within a few hours by a

doctor familiar with this type injury or gangrene

may result. Doctors unfamiliar with this type of

injury may call the Deere & Company Medical

Department in Moline, Illinois, or other

knowledgeable medical source.

Bleed the fuel system anytime the fuel system has been

opened up. This includes:

• After fuel filter changes.

• After injection pump or nozzle replacement.

• Anytime fuel lines have been disconnected.

• After engine has run out of fuel.

IMPORTANT: DO NOT pressurize fuel tank to push

fuel through system, as the pressure

can damage fuel injection pump seals

Continued on next page

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Service as Required

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.

1. Loosen the air bleed vent screws (A) two full turns by

hand on fuel filter base. (One screw with single filter

option.)

A—Air Bleed Vent Screws

Air Bleed Vent Screws (Final Filter at Left, Primary Filter with

Separator Bowl at Right)

OURGP11,000000D –19–18OCT06–2/7

2. Operate supply pump primer lever (B) until fuel flow is

free from air bubbles.

3. Tighten bleed plug securely, continue operating hand

primer until pumping action is not felt. Push hand

primer inward (toward engine) as far as it will go.

4. Start engine and check for leaks.

If engine will not start, it may be necessary to bleed air

from fuel system at fuel injection pump or injection

nozzles as explained next.

Fuel Supply Pump Primer Lever

B—Fuel Supply Pump Primer Lever

Continued on next page

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Service as Required

At Fuel Injection Pump

On Stanadyne rotary pumps:

1. Slightly loosen fuel return line connector (A) at fuel

injection pump.

2. Operate fuel supply pump primer lever until fuel,

without air bubbles, flows from fuel return line

connection.

3. Tighten return line connector to 27 N•m (20 lb-ft).

Stanadyne Rotary Fuel Injection Pump

4. Primer lever is spring-loaded and will return to normal

position.

A—Fuel Return Line Connector

OURGP11,000000D –19–18OCT06–4/7

On Lucas rotary pumps:

1. Loosen bleed screw (B) on pump cover.

NOTE: On Models DP200/201/203 Injection Pumps,

bleed screw is located on top of cover near the

fuel return line.

2. Operate fuel supply pump primer lever or turn ignition

switch to “ON”.

3. Wait until fuel flow is free of air bubbles. Tighten bleed

screw.

Lucas Rotary Fuel Injection Pumps

B—Bleed Screw

4. Primer lever is spring loaded and will return to normal

position.

C—Screw

CAUTION: NEVER loosen screw (C) securing

pump head, otherwise pump damage may

occur.

Continued on next page

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Service as Required

On DENSO and Motorpal in-line pumps:

1. On DENSO pump shown, unscrew hand primer on fuel

supply pump until it can be pulled by hand.

2. Open fuel filter port plug.

3. Operate the hand primer until a smooth flow of fuel,

free of bubbles, comes out of the filter plug hole.

4. Simultaneously stroke the hand primer down and close

the filter port plug. This prevents air from entering the

system. Tighten plug securely. DO NOT overtighten.

DENSO Fuel Injection Pump Shown

IMPORTANT: Be sure hand primer is all the way

down in barrel before tightening to

prevent internal thread damage.

5. On DENSO pump shown, lock hand primer in position.

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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.

2. Using two open-end wrenches, loosen fuel line

connection at injection nozzle as shown.

3. Crank engine over with starter motor, (but do not start

engine), until fuel free from bubbles flows out of

loosened connection.

Fuel Line Connection

4. Retighten connection to 27 N•m (20 lb-ft).

5. Repeat procedure for remaining injection nozzles (if

necessary) until all air has been removed from fuel

system.

If engine still will not start, see your authorized

servicing dealer or engine distributor.

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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.

A reliable program for troubleshooting engine problems

should include the following basic diagnostic thought

process:

• Know the engine and all related systems.

• Study the problem thoroughly.

• Relate the symptoms to your knowledge of engine

and systems.

Wiring diagrams are shown for the two types of

instrument panels offered for these engines.

• Diagnose the problem starting with the easiest

things first.

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.

• Double-check before beginning the disassembly.

• Determine cause and make a thorough repair.

• After making repairs, operate the engine under

normal conditions to verify that the problem and

cause was corrected.

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Troubleshooting

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Troubleshooting

Engine Wiring Diagram Legend (Standard Instrument Panel For North America)

A1 — Speed Control Unit

P6 — Ammeter

B1 — Magnetic Speed Sensor

B2 — Coolant Temperature Sensor

B3 — Oil Pressure Sensor

F1 — Starting Circuit Fuse (14 amp)

F3 — Fuse (Early Models)¹

G1 — Battery

R1 — Resistor (48 ohm)³

S1 — Key Switch

S2 — Magnetic Safety Switch—North American

Auto Override Module—European (Saran)

W1 — Ground on K1 Starter Relay Mounting Stud

Y1 — Starter Solenoid

Y2 — Fuel Shut-off Solenoid

BLK — Black

BLU — Blue

BRN — Brown

DK BLU — Dark Blue

GRN — Green

G2 — Alternator

H1 — Coolant Temperature Indicator Lamp

H2 — Oil Pressure Indicator Lamp

H3 — Alternator Indicator Lamp

K1 — Starter Relay

M1 — Starter Motor

P1 — Coolant Temperature Gauge

P2 — Oil Pressure Gauge

P3 — Crankcase Oil Level Switch/Gauge

P4 — Tachometer¹

ORG — Orange

PUR — Purple

RED — Red

YEL — Yellow

P5 — Hourmeter (Early Models)²

P4 tachometer has a built-in hourmeter. On some earlier engines,

a separate hourmeter (P5) and fuse (F3) were used.

P4 tachometer has a built-in hourmeter. On some engines, a

separate hourmeter (P5) and fuse (F3) are used.

Later harnesses have two parallel 100 ohm resistors for the

alternator.

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Troubleshooting

Wiring Diagram (Standard Instrument Panel For North America)

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Troubleshooting

Engine Wiring Diagram—VDO Instrument Panel (Except North America)

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Troubleshooting

Engine Wiring Diagram Legend—VDO Instrument Panel (Except North America)

A — 6 mm², Red

M — 0.75 mm², Green/Yellow

N — 0.75 mm², Red

O—R — Not Used

B — 1.5 mm², Black

C — 6 mm², Blue

D — 4 mm², Black

S — Preheater

E — 0.75 mm², Orange

F — 0.75 mm², White

G — 0.75 mm², Blue

H — 0.75 mm², Purple

I — 0.75 mm², Grey

J — 0.75 mm², Brown

K — 0.75 mm², Dark Blue

L — 0.75 mm², Black

T — Battery

U — Starter Motor

V — Electrical Shut-Off

W — Alternator

X — Oil Pressure Sensor

Y — Coolant Temperature Sensor

Z — Fuel Tank Gauge

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Troubleshooting

Engine Troubleshooting

Symptom

Problem

Solution

Engine cranks but will not start

Incorrect starting procedure.

No fuel.

Verify correct starting procedure.

Check fuel in tank and manual

shut-off valve.

Exhaust restricted.

Check and correct exhaust

restriction.

Fuel filter plugged or full of water.

Replace fuel filter or drain water

from filter.

Injection pump not getting fuel or air

in fuel system.

Check fuel flow at supply pump or

bleed fuel system.

Faulty injection pump or nozzles.

Engine starting under load.

Consult authorized diesel repair

station for repair or replacement.

Engine hard to start or will not

start

Disengage driveline.

Improper starting procedure.

No fuel.

Review starting procedure.

Check fuel tank.

Air in fuel line.

Bleed fuel line.

Cold weather.

Use cold weather starting aids.

See “Starter Cranks Slowly”.

Use oil of proper viscosity.

Slow starter speed.

Crankcase oil too heavy.

Improper type of fuel.

Consult fuel supplier; use proper

type fuel for operating conditions.

Water, dirt, or air in fuel system.

Clogged fuel filter.

Drain, flush, fill, and bleed system.

Replace filter element.

Dirty or faulty injection nozzles.

Have authorized servicing dealer or

engine distributor check injectors.

Injection pump shut-off not reset.

Turn key switch to “OFF” then to

“ON”.

Continued on next page

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Troubleshooting

Symptom

Problem

Solution

Engine knocks

Low engine oil level.

Add oil to engine crankcase.

Injection pump out of time.

See your authorized servicing dealer

or engine distributor.

Low coolant temperature.

Engine overheating.

Remove and check thermostat.

See “Engine Overheats”.

Engine runs irregularly or stalls

frequently

Low coolant temperature.

Remove and check thermostat.

Clogged fuel filter.

Replace fuel filter element.

