John Deere Powertech 6081afm75

POWERTECH6081AFM75

Marine Engines

OPERATORS MANUALPOWERTECH 6081AFM75 Marine

EnginesOMRG35860 Issue 02May06 (ENGLISH)

CALIFORNIAProposition 65 Warning

Diesel engine exhaust and some of its constituents areknown to the State of California to cause cancer, birth

defects, and other reproductive harm.

If this product contains a gasoline engine:

WARNINGThe engine exhaust from this product contains chemicals

known to the State of California to cause cancer, birthdefects or other reproductive harm.

The State of California requires the above two warnings.

John Deere Power SystemsLITHO IN U.S.A.

DCT

OM

RG35

860

Introduction

OURGP11,00000BD 1917APR061/1

Forward

READ THIS MANUAL carefully to learn how to operateand service your engine correctly. Failure to do socould result in personal injury or equipment damage.

THIS MANUAL SHOULD BE CONSIDERED apermanent part of your engine and should remain withthe vessel when you sell it.

MEASUREMENTS IN THIS MANUAL are given in bothmetric and customary U.S. unit equivalents. Use onlycorrect replacement parts and fasteners. Metric andinch fasteners may require a specific metric or inchwrench.

RIGHT-HAND AND LEFT-HAND sides are determinedby standing at the drive (rear) of the engine and facingtoward the front of the engine.

WRITE ENGINE SERIAL NUMBERS and option codesin the spaces indicated in the Record Keeping Section.Accurately record all the numbers. Your dealer alsoneeds these numbers when you order parts. File theidentification numbers in a secure place off the engine.

SETTING FUEL DELIVERY beyond published factoryspecifications or otherwise overpowering will result inloss of warranty protection for this engine.

CERTAIN ENGINE ACCESSORIES such as aircleaner, and some instruments are optional equipmenton John Deere OEM Engines. These accessories maybe provided by the equipment manufacturer instead ofJohn Deere. This operators manual applies only to theengine and those options available through the JohnDeere distribution network.

SETTING FUEL DELIVERY outside the publishedfactory specifications or otherwise modifying ortampering with the engine fuel system settingsincluding ECU software parameters may subject theuser to civil fines and penalties. Such actions will alsobe taken into consideration if claims are made underthe provisions John Deeres New Marine EngineWarranty.

NOTE: This manual covers emission-certified6081AFM75 Marine Engines manufactured in2004 and later. Earlier engines are covered ina separate manual, OMRG28995.

050206

PN=2

Introduction

OURGP11,0000251 1906NOV031/1

Engine Owner

John Deere Engine Owner:

Dont wait until you need warranty or other service tomeet your local John Deere Engine Distributor orService Dealer. To register your engine for warrantyvia the Internet, use the following URL:http://www.johndeere.com/enginewarranty

Learn who your dealer is and where he is. At your firstconvenience, go meet him. Hell want to get to knowyou and to learn what your needs might be.

Aux Utilisateurs De Moteurs John Deere:

Nattendez pas detre oblige davoir recours a` votreconcessionnaire John Deere ou au point de service leplus proche pour vous adresser a` lui. Pour enregistrervotre moteur pour la garantie via Internet, utilisezladresse suivante:http://www.johndeere.com/enginewarranty

Renseignez-vous de`s que possible pour lidentifier etle localiser. A la premie`re occasion, prenez contactavec lui et faites-vous connatre. Il sera lui aussiheureux de faire votre connaissance et de vousproposer ses services le moment venu.

An Den Besitzer Des John Deere Motors:

Warten Sie nicht auf einen evt. Reparaturfall, um dennachstgelegenen John Deere Handler kennen zulernen. Zur Registrierung Ihres Motors fur die Garantiedient folgende Internet-Adresse:http://www.johndeere.com/enginewarranty

Machen Sie sich bei ihm bekannt und nutzen Sie seinService Angebot.

Proprietario del motore John Deere:

Non aspetti fino al momento di far valere la garanzia odi chiedere assistenza per fare la conoscenza del

distributore dei motori John Deere o delconcessionario che fornisce lassistenza tecnica. Perregistrare via Internet la garanzia del suo motore, sicollegi al seguente sito URL:http://www.johndeere.com/enginewarranty

Lo identifichi e si informi sulla sua ubicazione. Allaprima occasione utile lo contatti. Egli desidera fare lasua conoscenza e capire quali potrebbero essere lesue necessita`.

Propietario De Equipo John Deere:

No espere hasta necesitar servicio de garanta o deotro tipo para conocer a su Distribuidor de MotoresJohn Deere o al Concesionario de Servicio. Registresu motor para la garanta en la siguiente direccion deinternet: http://www.johndeere.com/enginewarranty

Enterese de quien es, y donde esta situado. Cuandotenga un momento, vaya a visitarlo. A el le gustaraconocerlo, y saber cuales podran ser susnecesidades.

Till agare av John Deere motorer:

Ta reda pa vem din aterforsaljare ar och besok honomsa snart tillfalle ges. Vanta inte tills det ar dags forservice eller eventuellt garantiarbete. Din motorgarantiregistrerar Du via Internet pahttp://www.johndeere.com/enginewarranty

Din aterforsaljare vill mycket garna traffa dig for att larakanna dina behov och hur bast han kan hjalpa dig.

050206

PN=3

Introduction

OURGP11,0000102 1909OCT031/1

Identification Views

RG

1325

6UN

22J

AN04

6081AFM75 Diesel Engine

RG

1325

7UN

22D

EC03

6081AFM75 Diesel Engine

050206

PN=4

ContentsPage Page

Record Keeping Accessing Active Trouble Codes . . . . . . . . . . . 15-11Record Engine Serial Number . . . . . . . . . . . . . . 01-1 Engine Shutdown Codes . . . . . . . . . . . . . . . . . 15-13Engine Option Codes . . . . . . . . . . . . . . . . . . . . . 01-2 Adjusting Backlighting. . . . . . . . . . . . . . . . . . . . 15-15

Adjusting Contrast . . . . . . . . . . . . . . . . . . . . . . 15-17Selecting Units Of Measurement . . . . . . . . . . . 15-19Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-1Setup 1-Up Display . . . . . . . . . . . . . . . . . . . . . 15-21Setup 4-Up Display . . . . . . . . . . . . . . . . . . . . . 15-28Fuels, Lubricants, and Coolant Normal Engine Operation . . . . . . . . . . . . . . . . . 15-33Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 Break-In Service. . . . . . . . . . . . . . . . . . . . . . . . 15-34Lubricity of Diesel Fuel . . . . . . . . . . . . . . . . . . . . 10-1 Auxiliary Gear Drive Limitations . . . . . . . . . . . . 15-36Handling and Storing Diesel Fuel . . . . . . . . . . . . 10-2 Gen-Set Power Units . . . . . . . . . . . . . . . . . . . . 15-36Testing Diesel Fuel. . . . . . . . . . . . . . . . . . . . . . . 10-2 Starting the Engine. . . . . . . . . . . . . . . . . . . . . . 15-37Bio-Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 Restarting Engine That Has Run Out OfMinimizing the Effect of Cold Weather on Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-39Diesel Engines . . . . . . . . . . . . . . . . . . . . . . . . 10-4 Cold Weather Operation . . . . . . . . . . . . . . . . . . 15-39Diesel Engine Break-In Oil . . . . . . . . . . . . . . . . . 10-5 Warming Engine. . . . . . . . . . . . . . . . . . . . . . . . 15-40Diesel Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . 10-6 Idling Engine . . . . . . . . . . . . . . . . . . . . . . . . . . 15-41Extended Diesel Engine Oil Service Intervals . . . 10-7 Stopping the Engine . . . . . . . . . . . . . . . . . . . . . 15-42Mixing of Lubricants . . . . . . . . . . . . . . . . . . . . . . 10-7 Using A Booster Battery Or Charger . . . . . . . . 15-44OILSCANand COOLSCAN . . . . . . . . . . . . . . 10-8

Alternative and Synthetic Lubricants . . . . . . . . . . 10-8 Lubrication and MaintenanceLubricant Storage . . . . . . . . . . . . . . . . . . . . . . . . 10-9 Observe Service Intervals. . . . . . . . . . . . . . . . . . 20-1Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9 Use Correct Fuels, Lubricants And Coolant . . . . 20-1Diesel Engine Coolant . . . . . . . . . . . . . . . . . . . 10-10 Lubrication And Maintenance ServiceDrain Intervals for Diesel Engine Coolant . . . . 10-11 Interval ChartPropulsion Power Units . . . . . 20-2Supplemental Coolant Additives . . . . . . . . . . . . 10-12 Lubrication And Maintenance ServiceAdditional Information About Diesel Interval ChartGenerator Sets . . . . . . . . . . . . 20-4Engine Coolants and Supplemental CoolantAdditives . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13 Lubrication & Maintenance/DailyTesting Diesel Engine Coolant . . . . . . . . . . . . . 10-14 Daily Prestart Checks . . . . . . . . . . . . . . . . . . . . . 25-1Operating in Warm Temperature Climates . . . . 10-15

