Use and maintenance manual John – Deere POWERTECH...

Use and maintenance manual

John Deere POWERTECH Diesel engines

8.1L OEM 6081

Rf. constructeur : OMRG24828 Rf. GPAO : 33522043001 ind1

Danger

Warning about the dangers linked to fuel discharges under high pressure on engines equipped with Denso high pressure common rail (HPCR). Watch out for fuel under high pressure throughout the system Never dismantle the fuel lines, when the engine is running (lines under high pressure) It is better to work on the injection system when the fuel temperature is less than 30C Wait at least 5 minutes after the engine stops before carrying out work on the injection system (check the pressure before doing anything) After changing the component, check that there are no fuel leaks. Carry out this test with the engine protection closed (engine bonnet or other protection) Do not dismantle and reassemble the injector parts

Introduction

DPSG,OUOD007,1 1922MAY921/1

FOREWORD

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 engine 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 or flywheel end (rear) of theengine and facing toward 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 radiator,air cleaner, and instruments are optional equipment on

John Deere OEM Engines. These accessories may beprovided by the equipment manufacturer instead ofJohn Deere. This operators manual applies only to theengine and those options available through the JohnDeere distribution network.

IMPORTANT: This manual covers allPOWERTECH 8.1L OEM engines.Those engines produced starting inthe year 1996 are noted as engines( 199,999). Engines produced afterJanuary 2001 which are redesignedto meet the 2001 emission standardsare noted as engines (200,000 ).These engines also have a suffix070 in the engine model number,as in 6081HF070.

NOTE: This operators manual covers only enginesprovided to OEM (Outside EquipmentManufacturers). For engines in Deeremachines, refer to the machine operatorsmanual.

CALIFORNIA PROPOSITION 65 WARNING: Dieselengine exhaust and some of its constituents areknown to the State of California to cause cancer,birth defects and other reproductive harm.

POWERTECH is a trademark of Deere & Company

122000

PN=2

Introduction

DPSG,OUOE003,2736 1911JAN991/1

ENGINE OWNER

John Deere Engine Owner:

Dont wait until you need warranty or other service tomeet your local John Deere Engine Distributor orService Dealer.

Learn who he 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.

Utilisateurs De Moteurs John Deere:

Nattendez pas detre oblige davoir recours a votreConcessionnaire ou Point de Service le plus prochepour vous adresser a lui.

Renseignez-vous des que possible pour lidentifier etle localiser. A la premiere occasion, prenez contactavec lui et faites-vous connatre. Il sera lui aussiheureux de faire votre connaissance et de savoir quevous Perez computer Sur lui le moment menu.

An Den Besitzer Des John Deere Motors:

Warten Sie nicht auf einen evt. Reparaturfall um dennachstgelegenen John Deere Handler kennen zulernen.

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

Proprietario Del Motore John Deere:

Non aspetti fino a quando ha bisogno della garanzia odi un altro tipo di assistenza per incontrarsi con il SuoConcessionario che fornisce lassistenza tecnica.

Impari a conoscere chi e e dove si trova. Alla Suaprima occasione cerchi dincontrarlo. Egli desidera farsiconoscere e conoscere le Sue 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.

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

John Deere MotorAgare:

Vanta inte med att besoka Din John Deereaterforsaljare till dess att Du behover service ellergaranti reparation.

Bekanta Dig med var han ar och vem han ar. Tagforsta tillfalle att besoka honom. Han vill ocksa traffaDig for att fa veta vad Du behover och hur han kanhjalpa Dig.

122000

PN=3

Introduction

RG,RG34710,4001 1918JUN991/2

IDENTIFICATION VIEWS ENGINE SERIAL NUMBER ( 199,999)

RG

7362

UN

05J

AN

98

8.1 L Diesel Engine Right Front View Engines ( 199,999)

RG

7363

UN

05J

AN

98

8.1 L Diesel Engines Left Front ViewEngines ( 199,999)

RG

7385

UN

05J

AN

98

8.1 L Diesel Engines Right Side ViewEngines ( 199,999)

RG

7387

UN

05J

AN

98

8.1 L Diesel Engines Left Side ViewEngines ( 199,999)

122000

PN=4

Introduction

RG,RG34710,4001 1918JUN992/2

RG

7388

UN

20J

UN

00

8.1 L Diesel Engine Right Front ViewEngines ( 199,999)

RG

7386

UN

20J

UN

00

8.1 L Diesel Engine Left Front ViewEngines ( 199,999)

RG

7383

UN

05J

AN

98

8.1 L Diesel Engine Front ViewEngines ( 199,999)

RG

7384

UN

05J

AN

98

8.1 L Diesel Engine Rear ViewEngines ( 199,999)

122000

PN=5

Introduction

RG,OUOD007,4002 1901NOV001/1

IDENTIFICATION VIEWS ENGINE SERIAL NUMBER (200,000 )

RG

1151

1U

N1

3DE

C00

8.1 L Diesel Engine Right Front ViewEngines (200,000 )

RG

1151

2U

N3

1OC

T00

8.1 L Diesel Engines Left Front ViewEngines (200,000 )

RG

1151

3U

N3

1OC

T00

8.1 L Diesel Engine Front ViewEngines (200,000 )

RG

1151

4U

N3

1OC

T00

8.1 L Diesel Engine Rear ViewEngines (200,000 )

122000

PN=6

ContentsPagePage

Viewing Stored Service Codes (DTC) inRecord KeepingEngine ECU . . . . . . . . . . . . . . . . . . . . . . . . . 15-18Record Engine Serial Number . . . . . . . . . . . . . . 01-1

Break-In Service. . . . . . . . . . . . . . . . . . . . . . . . 15-19Engine Option Codes . . . . . . . . . . . . . . . . . . . . . 01-2Auxiliary Gear Drive Limitations . . . . . . . . . . . . 15-21Record Fuel Injection Pump Model Number . . . . 01-4Generator Set (Standby) Power Units. . . . . . . . 15-22Record PTO Serial Number . . . . . . . . . . . . . . . . 01-4Starting the Engine. . . . . . . . . . . . . . . . . . . . . . 15-22Restarting Engine That Has Run Out OfSafety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-1

Fuel - Engines (200,000- ) . . . . . . . . . . . . . . 15-26Normal Engine Operation . . . . . . . . . . . . . . . . . 15-28

Fuels, Lubricants, and Coolant Cold Weather Operation. . . . . . . . . . . . . . . . . . 15-29Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 Warming Engine. . . . . . . . . . . . . . . . . . . . . . . . 15-30Lubricity of Diesel Fuels . . . . . . . . . . . . . . . . . . . 10-1 Idling Engine . . . . . . . . . . . . . . . . . . . . . . . . . . 15-31Diesel Fuel Storage . . . . . . . . . . . . . . . . . . . . . . 10-2 Changing Engine Speed-StandardDIESELSCAN Fuel Analysis. . . . . . . . . . . . . . . . 10-2 (Mechanical) Governor . . . . . . . . . . . . . . . . . 15-31Minimizing the Effect of Cold Weather on Changing Engine Speed (Later Engines

Diesel Engines . . . . . . . . . . . . . . . . . . . . . . . . 10-3 w/Electronic Instrument Panels) . . . . . . . . . . 15-32Diesel Engine Break-In Oil . . . . . . . . . . . . . . . . . 10-4 Stopping the Engine (Engines WithDiesel Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . 10-5 Standard Instrument Panels). . . . . . . . . . . . . 15-33Extended Diesel Engine Oil Service Intervals . . . 10-6 Stopping the Engine (Engines WithMixing of Lubricants . . . . . . . . . . . . . . . . . . . . . . 10-6 Electronic Instrument Panel) . . . . . . . . . . . . . 15-34Oilscan and Coolscan. . . . . . . . . . . . . . . . . . . . . 10-7 Using a Booster Battery or Charger . . . . . . . . . 15-35Alternative and Synthetic Lubricants. . . . . . . . . . 10-7Lubricant Storage . . . . . . . . . . . . . . . . . . . . . . . . 10-8