Water, dirt, or air in fuel system.

Poor quality fuel.

Drain, flush, fill, and bleed system.

Change to better quality fuel.

Dirty or faulty injection nozzles.

Have authorized servicing dealer or

engine distributor check injectors.

Below normal engine

temperature

Defective thermostat.

Remove and check thermostat.

Defective temperature gauge or

sender.

Check gauge, sender, and

connections.

Continued on next page

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Troubleshooting

Symptom

Problem

Solution

Lack of power

Engine overloaded.

Reduce load.

Intake air restriction.

Service air cleaner.

Replace filter elements.

Use proper fuel.

Clogged fuel filter.

Improper type of fuel.

Overheated engine.

See “Engine Overheats”.

Remove and check thermostat.

Below normal engine temperature.

Improper valve clearance.

See your authorized servicing dealer

or engine distributor.

Dirty or faulty injection nozzles.

Injection pump out of time.

Have authorized servicing dealer or

engine distributor check injectors.

See your authorized servicing dealer

or engine distributor.

Turbocharger not functioning.

(Turbocharger engines only.)

See your authorized servicing dealer

or engine distributor.

Leaking exhaust manifold gasket.

Defective aneroid control line.

See your authorized servicing dealer

or engine distributor.

See your authorized servicing dealer

or engine distributor.

Restricted fuel hose.

Low fast idle speed.

Clean or replace fuel hose.

See your authorized servicing dealer

or engine distributor.

Low oil pressure

Low oil level.

Add oil.

Improper type of oil.

Drain, fill crankcase with oil of proper

viscosity and quality.

Continued on next page

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Troubleshooting

Symptom

Problem

Solution

High oil consumption

Crankcase oil too light.

Oil leaks.

Use proper viscosity oil.

Check for leaks in lines, gaskets,

and drain plug.

Restricted crankcase vent tube.

Defective turbocharger.

Clean vent tube.

See your authorized servicing dealer

or engine distributor.

Engine emits white smoke

Improper type of fuel.

Use proper fuel.

Low engine temperature.

Warm up engine to normal operating

temperature.

Defective thermostat.

Remove and check thermostat.

Defective injection nozzles.

See your authorized servicing dealer

or engine distributor.

Engine out of time.

See your authorized servicing dealer

or engine distributor.

Engine emits black or gray

exhaust smoke

Improper type of fuel.

Use proper fuel.

Clogged or dirty air cleaner.

Engine overloaded.

Service air cleaner.

Reduce load.

Injection nozzles dirty.

See your authorized servicing dealer

or engine distributor.

Engine out of time.

See your authorized servicing dealer

or engine distributor.

Turbocharger not functioning.

See your authorized servicing dealer

or engine distributor.

Continued on next page

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Troubleshooting

Symptom

Problem

Solution

Engine overheats

Engine overloaded.

Low coolant level.

Reduce load.

Fill radiator to proper level, check

radiator and hoses for loose

connections or leaks.

Faulty radiator cap.

Have serviceman check.

Stretched poly-vee belt or defective

belt tensioner.

Check automatic belt tensioner and

check belts for stretching. Replace

as required.

Low engine oil level.

Check oil level. Add oil as required.

Flush cooling system.

Cooling system needs flushing.

Defective thermostat.

Remove and check thermostat.

Defective temperature gauge or

sender.

Check water temperature with

thermometer and replace, if

necessary.

Incorrect grade of fuel.

Improper type of fuel.

Clogged or dirty air cleaner.

Engine overloaded.

Use correct grade of fuel.

Use proper type of fuel.

Service air cleaner.

Reduce load.

High fuel consumption

Improper valve clearance.

See your authorized servicing dealer

or engine distributor.

Injection nozzles dirty.

Engine out of time.

See your authorized servicing dealer

or engine distributor.

See your authorized servicing dealer

or engine distributor.

Defective turbocharger.

Low engine temperature.

See your authorized servicing dealer

or engine distributor.

Check thermostat.

Continued on next page

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Troubleshooting

Symptom

Problem

Solution

Undercharged electrical system

Excessive electrical load from added Remove accessories or install higher

accessories.

output alternator.

Excessive engine idling.

Increase engine rpm when heavy

electrical load is used.

Poor electrical connections on

battery, ground strap, starter, or

alternator.

Inspect and clean as necessary.

Defective battery.

Test battery.

Defective alternator.

Cracked battery case.

Test charging system.

Battery uses too much water

Check for moisture and replace as

necessary.

Defective battery.

Test battery.

Battery charging rate too high.

Loose or corroded connections.

Sulfated or worn-out batteries.

Test charging system.

Clean and tighten connections.

Batteries will not charge

See your authorized servicing dealer

or engine distributor.

Stretched poly-vee belt or defective

belt tensioner.

Adjust belt tension or replace belts.

Starter will not crank

Engine driveline engaged.

Loose or corroded connections.

Low battery output voltage.

Disengage engine driveline.

Clean and tighten loose connections.

See your authorized servicing dealer

or engine distributor.

Faulty start circuit relay.

See your authorized servicing dealer

or engine distributor.

Blown main system fuse (MDL-25)

Low battery output.

Replace fuse.

Starter cranks slowly

See your authorized servicing dealer

or engine distributor.

Crankcase oil too heavy.

Use proper viscosity oil.

Loose or corroded connections.

Clean and tighten loose connections.

Continued on next page

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Troubleshooting

Symptom

Problem

Solution

Starter and hour meter functions; Blown fuse on magnetic switch.

Replace fuse.

rest of electrical system does not

function

Entire electrical system does not

function

Faulty battery connection.

Clean and tighten connections.

Sulfated or worn-out batteries.

Blown main system fuse (MDL-25).

See your authorized servicing dealer

or engine distributor.

Replace fuse.

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Storage

Engine Storage Guidelines

1. John Deere engines can be stored outside for up to

three (3) months with no long term preparation IF

COVERED BY WATERPROOF COVERING. No

outside storage is recommended without a

waterproof covering.

4. John Deere engines expected to be stored more

than six (6) months MUST have long term storage

preparation. ( See PREPARING ENGINE FOR

LONG TERM STORAGE, later in this section.)

5. Long term storage includes the use of a stabilized

rust preventive oil to protect internal metal

2. John Deere engines can be stored in a standard

overseas shipping container for up to three (3)

months with no long term preparation.

components of the engine. This oil should be an

SAE 10 oil with 1-4 percent morpholine or

equivalent vapor corrosion inhibitor. These rust

preventive oils are available from area distributors.

3. John Deere engines can be stored inside for up to

six (6) months with no long term preparation.

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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.

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.

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

7. Crank the engine several revolutions with starter

(do not allow the engine to start). This will allow

rust preventive oil solution to circulate.

corrosion and deterioration.

8. Remove temporary lines installed in Step 6 above,

and replace any lines/plugs previously removed.

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

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

equivalent vapor corrosion inhibitor.

recommended to dispose of any water or other

impurities.

2. Service air cleaner. (See REPLACING AIR

CLEANER FILTER ELEMENTS in Service As

Required Section.)

9. Loosen, or remove and store, fan/alternator

poly-vee belt.

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 Section.)

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

water and touch up any scratched or chipped

painted surfaces with a good quality paint.

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.)

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.

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.

Continued on next page

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Storage

15. Store the engine in a dry protected place. If

engine must be stored outside, cover it with a

waterproof canvas or other suitable protective

material and use a strong waterproof tape.

OURGP11,000006C –19–27JUL06–2/2

Removing Engine from Long Term Storage

Refer to the appropriate section for detailed services

listed below or have your authorized servicing dealer

or engine distributor perform services that you may not

be familiar with.

IMPORTANT: DO NOT operate starter more than

30 seconds at a time. Wait at least 2

minutes for starter to cool before

trying again.

1. Remove all protective coverings from engine.

Unseal all openings in engine and remove covering

from electrical systems.

6. Crank engine for 20 seconds with starter (do not

allow the engine to start). Wait 2 minutes and crank

engine an additional 20 seconds to assure bearing

surfaces are adequately lubricated.

2. Remove the batteries from storage. Install batteries

(fully charged) and connect the terminals.

7. Start engine and run at low idle and no load for

several minutes. Warm up carefully and check all

gauges before placing engine under load.

3. Install fan/alternator poly-vee belt if removed.

4. Fill fuel tank.

8. On the first day of operation after storage, check

overall engine for leaks and check all gauges for

correct operation.

5. Perform all appropriate prestarting checks. ( See

DAILY PRESTARTING CHECKS in Lubrication and

Maintenance/Daily Section.)

