Attachment_D_John_Deer_PowerTech_E_4.5_L_and_L_OEM_Diesel_Engines_MANUAL.pdf

PowerTech™ E 4.5 L and 6.8 L OEM Diesel Engines

(Tier 3 / Stage III A Platform) O M R G

* OPERATOR'S MANUAL

PowerTech™ E 4.5 L and 6.8 L OEM Diesel Engines

OMRG37407 ISSUE 09JUL18 (ENGLISH)

CALIFORNIA

Proposition 65 Warning

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

If this product contains a gasoline engine:

WARNING

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

The State of California requires the above two warnings.

Additional Proposition 65 Warnings can be found in this manual.

John Deere Power Systems Worldwide Edition

PRINTED IN U.S.A.

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TP-6453 7/18

ko87353 Pen

Introduction

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OEM Engine and Drivetrain Warranty Registration

RG24614 —UN—21OCT13

Scan this code to register your OEM engine online. You can also visit us directly at JohnDeere.com/warranty.

Why registering your OEM engine or drivetrain product is a really smart idea:

• Get faster service. Registering your engine or drivetrain product gives us the information we need to meet your service needs promptly and completely.

• Protect your investment. You’ll be kept up-to-date on engine or drivetrain product updates.

• Extend your warranty. You’ll be given the option to extend your coverage before your standard warranty term expires.

• Stay informed. Be the first to know about new products and money-saving offers from John Deere.

You’re Covered

When you buy a John Deere engine or drivetrain product you aren’t just buying pistons and crankshafts and gear drives. You’re buying the ability to get work done. Without downtime, without worries, and without hassles. And you’re buying the assurance that if you do need help, a strong support network will be there — ready to step in.

Confidence. That's what John Deere engines, John Deere drivetrains, and John Deere Warranties are all about.

Long durations. Warranties designed to give you confidence in your engine or drivetrain product.

Worldwide support. Get service when and where you need it. John Deere has 4,000+ service locations worldwide.

Genuine John Deere parts and service. Authorized service outlets will use only new or remanufactured parts or components furnished by John Deere.

Warranty Duration

Equipment operators can’t afford downtime or unexpected repairs. That’s why we offer a 2-year/2,000-hour warranty, with unlimited hours in the first year, on our OEM industrial and marine engines. This warranty takes effect the date that the engine is delivered to the first retail purchaser. In addition, extended warranties are available under certain conditions. John Deere offers a variety of purchased warranties to extend the warranty period for your engine.

You'll be given the option to extend your coverage before your standard warranty term expires. Be sure to register your engine or drivetrain product and take full advantage of the John Deere service and support network.

Obtaining Warranty Service

Warranty service must be requested through an authorized John Deere service outlet before the expiration of the warranty. Evidence of the engine’s or drivetrain product’s delivery date to the first retail purchaser must be presented when requesting warranty service. Authorized service outlets include:

• John Deere distributor

• John Deere OEM service dealer

• John Deere equipment dealer

• John Deere marine dealer

Worldwide Support Network

Visit JohnDeere.com/dealer to find the authorized engine or drivetrain service location nearest you. For complete warranty details visit JohnDeere.com/warrantystatements to view, download, or print the warranty statement for your engine or drivetrain product.

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Foreword

THIS MANUAL CONTAINS INFORMATION to operate and service PowerTech E 4.5 L and 6.8 L Tier 3 / Stage IIIA emission-certified1 OEM engines.

READ THIS MANUAL carefully to learn how to operate and service your engine correctly. Failure to do so could result in personal injury or equipment damage.

THIS MANUAL SHOULD BE CONSIDERED a permanent part of your engine and should remain with the engine when you sell it.

MEASUREMENTS IN THIS MANUAL are given in both metric and customary U.S. unit equivalents. Use only correct replacement parts and fasteners. Metric and inch fasteners may require a specific metric or inch wrench.

WRITE ENGINE SERIAL NUMBERS and option codes in the spaces indicated in the Record Keeping Section.

Accurately record all the numbers. Your dealer also needs these numbers when you order parts. File the identification numbers in a secure place off the engine.

SETTING FUEL DELIVERY beyond published factory specifications or otherwise overpowering will result in loss of warranty protection for this engine.

CERTAIN ENGINE ACCESSORIES such as radiator, air cleaner, and instruments are optional equipment on John Deere OEM Engines. These accessories may be provided by the equipment manufacturer instead of John Deere. This operator's manual applies only to the engine and those options available through the John Deere distribution network.

IMPORTANT: This manual covers only POWERTECH™ E 4.5 L and 6.8 L Tier 3/ Stage IIIA emission certified OEM engines. (This is for both the U.S. EPA and European Union Council (EU) emission standards.)