Disposing of Coolant . . . . . . . . . . . . . . . . . . . . 10-15 Lubrication & Maintenance/250 Hour/6 MonthServicing Fire Extinguisher . . . . . . . . . . . . . . . . . 30-1

Engine Operating Guidelines Servicing Battery . . . . . . . . . . . . . . . . . . . . . . . . 30-2John Deere Instrument (Gauge) Panel . . . . . . . . 15-1 Changing Engine Oil And Replacing Oil Filter . . 30-4John Deere Instrument (Gauge) Panel Visually Inspect Coolant Pump . . . . . . . . . . . . . . 30-7

(Continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-3 Checking Engine Mounts . . . . . . . . . . . . . . . . . . 30-7Optional Electronic Displays to Monitor Inspect And Replace Zinc Plugs -

Engine and Navigation . . . . . . . . . . . . . . . . . . 15-4 Engines Equipped With Heat Exchanger. . . . . 30-8Using Diagnostic Gauge to Access Engine

Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5 Lubrication & Maintenance/500 Hour/12 MonthReplace Crankcase Vent Filter (If Equipped) . . . 35-1Main Menu Navigation . . . . . . . . . . . . . . . . . . . . 15-6

Engine Configuration Data . . . . . . . . . . . . . . . . . 15-7Continued on next pageAccessing Stored Trouble Codes . . . . . . . . . . . . 15-9

All information, illustrations and specifications in this manual are based onthe latest information available at the time of publication. The right isreserved to make changes at any time without notice.

COPYRIGHT 2006DEERE & COMPANY

Moline, IllinoisAll rights reserved

A John Deere ILLUSTRUCTION ManualPrevious EditionsCopyright 2004

i 050206PN=1

Contents

Page Page

Cleaning Crankcase Vent Tube . . . . . . . . . . . . . 35-1 Engine Troubleshooting . . . . . . . . . . . . . . . . . . . 50-9Electrical Troubleshooting. . . . . . . . . . . . . . . . . 50-11Checking Air Intake System . . . . . . . . . . . . . . . . 35-2

Replacing Fuel Filter Elements . . . . . . . . . . . . . . 35-3 Retrieving Diagnostic Trouble Codes . . . . . . . . 50-12Displaying Of Diagnostic Trouble CodesChecking Belt Tension And Belt Wear . . . . . . . . 35-5

Checking Cooling System. . . . . . . . . . . . . . . . . . 35-6 (DTCs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-13Listing Of Diagnostic Trouble Codes (DTC) . . . 50-14Testing Diesel Engine Coolant . . . . . . . . . . . . . . 35-7

Pressure Test Cooling System . . . . . . . . . . . . . . 35-8 Intermittent Fault Diagnostics . . . . . . . . . . . . . . 50-18Displaying Diagnostic Gauge Software . . . . . . . 50-18Checking And Adjusting Engine Speeds. . . . . . . 35-9

Checking Engine Electrical GroundConnections . . . . . . . . . . . . . . . . . . . . . . . . . . 35-9 Storage

Engine Storage Guidelines . . . . . . . . . . . . . . . . . 55-1Checking Crankshaft Vibration Damper . . . . . . 35-10Inspect And Clean Heat Exchanger Core (If Preparing Engine for Long-Term Storage . . . . . . 55-2

Removing Engine from Long-Term Storage . . . . 55-3Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-12General Engine Information . . . . . . . . . . . . . . . . 55-4

Lubrication&Maintenance/2000 Hour/24MonthSpecificationsFlushing Cooling System . . . . . . . . . . . . . . . . . . 40-1General Engine Specifications . . . . . . . . . . . . . . 60-1Testing Thermostats . . . . . . . . . . . . . . . . . . . . . . 40-4Power And Speed SpecificationsChecking Valve Clearance . . . . . . . . . . . . . . . . 40-8

Propulsion Applications . . . . . . . . . . . . . . . . . . 60-1Adjusting Valve Clearance . . . . . . . . . . . . . . . 40-11Power And Speed SpecificationsReplace Sea Water Pump Impeller With

Generator Set Applications . . . . . . . . . . . . . . . 60-1Pump Installed On Engine . . . . . . . . . . . . . . 40-15Engine Crankcase Oil Fill Quantities . . . . . . . . . 60-2Remove And Install Sea Water Pump . . . . . . . 40-17Unified Inch Bolt and Screw Torque Values . . . . 60-3Disassemble, Inspect And Repair SeaMetric Bolt and Screw Torque Values. . . . . . . . . 60-4Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . 40-18

Assemble Sea Water Pump . . . . . . . . . . . . . . . 40-20Lubrication and Maintenance RecordsUsing Lubrication And Maintenance Records . . . 65-1Service As RequiredDaily (Prestart) Service. . . . . . . . . . . . . . . . . . . . 65-1Additional Service Information . . . . . . . . . . . . . . 45-1250 Hour Service . . . . . . . . . . . . . . . . . . . . . . . . 65-2Do Not Modify Fuel System . . . . . . . . . . . . . . . . 45-1500 Hour/12 Month Service . . . . . . . . . . . . . . . . 65-3Drain Fuel/Water Separator Bowl (When2000 Hour/24 Month Service . . . . . . . . . . . . . . . 65-4Audible Alarm Signals Water In Fuel) . . . . . . . 45-2Service As Required. . . . . . . . . . . . . . . . . . . . . . 65-5Adding Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . 45-3

Servicing Air Cleaner Filter Element . . . . . . . . . . 45-4Emission System WarrantyReplacing Air Cleaner Filter Element . . . . . . . . . 45-8Emissions Control System Certification Label. . . 70-1Replacing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . 45-9U.S. EPA Emissions Control WarrantyChecking Fuses . . . . . . . . . . . . . . . . . . . . . . . . . 45-9

Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-2Bleeding Fuel System. . . . . . . . . . . . . . . . . . . . 45-10EU Declaration of Emissions Conformity . . . . . . 70-2

TroubleshootingGeneral Troubleshooting Information . . . . . . . . . 50-1Precautions For Welding On Vessels

Equipped With Electronic Engine Control Unit(ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-2

Engine Wiring Diagram for John DeereMain (Wheel House) Instrument Panel . . . . . . 50-3

Engine Wiring Diagram for John DeereMain Instrument Panel (Continued) . . . . . . . . . 50-4

Engine Wiring Diagram for John DeereOptional Fly Bridge Instrument Panel . . . . . . . 50-5

Engine Wiring Diagram for John DeereLevel III Electronic Control Unit . . . . . . . . . . . . 50-6

Engine Coolant and Sea Water Flow (HeatExchanger Engines) . . . . . . . . . . . . . . . . . . . . 50-8

ii 050206PN=2

Record Keeping

OURGP11,0000103 1909OCT031/1

Record Engine Serial Number

RG

1325

8UN

09O

CT03

Serial Number and Application Data

RG

7396

UN

21M

AR00

Engine Serial Number Plate

The engine serial number plate (C) is located on theleft-hand side of engine block between intake manifoldand starting motor.

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

This information is very important for repair parts orwarranty information.

Engine Serial Number (A)

Application Data or Type (B)

01-1 050206PN=7

Record Keeping

OURGP11,00000CE 1924SEP031/2

Engine Option Codes

RG

1325

9UN

09O

CT03

Engine Option Codes

In addition to the serial number plate, OEM engineshave an engine option code label affixed to the side ofthe cylinder block. These codes indicate which of theengine options were installed on your engine at thefactory. When in need of parts or service, furnish yourauthorized servicing dealer or engine distributor withthese numbers.

The first two digits of each code identify a specificgroup, such as alternators. The last two digits of eachcode identify one specific option provided on yourengine, such as a 24-volt, 60-amp alternator.

If an engine is ordered without a particular component,the last two digits of that functional group option codewill be 99, 00, or XX. The following list shows only thefirst two digits of the code numbers. For futurereference such as ordering repair parts, it is importantto have these code numbers available. To ensure thisavailability, enter the third and fourth digits shown onyour engine option code label in the spaces providedon the following page.

Continued on next page

01-2 050206PN=8

Record Keeping

OURGP11,00000CE 1924SEP032/2

NOTE: Your engine option code label may not containall option codes if an option has been addedafter the engine left the producing factory.