RG,RG34710,5613 –19–11OCT06–1/1

55-3

110306

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Specifications

General OEM Engine Specifications—4.5 L

Engines

ITEM

ENGINE

4045DF120 4045DF150 4045TF120 4045TF150 4045TF220 4045TF250 4045HF120 4045HF150

Number of Cylinders

Bore

106 mm

(4.19 in.)

106 mm

(4.19 in.)

106 mm

(4.19 in.)

106 mm

(4.19 in.)

106 mm

(4.19 in.)

106 mm

(4.19 in.)

106 mm

(4.19 in.)

106 mm

(4.19 in.)

Stroke

127 mm

(5.0 in.)

127 mm

(5.0 in.)

127 mm

(5.0 in.)

127 mm

(5.0 in.)

127 mm

(5.0 in.)

127 mm

(5.0 in.)

127 mm

(5.0 in.)

127 mm

(5.0 in.)

Displacement

4.5 L

(276 cu

in.)

4.5 L

(276 cu

in.)

4.5 L

(276 cu

in.)

4.5 L

(276 cu

in.)

4.5 L

(276 cu

in.)

4.5 L

(276 cu

in.)

4.5 L

(276 cu

in.)

4.5 L

(276 cu

in.)

Compression Ratio

17.8:1

17.6:1

17.0:1

Max. Crank Pressure

0.5 kPa

(2 H₂O)

0.5 kPa

(2 H₂O)

0.5 kPa

(2 H₂O)

0.5 kPa

(2 H₂O)

0.5 kPa

(2 H₂O)

0.5 kPa

(2 H₂O)

0.5 kPa

(2 H₂O)

0.5 kPa

(2 H₂O)

Governor Regulation (Industrial)

Governor Regulation (Generator)

7—10 %

N/A

7—10 %

5 %

N/A

7—10 %

5 %

N/A

7—10 %

5 %

N/A

7—10 %

5 %

Oil Pressure, Rated Speed, Full

Load (±15 psi)

345 kPa

(50 psi)

345 kPa

(50 psi)

345 kPa

(50 psi)

345 kPa

(50 psi)

345 kPa

(50 psi)

345 kPa

(50 psi)

345 kPa

(50 psi)

345 kPa

(50 psi)

Oil Pressure, Low Idle (Minimum)

105 kPa

(15 psi)

105 kPa

(15 psi)

105 kPa

(15 psi)

105 kPa

(15 psi)

105 kPa

(15 psi)

105 kPa

(15 psi)

105 kPa

(15 psi)

105 kPa

(15 psi)

Length

Width

844.0 mm

(33.2 in.)

861.0 mm 861.0 mm 861.0 mm 861.0 mm 861.0 mm 861.0 mm 861.0 mm

(33.9 in.)

550 mm

(21.7 in.)

598 mm

(23.5 in.)

598 mm

(23.5 in.)

598 mm

(23.5 in.)

598 mm

(23.5 in)

598 mm

(23.5 in.)

598 mm

(23.5 in.)

598 mm

(23.5 in.)

Height

Weight

871 mm

(34.3 in.)

854 mm

(33.6 in.)

980 mm

(38.6 in.)

980 mm

(38.6 in.)

980 mm

(38.6 in.)

980 mm

(38.6 in.)

980 mm

(38.6 in.)

980 mm

(38.6 in.)

429 kg

387 kg

396 kg

(945 lb)

(851 lb)

(872 lb)

NOTE: Engine models listed with numbers ending in “120” and “220” are emission non-certified. Engines with model numbers ending in “150”

and “250” are Tier 1 emission certified. (Later engines with model numbers ending in ”270”, “275” or “475” are Tier 2 emission certified with

mechanical or electronic fuel systems and are covered in another manual, OMRG33324.)

OURGP12,0000041 –19–18OCT06–1/1

60-1

110306

PN=136

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Specifications

General OEM Engine Specifications—6.8 L

Engines

ITEM

ENGINE

6068DF150 6068TF120 6068TF150 6068TF220 6068TF250 6068HF120 6068HF150 6068HF250

Number of Cylinders

Bore

106 mm

(4.19 in.)

106 mm

(4.19 in.)

106 mm

(4.19 in.)

106 mm

(4.19 in.)

106 mm

(4.19 in.)

106 mm

(4.19 in.)

106 mm

(4.19 in.)

106 mm

(4.19 in.)

Stroke

127 mm

(5.0 in.)

127 mm

(5.0 in.)

127 mm

(5.0 in.)

127 mm

(5.0 in.)

127 mm

(5.0 in.)

127 mm

(5.0 in.)

127 mm

(5.0 in.)

127 mm

(5.0 in.)

Displacement

6.8 L

(414 cu in.)

(414 cu in.) (414 cu in.) (414 cu in.) (414 cu in.) (414 cu in.) (414 cu in.) (414 cu in.)

Compression

17.6:1

17.0:1

Max. Crank Pressure

0.5 kPa

(2 H₂O)

0.5 kPa

(2 H₂O)

0.5 kPa

(2 H₂O)

0.5 kPa

(2 H₂O)

0.5 kPa

(2 H₂O)

0.5 kPa

(2 H₂O)

0.5 kPa

(2 H₂O)

0.5 kPa

(2 H₂O)

Governor Regulation

(Industrial)

7—10 %

N/A

7—10 %

N/A

7—10 %

Governor Regulation

(Generator)

5 %

Oil Pressure At Rated

Speed, Full Load (±15

psi)

345 kPa

(50 psi)

345 kPa (50

psi)

345 kPa

(50 psi)

345 kPa

(50 psi)

345 kPa

(50 psi)

345 kPa

(50 psi)

345 kPa

(50 psi)

345 kPa

(50 psi)

Oil Pressure At Low Idle

(Minimum)

105 kPa

(15 psi)

105 kPa (15

psi)

105 kPa

(15 psi)

105 kPa

(15 psi)

105 kPa

(15 psi)

105 kPa

(15 psi)

105 kPa

(15 psi)

105 kPa

(15 psi)

Length

1117 mm

(44.0 in.)

1117 mm

(44.0 in.)

1117 mm

(44.0 in.)

1116 mm

(43.9 in.)

1117 mm

(44.0 in.)

1141 mm

(44.9 in.)

1116 mm

(43.9 in.)

1141 mm

(44.9 in.)

Width

598 mm

(23.5 in.)

598 mm

(23.5 in.)

598 mm

(23.5 in.)

623 mm

(24.5 in.)

598 mm

(23.5 in.)

623 mm

(24.5 in.)

623 mm

(24.5 in.)

623 mm

(24.5 in.)

Height

Weight

956 mm

(37.6 in.)

984 mm

(38.7 in.)

984 mm

(38.7 in.)

1012 mm

(39.9 in.)

984 mm

(38.7 in.)

1009 mm

(39.7 in.)

1009 mm

(39.7 in.)

1009 mm

(39.7 in.)

522 kg

533 kg

551 kg

533 kg

568 kg

550 kg

568 kg

(1149 lb)

(1172 lb)

(1212 lb)

(1172 lb)

(1250 lb)

(1210 lb)

(1250 lb)

NOTE: Engine models listed with numbers ending in “120” and “220” are emission non-certified. Engines with model numbers ending in “150”

and “250” are Tier 1 emission certified. (Later engines with model numbers ending in ”270”, 275” or “475” are Tier 2 emission certified with

mechanical or electronic fuel systems and are covered in another manual, OMRG33324.)

OURGP12,0000042 –19–07JUL04–1/1

60-2

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PN=137

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Specifications

Engine Power Ratings And Fuel Injection Pump Specifications

NOTE: The power specifications shown below apply to

Dubuque, Torreon and Saran-built OEM

machine technical manual for engine speeds

that are different from those preset at the

factory.

engines. Specifications are subject to change.

Refer to factory DTAC for assistance.

Power ratings specify flywheel power for a

bare engine without the drag effect of a

cooling fan or other accessories like an air

compressor.

Engine speeds listed are as preset to factory

specification. In most cases, slow idle speed

will be reset depending upon specific vehicle

application requirements. Refer to your

POWER RATINGS ON DYNAMOMETER FOR OEM ENGINES

Original Replaced

By Injection

Injection

Pump

Option

Code

Injection

Pump (Part

No.)

Rated

No Load

Fast Idle

(rpm)

Power

Rating

kW (HP)

Pump (Part

No.)