Lubrication and MaintenanceGrease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8Observe Service Intervals. . . . . . . . . . . . . . . . . . 20-1Diesel Engine Coolant . . . . . . . . . . . . . . . . . . . . 10-9Use Correct Fuels, Lubricants and Coolants. . . . 20-1Diesel Engine Coolants And SupplementalLubrication and Maintenance ServiceAdditive Information . . . . . . . . . . . . . . . . . . . 10-10

Interval Chart - Prime Power. . . . . . . . . . . . . . 20-2Testing Diesel Engine Coolant . . . . . . . . . . . . . 10-11Lubrication and Maintenance ServiceSuppemental Coolant Additives . . . . . . . . . . . . 10-12

Interval Chart - Standby Power . . . . . . . . . . . . 20-4Operating in Warm Temperature Climates . . . . 10-12Disposing of Coolant . . . . . . . . . . . . . . . . . . . . 10-13

Lubrication & Maintenance/DailyDaily Prestarting Checks . . . . . . . . . . . . . . . . . . 25-1Engine Operating Guidelines

Instrument (Gauge) Panels (Standard) . . . . . . . . 15-1Instrument (Gauge) Panel (Electronic) . . . . . . . . 15-3 Lubrication & Maintenance/250 Hour/6 MonthUsing Diagnostic Gauge to Access Servicing Fire Extinguisher . . . . . . . . . . . . . . . . . 30-1

Engine Information (Electronic Panel) . . . . . . . 15-8 Lubricating PTO Clutch Shaft Bearings . . . . . . . 30-1Using Touch Switches to Display Servicing Battery . . . . . . . . . . . . . . . . . . . . . . . . 30-2

Information . . . . . . . . . . . . . . . . . . . . . . . . . . 15-11 Handling Batteries Safely . . . . . . . . . . . . . . . . . . 30-3Changing Units of Measure (English or Changing Engine Oil and Replacing Oil Filter. . . 30-4

Metric). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-13 Checking PTO Clutch Adjustment. . . . . . . . . . . . 30-6Viewing Engine Configuration Data . . . . . . . . . 15-15

Continued on next pageViewing Active Engine Service Codes (DTC) . . 15-17

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 2001DEERE & COMPANY

Moline, IllinoisAll rights reserved

A John Deere ILLUSTRUCTION ManualPrevious Editions

Copyright 1996, 2000

i 122000PN=1

Contents

Page Page

Visually Inspecting Coolant Pump . . . . . . . . . . . 30-7 TroubleshootingGeneral Troubleshooting Information . . . . . . . . . 50-1Checking Engine Mounts (Generator Sets). . . . . 30-8Engine Wiring Diagram (Engines w/Earlier

Standard Instrument Panel - Engines (Lubrication & Maintenance/600 Hour/12 Month-199,999) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-3Lubricating PTO Clutch Internal Levers and

Engine Wiring Diagram (Engines w/LaterLinkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-1Standard Instrument Panels) . . . . . . . . . . . . . 50-5Cleaning Crankcase Vent Tube . . . . . . . . . . . . . 35-1

Precautions for Welding on MachinesChecking Air Intake System . . . . . . . . . . . . . . . . 35-2Equipped with ECU. . . . . . . . . . . . . . . . . . . . . 50-6Replacing (Rectangular) Final Fuel Filter

Engine Wiring Diagram (Engines withElement - Engines ( -199,999) . . . . . . . . . . . . 35-3Electronic Instrument Panel) - Engines (Replacing (Round) Primary Fuel-199,999) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7Filter/Water Separator - Engines (

Engine Wiring Diagram (Engines with-199,999) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-4Electronic Instrument Panel) - EnginesClean Fuel Strainer - Engines (200,000- ) . . . . . 35-5(200,000- ) . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-9Replacing Main Fuel Filter - Engines

Engine Wiring Layout (Engines(200,000- ) . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-6w/Electronic Instument Panel) - Engines (Checking Belt Tensioner Spring Tension-199,999) . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-11and Belt Wear. . . . . . . . . . . . . . . . . . . . . . . . . 35-7

Engine Wiring Layout (EnginesChecking Belt Wear . . . . . . . . . . . . . . . . . . . . . . 35-7

w/Electronic Instument Panel) - Engines (200,000-)Checking Tensioner Spring Tension . . . . . . . . . . 35-7

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-12Checking Cooling System. . . . . . . . . . . . . . . . . . 35-8

Engine Troubleshooting . . . . . . . . . . . . . . . . . . 50-13Testing Diesel Engine Coolant . . . . . . . . . . . . . . 35-9

Electrical Troubleshooting. . . . . . . . . . . . . . . . . 50-20Replenishing Supplemental Coolant Lubrication System Troubleshooting . . . . . . . . . 50-22

Additives (SCAs) Between Coolant Cooling System Troubleshooting . . . . . . . . . . . 50-24Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-10 Air Intake System Troubleshooting . . . . . . . . . . 50-26

Pressure Testing Cooling System. . . . . . . . . . . 35-12 Diagnostic Trouble Code Procedure (EarlierChecking and Adjusting Engine Speeds . . . . . . 35-13 Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-29Checking Crankshaft Vibration Damper . . . . . . 35-13 Diagnostic Trouble Code Procedure (LaterChecking Engine Ground Connection . . . . . . . . 35-14 Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31

Displaying of Diagnostic Trouble CodesLubrication&Maintenance/2000Hour/24Month (DTCs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-32Flushing Cooling System . . . . . . . . . . . . . . . . . . 40-1 Listing of Diagnostic Trouble CodesChecking and Adjusting Engine Valve (DTCs) - Engines ( -199,999) . . . . . . . . . . . . 50-33

Clearance - Engines ( -199,999) . . . . . . . . . . . 40-3 Listing of Diagnostic Trouble Codes(DTCs) - Engines (200,000- ) . . . . . . . . . . . . 50-35Check Valve Clearance - Engines (200,000- ) . . 40-5

Adjust Valve Clearance - Engines (200,000- ) . . 40-8

StorageEngine Storage Guidelines . . . . . . . . . . . . . . . . . 55-1Service As RequiredUse AR41785 Engine Storage Kit. . . . . . . . . . . . 55-1Additional Service Information . . . . . . . . . . . . . . 45-1Preparing Engine for Long Term Storage . . . . . . 55-2Do Not Modify Fuel System . . . . . . . . . . . . . . . . 45-1Removing Engine from Long Term Storage . . . . 55-3Drain Fuel/Water Separator Bowl . . . . . . . . . . . . 45-2

Adding Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . 45-3Replacing Air Cleaner Filter Elements . . . . . . . . 45-4 SpecificationsInspecting Primary Filter Element . . . . . . . . . . . . 45-5 General OEM Engine Specifications. . . . . . . . . . 60-1Cleaning Primary Filter Element . . . . . . . . . . . . . 45-6 General OEM EngineElement Storage. . . . . . . . . . . . . . . . . . . . . . . . . 45-7 Specifications--Continued . . . . . . . . . . . . . . . . 60-3Replacing Fan/Alternator Belt . . . . . . . . . . . . . . . 45-8 Fuel Injection Pump Specifications (OEMPower Take-Off (PTO) Clutch. . . . . . . . . . . . . . . 45-9 Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-5Checking Fuses . . . . . . . . . . . . . . . . . . . . . . . . 45-10 Engine Crankcase Oil Fill Quantities . . . . . . . . . 60-8Bleeding Fuel System - Engines ( -199,999) . . 45-11

Continued on next pageBleeding Fuel System - Engines (200,000- ) . . 45-13

ii 122000PN=2

Contents

Page

Unified Inch Bolt and Cap Screw TorqueValues. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-9