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

Option Codes Description Option Codes Description

11 Rocker Arm Cover 51 Cylinder Head12 Oil Filter Inlet 52 Gear-Driven Auxiliary Drive13 Crankshaft Pulley/Damper 53 Fuel Heater14 Flywheel Housing 55 Transport Skid/Shipping Stand15 Flywheel 56 Paint16 Fuel Injection Pump 57 Coolant Pump Inlet17 Air Intake 59 Oil Cooler and Filter18 Air Cleaner 60 Add-0n Auxiliary Drive Pulley19 Oil Pan 62 Alternator Mounting20 Coolant Pump 63 Low Pressure Fuel Line21 Thermostat Cover 64 Exhaust Elbow22 Thermostats 65 Turbocharger23 Fan Drive 66 Coolant Temperature Sensor/Switch24 Fan Belts 67 Electronic Sensors (Base Engine)25 Fan 68 Crankshaft Rear Damper26 Engine Coolant Heater 69 Engine Serial Number Plate27 Radiator 71 Engine Oil Bypass Filter28 Exhaust System 72 ECU Software - Engine Performance29 Ventilator System 74 Air Conditioning (A/C) Compressor (Optional)30 Starter Motor 75 Air Restriction Indicator31 Alternator 76 Oil Pressure Sensor/Switch32 Instrument Panel 77 Timing Gear Cover33 Tachometer 78 Air Compressor (Optional)35 Fuel Filter 79 Engine Certification36 Front Plate 80 Sea Water Pump37 Fuel Transfer Pump 81 Primary Fuel Filter and Water Separator38 Operators Manual 83 ECU Software - Vehicle Performance39 Outlet Manifold 84 Electrical Wiring Harness40 Oil Dipstick 86 Fan Pulley41 Belt-Driven Front Auxiliary Drive 87 Belt Tensioner43 Starting Aid 88 Oil Filter44 Electronic Speed Sensor 92 Accessories (Factory Installed)(Rear PTO)45 Balancer Shafts 93 Emissions Label46 Cylinder Block 95 Special Equipment (Factory Installed)47 Crankshaft 96 Wiring Harness48 Pistons and Connecting Rods 97 Special Equipment (Field Installed)49 Rocker Arm Assembly 98 Engine Lift Straps and Trim50 Oil Pump 99 Service Kits

NOTE: These option codes are based on the latestinformation available at the time of publication.

The right is reserved to make changes at anytime without notice.

01-3 050206PN=9

Safety

DX,ALERT 1929SEP981/1

Recognize Safety Information

T813

89UN

07D

EC88

Safety-alert symbol

This is a safety-alert symbol. When you see this symbolon your machine or in this manual, be alert to thepotential for personal injury.

Follow recommended precautions and safe operatingpractices.

DX,SIGNAL 1903MAR931/1

Understand Signal Words

TS18

719

30S

EP88

Signal Words

A signal wordDANGER, WARNING, or CAUTIONisused with the safety-alert symbol. DANGER identifies themost serious hazards.

DANGER or WARNING safety signs are located nearspecific hazards. General precautions are listed onCAUTION safety signs. CAUTION also calls attention tosafety messages in this manual.

05-1 050206PN=10

Safety

DX,READ 1903MAR931/1

Follow Safety Instructions

TS20

1UN

23A

UG88

Safety Messages

Carefully read all safety messages in this manual and onyour machine safety signs. Keep safety signs in goodcondition. Replace missing or damaged safety signs. Besure new equipment components and repair parts includethe current safety signs. Replacement safety signs areavailable from your John Deere dealer.

Learn how to operate the engine and how to use controlsproperly. Do not let anyone operate without instruction.

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

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

DX,SIGNS1 1904JUN901/1

Replace Safety Signs

TS20

1UN

23A

UG88

Safety Signs

Replace missing or damaged safety signs. See themachine operators manual for correct safety signplacement.

05-2 050206PN=11

Safety

RG,RG34710,7508 1930JUN971/1

Prevent Bypass Starting

RG

5419

UN

28F

EB89

Prevent Bypass Starting

Avoid possible injury or death from engine runaway.

Do not start engine by shorting across starter terminal.Engine will start with PTO engaged if normal circuitry isbypassed.

Start engine only from operators station with PTOdisengaged or in neutral.

DX,FIRE1 1903MAR931/1

Handle Fuel SafelyAvoid Fires

TS20

2UN

23A

UG88

Avoid Fires

Handle fuel with care: it is highly flammable. Do not refuelthe engine while smoking or when near open flame orsparks.

Always stop engine before refueling machine. Fill fuel tankoutdoors.

Prevent fires by keeping engine clean of accumulatedtrash, grease, and debris. Always clean up spilled fuel.

05-3 050206PN=12

Safety

DX,FIRE2 1903MAR931/1

Prepare for Emergencies

TS29

1UN

23A

UG88

First Aid Kit

Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service,hospital, and fire department near your telephone.

DX,FIRE3 1916APR921/1

Handle Starting Fluid Safely

TS13

56UN

18M

AR92

Store Safely

Starting fluid is highly flammable.

Keep all sparks and flame away when using it. Keepstarting fluid away from batteries and cables.

To prevent accidental discharge when storing thepressurized can, keep the cap on the container, and storein a cool, protected location.

Do not incinerate or puncture a starting fluid container.

05-4 050206PN=13

Safety

DX,FLAME 1929SEP981/1

Handle Fluids SafelyAvoid Fires

TS22

7UN

23A

UG88

Avoid Fires

When you work around fuel, do not smoke or work nearheaters or other fire hazards.

Store flammable fluids away from fire hazards. Do notincinerate or puncture pressurized containers.

Make sure engine is clean of trash, grease, and debris.

Do not store oily rags; they can ignite and burnspontaneously.

DX,LOOSE 1904JUN901/1

Service Engines Safely

TS22

8UN

23A

UG88

Moving Parts

Tie long hair behind your head. Do not wear a necktie,scarf, loose clothing, or necklace when you work nearengine tools or moving parts. If these items were to getcaught, severe injury could result.

Remove rings and other jewelry to prevent electricalshorts and entanglement in moving parts.

05-5 050206PN=14

Safety

DX,WEAR 1910SEP901/1

Wear Protective Clothing

TS20

6UN

23A

UG88

Protective Clothing

Wear close fitting clothing and safety equipmentappropriate to the job.

Prolonged exposure to loud noise can cause impairmentor loss of hearing.

Wear a suitable hearing protective device such asearmuffs or earplugs to protect against objectionable oruncomfortable loud noises.

Operating equipment safely requires the full attention ofthe operator. Do not wear radio or music headphoneswhile operating machine.

DX,NOISE 1903MAR931/1

Protect Against Noise

TS20

7UN

23A

UG88

Noise Exposure

Prolonged exposure to loud noise can cause impairmentor loss of hearing.

Wear a suitable hearing protective device such asearmuffs or earplugs to protect against objectionable oruncomfortable loud noises.

05-6 050206PN=15

Safety

DX,MSDS,NA 1903MAR931/1

Handle Chemical Products Safely

TS11

32UN

26N

OV9

0

Material Safety Data Sheet

Direct exposure to hazardous chemicals can causeserious injury. Potentially hazardous chemicals used withJohn Deere equipment include such items as lubricants,coolants, paints, and adhesives.

A Material Safety Data Sheet (MSDS) provides specificdetails on chemical products: physical and health hazards,safety procedures, and emergency response techniques.

Check the MSDS before you start any job using ahazardous chemical. That way you will know exactly whatthe risks are and how to do the job safely. Then followprocedures and recommended equipment.

(See your John Deere dealer for MSDSs on chemicalproducts used with John Deere equipment.)

OUO1004,0000BD8 1903NOV001/1

Stay Clear of Rotating Drivelines

TS16

44UN

22A

UG95

Rotating Drivelines

Entanglement in rotating driveline can cause serious injuryor death.

Keep master shield and driveline shields in place at alltimes. Make sure rotating shields turn freely.

Wear close-fitting clothing. Stop the engine and be surePTO driveline is stopped before making adjustments,connections, or performing any type of service on theengine or PTO-driven equipment.

05-7 050206PN=16

Safety

DX,SERV 1917FEB991/1

Practice Safe Maintenance

TS21

8UN

23A

UG88

Keep Area Clean

Understand service procedure before doing work. Keeparea clean and dry.

Never lubricate, service, or adjust engine while it ismoving. Keep hands, feet, and clothing from power-drivenparts. Disengage all power and operate controls to relievepressure. Lower equipment to the ground. Stop theengine. Remove the key. Allow engine to cool.

Securely support any engine elements that must be raisedfor service work.

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

Disconnect battery ground cable (-) before makingadjustments on electrical systems or welding on engine.

DX,AIR 1917FEB991/1

Work In Ventilated Area

TS22

0UN

23A

UG88

Engine exhaust fumes

Engine exhaust fumes can cause sickness or death. If it isnecessary to run an engine in an enclosed area, removethe exhaust fumes from the area with an exhaust pipeextension.