Governor

Regulation

Speed (rpm) Slow Idle

At Full Load (rpm)

Engine Model

4045DF120

16MR

16MS

165F

165G

16RB

16RC

16ZW

16ZX

16ZY

1601

1602

1603

1663

1671

1673

1674

1691

16BG

RE504463

RE504464

RE503729

RE504693

RE503729

RE504693

RE509527

RE509528

RE509529

RE61649

RE67557

RE59809

RE63555

RE67558

RE505070

RE506132

RE71089

RE500949

RE67559

RE502714

RE60085

RE67560

RE506130

RE60089

RE67561

RE506131

RE61649

RE500831

RE500948

RE69778

RE502712

STD

2500

1500

2500

1800

2500

1800

2500

850

—

2700

1560

2700

1870

2700

1870

2700

63 (85)

44 (59)

63 (85)

60 (80)

63 (85)

53 (71)

60 (80)

53 (71)

60 (80)

63 (85)

STD

3—5%

STD

—

850

1150

1600

850

1400

850

4045DF150

RE67557

STD

RE67558

RE505070

RE506132

3—5%

STD

RE500949

RE502714

STD

RE67560

3—5%

STD

RE506130

RE67561

RE506131

RE500831

RE500948

STD

RE502712

STD

Continued on next page

OURGP11,000001D –19–13OCT06–1/9

110306

60-3

PN=138

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Specifications

POWER RATINGS ON DYNAMOMETER FOR OEM ENGINES

Injection

Pump

Option

Code

Original

Replaced

By Injection

Pump (Part

No.)

Injection

Pump (Part

No.)

Rated

No Load

Fast Idle

(rpm)

Power

Rating

kW (HP)

Governor

Regulation

Speed (rpm) Slow Idle

At Full Load (rpm)

Engine Model

16BH

16BJ

16CL

16DL

16EN

16GB

16GC

16HJ

16HK

16HV

16KE

16LM

16LN

16RB

16RC

165W

1663

RE500873

RE502715

RE500589

RE501364

RE502713

RE70452

RE502715

STD

2500

2250

2200

2400

2500

2250

2500

1800

1500

2500

2400

1500

2400

1800

2400

1500

1800

2400

1500

850

2700

2450

2400

2600

2700

2450

2700

1870

1560

2700

2600

1560

2600

1870

2600

1560

1870

2600

1560

63 (85)

STD

850

63 (85)

STD

850

36 (48)

RE502713

STD

950

58 (78)

STD

950

58 (78)

STD

850

61 (82)

RE502019

RE502711

RE502716

RE500948

RE500949

RE503258

RE503560

RE502711

RE67558

STD

850

60 (80)

STD

850

60 (80)

STD

850

60 (80)

STD

1400

1600

850

60 (80)

STD

60 (80)

STD

36 (48)

STD

850

52 (70)

STD

850

53 (71)

RE505070

RE506132

3—5%

STD

1150

1400

1600

850

53 (71)

RE505070

RE506132

RE503729

RE504693

RE500949

RE71089

53 (71)

44 (59)

60 (80)

4045DF151

4045DF152

4045DF154

4045HF120

4045HF150

RE500949

STD

60 (80)

1663

RE500949

RE67557

STD

60 (80)

1601

STD

60 (80)

16GB

16AY

16JS

16GR

16LW

1610

RE502711

RE500505

RE503050

RE503832

RE68826

STD

850

60 (80)

STD

850

62 (83)

STD

850

62 (83)

RE506965

RE506966

RE505928

3—5%

STD

1400

850

102 (137)

104 (140)

95 (127)

104 (140)

100 (134)

120 (161)

123 (164)

111 (149)

104 (140)

102 (137)

1611

RE60237

3—5%

STD

1400

850

160B

160C

16GR

16LW

16ME

16MF

16QZ

16RA

16RM

16GR

16LW

RE68827

RE69588

RE505959

RE503050

RE503832

RE503739

RE504966

RE503050

RE503832

RE505959

RE503050

RE503832

3—5%

STD

1150

—

1400

850

4045HF152

4045HF157

—

Continued on next page

OURGP11,000001D –19–13OCT06–2/9

110306

60-4

PN=139

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Specifications

POWER RATINGS ON DYNAMOMETER FOR OEM ENGINES

Injection

Pump

Option

Code

Original

Replaced

By Injection

Pump (Part

No.)

Injection

Pump (Part

No.)

Rated

No Load

Fast Idle

(rpm)

Power

Rating

kW (HP)

Governor

Regulation

Speed (rpm) Slow Idle

At Full Load (rpm)

Engine Model

4045HF158

16GR

16LW

16ME

16MF

RE503050

RE503832

RE503739

RE504698

RE504966

RE522414

RE522698

RE522414

RE522698

RE503733

RE506989

RE505050

RE506990

RE509527

RE509528

RE509529

RE506989

RE506990

RE61668

RE69781

RE64133

RE505927

RE63610

RE67562

RE60091

RE69782

RE60093

3—5%

STD

1500

1800

3000

1500

2500

2400

1800

2500

1800

2500

2200

2500

2200

2300

1150

1400

850

1560

1870

3120

1560

2700

2600

1870

2700

1870

2700

2400

2700

2400

2500

100 (134)

123 (165)

123 (170)

125 (168)

152 (204)

70 (94)

RE504966

4045HF252

4045TF120

850

169E

169F

16MT

16MU

16ZW

16ZX

16ZY

165D

165E

1605

1606

1656

1675

1676

1677

1692

1694

1695

16AB

16BF

16CE

16CM

16GL

850

RE505989

RE506990

1400

—

70 (94)

—

70 (94)

4045TF150

RE69781

RE505927

RE67562

RE69782

850

86 (115)

93 (125)

75 (100)

86 (115)

75 (100)

86 (115)

75 (100)

73 (98)

STD

850

STD

850

STD

850

3—5%

STD

1150

850

STD

850

RE61668

RE67563

STD

850

STD

850

RE60096

RE67563

RE61668

RE500881

RE502416

RE67863

RE69779

RE69739

RE69780

RE69779

RE500848

RE501180

RE501365

RE502706

3—5%

STD

1150

1400

850

RE500881

RE502416

STD

RE69779

RE69780

STD

850

STD

850

STD

850

STD

850

STD

950

STD

850

75 (100)

66.6 (89)

78 (105)

STD

950

STD

850

Continued on next page

OURGP11,000001D –19–13OCT06–3/9

110306

60-5

PN=140

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Specifications

POWER RATINGS ON DYNAMOMETER FOR OEM ENGINES

Injection

Pump

Option

Code

Original

Replaced

By Injection

Pump (Part

No.)

Injection

Pump (Part

No.)

Rated

No Load

Fast Idle

(rpm)

Power

Rating

kW (HP)

Governor

Regulation

Speed (rpm) Slow Idle

At Full Load (rpm)

Engine Model

16LP

16LZ

16MA

16MT

16MU

16TG

16YJ

16YU

16ZC

1677

RE67562

3—5%

STD

1800

1500

2000

1800

2200

1800

2200

1800

2400

2500

2400

1500

1800

1500

2200

2300

1500

1800

2500

1150

1400

850

—

1870

1870‘

1870

1560

2185

1870

2400

1870

2400

2240

2600

2700

2600

1560

1870

1560

2400

2500

1560

1870

2700

75 (100)

70 (94)

RE503735

RE504696

RE504931

RE503733

RE505050

RE504695

RE505050

RE506990

RE507941

RE508834

RE508754

RE518780

RE60096

RE504931

RE505050

82 (110)

70 (94)

RE505050

RE506990

70 (94)

77 (103)

75 (101)

66 (89)

STD

3—5%

STD

950

850

1150

850

—

4045TF151

RE67563

3—5%

STD

75 (100

79.5 (107)

75 (100)

76 (102)

86 (115)

76 (102)

83 (111)

82 (110)

70 (94)

1677

RE67563

16CU

16NH

16AX

1605

RE501192

RE505411

RE500551

RE69781

3—5%

STD

4045TF152

4045TF154

4045TF155

STD

16AX

16JT

RE500551

RE503048

RE503830

RE503048

RE503735

RE504696

RE503733

RE506989

RE504695

RE505050

RE506990

RE500848

RE502706

RE503048

RE506544

RE503830

RE506545

RE503733

RE503736

RE504682

RE504465

STD

4045TF157

4045TF158

16GQ

16LV

16GQ

16LZ

16MA

16MT

16MU

16PZ

16GL

16GQ

16LV

16MT

16MV

16MW

16NT

3—5%

STD

—

RE506989

—

70 (94)

RE505050

RE506990

—

70 (94)

—

70 (94)

—

70 (94)

4045TF161

4045TF162

4045TF220

850

1400

850

73 (98)

STD

78 (104)

83 (111)

70 (94)

RE506544

RE506545

3—5%

STD

100 (134)

86 (115)

Continued on next page

OURGP11,000001D –19–13OCT06–4/9

110306

60-6

PN=141

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Specifications

POWER RATINGS ON DYNAMOMETER FOR OEM ENGINES

Injection

Pump

Option

Code

Original

Replaced

By Injection

Pump (Part

No.)