Metric Bolt and Cap Screw Torque Values . . . . 60-10

Lubrication and Maintenance RecordsUsing Lubrication and Maintenance Records . . . 65-1Daily (Prestarting) Service . . . . . . . . . . . . . . . . . 65-1250 Hour/6 Month Service . . . . . . . . . . . . . . . . . 65-2600 Hour/12 Month Service . . . . . . . . . . . . . . . . 65-32000 Hour/24 Month Service . . . . . . . . . . . . . . . 65-4Service as Required . . . . . . . . . . . . . . . . . . . . . . 65-5

Emission System WarrantyEmissions Control System Certification Label. . . 70-1U.S. Emissions Control Warranty Statement. . . . 70-2

iii 122000PN=3

Contents

iv 122000PN=4

Record Keeping

RG,RG34710,4001 1901JAN961/1

RECORD ENGINE SERIAL NUMBER

RG

1107

2U

N0

6JU

L00

Engine Serial Number Plate

RG

7396

UN

21M

AR

00

Location of Engine Serial Number Plate

AEngine Serial NumberBApplication Data or TypeCSerial Number Plate

The engine serial number plate (C) is located on theleft-hand side of engine block between intake manifoldand starter 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 122000PN=9

Record Keeping

RG,RG34710,4002 1901JAN961/2

ENGINE OPTION CODES

RG

1107

4U

N1

4AU

G00

Option Code Label

AEngine Base Code

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 engine option code label includes an engine basecode (A). This base code must also be recorded alongwith the option codes.

The first two digits of each option code identify aspecific group, such as alternators. The last two digitsof each code identify one specific option provided onyour engine, such as a 24-volt, 42-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.

Engine Base Code (A):

01-2 122000PN=10

Continued on next page

Record Keeping

RG,RG34710,4002 1901JAN962/2

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 46 Cylinder Block

13 Crankshaft Pulley/Damper 47 Crankshaft

14 Flywheel Housing 48 Pistons and Connecting Rods

15 Flywheel 49 Valve Actuating Mechanism

16 Fuel Injection Pump 50 Oil Pump

17 Air Intake 51 Cylinder Head

19 Oil Pan 52 Gear-Driven Auxiliary Drive

20 Water Pump 55 Transport Skid/Shipping Stand

21 Thermostat Cover 56 Paint

22 Thermostats 57 Water Pump Inlet

23 Fan Drive 59 Oil Cooler and Filter

24 Fan Belts 62 Alternator Mounting

26 Engine Coolant Heater 64 Exhaust Elbow

28 Exhaust System 65 Turbocharger

29 Vent Hose 66 Coolant Temperature Sensor/Switch

30 Starter Motor 74 Air Conditioning (A/C) Compressor (Optional)

31 Alternator 76 Oil Pressure Sensor/Switch

35 Fuel Filter 77 Timing Gear Cover

38 Operators Manual 78 Air Compressor (Optional)

39 Outlet Manifold 92 Accessories (Factory Installed)

40 Oil Dipstick 96 Wiring Harness

44 Electronic Speed Sensor 97 Special Equipment (Field Installed)

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 122000PN=11

Record Keeping

RG,RG34710,4005 1901JAN961/1

RECORD FUEL INJECTION PUMP MODELNUMBER

RG

7393

UN

20J

UN

00

Fuel Injection Pump Serial Number PlateASerial Number Plate

Record the fuel injection pump model and serialinformation found on the serial number plate (A).

Model No. RPM

Manufacturers No.

Serial No.

RG,RG34710,4004 1901JAN961/1

RECORD PTO SERIAL NUMBER (IFEQUIPPED)

RG

4622

UN

15D

EC

88

PTO Serial Number Plate

Serial number and model number are located on coverplate of PTO housing. Record the numbers in thefollowing spaces:

Serial Number

Model Number

01-4 122000PN=12

Safety

DX,ALERT 1929SEP981/1

RECOGNIZE SAFETY INFORMATION

T81

389

UN

07D

EC

88

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

TS

187

19

30S

EP

88

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.

DX,READ 1903MAR931/1

FOLLOW SAFETY INSTRUCTIONS

TS

201

UN

23A

UG

88

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 machine and how to usecontrols properly. Do not let anyone operate withoutinstruction.

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

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

05-1 122000PN=13

Safety

DX,SIGNS1 1904JUN901/1

REPLACE SAFETY SIGNS

TS

201

UN

23A

UG

88

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

DPSG,OUOD002,1569 1920JUN001/1

PREVENT BYPASS STARTING

RG

5419

UN

28F

EB

89

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

TS

202

UN

23A

UG

88

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

Always stop engine before refueling machine. Fill fuel tankoutdoors.

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

05-2 122000PN=14

Safety

DX,FIRE2 1903MAR931/1

PREPARE FOR EMERGENCIES

TS

291

UN

23A

UG

88

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

TS

1356

UN

18M

AR

92

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.

DX,FLAME 1929SEP981/1

HANDLE FLUIDS SAFELYAVOID FIRES

TS

227

UN

23A

UG

88

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 machine is clean of trash, grease, and debris.

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

05-3 122000PN=15

Safety

DX,LOOSE 1904JUN901/1

SERVICE MACHINES SAFELY

TS

228

UN

23A

UG

88

Tie long hair behind your head. Do not wear a necktie,scarf, loose clothing, or necklace when you work nearmachine 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.

DX,WEAR 1910SEP901/1

WEAR PROTECTIVE CLOTHING

TS

206

UN

23A

UG

88

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

TS

207

UN

23A

UG

88

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.

05-4 122000PN=16

Safety

DX,MSDS,NA 1903MAR931/1

HANDLE CHEMICAL PRODUCTS SAFELY

TS

1132

UN

26N

OV

90

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.)

RG,RG34710,4016 1901JAN961/1

STAY CLEAR OF ROTATING DRIVELINES

TS

1644

UN

22A

UG

95

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 surethe PTO driveline is stopped before making adjustmentsor performing any type service on the engine orPTO-driven equipment.

05-5 122000PN=17

Safety

DX,SERV 1917FEB991/1

PRACTICE SAFE MAINTENANCE

TS

218

UN

23A

UG

88

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

Never lubricate, service, or adjust machine while it ismoving. Keep hands, feet , and clothing frompower-driven parts. Disengage all power and operatecontrols to relieve pressure. Lower equipment to theground. Stop the engine. Remove the key. Allow machineto cool.

Securely support any machine elements that must beraised for 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.

On self-propelled equipment, disconnect battery groundcable (-) before making adjustments on electrical systemsor welding on machine.

On towed implements, disconnect wiring harnesses fromtractor before servicing electrical system components orwelding on machine.

DX,AIR 1917FEB991/1

WORK IN VENTILATED AREA

TS

220

UN

23A

UG

88

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

05-6 122000PN=18

Safety

DX,REPAIR 1917FEB991/1

USE PROPER TOOLS

TS

779

UN

08N

OV

89

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,LIFT 1904JUN901/1

USE PROPER LIFTING EQUIPMENT

TS

226

UN

23A

UG

88

Lifting heavy components incorrectly can cause severeinjury or machine damage.

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

05-7 122000PN=19

Safety

DX,FLUID 1903MAR931/1

AVOID HIGH-PRESSURE FLUIDS

X98

11U

N2

3AU

G88

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.

DX,TORCH 1903MAR931/1

AVOID HEATING NEAR PRESSURIZED FLUIDLINES

TS

953

UN

15M

AY

90

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 can beaccidentally cut when heat goes beyond the immediateflame area.

05-8 122000PN=20

Safety

DX,PAINT 1922OCT991/1

REMOVE PAINT BEFORE WELDING ORHEATING

TS

220

UN

23A

UG

88

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 76 mm (3 in.) from area tobe affected by heating.