NOTE: This manual covers engines provided to OEM (Original Equipment Manufacturers).

For engines in Deere machines, refer to the machine operator's manual.

POWERTECH is a trademark of Deere & Company 1Emission certified for United States as EPA Tier 3 and for European Union as Stage IIIA.

Engine Owner

John Deere Engine Owner:

It is important for you to register your new engine for factory warranty. Registering your engine will allow your Service Dealer to verify that your warranty status should a repair be needed. The easiest way to register your engine is via the internet. To register your engine for warranty via the internet, please use the following URL:

http://www.johndeere.com/enginewarranty

Your John Deere Engine Distributor or local John Deere Service Dealer will also be happy to provide this service.

Engine service can be done by all Ag, C&FD, and JDPS branded dealers. To view the John Deere Service Dealer network or locate your nearest Dealer, use the following URL: http://www.johndeere.com/dealer

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PowerTech™ E 4.5 L Engine With Electronic Fuel Systems (HPCR Fuel System) (Two-Valve Cylinder Head)

R G U N A P R

4045HF285 Engine

R G U N A P R

4045HF285 Engine

PowerTech is a trademark of Deere & Company

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PowerTech ™ E 6.8 L Engine With Electronic Fuel Systems (HPCR Fuel System) (Two-Valve Cylinder Head)

R G U N A P R

6068HF285 Engine

PowerTech E is a trademark of Deere & Company

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Trademarks Trademarks

AdBlue® AdBlue is a trademark of VDA, the German Association of the Automotive Industry.

AMP® AMP is a trademark of Tyco Electronics BIO-GREASE-GARD™ BIO-GREASE-GARD is a trademark of Deere & Company Bio Hy-Gard™ Bio Hy-Gard is a trademark of Deere & Company Bluetooth® Bluetooth is a trademark of Bluetooth SIG Break-In™ Plus Break-In is a trademark of Deere & Company CINCH™ CINCH is a trademark of Cinch Inc.

COOL-GARD™ PLUS COOL-GARD is a trademark of Deere & Company CoolScan™ CoolScan is a trademark of Deere & Company COOLSCAN™ PLUS COOLSCAN is a trademark of Deere & Company Custom Performance™ Custom Performance is a trademark of Deere & Company Deere™ Deere is a trademark of Deere & Company DENSO® DENSO is a trademark of DENSO Corporation DEUTSCH® DEUTSCH is a trademark of Deutsch Co.

DieselScan™ DieselScan is a trademark of Deere & Company DuPont® DuPont is a trademark of E.I. DuPont de Nemours and Company EXTREME-GARD™ EXTREME-GARD is a trademark of Deere & Company FleetGard™ FleetGard is a trademark of Deere & Company Fuelscan™ Fuelscan is a trademark of Deere & Company Funk™ Funk is a trademark of Deere & Company GREASE-GARD™ GREASE-GARD is a trademark of Deere & Company Hy-Gard™ Hy-Gard is a trademark of Deere & Company JDLink™ JDLink is a trademark of Deere & Company JDParts™ JDParts is a trademark of Deere & Company John Deere™ John Deere is a trademark of Deere & Company Loctite® Loctite is a trademark of Henkel Corporation Metri-Pack® Metri-Pack is a trademark of Delphi Connection Systems OILSCAN PLUS™ OILSCAN PLUS is a trademark of Deere & Company Oilscan™ Oilscan is a trademark of Deere & Company Permatex® Permatex is a trademark of Illinois Tool Works Inc.

Phoenix™ Phoenix is a trademark of Deere & Company Plastigage® Plastigage is a trademark of Perfect Circle Corporation Plus-50™ II Plus-50 is a trademark of Deere & Company PowerSight™ PowerSight is a trademark of Deere & Company PowerTech™ PowerTech is a trademark of Deere & Company PowerTech™ E PowerTech is a trademark of Deere & Company PowerTech™ M PowerTech is a trademark of Deere & Company PowerTech™ Plus PowerTech is a trademark of Deere & Company Restore® Restore is a trademark of "Restore, Inc."

Scotch-Brite® Scotch-Brite is a trademark of 3M Co.

Scotch-Grip® Scotch-Grip is a trademark of 3M Co.

Service ADVISOR™ Service ADVISOR is a trademark of Deere & Company SERVICEGARD™ SERVICEGARD is a trademark of Deere & Company SPEEDI-SLEEVE® SPEEDI-SLEEVE is a registered trademark of the SKF Group.

SWEDA™ SWEDA is a trademark of Deere & Company Swagelok® Swagelok is a registered trademark of Swagelok Company.

TACH-N-TIME™ TACH-N-TIME is a trademark of Bosch Automotive Service Solutions Inc.