If you do not have an exhaust pipe extension, open thedoors and get outside air into the area

05-8 050206PN=17

Safety

DX,WW,HPCR1 1907JAN031/1

Do Not Open High-Pressure Fuel System

TS13

43UN

18M

AR92

High-Pressure Fuel Lines

High-pressure fluid remaining in fuel lines can causeserious injury. Do not disconnect or attempt repair of fuellines, sensors, or any other components between thehigh-pressure fuel pump and nozzles on engines withHigh Pressure Common Rail (HPCR) fuel system.

Only technicians familiar with this type of system canperform repairs. (See your John Deere dealer.)

DX,FLUID 1903MAR931/1

Avoid High-Pressure Fluids

X981

1UN

23A

UG88

High-Pressure Fluids

Escaping fluid under pressure can penetrate the skincausing serious injury.

Avoid the hazard by relieving pressure beforedisconnecting hydraulic or other lines. Tighten allconnections before applying pressure.

Search for leaks with a piece of cardboard. Protect handsand body from high pressure fluids.

If an accident occurs, see a doctor immediately. Any fluidinjected into the skin must be surgically removed within afew hours or gangrene may result. Doctors unfamiliar withthis type of injury should reference a knowledgeablemedical source. Such information is available from Deere& Company Medical Department in Moline, Illinois, U.S.A.

05-9 050206PN=18

Safety

DX,TORCH 1910DEC041/1

Avoid Heating Near Pressurized Fluid Lines

TS95

3UN

15M

AY90

Flammable spray can be generated by heating nearpressurized fluid lines, resulting in severe burns toyourself and bystanders. Do not heat by welding,soldering, or using a torch near pressurized fluid lines orother flammable materials. Pressurized lines canaccidentally burst when heat goes beyond the immediateflame area.

DX,PAINT 1924JUL021/1

Remove Paint Before Welding or Heating

TS22

0UN

23A

UG88

Avoid potentially toxic fumes and dust.

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

Remove paint before heating:

Remove paint a minimum of 101 mm (4 in.) from areato 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 withsoap and water before welding. Remove solvent orpaint stripper containers and other flammable materialfrom area. Allow fumes to disperse at least 15 minutesbefore welding or heating.

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

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

Dispose of paint and solvent properly.

05-10 050206PN=19

Safety

DX,RCAP 1904JUN901/1

Service Cooling System Safely

TS28

1UN

23A

UG88

Cooling System

Explosive release of fluids from pressurized coolingsystem can cause serious burns.

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

OUOD006,000009D 1904DEC021/1

Install Fan Guards

TS67

7UN

21S

EP89

Rotating Fan

Rotating cooling system fans can cause serious injury.

Keep fan guards in place at all times during engineoperation. Wear close fitting clothes. Stop the engine andbe sure fan is stopped before making adjustments orconnections, or cleaning near the front of the engine.

05-11 050206PN=20

Safety

OURGP12,0000135 1919JUL051/1

Avoid Hot Parts

TS27

1UN

23A

UG88

Hot Surface

Avoid skin contact with exhaust manifolds, turbochargersand mufflers. Keep flammable materials clear of theturbocharger.

External dry exhaust parts become very hot duringoperation. Turbochargers and exhaust manifolds mayreach temperatures as high as 600C (1112F) under fullload. This may ignite paper, cloth or wooden materials.Parts on engines that have been at full load and reducedto no load idle will maintain approximately 150C (302F).

DX,DUST 1915MAR911/1

Avoid Harmful Asbestos Dust

TS22

0UN

23A

UG88

Asbestos Dust

Avoid breathing dust that may be generated whenhandling components containing asbestos fibers. Inhaledasbestos fibers may cause lung cancer.

Components in products that may contain asbestos fibersare brake pads, brake band and lining assemblies, clutchplates, and some gaskets. The asbestos used in thesecomponents is usually found in a resin or sealed in someway. Normal handling is not hazardous as long asairborne dust containing asbestos is not generated.

Avoid creating dust. Never use compressed air forcleaning. Avoid brushing or grinding material containingasbestos. When servicing, wear an approved respirator. Aspecial vacuum cleaner is recommended to cleanasbestos. If not available, apply a mist of oil or water onthe material containing asbestos.

Keep bystanders away from the area.

05-12 050206PN=21

Safety

DX,SPARKS 1903MAR931/1

Prevent Battery Explosions

TS20

4UN

23A

UG88

Battery Explosions

Keep sparks, lighted matches, and open flame away fromthe top of battery. Battery gas can explode.

Never check battery charge by placing a metal objectacross the posts. Use a volt-meter or hydrometer.

Do not charge a frozen battery; it may explode. Warmbattery to 16C (60F).

DX,POISON 1921APR931/1

Prevent Acid Burns

TS20

3UN

23A

UG88

Sulfuric acid in battery electrolyte is poisonous. It is strongenough to burn skin, eat holes in clothing, and causeblindness 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 1530 minutes. Get

medical attention immediately.

If acid is swallowed:

1. Do not induce vomiting.2. Drink large amounts of water or milk, but do not

exceed 2 L (2 quarts).3. Get medical attention immediately.

05-13 050206PN=22

Safety

DX,SPRAY 1916APR921/1

Protect Against High Pressure Spray

TS13

43UN

18M

AR92

High Pressure Spray

Spray from high pressure nozzles can penetrate the skinand cause serious injury. Keep spray from contactinghands or body.

If an accident occurs, see a doctor immediately. Any highpressure spray injected into the skin must be surgicallyremoved within a few hours or gangrene may result.Doctors unfamiliar with this type of injury should referencea knowledgeable medical source. Such information isavailable from Deere & Company Medical Department inMoline, Illinois, U.S.A.

DX,LIFT 1904JUN901/1

Use Proper Lifting Equipment

TS22

6UN

23A

UG88

Proper Lifting Equipment

Lifting heavy components incorrectly can cause severeinjury or machine damage.

Follow recommended procedure for removal andinstallation of components in the manual.

05-14 050206PN=23

Safety

DX,REPAIR 1917FEB991/1

Use Proper Tools

TS77

9UN

08N

OV8

9

Proper Tools

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

Use power tools only to loosen threaded parts andfasteners.

For loosening and tightening hardware, use the correctsize tools. DO NOT use U.S. measurement tools onmetric fasteners. Avoid bodily injury caused by slippingwrenches.

Use only service parts meeting John Deere specifications.

DX,DRAIN 1903MAR931/1

Dispose of Waste Properly

TS11

33UN

26N

OV9

0

Recycle Waste

Improperly disposing of waste can threaten theenvironment and ecology. Potentially harmful waste usedwith John Deere equipment include such items as oil, fuel,coolant, brake fluid, filters, and batteries.

Use leakproof containers when draining fluids. Do not usefood or beverage containers that may mislead someoneinto drinking from them.

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

Air conditioning refrigerants escaping into the air candamage the Earths atmosphere. Government regulationsmay require a certified air conditioning service center torecover and recycle used air conditioning refrigerants.

Inquire on the proper way to recycle or dispose of wastefrom your local environmental or recycling center, or fromyour John Deere dealer.

05-15 050206PN=24

Fuels, Lubricants, and Coolant

DX,FUEL1 1917NOV051/1

Diesel Fuel

Consult your local fuel distributor for properties of thediesel fuel available in your area.

In general, diesel fuels are blended to satisfy the lowtemperature requirements of the geographical area inwhich they are marketed.

Diesel fuels specified to EN 590 or ASTM D975 arerecommended.

Required fuel properties

In all cases, the fuel shall meet the followingproperties:

Cetane number of 45 minimum. Cetane numbergreater than 50 is preferred, especially fortemperatures below -20C (-4F) or elevations above1500 m (5000 ft).

Cold Filter Plugging Point (CFPP) below theexpected low temperature OR Cloud Point at least5C (9F) below the expected low temperature.

Fuel lubricity should pass a minimum level of 3100grams as measured by ASTM D6078 or maximum

scar diameter of 0.45 mm as measured by ASTMD6079 or ISO 12156-1.

Sulfur content:

Diesel fuel quality and fuel sulfur content mustcomply with all existing emissions regulations for thearea in which the engine operates.

Use of diesel fuel with sulfur content less than0.10% (1000 ppm) is STRONGLY recommended.

Use of diesel fuel with sulfur content 0.10% (1000ppm to 0.50% (5000 ppm) may result in REDUCEDoil and filter change intervals.

BEFORE using diesel fuel with sulfur content greaterthan 0.50% (5000 ppm), contact your John Deeredealer.

DO NOT use diesel fuel with sulfur content greaterthan 1.0%.

IMPORTANT: Do not mix used diesel engine oil orany other type of lubricating oil withdiesel fuel.

IMPORTANT: Improper fuel additive usage maycause damage on fuel injectionequipment of diesel engines.