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

Dispose of paint and solvent properly.

DX,RCAP 1904JUN901/1

SERVICE COOLING SYSTEM SAFELY

TS

281

UN

23A

UG

88

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.

05-9 122000PN=21

Safety

DX,DUST 1915MAR911/1

AVOID HARMFUL ASBESTOS DUST

TS

220

UN

23A

UG

88

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.

DX,SPARKS 1903MAR931/1

PREVENT BATTERY EXPLOSIONS

TS

204

UN

23A

UG

88

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).

05-10 122000PN=22

Safety

DX,POISON 1921APR931/1

PREVENT ACID BURNS

TS

203

UN

23A

UG

88

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.

DX,SPRAY 1916APR921/1

PROTECT AGAINST HIGH PRESSURESPRAY

TS

1343

UN

18M

AR

92

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.

05-11 122000PN=23

Safety

DX,DRAIN 1903MAR931/1

DISPOSE OF WASTE PROPERLY

TS

1133

UN

26N

OV

90

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.

05-12 122000PN=24

Fuels, Lubricants, and Coolant

DX,FUEL1 1924JAN001/1

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.

In all cases, the fuel shall meet the followingproperties:

Cetane number of 40 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 of 3100 gramload level as measured by the BOCLE scuffing test.

Sulfur content:

Sulfur content should not exceed 0.5%. Sulfurcontent less than 0.05% is preferred.

If diesel fuel with sulfur content greater than 0.5%sulfur content is used, reduce the service interval forengine oil and filter by 50%.

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

Bio-diesel fuels may be used ONLY if the fuelproperties meet DIN 51606 or equivalent specification.

DO NOT mix used engine oil or any other type oflubricant with diesel fuel.

DX,FUEL5 1924JAN001/1

LUBRICITY OF DIESEL FUELS

Diesel fuel must have adequate lubricity to ensureproper operation and durability of fuel injection systemcomponents.

Diesel fuels for highway use in the United States andCanada require sulfur content less than 0.05%.

Diesel fuel in the European Union requires sulfurcontent less than 0.05%.

Experience shows that some low sulfur diesel fuelsmay have inadequate lubricity and their use mayreduce performance in fuel injection systems due toinadequate lubrication of injection pump components.The lower concentration of aromatic compounds inthese fuels also adversely affects injection pump sealsand may result in leaks.

Use of low lubricity diesel fuels may also causeaccelerated wear, injection nozzle erosion or corrosion,engine speed instability, hard starting, low power, andengine smoke.

Fuel lubricity should pass a minimum of 3100 gramload level as measured by the BOCLE scuffing test.

ASTM D975 and EN 590 specifications do not requirefuels to pass a fuel lubricity test.

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

10-1 122000PN=25


RG,RG34710,7526 1930JUN971/1

DIESEL FUEL STORAGE

Proper fuel storage is critically important. Use cleanstorage and transfer tanks. Periodically drain waterand sediment from bottom of tank. Store fuel in aconvenient place away from buildings.

IMPORTANT: DO NOT store diesel fuel ingalvanized containers. Diesel fuelstored in galvanized containersreacts with zinc coating on containerto form zinc flakes. If fuel containswater, a zinc gel will also form. Thegel and flakes will quickly plug fuelfilters, damage injection nozzles andinjection pump.

DO NOT use brass-coated containersfor fuel storage. Brass is an alloy ofcopper and zinc.

Store diesel fuel in plastic, aluminum, and steelcontainers specially coated for diesel fuel storage.

Avoid storing fuel over long periods of time. If fuel isstored for more than a month prior to use, or there is aslow turnover in fuel tank or supply tank, add a fuelconditioner such as John Deere PREMIUM DIESELFUEL CONDITIONER or equivalent to stabilize the fueland prevent water condensation. John DeerePREMIUM DIESEL FUEL CONDITIONER is availablein winter and summer formulas. Fuel conditioner alsoreduces fuel gelling and controls wax separation duringcold weather.

Consult your John Deere engine distributor or servicingdealer for recommendations and local availability.Always follow manufacturers directions on label.

DX,FUEL6 1906DEC001/1

DIESELSCAN FUEL ANALYSIS

DIESELSCAN is a John Deere fuel sampling program tohelp you monitor the quality of your fuel source. It verifiesfuel type, cleanliness, water content, suitability for coldweather operation, and if fuel is within ASTMspecifications. Check with your John Deere dealer foravailability of DIESELSCAN kits.

DIESELSCAN is a trademark of Deere & Company

10-2 122000PN=26


RG,RG34710,4030 1901JAN961/1

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 authorized enginedistributor or servicing dealer for additional informationand local availability of cold weather aids.

Use Grade No. 1-D Fuel

When temperatures fall below 5C (40F), Grade No.1-D fuel is best suited for cold weather operation.Grade No. 1-D fuel has a lower cloud point and alower 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 become more resistant to flowthrough fuel pumps and lines.

NOTE: On an average, Grade No. 1-D fuel has alower BTU (heat content) rating than GradeNo. 2-D fuel. When using Grade No. 1-D fuelyou may notice a drop in power and fuelefficiency, but should not experience any otherengine performance effects. Check the gradeof fuel being used before troubleshooting forlow power complaints in cold weatheroperation.

Diesel Fuel Flow Additive

IMPORTANT: Treat fuel when outside temperaturedrops below 0C (32F). For best

results, use with untreated fuel.Follow all recommended instructionson label.

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.

For more information, see your John Deere enginedistributor or servicing dealer.

Cold Weather Starting Aids

Coolant heaters, air intake heaters, or ether startingaids are available options to aid in cold weatherstarting.

Seasonal Viscosity Oil and Proper CoolantConcentration

Use seasonal grade viscosity engine oil based onexpected air temperature range between oil changesand a proper concentration of low silicate antifreeze asrecommended. (See DIESEL ENGINE OIL andENGINE COOLANT REQUIREMENTS later in thissection).

For more information, see your John Deere enginedistributor or servicing dealer.

10-3 122000PN=27


DX,ENOIL4 1924JAN001/1

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

ACEA Specification E1

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

IMPORTANT: Do not use PLUS-50 oil or engineoils meeting API CH-4, API CG4, APICF4, ACEA E3, or ACEA E2performance levels during the first100 hours of operation of a new orrebuilt engine. These oils will notallow the engine to break-inproperly.

PLUS-50 is a registered trademark of Deere & Company.

10-4 122000PN=28


DX,ENOIL 1924JAN001/1

DIESEL ENGINE OIL

TS

1661

UN

10O

CT

97

Diesel Engine Oil

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

The following oil is preferred:

John Deere PLUS-50

The following oil is also recommended:

John Deere TORQ-GARD SUPREME

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

API Service Classification CH-4 API Service Classification CG-4 API Service Classification CF-4 ACEA Specification E3 ACEA Specification E2

Multi-viscosity diesel engine oils are preferred.

If diesel fuel with sulfur content greater than 0.5% is used,reduce the service interval by 50%.

Extended service intervals may apply when John Deerepreferred engine oils are used. Consult your John Deeredealer for more information.

PLUS-50 is a registered trademark of Deere & Company.TORQ-GARD SUPREME is a registered trademark of Deere &Company

10-5 122000PN=29


DX,ENOIL6 1910OCT971/1

EXTENDED DIESEL ENGINE OIL SERVICEINTERVALS

When John Deere PLUS-50 oil and the specified JohnDeere filter are used, the service interval for engine oiland filter changes may be increased by 50%.

If other thanoil and the specified John Deere filter areused, change the engine oil and filter at the normalservice interval.

PLUS-50 is a registered 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.

10-6 122000PN=30


DPSG,OUOD002,1824 1902AUG001/1

OILSCANAND COOLSCAN

T68

28A

BU

N1

5JU

N89

OILSCAN

T68

29A

BU

N1

8OC

T88

Sampling Program

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 registered trademark of Deere & Company.