Injection

Pump (Part

No.)

Rated

No Load

Fast Idle

(rpm)

Power

Rating

kW (HP)

Governor

Regulation

Speed (rpm) Slow Idle

At Full Load (rpm)

Engine Model

16NU

16ZZ

161A

161B

168Q

168R

1606

1608

1667

1682

1683

160R

16CV

16GQ

16LQ

16LV

16MB

16MC

161C

161D

163Z

1606

169P

169Q

16TE

16GQ

16LV

16GQ

16LV

16MB

16MC

16MV

16MW

1613

1678

16LR

16GT

16LY

RE504466

RE508613

RE509525

RE509526

RE521143

RE522388

RE64133

RE505927

RE67564

RE59968

RE67566

RE60124

RE505926

RE70941

RE501346

RE503048

RE67564

RE503830

RE503737

RE504932

RE507525

RE507526

RE505927

RE64133

RE505927

RE522714

RE522697

RE507257

RE503048

RE503830

RE503048

RE503830

RE503737

RE504932

RE503736

RE504682

RE59861

RE60101

RE59861

RE503051

RE503834

STD

2500

2100

1500

2400

1800

2400

1800

2400

1800

2200

1500

1800

1500

1800

2400

3000

2400

1500

1800

2500

1500

850

—

2700

2200

1560

2600

1870

2600

1870

2600

1870

2400

1560

1870

1560

1870

2600

3120

2600

1560

1870

2700

1560

86 (115)

107 (143)

83 (111)

93 (125)

84 (113)

93 (125)

84 (113)

93 (125)

84 (113)

85 (114)

83 (111)

84 (113)

83 (111)

91(122)

STD

3—5%

STD

—

4045TF250

RE505927

RE505926

850

1400

850

1400

850

1400

950

1150

1400

1150

1400

850

—

STD

3—5%

STD

3—5%

STD

3—5%

STD

3—5%

STD

91 (122)

100 (134)

93 (125)

119 (160)

85 (114)

83 (111)

91 (122)

100 (134)

93 (125)

155 (208)

RE506881

RE506882

4045TF251

4045TF252

RE505927

STD

3—5%

STD

4045TF253

4045TF257

3—5%

STD

—

4045TF258

—

1400

850

1400

6068DF150

6068HF120

STD

3—5%

Continued on next page

OURGP11,000001D –19–13OCT06–5/9

110306

60-7

PN=142

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Specifications

POWER RATINGS ON DYNAMOMETER FOR OEM ENGINES

Injection

Pump

Option

Code

Original

Replaced

By Injection

Pump (Part

No.)

Injection

Pump (Part

No.)

Rated

No Load

Fast Idle

(rpm)

Power

Rating

kW (HP)

Governor

Regulation

Speed (rpm) Slow Idle

At Full Load (rpm)

Engine Model

16RL

16SJ

16TP

16TQ

16ZQ

16ZR

1621

RE506085

RE506627

RE506883

RE506884

RE509428

RE509429

RE66575

3—5%

STD

2100

1500

2100

2400

2200

1500

1800

1500

1800

2400

1800

2400

3000

2800

1800

1500

950

1150

950

850

1350

1400

—

2200

1560

2200

2600

2400

1560

1870

1560

1870

2600

1870

2550

2600

3120

3000

1870

1560

197 (264)

183 (245)

197 (264)

157 (210)

143 (192)

153 (205)

187 (251)

166 (223)

210 (282)

155 (208)

187 (251)

168 (225)

148 (198)

168 (225)

138 (185)

225 (302)

226 (303)

184 (247)

210 (282)

183 (245)

105 (141)

6068HF150

RE505930

RE505962

1621

RE505930

RE69589

STD

160D

16CY

16GT

16LY

16ML

16MM

16QV

16QW

16TM

16TN

16GT

16LY

16GT

16LY

16ML

16MM

1622

STD

RE505962

RE501345

RE503051

RE503836

RE503746

RE504702

RE505049

RE503051

RE503836

RE506885

RE506886

RE503051

RE503836

RE503051

RE503836

RE503746

RE504702

RERE505049

RE59521^a

RE66761^a

RE506398

RE59969

STD

3—5%

STD

RE505049

—

6068HF157

6068HF158

—

1400

850

—

RE505049

6068HF250

1623

3—5%

STD

16TV

16YH

169A

168Z

800

850

—

STD

6068HF252

6068HF254

6068HF258

RE522694

RE522415

3—5%

16TM (12V)

16TN (24V)

16TP (12V)

16TQ (24V)

16MX

RE506885

RE506886

RE506883

RE506884

RE503740

—

6068TF120

1400

^aIn-line fuel injection pump.

Continued on next page

OURGP11,000001D –19–13OCT06–6/9

110306

60-8

PN=143

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Specifications

POWER RATINGS ON DYNAMOMETER FOR OEM ENGINES

Injection

Pump

Option

Code

Original

Replaced

By Injection

Pump (Part

No.)

Injection

Pump (Part

No.)

Rated

No Load

Fast Idle

(rpm)

Power

Rating

kW (HP)

Governor

Regulation

Speed (rpm) Slow Idle

At Full Load (rpm)

Engine Model

16MY

1614

1680

1681

1688

1696

1697

16BE

16CN

16CP

16DK

16DY

16GM

16GN

16LS

16MG

16MH

1681

16NJ

1696

16JU

16GS

16LX

16GS

165H

165J

RE505052

RE61669

RE69789

RE60105

RE69790

RE60107

RE67571

RE67572

RE67864

RE69787

RE68740

RE69788

RE63559

RE501302

RE501522

RE509681

RE501523

RE70938

RE501758

RE502693

RE502704

RE67572

RE503742

RE504967

RE60107

RE67651

RE505358

RE69787

RE503049

RE503834

RE503049

RE503740

RE505052

RE503742

RE504966

RE504967

RE503740

RE504699

RE505052

3—5%

STD

1500

2500

1800

2500

2200

2100

2200

2100

2500

2300

2400

1800

2500

1500

1800

1500

1400

850

1150

850

950

900

850

1150

1400

1150

850

—

1560

2700

1870

2700

2400

2300

2400

2300

2700

2500

2600

1870

2700

1560

1870

1560

105 (141)

127 (170)

112 (150)

116 (155)

117 (157)

110.5 (148)

94 (126)

6068TF150

RE69789

RE69790

RE67571

STD

3—5%

STD

RE69787

RE69788

RE501302

RE509681

STD

96 (129)

STD

116 (155)

110 (148)

116 (155)

112 (150)

123 (165)

112 (150)

116 (155)

121 (162)

105 (141)

123 (165)

105 (141)

STD

3—5%

STD

6068TF151

RE67651

6068TF152

6068TF157

6068TF158

STD

3—5%

—

16MG

16MH

16MX

16MY

—

RE504967

RE505052

—

Continued on next page

OURGP11,000001D –19–13OCT06–7/9

110306

60-9

PN=144

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Specifications

POWER RATINGS ON DYNAMOMETER FOR OEM ENGINES

Injection

Pump

Option

Code

Original

Replaced

By Injection

Pump (Part

No.)

Injection

Pump (Part

No.)

Rated

No Load

Fast Idle

(rpm)

Power

Rating

kW (HP)

Governor

Regulation

Speed (rpm) Slow Idle

At Full Load (rpm)

Engine Model

6068TF159

6068TF220

16PD

16GS

16KK

16LX

16RK

16RJ

16SG

16SH

16ZL

16ZM

16ZN

16ZP

165K

165L

1615

1619

1668

1685

1686

16CW

16CX

16GS

16LT

16LU

16LX

16MJ

16MK

163D

16UG

16YH

1615

16ZH

16GS

16LX

16GS

16LX

RE70938

RE503049

RE502694

RE503836

RE506083

RE506084

RE506625

RE506626

RE509424

RE509425

RE509426

RE509427

RE503049

RE503834

RE62366

RE69791

RE67573

RE59969^a

RE67574

RE60131

RE69792

RE501344

RE70390

RE503049

RE69791

RE67573

RE503834

RE503744

RE504701

RE504968

RE516159

RE506956

RE504321

RE59969

RE62366

RE503049

RE503834

RE503049

RE503834

STD

2100

1500

2500

1500

2600

2100

2600

2100

2600

1500

2400

1800

2400

1800

2400

2200

2300

1500

2400

1800

1500

1800

2200

2400

1500

850

1400

850

1400

850

950

850

950

850

—

2250

1560

2700

1560

2700

2200

2700

2200

2800

1560

2600

1870

2600

1870

2600

2400

2500

1560

2600

1870

1560

1870

2400

2600

1560

96 (129)

3—5%

STD

121 (162)

127 (170)

121 (162)

138 (185)

172 (231)

138 (185)

172 (231)

138 (185)

120 (161)

138 (185)

124 (166)

138 (185)

124 (166)

138 (185)

106 (142)

128 (172)

120 (161)

138 (185)

124 (166)

120 (161)

142 (190)

125 (168)

149(200)

149 (200)

138 (185)

121 (162)

155 (208)

121 (162)

155 (208)

3—5%

STD

3—5%

STD

—

6068TF250

RE69791

RE69792

850

1150

850

1150

850

950

900

1400

850

1150

1400

850

925

850

—

STD

3—5%

STD

3—5%

STD

3—5%

STD

3—5%

STD

RE504968

RE504321

STD

6068TF251

6068TF257

6068TF258

STD

3—5%

—

^aIn-line fuel injection pump.