DX,FUEL5 1927OCT051/1

Lubricity of Diesel Fuel

Most diesel fuels manufactured in the United States,Canada, and the European Union have adequatelubricity to ensure proper operation and durability offuel injection system components. However, dieselfuels manufactured in some areas of the world maylack the necessary lubricity.

IMPORTANT: Make sure the diesel fuel used inyour machine demonstrates goodlubricity characteristics.

Fuel lubricity should pass a minimum load level of3100 grams as measured by ASTM D6078 or amaximum scar diameter of 0.45 mm as measured byASTM D6079 or ISO 12156-1.

If fuel of low or unknown lubricity is used, add JohnDeere PREMIUM DIESEL FUEL CONDITIONER (orequivalent) at the specified concentration.

10-1 050206PN=25


DX,FUEL4 1919DEC031/1

Handling and Storing Diesel Fuel

CAUTION: Handle fuel carefully. Do not fillthe fuel tank when engine is running.

DO NOT smoke while you fill the fuel tank orservice the fuel system.

Fill the fuel tank at the end of each days operation toprevent water condensation and freezing during coldweather.

Keep all storage tanks as full as practicable tominimize condensation.

Ensure that all fuel tank caps and covers are installedproperly to prevent moisture from entering.

Monitor water content of the fuel regularly.

When using bio-diesel fuel, the fuel filter may requiremore frequent replacement due to premature plugging.

Check engine oil level daily prior to starting engine. Arising oil level may indicate fuel dilution of the engineoil.

IMPORTANT: The fuel tank is vented through thefiller cap. If a new filler cap isrequired, always replace it with anoriginal vented cap.

When fuel is stored for an extended period or if thereis a slow turnover of fuel, add a fuel conditioner tostabilize the fuel and prevent water condensation.Contact your fuel supplier for recommendations.


Testing Diesel Fuel

DIESELSCAN is a John Deere fuel analysis programthat can be used to monitor the quality of your fuel. TheDIESELSCAN analysis verifies fuel type, cleanliness,water content, suitability for cold weather operation, andwhether the fuel meets specifications.

Check with your John Deere dealer for availability ofDIESELSCAN kits.

DIESELSCAN is a trademark of Deere & Company

10-2 050206PN=26



Bio-Diesel Fuel

Consult your local fuel distributor for properties of thebio-diesel fuel available in your area.

Bio-diesel fuels may be used ONLY if the bio-dieselfuel properties meet the latest edition of ASTM D6751,EN 14214, or equivalent specification.

It is recommended to purchase bio-diesel fuel blendedwith B100 from a BQ-9000 Accredited Producer or aBQ-9000 Certified Marketer as recommended by theNational Bio-diesel Board.

The maximum allowable bio-diesel concentration is a5% blend (also known as B5) in petroleum diesel fuel.It has been found that bio-diesel fuels may improvelubricity in concentrations up to this 5% blend.

When using a blend of bio-diesel fuel, the engine oillevel must be checked daily when the air temperatureis 10C (14F) or lower. If oil becomes diluted withfuel, shorten oil change intervals accordingly.

IMPORTANT: Raw pressed vegetable oils are NOTacceptable for use as fuel in anyconcentration in John Deereengines.

These oils do not burn completely,and will cause engine failure by

leaving deposits on injectors and inthe combustion chamber.

A major environmental benefit of bio-diesel fuel is itsability to biodegrade. This makes proper storage andhandling of bio-diesel fuel especially important. Areasof concern include:

Quality of new fuel Water content of the fuel Problems due to aging of the fuel

Potential problems resulting from deficiencies in theabove areas when using bio-diesel fuel inconcentrations above 5% may lead to the followingsymptoms:

Power loss and deterioration of performance Fuel leakage Corrosion of fuel injection equipment Coked and/or blocked injector nozzles, resulting in

engine misfire Filter plugging Lacquering and/or seizure of internal components Sludge and sediments Reduced service life of engine components

Consult your fuel supplier for additives to improvestorage and performance of bio-diesel fuels.

10-3 050206PN=27



Minimizing the Effect of Cold Weather on Diesel Engines

John Deere diesel engines are designed to operateeffectively in cold weather.

However, for effective starting and cold weatheroperation, a little extra care is necessary. Theinformation below outlines steps that can minimize theeffect that cold weather may have on starting andoperation of your engine. See your John Deere dealerfor additional information and local availability of coldweather aids

Use Winter Grade Fuel

When temperatures fall below 5C (40F), winter gradefuel (Grade No. 1-D fuel in North America) is bestsuited for cold weather operation. Winter grade fuelhas a lower cloud point and a lower pour point.

Cloud point is the temperature at which wax will beginto form in the fuel and this wax causes fuel filters toplug. Pour point is the temperature at which fuelbegins to thicken and becomes more resistant to flowthrough fuel pumps and lines.

NOTE: On an average, winter grade fuel has a lowerBTU (heat content) rating. Using winter gradefuel may reduce power and fuel efficiency, butshould not cause any other engineperformance effects. Check the grade of fuelbeing used before troubleshooting for lowpower complaints in cold weather operation.

Air Intake Heater

An air intake heater is an available option to aid coldweather starting.

CAUTION: Do not use any starting fluid withan air intake heater.

Starting Fluid

A starting fluid port on the intake is available to aidcold weather starting.

CAUTION: Do not use any starting fluid withan engine equipped with glow plugs

Coolant Heater

An engine block heater (coolant heater) is an availableoption to aid cold weather starting.

Seasonal Viscosity Oil and Proper CoolantConcentration

Use seasonal grade viscosity engine oil based ion theexpected air temperature range between oil changesand proper concentration of low silicate antifreeze asrecommended. (See DIESEL ENGINE OIL andENGINE COOLANT requirements this section.)

Diesel Fuel Flow Additive

Use John Deere Premium Diesel Fuel Conditioner(Winter) or equivalent to treat fuel during the coldweather season. This winter formulation is acombination diesel fuel conditioner and anti-geladditive.

IMPORTANT: Treat fuel when outside temperaturedrops below 0C (32F). For bestresults, use with untreated fuel.Follow all recommended instructionson label.

Winterfronts

Use of fabric, cardboard , or solid winterfronts is notrecommended with any John Deere engine. Their usecan result in excessive engine coolant, oil, and chargeair temperatures. This can lead to reduced engine life,loss of power and poor fuel economy. Winterfrontsmay also put abnormal stress on fan and fan drivecomponents potentially causing premature failures.

10-4 050206PN=28




If winterfronts are used, they should never totally closeoff the grill frontal area. Approximately 25% area in thecenter of the grill should remain open at all times. Atno time should the air blockage device be applieddirectly to the radiator core.

Radiator Shutters

If equipped with a thermostatically controlled radiatorshutter system, this system should be regulated insuch a way that the shutters are completely open by

the time the coolant reaches 93C (200F) to preventexcessive intake manifold temperatures. Manuallycontrolled systems are not recommended.

If air-to-air aftercooling is used, the shutters must becompletely open by the time the intake manifold airtemperature reaches the maximum allowabletemperature out of the charge air cooler.

For more information, see your John Deere dealer.

DX,ENOIL4 1919DEC051/1

Diesel Engine Break-In Oil

New engines are filled at the factory with John DeereENGINE BREAK-IN OIL. During the break-in period,add John Deere ENGINE BREAK-IN OIL as needed tomaintain the specified oil level.

Change the oil and filter after the first 100 hours ofoperation of a new or rebuilt engine.

After engine overhaul, fill the engine with John DeereENGINE BREAK-IN OIL.

If John Deere ENGINE BREAK-IN OIL is not available,use a diesel engine oil meeting one of the followingduring the first 100 hours of operation:

API Service Classification CE API Service Classification CD API Service Classification CC ACEA Oil Sequence E2

ACEA Oil Sequence E1

After the break-in period, use John Deere PLUS-50or other diesel engine oil as recommended in thismanual.

IMPORTANT: Do not use PLUS-50 oil or engineoils meeting any of the followingduring the first 100 hours ofoperation of a new or rebuilt engine:

API CI-4 PLUS API CFAPI CI-4 ACEA E7API CH-4 ACEA E6API CG-4 ACEA E5API CF-4 ACEA E4API CF-2 ACEA E3

These oils will not allow the engineto break-in properly.

PLUS-50 is a trademark of Deere & Company.

10-5 050206PN=29


DX,ENOIL7 1923NOV051/1

Diesel Engine Oil

TS16

75UN

31O

CT03

Oil Viscosities for Air TemperatureRanges

Use oil viscosity base on the expected air temperaturerange during the period between oil changes.

John Deere PLUS-50 oil is preferred.

Oil meeting one of the following specifications are alsorecommended:

ACEA Oil Sequence E7 ACEA Oil Sequence E6 ACEA Oil Sequence E5 ACEA Oil Sequence E4

Extended service intervals may apply when John DeerePLUS-50, ACEA E7, ACEA E6, ACEA E5, or ACEA E4engine oils are used. Consult your John Deere dealer formore information.