DX,ALTER 1915JUN001/1

ALTERNATIVE AND SYNTHETICLUBRICANTS

Conditions in certain geographical areas may requirelubricant recommendations different from those printed inthis manual.

Some John Deere brand coolants and lubricants may notbe available in your location.

Consult your John Deere dealer to obtain information andrecommendations.

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

The temperature limits and service intervals shown in thismanual apply to both conventional and synthetic oils.

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

10-7 122000PN=31


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 1924JAN001/1

GREASE

TS

1667

UN

30J

UN

99

Grease

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.

10-8 122000PN=32


DX,COOL3 1905FEB991/1

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).

The following engine coolant is preferred for service:

John Deere COOL-GARD Prediluted Coolant

The following engine coolant is also recommended:

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

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

ASTM D5345 (prediluted coolant) ASTM D4985 (coolant concentrate) in a 40 to 60%

mixture of concentrate with quality water

Coolants meeting these specifications require use ofsupplemental coolant additives, formulated forheavy-duty diesel engines, for protection againstcorrosion and cylinder liner erosion and pitting.

A 50% mixture of ethylene glycol engine coolant inwater provides freeze protection to -37C (-34F). If

protection at lower temperatures is required, consultyour John Deere dealer for recommendations.

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

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

Coolant Drain Intervals

Drain the factory fill engine coolant, flush the coolingsystem, and refill with new coolant after the first 3years or 3000 hours of operation. Subsequent drainintervals are determined by the coolant used forservice. At each interval, drain the coolant, flush thecooling system, and refill with new coolant.

When John Deere COOL-GARD is used, the draininterval may be extended to 5 years or 5000 hours ofoperation, provided that the coolant is tested annuallyAND additives are replenished, as needed, by addinga supplemental coolant additive.

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

10-9 122000PN=33


DPSG,OUOD002,1835 1903AUG001/2

DIESEL ENGINE COOLANTS AND SUPPLEMENTAL ADDITIVE INFORMATION

Engine coolants are a combination of three chemicalcomponents: ethylene glycol (antifreeze), inhibitingcoolant additives, and quality water.

Coolant Specifications

Some products, including John Deere John DeereCOOL-GARD Prediluted Coolant, are fully formulatedcoolants that contain all three components in theircorrect concentrations. Do not add an initial charge ofsupplemental coolant additives to these fullyformulated products.

Some coolant concentrates, including John DeereCOOL-GARD Coolant Concentrate, contain bothethylene glycol antifreeze and inhibiting coolantadditives. Mix these products and quality water, but donot add an initial charge of supplemental coolantadditives.

Coolants meeting ASTM D5345 (prediluted coolant) orASTM D4985 (coolant concentrate) 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 is used. Follow therecommendations in this manual for the use ofsupplemental 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. Asimple mixture of ethylene glycol and water will notgive 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 or ASTM D4656). Thesecoolants do not contain the correct additives to protectheavy-duty diesel engines. They often contain a highconcentration of silicates and may damage the engineor cooling system.

Non-Aqueous Propylene Glycol

Non-aqueous propylene glycol should not be used withJohn Deere diesel engines. This coolant works bestwith coolant temperatures above the acceptableengine operating range. This could decrease enginelife due to lower engine oil viscosity. In addition,electronically controlled engines could experiencepremature power de-rate due to high coolanttemperature.

Water Quality

Water quality is important to the performance of thecooling system. Distilled, deionized, or demineralizedwater is recommended for mixing with ethylene glycolbase engine coolant concentrate. All water used in thecooling system should meet the following minimumspecifications for quality:

Chlorides 40 mg/L or less

Sulfates 100 mg/L or less

Total Dissolved Solids 340 mg/L or less

Total Hardness 170 mg/L or less

pH Level 5.5 to 9.0

Freeze Protection

The relative concentrations of ethylene glycol andcoolant in the engine coolant determine its freezeprotection limit. Refer to the chart on the followingpage.

10-10 122000PN=34



DPSG,OUOD002,1835 1903AUG002/2

Ethylene Glycol Freeze Protection Limit

40% -24C (-12F)

50% -37C (-34F)

60% -52C (-62F)

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

DPSG,OUOD002,1825 1902AUG001/1

TESTING DIESEL ENGINE COOLANT

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

Test the coolant solution at intervals of 12 months or lessand whenever excessive coolant is lost through leaks oroverheating.

Coolant Test Strips

Coolant test strips are available from your John Deeredealer. These test strips provide a simple, effectivemethod to check the freeze point and additive levels ofyour engine coolant.

Compare the results to the supplemental coolant additive(SCA) chart to determine the amount of inhibitingadditives in your coolant and whether more John DeereCOOLANT CONDITIONER should be added.

COOLSCAN

For a more thorough evaluation of your coolant, perform aCOOLSCAN analysis. See your John Deere dealer forinformation about COOLSCAN.

10-11 122000PN=35


DX,COOL4 1915JUN001/1

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 John DeereCOOL-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.

DX,COOL6 1918MAR961/1

OPERATING IN WARM TEMPERATURECLIMATES

John Deere engines are designed to operate using glycolbase engine coolants.

Always use a recommended glycol base engine coolant,even when operating in geographical areas where freezeprotection is not required.

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

Foaming, hot surface aluminum andiron corrosion, scaling, and cavitationwill occur when water is used as thecoolant, even when coolantconditioners are added.

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

10-12 122000PN=36


RG,RG34710,7543 1930JUN971/1

DISPOSING OF COOLANT

TS

1133

UN

26N

OV

90

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.

10-13 122000PN=37

Engine Operating Guidelines

RG,RG34710,4046 1901JAN961/2

INSTRUMENT (GAUGE) PANELS (STANDARDINSTRUMENT PANELS)

RG

1107

7U

N2

1AU

G00

Standard Instrument Panel for Earlier Engines

RG

1129

9CU

N2

1AU

G00

Standard Instrument Panel for Later Engines

AOil Pressure GaugeBAmmeterCCoolant Temperature GaugeDKey SwitchEReset (Safety) SwitchFTachometer (With Hour Meter, Some Engines)GHand ThrottleHTachometer Binary CodeIHour Meter (Separate on Some Engines)JFuse Holder (14 Amp) (Later Engines)

All controls and gauges are optional equipment for JohnDeere OEM Engines. They may be provided by theequipment manufacturer instead of John Deere. Thefollowing information applies only to those controls andgauges provided by John Deere.

IMPORTANT: Any time an electric gauge or meterdoes not register correctly, replace itwith a new one. Do not attempt to repairit.

Following is a brief description of the components on theJohn Deere instrument (gauge) panel:

AOil Pressure Gauge - Indicates engine oil pressure.

BAmmeter - Indicates charging current within electricalsystem.

CCoolant Temperature Gauge - Indicates the enginecoolant temperature.

DKey Switch - The four-position key switch controls theelectrical system.

EReset (Safety) Switch - Overrides safety shutdownswitch when depressed and held in during engine startup.Hold button in until engine oil pressure is at a safeoperating level. Switch will shut engine down when oilpressure drops below or coolant temperature rises abovea (preset) safe operating level.

FTachometer (with Electric Hour Meter, SomeEngines) - Tachometer senses engine speed from aspeed sensor in front timing gear cover and indicatesengine speed in revolutions per minute (rpm). Hour meterindicates the operating hours of the engine while keyswitch is in the ON position. The hour meter should beused as a guide for scheduling periodic service.

GHand Throttle - Controls engine speed.

15-1 122000PN=38



RG,RG34710,4046 1901JAN962/2

RG

6861

UN

30J

UN

93

Setting Code for Tachometer

H Tachometer Binary Code - Located in back oftachometer and must be set at 00010011 to operate at27 pulses per revolution as shown.