Continued on next page

OURGP11,000001D –19–13OCT06–8/9

110306

60-10

PN=145

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Specifications

POWER RATINGS ON DYNAMOMETER FOR OEM ENGINES

Injection

Pump

Option

Code

Original

Replaced

By Injection

Pump (Part

No.)

Injection

Pump (Part

No.)

Rated

No Load

Fast Idle

(rpm)

Power

Rating

kW (HP)

Governor

Regulation

Speed (rpm) Slow Idle

At Full Load (rpm)

Engine Model

16MJ

16MK

RE503744

RE504701

RE504968

3—5%

1800

—

1870

142 (190)

RE504968

OURGP11,000001D –19–13OCT06–9/9

Engine Crankcase Oil Fill Quantities

NOTE: Crankcase oil capacity may vary slightly from

amount shown. ALWAYS fill crankcase to within

crosshatch on dipstick. DO NOT overfill.

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 table lists engine crankcase oil fill quantities

for each “19__” option code for these engines.

Continued on next page

OURGP11,000001E –19–31OCT06–1/4

60-11

110306

PN=146

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Specifications

Engine Model

Oil Pan Option

Code(s)

Crankcase Oil

Capacity L (qt)

Engine Model

Oil Pan Option

Code(s)

Crankcase Oil

Capacity L (qt)

4045DF120

1901

1902

1903

1904

1923

1949

19AE

7.5 (8.0)

4045TF150

1903

1904

1923

1949

19AE

12.0 (12.7)

13.5 (14.3)

15.0 (15.8)

12.5 (13.2)

14.7 (15.5)

8.0 (8.5)

12.0 (12.7)

13.5 (14.3)

15.0 (15.8)

12.0 (12.7)

14.7 (15.5)

4045TF151

1903

1934

1936

12.0 (12.7)

12.5 (13.2)

4045DF150

1901

1902

1903

1904

1923

1949

19AE

7.5 (8.0)

8.0 (8.5)

12.0 (12.7)

13.5 (14.3)

15.0 (15.8)

12.5 (13.2)

15.0 (15.8)

4045TF152

4045TF154

4045TF155

4045TF157

4045TF158

4045TF161

4045TF162

4045TF220

1937

1904

1937

1949

1903

12.5 (13.2)

13.5 (14.3)

12.5 (13.2)

12.0 (12.7)

4045DF151

4045DF152

4045DF154

4045HF120

1901

1902

1937

7.5 (8.50)

8.0 (8.5)

12.5 (13.2)

1904

1923

1949

19AE

13.5 (14.3)

15.0 (15.8)

12.5 (13.2)

14.7 (15.5)

1903

1904

1923

1949

19AE

1903

1904

1923

1949

19AE

12.0 (12.7)

13.5 (14.3)

15.0 (15.8)

12.5 (13.2)

14.7 (15.5)

12.0 (12.7)

13.5 (14.3)

15.0 (15.8)

12.5 (13.2)

14.7 (15.5)

4045HF150

1904

1921

1922

1923

1949

19AE

13.5 (14.3)

16.5 (17.4)

15.0 (15.8)

12.5 (13.2)

14.7 (15.5)

4045TF250

4045HF152

4045HF157

4045HF158

4045HF252

4045TF120

1962

1949

19AE

1903

14.0 (14.8)

12.5 (13.2)

14.7 (15.5)

12.0 (12.7)

4045TF251

4045TF252

4045TF253

4045TF257

1904

19AE

1937

1949

13.5 (14.3)

14.7 (15.5)

12.5 (13.2)

Continued on next page

OURGP11,000001E –19–31OCT06–2/4

110306

60-12

PN=147

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Specifications

Engine Model

Oil Pan Option

Code(s)

Crankcase Oil

Capacity L (qt)

Engine Model

Oil Pan Option

Code(s)

Crankcase Oil

Capacity L (qt)

1904

1923

1949

19AE

13.5 (14.3)

15.0 (15.8)

12.5 (13.2)

14.7 (15.5)

4045TF258

1949

12.5 (13.2)

6068DF150

1907

1908

1909

1944

1948

1950

19.5 (20.6)

19.0 (20.1)

20.0 (21.1)

Continued on next page

OURGP11,000001E –19–31OCT06–3/4

60-13

110306

PN=148

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Specifications

Engine Crankcase Oil Fill Quantities (Continued)

Engine Model

Oil Pan Option

Code(s)

Crankcase Oil

Capacity L (qt)

Engine Model

Oil Pan Option

Code(s)

Crankcase Oil

Capacity L (qt)

6068TF120

1907

1908

1909

1944

1956

19.0 (20.1)

20.0 (21.1)

18.0 (19.0)

6068TF251

6068TF257

6068TF258

6068HF120

1909

1950

19.0 (20.1)

20.0 (21.1)

6068TF150

1907

1908

1909

1944

1948

1950

1956

19.0 (20.1)

20.0 (21.1)

18.0 (19.0)

1907

1908

1909

1950

1956

1961

19.0 (20.1)

20.0 (21.1)

18.0 (19.0)

32.0 (34.0)

6068HF150

1907

1908

1909

1924

1944

1948

1950

1956

1968

19.0 (20.1)

23.7 (25.0)

20.0 (21.1)

18.0 (19.0)

32.0 (34.0)

6068TF151

1907

1909

1944

19.0 (20.1)

20.0 (21.1)

6068TF152

6068TF157

6068TF158

6068TF159

6068TF220

1909

1950

1963

19.0 (20.1)

20.0 (21.1)

21.5 (22.7)

6068HF157

6068HF158

6068HF250

1950

20.0 (21.1)

1907

1908

1909

1944

1948

1950

1956

19.0 (20.1)

20.0 (21.1)

18.0 (19.0)

1907

1908

1909

1924

1944

1948

1961

1968

19AC

19.0 (20.1)

23.7 (25.0)

20.0 (21.1)

32.0 (34.0)

28.0 (29.6)

6068TF250

1907

1908

1909

1924

1944

1948

1950

1956

1961

19AC

19.0 (20.1)

23.7 (25.0)

20.0 (21.1)

18.0 (19.0)

32.0 (34.0)

28.0 (29.6)

6068HF252

6068HF258

1907

1968

19.0 (20.1)

32.0 (34.0)

OURGP11,000001E –19–31OCT06–4/4

110306

60-14

PN=149

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Specifications

Unified Inch Bolt and Screw Torque Values

TS1671 –UN–01MAY03

Bolt or

SAE Grade 1

Lubricated^bDry^c

SAE Grade 2^a

Lubricated^bDry^c

SAE Grade 5, 5.1 or 5.2

Lubricated^bDry^c

SAE Grade 8 or 8.2

Lubricated^bDry^c

N•m

Screw

Size

N•m

lb-in

N•m

lb-in

N•m

lb-in

N•m

lb-in

N•m

lb-in

N•m

lb-in

N•m

13.5

N•m

lb-in

120

lb-in

150

lb-ft

1/4

3.7

4.7

9.8

7.5

9.5

106

N•m

lb-ft

20.5

5/16

3/8

7.7

106

15.5

137

19.5

N•m

172

lb-ft

N•m

221

lb-ft

32.5

13.5

120

17.5

N•m

155

lb-ft

20.5

N•m

194

lb-ft

N•m

240

lb-ft

32.5

7/16

N•m

194

lb-ft

100

1/2

9/16

5/8

125

170

300

490

730

910

110

155

215

380

615

920

115

160

280

455

120

175

240

425

690

130

175

315

510

155

220

305

540

870

115

165

225

400

640

960

35.5

105

190

285

400

570

750

990

135

240

360

510

725

950

100

175

265

375

125

220

360

540

3/4

120

190

285

400

570

750

990

150

240

360

510

725

950

110

175

265

375

535

700

930

140

210

300

420

550

7/8

140

210

300

420

550

680 1030

760 1300

1-1/8

1-1/4

1-3/8

1-1/2

670 1150

850 1450 1075 1850 1350

535 1280

945 1630 1200 2050 1500 2600 1920

700 1700 1250 2140 1580 2700 2000 3400 2500

930 2250 1650 2850 2100 3600 2650 4550 3350

730 1250

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 with identical grade.