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

John Deere TORQ-GARD SUPREME API Service Category CI-4 PLUS API Service Category CI-4 API Service Category CH-4 ACEA Oil Sequence E3

Multi-viscosity diesel engine oils are preferred.

Diesel fuel quality and fuel sulfur content must complywith all existing emissions regulations for the area inwhich the engine operates.

DO NOT use diesel fuel with sulfur content greater than1.0% (10 000 ppm).

PLUS-50 is a trademark of Deere & CompanyTORQ-GARD SUPREME is a trademark of Deere & Company

10-6 050206PN=30


OURGP12,0000217 1928APR061/1

Extended Diesel Engine Oil Service Intervals

When John Deere PLUS-50, ACEA E7, ACEA E6,ACEA E5, or ACEA E4 oils are used with the specifiedJohn Deere filter, the service interval for engine oil andfilter changes may be increased by 50 percent but notto exceed a maximum of 375 hours.

If John Deere PLUS-50, ACEA E7, ACEA E6, ACEAE5, or ACEA E4 oils are used with other than thespecified John Deere filter, change the engine oil andfilter at the normal service interval.

If John Deere TORQ-GARD SUPREME, API CI-4Plus, API CI-4, API CH-4, or ACEA E3 oils are used,change the engine oil and filter at the normal serviceinterval.

NOTE: On Gen Set engines used as standby units, oiland filter change can be extended to 350hours. No extended interval for oil/filter changeis allowed beyond 350 hours.

PLUS-50 is a trademark of Deere & CompanyTORQ-GARD SUPREME is a trademark of Deere & Company

DX,LUBMIX 1918MAR961/1

Mixing of Lubricants

In general, avoid mixing different brands or types of oil.Oil manufacturers blend additives in their oils to meetcertain specifications and performance requirements.

Mixing different oils can interfere with the properfunctioning of these additives and degrade lubricantperformance.

Consult your John Deere dealer to obtain specificinformation and recommendations.

10-7 050206PN=31


DX,OILSCAN 1902DEC021/1

OILSCANand COOLSCAN

T682

8AB

UN

15J

UN89

T682

9AB

UN

18O

CT88

OILSCANand COOLSCAN are John Deere samplingprograms to help you monitor machine performance andidentify potential problems before they cause seriousdamage.

Oil and coolant samples should be taken from eachsystem prior to its recommended change interval.

Check with your John Deere dealer for the availability ofOILSCAN and COOLSCAN kits.

OILSCAN is a registered trademark of Deere & Company.COOLSCAN is a trademark of Deere & Company.

DX,ALTER 1915JUN001/1

Alternative and Synthetic Lubricants

Conditions in certain geographical areas may requirelubricant recommendations different from those printedin this manual.

Some John Deere brand coolants and lubricants maynot be available in your location.

Consult your John Deere dealer to obtain informationand recommendations.

Synthetic lubricants may be used if they meet theperformance requirements as shown in this manual.

The temperature limits and service intervals shown inthis manual apply to both conventional and syntheticoils.

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

10-8 050206PN=32


DX,LUBST 1918MAR961/1

Lubricant Storage

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

Use clean containers to handle all lubricants.

Whenever possible, store lubricants and containers inan area protected from dust, moisture, and othercontamination. Store containers on their side to avoidwater and dirt accumulation.

Make certain that all containers are properly marked toidentify their contents.

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

DX,GREA1 1914NOV031/1

Grease

TS16

67UN

30J

UN99

Use grease based on NLGI consistency numbers and theexpected air temperature range during the service interval.

The following greases are preferred:

John Deere SD POLYUREA GREASE

The following greases are also recommended:

John Deere HD MOLY GREASE 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 thickener are notcompatible with others. Consult yourgrease supplier before mixing differenttypes of grease.

10-9 050206PN=33


DX,COOL3 1927OCT051/2

Diesel Engine Coolant

The engine cooling system is filled to provideyear-round protection against corrosion and cylinderliner pitting, and winter freeze protection to -37C(-34F). If protection at lower temperatures is required,consult your John Deere dealer for recommendations.

John Deere COOL-GARD Prediluted Coolant ispreferred for service.

John Deere COOL-GARD Prediluted Coolant isavailable in a concentration of either 50% ethyleneglycol or 55% propylene glycol.

Additional recommended coolants

The following engine coolant is also recommended:

John Deere COOL-GARD Coolant Concentrate in a40% to 60% mixture of concentrate with qualitywater.

John Deere COOL-GARD coolants do not require useof supplemental coolant additives, except for periodicreplenishment of additives during the drain interval.

Other fully formulated coolants

Other fully formulated low silicate ethylene orpropylene glycol base coolants for heavy-duty enginesmay be used if they meet one of the followingspecifications:

ASTM D6210 prediluted (50%) coolant ASTM D6210 coolant concentrate in a 40% to 60%

mixture of concentrate with quality water

Coolants meeting ASTM D6210 do not require use ofsupplemental coolant additives, except for periodicreplenishment of additives during the drain interval.

Coolants requiring supplemental coolant additives

Other low silicate ethylene glycol base coolants forheavy-duty engines may also be used if they meet oneof the following specifications:

ASTM D4985 ethylene glycol base prediluted (50%)coolant

ASTM D4985 ethylene glycol base coolantconcentrate in a 40% to 60% mixture of concentratewith quality water

Coolants meeting ASTM D4985 require an initialcharge of supplemental coolant additives, formulatedfor protection of heavy duty diesel engines againstcorrosion and cylinder liner erosion and pitting. Theyalso require periodic replenishment of additives duringthe drain interval.

Other coolants

It is possible that neither John Deere COOL-GARD norcoolants meeting one of the coolant standards listedabove is available in the geographical area whereservice is performed. If these coolants are unavailable,use a coolant concentrate or prediluted coolant with aquality additive package that provides cylinder linercavitation protection and protects the cooling systemmetals (cast iron, aluminum alloys, and copper alloyssuch as brass) from corrosion.

The additive package must be part of one of thefollowing coolant mixtures:

ethylene glycol or propylene glycol base prediluted(40% to 60%) coolant

ethylene glycol or propylene glycol base coolantconcentrate in a 40% to 60% mixture of concentratewith quality water

Water quality

COOL-GARD is a trademark of Deere & Company

10-10 050206PN=34



DX,COOL3 1927OCT052/2

Water quality is important to the performance of thecooling system. Distilled, deionized, or demineralizedwater is recommended for mixing with ethylene glycoland propylene glycol base engine coolant concentrate.

IMPORTANT: Do not use cooling system sealingadditives or antifreeze that containssealing additives.

IMPORTANT: Do not mix ethylene glycol andpropylene glycol base coolants.

DX,COOL11 1919DEC031/1

Drain Intervals for Diesel Engine Coolant

Drain the factory fill engine coolant, flush the coolingsystem, and refill with new coolant after the first 3years or 3000 hours of operation.

Subsequent drain intervals are determined by thecoolant used for service. At each interval, drain thecoolant, flush the cooling system, and refill with newcoolant.

When John Deere COOL-GARD is used, the draininterval may be extended to 5 years or 5000 hours of

operation, provided that the coolant is tested annuallyAND additives are replenished, as needed, by addinga supplemental coolant additive.

If John Deere COOL-GARD is used but the coolant isnot tested OR additives are not replenished by addinga supplemental coolant additive, the drain interval is 3years or 3000 hours of operation

If COOL-GARD is not used, the drain interval isreduced to 2 years or 2000 hours of operation.


10-11 050206PN=35


DX,COOL4 1907NOV031/1

Supplemental Coolant Additives

The concentration of coolant additives is graduallydepleted during engine operation. For allrecommended coolants, replenish additives betweendrain intervals by adding a supplemental coolantadditive every 12 months or as determined necessaryby coolant testing.

John Deere COOLANT CONDITIONER isrecommended as a supplemental coolant additive inJohn Deere engines.

IMPORTANT: Do not add a supplemental coolantadditive when the cooling system isdrained and refilled with JohnDeereCOOL-GARD.

If other coolants are used, consult the coolant supplierand follow the manufacturers recommendation for useof supplemental coolant additives.

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

Add the manufacturers recommended concentration ofsupplemental coolant additive. DO NOT add more thanthe recommended amount.


10-12 050206PN=36



Additional Information About Diesel Engine Coolants and Supplemental CoolantAdditives

Engine coolants are a combination of three chemicalcomponents: ethylene glycol or propylene glycolantifreeze, inhibiting coolant additives, and qualitywater.

Coolant specifications

Some products, including John Deere COOL-GARDPrediluted Coolant, are fully formulated coolants thatcontain all three components in their correctconcentrations. Do not add an initial charge ofsupplemental coolant additives to these fullyformulated products.