I Hour Meter (Separate on Some Engines) - On someinstrument panels, the hour meter is a separate gaugefrom the tachometer. This electric hour meter shows theaccumulated hours of engine service. The hour meteroperates when the engine is operating, or when the resetbutton is manually held in while the key switch is in theON Position. The accumulated hours are displayed inhours and tenths of hours.

J Fuse Holder (14 Amp Fuse) (Later Engines) - Onlater instrument panels the fuse holder is located on thepanel. (On earlier panels, fuse is a 25-amp located on theback of the panel.) See Checking Fuses in Service asRequired section later in this manual.

15-2 122000PN=39


DPSG,OUOD002,1571 1920JUN001/1

INSTRUMENT (GAUGE) PANEL (ENGINESWITH ELECTRONIC INSTRUMENT PANEL)

RG

9547

UN

14A

UG

00Instrument Panel (Engines With Electronic Instrument Panel)

AEngine Oil Pressure GaugeBAmber WARNING IndicatorCRed STOP ENGINE IndicatorDDiagnostic Gauge/Hour MeterETouch SwitchFTouch SwitchGAudible AlarmHAudible Alarm Override Switch (Optional)IThrottle Control (Optional)JDimmer Control (Optional)KEngine Preheater Indicator (Optional)LKey Start SwitchMOverride Shutdown Rocker Switch (Optional)NHigh-Low Speed Select Rocker Switch (Optional)OBump Speed Enable Rocker Switch (Optional)PSpeed Select Rocker Switch (Optional)QFuse Holder (5-Amp Fuse)RTachometerSPower Meter (Percent Load) (Optional)TVoltmeterUEngine Coolant Temperature Gauge

This electronic instrument panel was introduced in 1999. Itis linked to the John Deere engine control unit (ECU).This allows the operator to monitor engine performance aswell as to diagnose any troubles during engine operation.

IMPORTANT: Any time an electric gauge or meterdoes not register correctly, replace witha new one. Do not attempt to repair it.All gauges are plug-in type.

Refer to manufacturers literature for information oncontrols not provided by Deere.

Following is a brief description of the gauges and controlson the John Deere electronic instrument panel.

15-3 122000PN=40


DPSG,OUOD002,1572 1920JUN001/1

ENGINE OIL PRESSURE GAUGE

The engine oil pressure gauge (A) indicates engine oilpressure in pounds per square inch (psi). It isconnected to an audible alarm (G) to warn theoperator if oil pressure drops below the preset safeoperating pressure set for the engine.

AMBER WARNING INDICATOR

The amber WARNING indicator (B) signals anabnormal condition such as low oil pressure, highcoolant temperature, water in fuel, low battery voltage,etc. Use the Service Code menu of the diagnosticgauge (D) to identify the trouble.

RED STOP ENGINE INDICATOR

The red STOP ENGINE indicator (C) signals operatorto stop engine immediately or as soon as safelypossible. A condition exists that could cause damageto engine.

DIAGNOSTIC GAUGE/HOUR METER

The diagnostic gauge (D) displays diagnostic troublecodes (DTCs) as they occur. Other information on theengine can be accessed using the touch switches (Eand F). The hour meter shows the operating hours ofthe engine. Normally, the gauge will alternately flashfrom the displayed parameters to the messageSvrcCode. (See following in this section for operatingthe diagnostic gauge switches to access engine

information. Also see TROUBLESHOOTING sectionfor a list of diagnostic trouble codes (DTCs) andcorresponding engine problems.)

TOUCH SWITCHES

The touch switches are used to change the display onthe window of the diagnostic gauge to access engineperformance data. Pressing the DOWN switch (E) orUP switch (F) scrolls through various engineparameters and diagnostic fault codes.

AUDIBLE ALARM

The audible alarm (G) sounds whenever a low oilpressure or high coolant temperature condition exists.

AUDIBLE ALARM OVERRIDE SWITCH (OPTIONAL)

The audible alarm override switch (H) can be pressedto silence the alarm for approximately 2-1/2 minutes.

THROTTLE CONTROL (OPTIONAL)

The throttle control (I) is used to control engine speed.This control is available as part of the panel only onengines with analog throttle.

DIMMER CONTROL (OPTIONAL)

The dimmer control (J) is used to control illumination ofthe instrument panel gauges.

15-4 122000PN=41


DPSG,OUOD002,1573 1920JUN001/1

RG

9547

UN

14A

UG

00Instrument Panel (Engines With Electronic Instrument Panel)

ENGINE PREHEATER INDICATOR (OPTIONAL)

The engine preheater indicator (K) lights up while theengine is being preheated for cold weather starting. Whenthe engine is warmed up, the light goes off, indicating theengine can now be started.

KEY START SWITCH

The three-position key switch (L) controls the engineelectrical system. When the key switch is turned clockwiseto START, the engine will crank. When the engine starts,the key is released and returns to the ON (Run) position.

OVERRIDE SHUTDOWN ROCKER SWITCH(OPTIONAL)

NOTE: This switch may be present, but not active,depending on panel options originally selected.

Pressing the upper half of the override shutdown switch(M) will override an engine shutdown signal. The switchmust be pressed within 30 seconds to prevent undesiredshutdown of engine.

HIGH-LOW SPEED SELECT ROCKER SWITCH(OPTIONAL)

The high-low speed select switch (N) is used to set theengine at operating speeds of slow (turtle) or fast (rabbit).Factory preset idle speeds can then be adjusted using theBump Enable Switch (O) with the Speed Select Switch(P).

BUMP SPEED ENABLE ROCKER SWITCH

The bump speed enable switch (O) has a center positionwhich locks the speed select switch (P) to preventaccidental changes in operating speed. To unlock thespeed select switch, press and hold either the upper orlower half of the speed enable switch (O).

15-5 122000PN=42


AG,OUOD002,1620 1905JUL001/2

SPEED SELECT ROCKER SWITCH

The speed select switch (P) is used to bump enginespeed up (+) or down (-) in small increments duringoperation. This switch must be used with the bumpspeed enable switch (O) in the unlocked position (topor bottom half of button depressed).

HOW TO SELECT PRESET OPERATING SPEEDS(BUMP SPEEDS)

First select slow or fast speed option by pressingspeed select switch (N) to turtle (slow) or rabbit(fast). Then you can press either the upper or lowerportion of the bump enable switch (O) to unlock thehigh or low speed setting. The bump enable must beheld down as the speed select rocker (P) is used tochange the high or low speed setting by pressing (+)to increase speed or (-) to decrease speed.

Once the speed has been set, the bump enable rockermust be pressed and released three times within twoseconds to commit the operating speed to memory. Ifnot done, the engines new speed will only be effectiveuntil the key switch is shut off. Then the high or lowoperating speed will revert back to the previoussetting.

FUSE HOLDER

The fuse holder (Q) contains a 5-amp fuse for powerto the instrument panel.

TACHOMETER

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

POWER (PERCENT LOAD) METER (OPTIONAL)

The power meter (S) shows percent of available powerbeing used by the engine.

VOLTMETER

The voltmeter (T) indicates system battery voltage.The amber WARNING light (B) will illuminate when

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

ENGINE COOLANT TEMPERATURE GAUGE

The coolant temperature gauge (U) indicates enginecoolant temperature in degrees Centigrade orFahrenheit. It is connected to an audible alarm (G) towarn the operator if coolant temperature rises abovethe preset safe operating temperature.

CRUISE CONTROL (OPTIONAL)

Engine ECUs are available with and without theCruise Control function. The Cruise Control is anOff-Road type that maintains a constant engine RPMunder varying load conditions. An automotive typecruise control maintains a constant road speed.