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.

^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.

^b“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 zinc flake coating.

^c“Dry” means plain or zinc plated without any lubrication, or 1/4 to 3/4 in. fasteners with JDM F13B zinc flake coating.

DX,TORQ1 –19–24APR03–1/1

60-15

110306

PN=150

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Specifications

Metric Bolt and Screw Torque Values

12.9

4.8

8.8

9.8

10.9

12.9

Bolt or

Screw

Size

Class 4.8

Class 8.8 or 9.8

Lubricated^aDry^b

Class 10.9

Lubricated^a

Class 12.9

Lubricated^a

Dry^b

N•m

Lubricated^a

Dry^b

N•m

lb-in

N•m lb-in

N•m

lb-in

N•m

lb-in

N•m

lb-in

115

lb-in

146

N•m

15.5

N•m

lb-in

137

N•m

lb-in

172

lb-ft

4.7

8.9

11.3

100

16.5

N•m

19.5

N•m

lb-ft

23.5

lb-ft

29.5

lb-ft

27.5

11.5

102

14.5

N•m

128

lb-ft

N•m

194

lb-ft

27.5

N•m

243

lb-ft

M10

N•m

204

lb-ft

29.5

M12

M14

M16

M18

M20

M22

M24

M27

M30

M33

M36

120

190

265

375

510

650

950

150

240

330

475

650

820

110

175

245

350

480

600

110

175

275

375

530

725

920

130

200

275

390

535

140

220

350

475

675

920

105

165

255

350

500

680

130

205

320

440

625

850

150

235

325

460

165

260

400

560

790

120

190

300

410

580

800

100

135

190

265

330

490

660

900

1150

125

170

245

330

425

625

850

140

195

275

375

480

100

140

195

245

360

490

125

180

245

315

460

625 1080

680 1150

850 1080

800 1350 1000

700 1200

950 1630 1200 1850 1350 2300 1700 2140 1580 2700 2000

850 1750 1300 2200 1625 2500 1850 3150 2325 2900 2150 3700 2730

850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2770 4750 3500

885 1350 1000 1700 1250 1580 1160 2000 1475

625 1290

665 1150

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.

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 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.

^a“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.

^b“Dry” means plain or zinc plated without any lubrication, or M6 to M18 fasteners with JDM F13B zinc flake coating.

DX,TORQ2 –19–24APR03–1/1

60-16

110306

PN=151

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Lubrication and Maintenance Records

Using Lubrication and Maintenance Records

Refer to specific Lubrication and Maintenance Section

for detailed service procedures.

complete listing of all items to be performed and the

service intervals required, refer to the

quick-reference chart near the front of the

Lubrication and Maintenance Section.

1. Keep a record of the number of hours you operate

your engine by regular observation of hour meter.

IMPORTANT: The service recommendations

covered in this manual are for the

accessories that are provided by

John Deere. Follow manufacturer’s

service recommendations for

2. Check your record regularly to learn when your

engine needs service.

3. DO ALL the services within an interval section.

Write the number of hours (from your service

records) and the date in the spaces provided. For a

servicing engine driven equipment

not supplied by Deere.

RG,RG34710,5620 –19–27JUL06–1/1

Daily (Prestarting) Service

• Check engine oil level.

• Check coolant level.

IMPORTANT: Drain water by rotating drain valve on

fuel/water separator bowl

counterclockwise. Premature injection

pump failure may occur if water is not

drained daily.

• Check fuel filter/water separator bowl.

• Check air cleaner dust unloader valve and air restriction

indicator, if equipped.

• Visual walkaround inspection.

RG,RG34710,5621 –19–07JAN02–1/1

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Lubrication and Maintenance Records

250 Hour/6 Month Service

• Change engine oil and filter.¹

• Service fire extinguisher.

• Check engine mounts.

• Service battery.

• Check automatic belt tensioner and belt wear.

Hours

Date

Hours

Date

Hours

Date

Hours

Date

Hours

Date

Hours

Date

Hours

Date

Hours

Date

¹If John Deere PLUS-50 or ACEA-E4/E5 oil is used along with a

John Deere oil filter, the oil and filter change interval may be

extended by 50 percent.

OURGP12,0000043 –19–31OCT06–1/1

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Lubrication and Maintenance Records

500 Hour/12 Month Service

• Clean crankcase vent tube.

• Check engine electrical ground connection.

• Check cooling system.

• Coolant solution analysis – add SCAs as needed.

• Pressure test cooling system.

• Check air intake hoses, connections, and system.

• Replace single or dual fuel filter elements.

• Check automatic belt tensioner and belt wear.

• Check engine speeds.

Hours

Date

Hours

Date

Hours

Date

Hours

Date

Hours

Date

Hours

Date

Hours

Date

Hours

Date

OURGP12,0000044 –19–07JUL04–1/1

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Lubrication and Maintenance Records

2000 Hour/24 Month Service

• Check crankshaft vibration damper (6-cylinder only).

• Test thermostats.

• Check and adjust valve clearance.

• Flush cooling system.¹

Hours

Date

Hours

Date

Hours

Date

Hours

Date

Hours

Date

Hours

Date

Hours

Date

Hours

Date

¹If 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 –19–20MAY96–1/1

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Lubrication and Maintenance Records

Service as Required

• Add coolant

• Service air cleaner.

• Replace poly-vee belts.

• Check fuses

• Check air compressor (if equipped).

• Bleed fuel system

Hours

Date

Hours

Date

Hours

Date

Hours

Date

Hours

Date

Hours

Date

Hours

Date

Hours

Date

OURGP12,0000045 –19–07JUL04–1/1

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Emission System Warranty

U.S. EPA Emissions Control Warranty Statement

Emissions control-related parts and components are

warranted by John Deere for five years or 3000 hours

of operation, whichever occurs first. John Deere further

warrants that the engine covered by this warranty was

designed, built, and equipped so as to conform at the

time of sale with all U.S. emissions standards at the

time of manufacture, and that it is free of defects in

materials and workmanship which would cause it not

to meet these standards within the period of five years

or 3000 hours of operation, whichever occurs first.

Warranties stated in this manual refer only to

emissions-related parts and components of your

engine. The complete engine warranty, less

emissions-related parts and components, is provided

separately as the “John Deere New Off-Highway

Engine Warranty”.

OUOD006,000004E –19–01NOV06–1/1

Emissions Control System Certification Label

CAUTION: Statutes providing severe penalties

for tampering with emissions controls may

apply to the user or dealer.

The emissions warranty described above 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. The

presence of an emissions label like the one shown

signifies that the engine has been certified with the EPA

and/or CARB. The EPA and CARB warranties only apply

to new 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.

Emissions Label

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.

OUOD006,000004D –19–13OCT06–1/1

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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:

• PARTS CATALOGS list service parts available for your

machine with exploded view illustrations to help you

identify the correct parts. It is also useful in assembling

and disassembling.

• OPERATOR’S MANUALS providing safety, operating,

maintenance, and service information. These manuals

and safety signs on your machine may also be available

in other languages.

• OPERATOR’S VIDEO TAPES showing highlights of

safety, operating, maintenance, and service information.

These tapes may be available in multiple languages

and formats.

• TECHNICAL MANUALS outlining service information for

your machine. Included are specifications, illustrated

assembly and disassembly procedures, hydraulic oil

flow diagrams, and wiring diagrams. Some products

have separate manuals for repair and diagnostic

information. Some components, such as engines, are

available in separate component technical manuals

• FUNDAMENTAL MANUALS detailing basic information

regardless of manufacturer:

– Agricultural Primer series covers technology in

farming and ranching, featuring subjects like

computers, the Internet, and precision farming.

– Farm Business Management series examines

“real-world” problems and offers practical solutions in

the areas of marketing, financing, equipment

selection, and compliance.

– Fundamentals of Services manuals show you how to

repair and maintain off-road equipment.