Coolants meeting ASTM D6210 do not require aninitial charge of supplemental coolant additives.

Some coolant concentrates, including John DeereCOOL-GARD Coolant Concentrate, contain both glycolantifreeze and inhibiting coolant additives. Mix theseproducts with quality water, but do not add an initialcharge of supplemental coolant additives.

Coolants meeting ASTM D4985 require an initialcharge of supplemental coolant additives.

Replenish coolant additives

The concentration of coolant additives is graduallydepleted during engine operation. Periodicreplenishment of inhibitors is required, even whenJohn Deere COOL-GARD or another fully formulatedcoolant is used. Follow the recommendations in thismanual for the use of supplemental coolant additives.

Why use supplemental coolant additives?

Operating without proper coolant additives will result inincreased corrosion, cylinder liner erosion and pitting,and other damage to the engine and cooling system. A

simple mixture of ethylene glycol or propylene glycoland water will not give adequate protection.

Use of supplemental coolant additives reducescorrosion, erosion, and pitting. These chemicalsreduce the number of vapor bubbles in the coolant andhelp form a protective film on cylinder liner surfaces.This film acts as a barrier against the harmful effectsof collapsing vapor bubbles.

Avoid automotive-type coolants

Never use automotive-type coolants (such as thosemeeting ASTM D3306). These coolants do not containthe correct additives to protect heavy-duty dieselengines. They often contain a high concentration ofsilicates and may damage the engine or coolingsystem.

Water quality

Water quality is important to the performance of thecooling system. Distilled, deionized, or demineralizedwater is recommended for mixing with ethylene glycoland propylene glycol base engine coolant concentrate.All water used in the cooling system should meet thefollowing minimum specifications for quality:

Chlorides



Ethylene Glycol Freeze Protection Limit40% -24C (-12F)50% -37C (-34F)60% -52C (-62F)

Propylene Glycol Freeze Protection Limit40% -21C (-6F)50% -33C (-27F)60% -49C (-56F)

DO NOT use a coolant-water mixture greater than60% ethylene glycol or 60% propylene glycol.


Testing Diesel Engine Coolant

Testing Diesel Engine Coolant

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

Test the coolant solution at intervals of 12 months orless and whenever excessive coolant is lost throughleaks or overheating.

Coolant test strips

Coolant test strips are available from your John Deeredealer. These test strips provide a simple, effective

method to check the freeze point and additive levels ofyour engine coolant.

Compare the results to the supplemental coolantadditive (SCA) chart to determine the amount ofinhibiting additives in your coolant and whether moreJohn Deere COOLANT CONDITIONER should beadded.

COOLSCAN and COOLSCAN PLUS

For a more thorough evaluation of your coolant,perform a COOLSCAN or COOLSCAN PLUS analysis,where available. See your John Deere dealer forinformation.

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

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DX,COOL6 1918MAR961/1

Operating in Warm Temperature Climates

John Deere engines are designed to operate usingglycol base engine coolants.

Always use a recommended glycol base enginecoolant, even when operating in geographical areaswhere freeze protection is not required.

IMPORTANT: Water may be used as coolant inemergency situations only.

Foaming, hot surface aluminum andiron corrosion, scaling, andcavitation will occur when water isused as the coolant, even whencoolant conditioners are added.

Drain cooling system and refill withrecommended glycol base enginecoolant as soon as possible.

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Disposing of Coolant

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Recycle Waste

Improperly disposing of engine coolant can threaten theenvironment and ecology.

Use leakproof containers when draining fluids. Do not usefood or beverage containers that may mislead someoneinto drinking from them.

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

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

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Engine Operating Guidelines

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John Deere Instrument (Gauge) Panel

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Instrument Panel (Main Station Panel Shown)

AOil Pressure Gauge EAudible Alarm IStart Button NEnter KeyBCoolant Temperature FAudible Alarm Override JKey Switch ORed STOP ENGINE

Gauge Button KDiagnostic Gauge Indicator LightCVoltmeter GTachometer LMenu Key PAmber WARNINGDPercent Load Gauge HDimmer Switch MArrow Keys Indicator Light

Tier 2 John Deere POWERTECH Marine Engines havean electronic control system, which has the followingcontrols and gauges as shown. The followinginformation applies only to those controls and gauges

supplied by John Deere. Refer to your engineapplication manual or boat builder for specificguidelines if John Deere-sourced controls andinstrumentation are not used.

POWERTECH is a trademark of Deere & Company.

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NOTE: On generator-set engines, the gauges aresupplied by the gen-set manufacturer.Minimum gauges required are: hour meter, oilpressure gauge and coolant temperaturegauge as well as safety shutdown devices.

IMPORTANT: Whenever an electronic gauge orsensor does not register a correctreading, replace it with a new one.DO NOT attempt to repair it. Wiringdiagrams are located in theTROUBLESHOOTING Section later inthis manual.

NOTE: The standard main station (wheel house)instrument panel is shown. An optional flybridge panel is also available that includes thesame gauges as the standard panel but has astop button in place of the key start switch.

Following is a brief description of the available optionalelectronic controls and gauges found on John Deereprovided instrument panels. Refer to manufacturersliterature for information on controls not provided byDeere.

AEngine Oil Pressure Gauge

The oil pressure gauge (A) indicates engine oilpressure. An audible alarm (E) warns the operator ifengine oil pressure falls below a safe operatingpressure.

BEngine Coolant Temperature Gauge

The engine coolant temperature gauge (B) indicatesengine coolant temperature. An audible alarm (E)warns the operator if coolant temperature rises abovethe preset safe operating temperature.

CVoltmeter

The voltmeter (C) indicates system battery voltage.The amber Warning light (P) will illuminate when

battery voltage is too low for proper operation of thefuel injection system.

DPercent Load Gauge

The percent load gauge shows percent of availableengine power being used by the vessel.

EAudible Alarm

The audible alarm (E) will sound whenever low oilpressure, high coolant temperature, or water-in-fuelconditions exist. This includes all signals that light upthe amber warning indicator (intermittent alarm) orthe red stop engine indicator (steady alarm).

FAudible Alarm Override Button

The audible alarm has an override button (F) thatsilences the audible alarm for approximately Twominutes when pressed.

GTachometer

The tachometer (G) indicates engine speed inhundreds of revolutions per minute (rpm).

HDimmer Switch

The dimmer switch (H) allows the operator to dim orbrighten the illumination of the instrument panel. Thediagnostic gauge (K) also has a backlight adjustmentfunction.

IStart Button

The start button (I), when pressed and held in,operates the starting motor to start the engine. Theengine will only start with key switch (J) in the ONposition.

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John Deere Instrument (Gauge) Panel (Continued)JKey Switch

The wheel house instrument panel has a two-position(OFF/ON) key switch (J) which controls the engineelectrical system, starts and stops the engine. Whenthe switch is in the ON position, the engine may bestarted by pressing the start button (I).

The fly bridge instrument panel has a stop button inplace of the key switch. With the key switch on thewheel house instrument panel in the ON position, theengine can be started and stopped from the fly bridgeinstrument panel.

KDiagnostic Gauge/Hour Meter

The diagnostic gauge (K) displays diagnostic troublecodes (DTCs) as they are accessed. Other informationon the engine can be accessed using the touch keys(L, M and N). The hour meter feature shows theoperating hours of the engine and should be used as aguide for scheduling periodic maintenance. If thediagnostic gauge receives a trouble code from anengine control unit, the current display will switch to awarning or shutdown (depending on the severity of thecode) screen that will display the trouble code number,the description of the code and the corrective actionneeded. (Refer to the following pages for use of thediagnostic gauge.)

LMenu Key

The menu key is pressed to either enter or exit themenu screens.

MArrow Keys

Use the touch keys (M) to change the display on thewindow of the diagnostic gauge and to access engineperformance data.

Pressing the left arrow to scroll to the left or upward orthe right arrow to scroll to the right or downward. Thiswill allow you to view various engine parameters andany diagnostic trouble codes that occur.

Refer to the following story for accessing engineinformation on the diagnostic gauge using the touchkeys.

NEnter Key

The enter key is pressed to select the parameter thatis highlighted on the screen.

ORed STOP ENGINE Indicator Light

When light comes on, stop engine immediately or assoon as safely possible to prevent engine damage.Correct problem before restarting.

PAmber WARNING Indicator Light

When light comes on, an abnormal condition exists. Itis not necessary to shutdown engine immediately, butproblem should be corrected as soon as possible.

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Optional Electronic Displays to MonitorEngine and Navigation

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Optional Electronic Displays

Optional electronic software for display of various engineoperations and navigation functions on the instrumentpanel will be available in late 2006 (see illustration).Vendor operating information will be available for thesenew software packages.

These new programs are in addition to the electronicinstrument panel currently available.