The Cruise Cancel/Resume function is a one-buttonCancel then Resume function. The first time contact ismade with Cruise Control active, the Cruise Controlwill disengage and the engine speed will drop to idle. Ifthe contact is made again within one minute and withthe engine speed above 1300 RPM, the Cruise Controlwill Resume. This feature allows the placement of theCancel/Resume button in a convenient location in thevehicle cab and does not require the use of the normalCruise controls for momentary interruptions in cruiseoperation.

The Cancel/Resume function is intended forapplications like ag tractors and sprayers that turnaround at the end of each row in a field. This allowsthe operator to use the throttle and/or brake to turn thevehicle around. When ready to resume fieldoperations, the operator brings the engine speedabove 1300 RPM and activates the Cancel/Resumefunction again to resume cruise speed. An internaltimer gives the operator one minute to complete theturn around maneuver.

The Cruise Control has the normal functions of:

Cruise Control power ON or OFF Set or Bump Up Engine Speed Resume or Bump Down Engine Speed

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AG,OUOD002,1620 1905JUL002/2

Vehicle brake or clutch pedal to disengage CruiseControl.

The Bump Up and Bump Down speed controlsallow the operator to change the set speed. Smallengine speed changes can be made by bumping thecontrol switch. Holding the Bump Up or Bump Downswitch will result in greater engine RPM changes untilthe engine reaches either full speed or idle. The CruiseControl cannot operate beyond the normal min-maxengine speeds.

NOTE: The Bump Throttle feature cannot be usedwhile operating cruise control.

On 12-volt ECUs, the engine speed can be set fromtwo different locations. The primary location wouldnormally be in the cab of the vehicle and is used to seta constant engine speed while the vehicle is beingdriven. The secondary cruise control is normally usedin a location that provides for engine PTO speedcontrol and is used with the engine in neutral or outof gear. Both locations can have the normal cruisefunctions.

See Specifications section under Fuel Injection PumpSpecifications for the 1600 option code group whichmatches your code to find rated speeds and idlespeeds for your engine.

15-7 122000PN=44


DPSG,OUOD007,2840 1921OCT991/2

Using Diagnostic Gauge To Access EngineInformation

RG

1003

1U

N2

8OC

T99

Diagnostic Gauge

ADiagnostic GaugeBTouch SwitchesCAmber and Red Lights

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

Press the two touch switches (B) to view the variousengine functions in sequence. The displays can beselected as either 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 Fuel economy Throttle position Current fuel consumption Active service (diagnostic) codes Stored service (diagnostic) codes from the engine Set the units for display View the engine configuration parameters Accelerator pedal position Percentage load at current speed Actual engine percent torque Engine speed Trip distance Total vehicle distance Engine hours Trip fuel Total fuel used Coolant temperature Fuel temperature Engine oil temperature Engine intercooler temperature Fuel deliver pressure Engine oil level Engine oil pressure

15-8 122000PN=45



DPSG,OUOD007,2840 1921OCT992/2

Coolant pressure Coolant level Wheel base vehicle speed Fuel rate Instant fuel economy check Average fuel economy Barometric pressure Air inlet temperature Boost pressure Intake manifold temperature Air filter differential pressure Exhaust gas temperature Electrical potential (voltage) Battery potential (voltage), switched Transmission oil pressure Transmission oil temperature Injector metering rail No. 1 pressure Injector metering rail No. 2 pressure Estimated percent fan speed

NOTE: Engine parameters which can be accessed willvary with the engine application.

The diagnostic gauge includes a two-line byeight-character backlit Liquid Crystal Display (LCD). Thetop line displays the data label, i.e. EngHrs and thebottom line displays the matching unit information, i.e.1200 Hrs. The diagnostic gauge uses two touchswitches (UP and DOWN) for scrolling through the engineparameter list and viewing the menu list. Two lights (C)(amber and red) are used to signal active troublemessages received by the diagnostic gauge.

15-9 122000PN=46


15-10 122000PN=47


DPSG,OUOD007,2841 1921OCT991/2

USING TOUCH SWITCHES TO DISPLAY INFORMATION

RG

9947

19

09D

EC

99

Using Touch Switches

15-11 122000PN=48



DPSG,OUOD007,2841 1921OCT992/2

The touch switches on the diagnostic gauge allowquick and easy navigation through the menu to find theinformation needed. The diagram on the previous pageis a typical Main Menu of Engine Parameters. TheMain Menu has 14 entries; the first 10 are engine dataparameters, and the last four are sub-menu entrypoints. The following two rules are used for accessingthe various items on the menus:

1. To scroll through the parameter list, press eitherthe UP or DOWN touch switches.

2. To select or exit a sub-menu, simultaneouslypress the UP and DOWN switches.

Selecting Engine Data Parameters

To read any of the engine parameters, press either UPor DOWN switches (as shown on diagram) until thetop line of the display shows the desired information.

Selecting Sub-Menus

Press either the UP or DOWN switches until the topline of the display shows the label of the desiredsub-menu. Then press BOTH the UP and DOWNswitches at the same time. This action will select thesub-menu and the next screen on the display will listthe Sub-Menu items. This is also the way to accessDiagnostic Trouble Codes (DTCs).

15-12 122000PN=49


DPSG,OUOD007,2842 1921OCT991/1

CHANGING UNITS OF MEASURE (ENGLISH OR METRIC)

RG

1001

81

928

OC

T99

Changing Units Of Measure

The diagnostic gauge can display engine data in eitherEnglish or Metric units. To toggle between these, theUnits Sub-Menu, must be selected.

To select the Units Sub-Menu, press the UP or DOWNswitches until the top line of the display reads UNITS.Then press BOTH the UP and DOWN switches at thesame time to select the Units Sub-Menu. The above

diagram shows the steps for selecting the desired unitsof measure. Two options are available:

1. Press both the switches to retain the current unitsdesignation.

2. Press either UP or DOWN switch to toggle the unitsselection, then press both switches to select thedesired unit of measure.

15-13 122000PN=50


15-14 122000PN=51


DPSG,OUOD002,1927 1919DEC001/2

VIEWING ENGINE CONFIGURATION DATA

RG

1001

91

928

OC

T99

Viewing Engine Configuration Data

15-15 122000PN=52



DPSG,OUOD002,1927 1919DEC002/2

The diagnostic gauge can display the engineconfiguration data stored in the Engine Control Unit(ECU). To select the Engine Configuration Sub-Menu(see diagram on previous page), press the UP orDOWN switches until the top line of the display reads

E-Config. Then press BOTH the UP and DOWNswitches at the same time to select the EngineConfiguration Sub-Menu . The diagnostic gauge willdisplay the engine configuration data as shown in thediagram.

15-16 122000PN=53


DPSG,OUOD002,1928 1919DEC001/1

VIEWING ACTIVE ENGINE SERVICE CODES (DTC)

RG

1151

01

931

OC

T00

Viewing Active Service Codes

The diagnostic gauge continuously monitors allmessages broadcast over the Control Area Network(CAN) and displays all Active Service Codes (DTCs) atthe time the message is broadcast. The wordSrvcCode is displayed on the second line. Thedisplay will cycle every 5 seconds between thecurrently displayed parameter and the SrvcCodemessage until the active trouble code clears. To viewthe active codes, select the Service Code Sub-Menuby pressing the UP or DOWN switches until the topline of the display reads SrvcCode. Then press

BOTH the UP and DOWN switches at the same timeto select the Service (DTC) Code Sub-Menu. Thediagnostic gauge has the ability to display all ActiveService Codes received. The diagram above titledService Codes Sub-Menu shows the process forselecting Active Service Codes and their values.

NOTE: For a list of Service Codes or DiagnosticTrouble Codes (DTCs) and their causes, referto TROUBLESHOOTING section later in thismanual.