Continued on next page

DX,SERVLIT –19–31JUL03–1/2

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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

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Index

Page

Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-10

Flush. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-4

Pressure test. . . . . . . . . . . . . . . . . . . . . . . . . 35-13

Pressure test radiator cap. . . . . . . . . . . . . . . 35-13

Refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-4

Crankcase vent tube, clean . . . . . . . . . . . . . . . . 35-1

Crankshaft vibration damper. . . . . . . . . . . . . . . . 40-3

Acid burns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5

Air cleaner

Air intake restriction indicator . . . . . . . . . . . . . 25-1

Dust unloader valve . . . . . . . . . . . . . . . . . . . . 25-1

Replace single stage element . . . . . . . . . . . . . 45-3

Air compressor . . . . . . . . . . . . . . . . . . . . . . . . . 45-10

Air intake system, check. . . . . . . . . . . . . . . . . . . 35-2

Alternator belts . . . . . . . . . . . . . . . . . . . . . . . . . . 45-8

Ammeter. . . . . . . . . . . . . . . . . . . . . . . . . . .15-2, 15-4

Auxiliary gear drive, limitations . . . . . . . . . . . . . . 15-9

Aviation fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4

Damper, checking. . . . . . . . . . . . . . . . . . . . . . . . 40-3

Diesel engine oil. . . . . . . . . . . . . . . . . . . . . . . . . 10-7

Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . .10-1, 10-3

Batteries

Charge/Boost . . . . . . . . . . . . . . . . . . . . . . . . 15-17

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5

Battery acid burns . . . . . . . . . . . . . . . . . . . . . . . 30-5

Battery explosion . . . . . . . . . . . . . . . . . . . . . . . . 30-5

Belt tensioner

Manual tensioner, adjust . . . . . . . . . . . . . . . . . 30-7

Manual tensioner, adjust with tool . . . . . . . . . . 30-8

Belt tensioner, automatic . . . . . . . . . . . . . . . . . . 35-6

Belts, fan and alternator

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-8

Bleeding fuel system . . . . . . . . . . . . . . . . . . . . 45-11

Break-in engine oil . . . . . . . . . . . . . . . . . . . . . . . 10-6

Break-in, engine . . . . . . . . . . . . . . . . . . . . . . . . . 15-6

Burner fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4

Emissions

EPA Statement . . . . . . . . . . . . . . . . . . . . . . . . 70-1

Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-1

Engine

Break-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6

Check electrical ground. . . . . . . . . . . . . . . . . . 35-9

Idling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-15

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-13

Option codes. . . . . . . . . . . . . . . . . . . . . . . . . . 01-3

Power ratings . . . . . . . . . . . . . . . . . . . . . . . . . 60-3

Serial number . . . . . . . . . . . . . . . . . . . . . . . . . 01-1

Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-10

Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-16

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 50-7

Warming . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-12

Engine coolant

Disposing of . . . . . . . . . . . . . . . . . . . . . . . . . 10-18

Engine mounts

Chart, service interval. . . . . . . . . . . . . . . . .20-2, 20-4

Check engine electrical ground. . . . . . . . . . . . . . 35-9

Cold weather aids. . . . . . . . . . . . . . . . . . . . . . . 15-14

Compressor, air . . . . . . . . . . . . . . . . . . . . . . . . 45-10

Coolant

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

Additional information . . . . . . . . . . . . .10-14, 10-16

Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . 10-12

Disposing . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18

Replenishing supplemental additives. . . . . . . 35-11

Supplemental additives . . . . . . . . . . . . . . . . . 10-15

Testing . . . . . . . . . . . . . . . . . . . . . . . .10-17, 35-12

Warm temperature climates . . . . . . . . . . . . . 10-18

Cooling system

Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4

Engine oil

Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6

Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-2

Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7

Engine speed, changing . . . . . . . . . . . . . . . . . . 15-15

Fan belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-8

Filter, replace

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-3

Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-2

Adding coolant . . . . . . . . . . . . . . . . . . . . . . . . 45-2

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Index

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Fire extinguisher, service . . . . . . . . . . . . . . . . . . 30-1

Fuel

Aviation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4

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

Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1, 10-3

Handling and storing . . . . . . . . . . . . . . . . . . . . 10-2

Jet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4

Kerosene . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4

Lubricity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

Fuel filter

Lubricant

Mixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8

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

Lubrication and Maintenance

Service Interval Chart . . . . . . . . . . . . . . .20-2, 20-4

Lubricity of diesel fuel. . . . . . . . . . . . . . . . . . . . . 10-1

Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-1

Draining water. . . . . . . . . . . . . . . . . . . . . . . . . 25-1

Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-3

Fuel injection pump model number. . . . . . . . . . . 01-5

Fuel system

Maintenance interval chart

Generator (Standby) applications . . . . . . . . . . 20-4

Standard industrial applications. . . . . . . . . . . . 20-2

Manual belt tensioner . . . . . . . . . . . . . . . . . . . . . 30-7

Manual belt tensioner - using belt tension tool . . 30-8

Mixing lubricants. . . . . . . . . . . . . . . . . . . . . . . . . 10-8

Mounts, engine

Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-11

Fuses, checking . . . . . . . . . . . . . . . . . . . . . . . . . 45-9

Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4

Gauge panel. . . . . . . . . . . . . . . . . . . . . . . .15-2, 15-4

Gauges . . . . . . . . . . . . . . . . . . . . . 15-2, 15-4, 15-12

Generator (Standby) Applications . . . . . . . . . . . . 20-4

Grease

Oil

Extreme pressure and multipurpose . . . . . . . 10-11

Dipstick. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-1

Fill quantity . . . . . . . . . . . . . . . . . . . . . . . . . . 60-11

Filler locations. . . . . . . . . . . . . . . . . . . . . . . . . 25-1

Oil filter, change . . . . . . . . . . . . . . . . . . . . . . . . . 30-2

Oil filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10

Oil pressure gauge. . . . . . . . . . . . . . . . . . .15-2, 15-4

Operating engine

Hand throttle. . . . . . . . . . . . . . . . . . . . . . . .15-2, 15-4

Break-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6

Cold weather. . . . . . . . . . . . . . . . . . . . . . . . . 15-14

Normal operation . . . . . . . . . . . . . . . . . . . . . 15-13

Option codes . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-3

Idling engine. . . . . . . . . . . . . . . . . . . . . . . . . . . 15-15

Instrument panels. . . . . . . . . . . . . . . . . . . .15-2, 15-4

Poly-vee belts

Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-8

Power ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-3

Jet fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4

Radiator cap testing . . . . . . . . . . . . . . . . . . . . . 35-13

Recordkeeping

Key switch . . . . . . . . . . . . . . . . . . . . . . . . .15-2, 15-4

Engine option codes . . . . . . . . . . . . . . . . . . . . 01-3

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Index

Page

Engine serial number . . . . . . . . . . . . . . . . . . . 01-1

Injection pump model number. . . . . . . . . . . . . 01-5

Vibration damper . . . . . . . . . . . . . . . . . . . . . . . . 40-3

Warming engine . . . . . . . . . . . . . . . . . . . . . . . . 15-12

Wiring diagram

Except North America . . . . . . . . . . . . . . . . . . . 50-5

North America. . . . . . . . . . . . . . . . . . . . . . . . . 50-3

Serial number

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1

Fuel injection pump. . . . . . . . . . . . . . . . . . . . . 01-5

Service

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5

Fire extinguisher . . . . . . . . . . . . . . . . . . . . . . . 30-1

Intervals . . . . . . . . . . . . . . . . . . . . . . . . .20-2, 20-4

Specifications

Battery capabilities . . . . . . . . . . . . . . . . . . . . . 30-5

Belt tensioner . . . . . . . . . . . . . . . . . . . . . . . . . 35-6

Damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-3

Engine crankcase oil fill . . . . . . . . . . . . . . . . 60-11

Fuel injection pump. . . . . . . . . . . . . . . . . . . . . 60-3

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

6.8 L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-2

Standby power units. . . . . . . . . . . . . . . . . . . . . . 15-9

Starting engine . . . . . . . . . . . . . . . . . . . . . . . . . 15-10

Stopping engine . . . . . . . . . . . . . . . . . . . . . . . . 15-16

Storage

Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-1

Long term . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-2

Removing from . . . . . . . . . . . . . . . . . . . . . . . . 55-3

Storing fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

Storing lubricants . . . . . . . . . . . . . . . . . . . . . . . 10-10

Supplemental coolant additives

Replenishing . . . . . . . . . . . . . . . . . . . . . . . . . 35-11

Temperature gauge (coolant) . . . . . . . . . . .15-2, 15-4

Tensioner, belt

Automatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-6

Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-7

Thermostat

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-7

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-7

Test opening temperature . . . . . . . . . . . . . . . . 40-7

Troubleshooting

General, engine . . . . . . . . . . . . . . . . . . . . . . . 50-7

Valves

Clearance, check and adjust. . . . . . . . . . . . . 40-10

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Index

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