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Using Diagnostic Gauge to Access EngineInformation

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Diagnostic Gauge

ADiagnostic GaugeBMenu KeyCArrow KeysDEnter KeyERed STOP ENGINE Indicator LightFAmber WARNING Indicator Light

The diagnostic gauge (A) allows the operator to viewmany readouts of engine functions and trouble codes(DTCs). The gauge is linked to the electronic controlsystem and its sensors. This allows the operator tomonitor engine functions and to troubleshoot the enginesystems when needed.

Press the menu key (B) to access the various enginefunctions in sequence. The displays can be selected aseither customary English or metric units.

The following menu of engine parameters can bedisplayed on the diagnostic gauge window:

Engine hours Engine rpm System voltage Percent engine load at the current rpm Coolant temperature Oil pressure Throttle position Intake manifold temperature Current fuel consumption Active service (diagnostic) codes Stored service (diagnostic) codes from the engine Set the units for display View the engine configuration parameters

The diagnostic gauge includes a graphical backlit LiquidCrystal Display (LCD) screen. The display can show eithera single parameter or a quadrant display showing fourparameters simultaneously. The diagnostic gauge usestwo arrow keys (C) for scrolling through the engineparameter list and viewing the menu list and an enter key(D) for selecting highlighted items. The red (E) and amber(F) lights are used to signal active trouble code receivedby the diagnostic gauge.

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OURGP11,00000A9 1903SEP031/5

Main Menu Navigation

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Menu Key

NOTE: The engine does not need to be running tonavigate the diagnostic gauge screens. If enginestart up is desired, See Starting The Engine. All ofthe engine values illustrated on the diagnosticgauge indicate the engine is running.

1. Turn the key switch to the ON position. Starting at thesingle or four engine parameter display, press the"Menu" key.

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Menu Display

2. The first seven items of the "Main Menu" will bedisplayed.

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Main Menu Items

3. Pressing the "Arrow" keys will scroll through the menuselections.

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Last Items On Main Menu

4. Pressing the right arrow key will scroll down to revealthe last items of "Main Menu" screen, highlighting thenext item down.

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Use Arrow Buttons To Scroll / Quadrant Display

5. Use the arrow keys to scroll to the desired menu itemor press the "Menu Button" to exit the main menu andreturn to the engine parameter display.

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Engine Configuration DataR

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Menu Key

NOTE: The engine configuration data is a read onlyfunction.

NOTE: The engine does not need to be running tonavigate the diagnostic gauge screens. If enginestart up is desired, See Starting The Engine, laterin this section. All of the engine values illustratedon the diagnostic gauge indicate the engine isrunning.


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Select Engine Configuration

2. The main menu will be displayed. Use the "Arrow" keysto scroll through the menu until "Engine Config" ishighlighted.

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Enter Key

3. Once "Engine Config" menu item has been highlighted,press the "Enter" key to view the engine configurationdata.

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Use Arrow Keys To Scroll

4. Use the "Arrow" keys to scroll through the engineconfiguration data.

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Return To Main Menu

5. Press the "Menu" key to return to the main menu.

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Exit Main Menu

6. Press the "Menu" key to exit the main menu and returnto the engine parameter display.

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Accessing Stored Trouble Codes

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Menu Key


For description of trouble codes, see chart inTroubleshooting Section.


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Select Stored Codes

2. The main menu will be displayed. Use the "Arrow" keysto scroll through the menu until "Stored Codes" ishighlighted.

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Enter Key

3. Once the "Stored Codes" menu item has beenhighlighted press the "Enter" key to view the storedcodes.

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4. If the word "Next" appears above the "Arrow" keys,there are more stored codes that may be viewed. Usethe "Arrow" key to scroll to the next stored code.

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Return To Main Menu



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Exit Main Menu


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Accessing Active Trouble Codes

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Normal Operation


For description of trouble codes, see chart inTroubleshooting Section.

1. During normal operation the single or four parameterscreen will be displayed.

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Active Trouble Codes Displayed

2. When the diagnostic gauge receives a trouble codefrom an engine control unit, the single or fourparameter screen will be replaced with the "Warning"message. The SPN and FMI number will be displayedalong with a description of the problem and thecorrective action needed.

IMPORTANT: Ignoring active trouble codes can resultin severe engine damage.


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3. If the word "Next" appears above the arrow keys, thereare more trouble codes that can be viewed by usingthe arrow keys to scroll to the next trouble code.

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Hide Trouble Codes


4. To acknowledge and hide the code and return to thesingle or four parameter display, press the "Enter" Key.

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Active Trouble Code Icon

5. The display will return to the single or four parameterdisplay, but the display will contain the warning icon.Pressing the "Enter" key will redisplay the hiddentrouble code.

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Enter Key


6. Pressing the "Enter" key once again will hide thetrouble code and return the screen to the single or fourparameter display.

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Active Trouble Code Condition

7. The single or four parameter screen will display thewarning icon until the trouble code condition iscorrected.

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Engine Shutdown Codes

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Normal Operation

1. During normal operation the single or four parameterscreen will be displayed.

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Shutdown Message

2. When the diagnostic gauge receives a severe troublecode from an engine control unit, the single or fourparameter screen will be replaced with the "Shutdown"message. The SPN and FMI number will be displayedalong with a description of the problem and thecorrective action needed.

If the word "Next" appears above the arrow keys, thereare more trouble codes that can be viewed by usingthe arrow keys to scroll to the next trouble code.

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Hide Trouble Code

3. To acknowledge and hide the trouble code and returnto the single or four parameter display, press the"Enter" key".

IMPORTANT: Ignoring the shutdown message canresult in severe engine damage.

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Flashing Shutdown Icon

4. The display will return to the single or four parameterdisplay, but the display will contain the "Shutdown"icon. Pressing the "Enter" key will redisplay the hiddentrouble code.


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Redisplay Trouble Code

5. Pressing the "Enter" key once again will hide thetrouble code and return the screen to the single or fourparameter display.

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Shutdown Icon

6. The single or four parameter screen will display theshutdown icon until the trouble code condition iscorrected.


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Adjusting Backlighting

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Menu Key

NOTE: The backlight control on the instrument panel mayalso be used to adjust backlighting. This controlwill override any adjustment made on thediagnostic gauge.



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Select Adjust Backlight

2. The main menu will be displayed. Use the "Arrow" keysto scroll through the menu until "Adjust Backlight" ishighlighted.

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Press Enter Key

3. Once the "Adjust Backlight" menu item has beenhighlighted, press the "Enter" key to activate the"Adjust Backlight" function.


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Adjust Backlight Intensity

4. Use the "Arrow" keys to select the desired backlightintensity.

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Return To Main Menu


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Exit Main Menu


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Adjusting Contrast

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Menu Key

1. Turn the key switch to the ON position. Starting at thesingle or four engine parameter display press the"Menu" key.

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Select Adjust Contrast

2. The main menu will be displayed. Use the "Arrow" keysto scroll through the menu until "Adjust Contrast" ishighlighted.

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Press Enter Key

3. Once the "Adjust Contrast" menu item has beenhighlighted, press the "Enter" key to activate the"Adjust Contrast" function.

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Adjust Contrast Intensity

4. Use the "Arrow" keys to select the desired contrastintensity.

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Return To Main Menu


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Exit Main Menu


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Selecting Units Of Measurement

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Menu Key


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Select Units

2. The main menu will be displayed. Use the "Arrow" keysto scroll through the menu until "Select Units" ishighlighted.

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Press Enter Key

3. Once the "Select Units" menu item has beenhighlighted press the "Enter" key to access the "SelectUnits" function.


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Select Desired Units

4. There are three choices for units of measurement,English, Metric kPa or Metric Bar.

English is for Imperial units, with pressures displayedin PSI and temperatures in F.

Metric kPa and Metric bar are for IS units, withpressures displayed in kPa and bar respectively, andtemperatures in C.

Use the "Arrow" keys to highlight the desired units ofmeasurement.

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Press Enter Key to Select

5. Press the "Enter" key to select the highlighted units.

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Return To Main Menu


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Press Menu Key

7. Press the "Menu" key to return to the engineparameter display.

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Setup 1-Up Display

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Menu Key

1. Turn the key switch to the ON position. Starting at thesingle engine parameter display, press the "Menu" key.

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Setup 1-Up Display

2. Use the "Arrow" keys to scroll through the menu until"Setup 1-Up Display" is highlighted.


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Press Enter Key

3. Once "Setup 1-Up Display" menu item has beenhighlighted press the "Enter" key to access the "Setup1-Up Display" function.

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1-Up Display Options

4. Three options are available for modification of the 1-UpDisplay.

a. Use Defaults This option contains the followingengine parameters for display: Engine Hours,Engine Speed, Battery Voltage, % Load, CoolantTemperature and Oil Pressure.

b. Custom Setup This option contains a list ofengine parameters.

John Deere Powertech 6081afm75

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