15-17 122000PN=54


DPSG,OUOD002,1929 1919DEC001/1

VIEWING STORED SERVICE CODES (DTC) IN THE ENGINE ECU

RG

1002

11

928

OC

T99

Viewing Stored Service Codes

The diagnostic gauge can request Stored ServiceCodes (DTCs) from the engine. The Stored ServiceCodes may be used for diagnostic and service needs.To view the Stored Service Codes, it is necessary toselect the DM2Codes Sub-Menu by pressing the UPor DOWN switches until the top line of the display

reads DM2Codes. Then press BOTH the UP andDOWN switches at the same time to select theDM2Codes Sub-Menu. The gauge will display theStored Service Codes according to the menus shownin the diagram.

15-18 122000PN=55


RG,RG34710,4048 1901JAN961/4

BREAK-IN SERVICE

RG

7359

UN

20J

UN

00

Check Engine Oil Level

RG

5895

UN

13A

UG

91

Engine Oil Level Dipstick

The engine is ready for normal operation. However,extra care during the first 100 hours will result in moresatisfactory long-term engine performance and life. DONOT exceed 100 hours of operation with break-in oil.

1. This engine is factory-filled with John Deere EngineBreak-in Oil. Operate the engine at heavy loadswith minimal idling during the break-in period.

2. If the engine has significant operating time at idle,constant speeds, and/or light load usage, ormake-up oil is required in the first 100 hour period,a longer break-in period may be required. In thesesituations, an additional 100 hour break-in period isrecommended using a new change of John DeereEngine Break-In Oil and new John Deere oil filter.

IMPORTANT: Do not add makeup oil until the oillevel is BELOW the add mark ondipstick. If make-up oil is requiredduring the break-in period, an

additional 100 hour break-in periodis required. John Deere EngineBreak-In Oil (TY22041) should beused to make up any oil consumedduring the break-in period.

DO NOT use PLUS-50 Engine Oil orengine oils meeting API CG4, APICF4, ACEA E3, ACEA E2 or CCMCD5 performance levels during thefirst 100 hours of operation of a newor rebuilt engine. These oils will notallow a new or rebuilt engine tobreak-in properly.

3. Check oil more frequently during engine break-inperiod. If oil must be added during this period, JohnDeere Engine Break-In Oil is preferred. SeeENGINE BREAK-IN OIL, in Fuels, Lubricants, andCoolant Section.


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RG,RG34710,4048 1901JAN962/4

IMPORTANT: DO NOT fill above the top of thecrosshatch pattern or the FULLmark, whichever is present. Oillevels anywhere within crosshatchare considered in the acceptableoperating range.

SpecificationOil Pressure at Rated FullLoad Speed1 345 103 kPa (3.45 1.03

bar) (50 15 psi)............................................

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

4. During the first 20 hours, avoid prolonged periodsof engine idling or sustained maximum loadoperation.

5. If engine will idle longer than 5 minutes, stopengine.

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

RG,RG34710,4048 1901JAN963/4

RG

7379

UN

20J

UN

00

Replacing Engine Oil Filter

6. After the first 100 hours maximum, change engineoil and replace engine oil filter as shown. (SeeCHANGING ENGINE OIL AND REPLACING FILTERin Lubrication and Maintenance/250 Hour Section.) Fillcrankcase with seasonal viscosity grade oil. (SeeDIESEL ENGINE OIL, in Fuels, Lubricants, andCoolant Section.)

NOTE: Some increase in oil consumption may beexpected when low viscosity oils are used. Checkoil levels more frequently.

If air temperature is below -10 C (14 F), use anengine block heater.


15-20 122000PN=57


RG,RG34710,4048 1901JAN964/4

RG

1129

9DU

N2

1AU

G00

Engine Coolant Temperature Gauge

ACoolant Temperature Gauge

7. Watch coolant temperature gauge (A) closely. If coolanttemperature rises above 104 C (220 F), reduce load onengine. Unless temperature drops quickly, stop the engineand determine the cause before resuming operation.

NOTE: When the coolant temperature gauge readsapproximately 104 C (220 F), the engine willreduce power automatically if equipped withrecommended safety controls.

8. Check belt for proper alignment and seating in pulleygrooves.

RG,RG34710,4051 1901JAN961/1

AUXILIARY GEAR DRIVE LIMITATIONS

RG

7367

UN

21M

AR

00

Auxiliary Drives

ASAE Drive, FrontBSAE Drive, Rear

IMPORTANT: When attaching an air compressor,hydraulic pump, or other accessory tobe driven by the auxiliary gear drive(engine timing gear train at front ofengine), power requirements of theaccessory must be limited to valueslisted below:

SAE Drive Continuous Power Intermittent PowerA ............................... 19 kW (25 hp) ......... 22.5 kW (30 hp)B or (A + B) ............. 37 kW (50 hp) ......... 45 kW (60 hp)

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RG,RG34710,4052 1901JAN961/1

GENERATOR SET (STANDBY) POWERUNITS

To assure that your engine will deliver efficient standbygenerator operation when needed, start engine and run atrated speed (with 50%70% load) for 30 minutes every 2weeks. DO NOT allow engine to run for an extendedperiod of time with no load.

RG,RG34710,4053 1901JAN961/4

STARTING THE ENGINE

TS

220

UN

23A

UG

88

Use Proper Ventilation

The following instructions apply to the optional controlsand instruments available through the John Deere PartsDistribution Network. The controls and instruments foryour engine may be different from those shown here;always follow manufacturers instructions.

CAUTION: Before starting engine in a confinedbuilding, install proper outlet exhaustventilation equipment. Always use safetyapproved fuel storage and piping.

NOTE: If temperature is below 0C (32F), it may benecessary to use cold weather starting aids (SeeCOLD WEATHER OPERATION, later in thissection).

IMPORTANT: If engine has run out of fuel, it may benecessary to prime the fuel system,engines (200,000 ). See following inthis section.

1. Perform all prestarting checks outlined in DAILYPRESTARTING CHECKS in Lubrication &Maintenance/Daily Section.

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


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RG,RG34710,4053 1901JAN962/4

RG

5602

UN

16J

UN

00

PTO Clutch Control Lever

3. If equipped with PTO clutch, pull lever (arrow) rearward(away from engine) to disengage PTO clutch.


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RG,RG34710,4053 1901JAN963/4

RG

4695

UN

15D

EC

88

Instrument PanelEngines with Standard Panel

RG

1106

3U

N2

6JU

N00

Instrument PanelEngines With Electronic Panel

AHand ThrottleBReset ButtonCKey SwitchDOil Pressure Gauge

NOTE: Some electronically controlled governorapplications may be equipped with a rotary speedpotentiometer on instrument panel. (See (A) inlower drawing.)

4. On standard, mechanical governor (7-10% regulation)engines, pull hand throttle (A) 1/3 of the way out. Turnthe handle in either direction to lock it in place.

On later engines, turn throttle (A) clockwise 1/3 of theway (see lower illustration). (If not equipped withanalog throttle, move throttle control 1/3 of the distanceaway from slow idle stop.)

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

IMPORTANT: Do not operate the starter for more than30 seconds at a time. To do so mayoverheat the starter. If the engine doesnot start the first time, wait at least 2minutes before trying again. If enginedoes not start after four attempts, seeTroubleshooting Section.

6. Turn the key switch (C) clockwise to crank the engine.When the engine starts, release the key so that itreturns to the ON position.

IMPORTANT: If the key switch is released before theengine starts, wait until the starter andthe engine stop turning before tryingagain. This will prevent possibledamage to the starter and/or flywheel.

7. After the engine starts, continue to hold the resetbutton in until the oil pressure gauge (D) reads at least140 kPa (1.4 bar) (20 psi). The safety controls will notallow the engine to run at a lower oil pressure unlessthe reset button is held in.

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RG,RG34710,4053 1901JAN964/4

IMPORTANT: Should the engine die when operatingunder load, immediately disengage PTOclutch and restart the engine.Overheating of turbocharger parts mayoccur when oil flow is stopped

Use and maintenance manual John – Deere POWERTECH...

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