TeamMate™ TeamMate is a trademark of Deere & Company TEFLON® TEFLON is a trademark of Du Pont Co.

Torq-Gard™ Torq-Gard is a trademark of Deere & Company

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TORX® TORX is a registered trademark of Acument Intellectual Properties, LLC Vari-Cool™ Vari-Cool is a trademark of Deere & Company WEATHER PACK® WEATHER PACK is a trademark of Packard Electric WINDOWS® WINDOWS is a trademark of Microsoft Corporation

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Contents

Page

Record Keeping Engine Serial Number Plate ...............................01-1 Record Engine Serial Number............................01-1 Engine Option Codes .........................................01-2 Record Engine Control Unit (ECU)

Serial Number ................................................01-3 Record High-Pressure Fuel Pump

Model Number................................................01-4 Emergency Stationary Engine Rule....................01-4

Safety Recognize Safety Information ............................05-1 Understand Signal Words...................................05-1 Follow Safety Instructions...................................05-1 Replace Safety Signs .........................................05-2 California Proposition 65 Warning ......................05-2 Illuminate Work Area Safely ...............................05-2 Work in Clean Area ............................................05-2 Use Proper Tools ................................................05-3 Live With Safety..................................................05-3 Prevent Machine Runaway.................................05-3 Handle Fuel Safely—Avoid Fires........................05-4 Prepare for Emergencies....................................05-4 Handle Starting Fluid Safely ...............................05-4 In Case of Fire ....................................................05-5 Handle Fluids Safely—Avoid Fires .....................05-5 Avoid Static Electricity Risk When Refueling......05-6 Service Machines Safely ....................................05-6 Wear Protective Clothing....................................05-6 Protect Against Noise.........................................05-7 Handling Batteries Safely ...................................05-7 Prevent Acid Burns.............................................05-8 Stay Clear of Rotating Drivelines........................05-8 Install All Guards ................................................05-9 Practice Safe Maintenance.................................05-9 Remove Paint Before Welding or Heating........05-10 Avoid Heating Near Pressurized Fluid Lines ....05-10 Avoid High-Pressure Fluids ..............................05-10 Do Not Open High-Pressure Fuel System........ 05-11 Protect Against High Pressure Spray ............... 05-11 Prevent Battery Explosions .............................. 05-11 Avoid Hot Exhaust ............................................05-12 Work In Ventilated Area....................................05-12 Service Cooling System Safely ........................05-12 Decommissioning — Proper Recycling and Disposal of Fluids and Components .....05-13

Page

Fuels, Lubricants, and Coolant Diesel Fuel..........................................................10-1 Supplemental Diesel Fuel Additives ...................10-1 Lubricity of Diesel Fuel .......................................10-2 Handling and Storing Diesel Fuel .......................10-2 Biodiesel Fuel .....................................................10-3 Testing Diesel Fuel .............................................10-4 Fuel Filters..........................................................10-4 Minimizing the Effect of Cold Weather on Diesel Engines ..........................................10-5 Diesel Engine Break-In Oil —

Non-Emissions Certified and Certified Tier 1, Tier 2, Tier 3, Stage I, Stage II, and Stage III .................................10-6

Diesel Engine Oil — Tier 3 and Stage III ............10-7 Engine Oil and Filter Service Intervals

— Tier 3 and Stage IIIA — OEM Applications....................................................10-8

Diesel Engine Oil and Filter Service Intervals ....10-9 Diesel Engine Oil Service Interval for

Operation at High Altitude ............................10-10 Mixing of Lubricants..........................................10-10 Alternative and Synthetic Lubricants ................ 10-11 Lubricant Storage ............................................. 10-11 Oil Filters .......................................................... 10-11 Diesel Engine Coolant (engine with wet sleeve cylinder liners) ............................10-12 Water Quality for Mixing with Coolant

Concentrate..................................................10-13 Operating in Warm Temperature Climates .......10-13 Testing Coolant Freeze Point ...........................10-14 Disposing of Coolant ........................................10-14

Instrument Panels PV101 Instrument Panels...................................15-1 PV101 Diagnostic Gauge — Using ....................15-3 PV101 Diagnostic Gauge — Main Menu............15-4 PV101 Diagnostic Gauge — Essential Menus ...15-5 DG14 Diagnostic Gauge — Using......................15-5 DG14 Diagnostic Gauge — Main Menu .............15-6 DG14 Diagnostic Gauge — Essential Menus.....15-7 PV480 Instrument Panel.....................................15-8 PV480 Diagnostic Gauge — Using ....................15-9 PV480 Diagnostic Gauge — Main Menu..........15-10 PV480 Diagnostic Gauge— Essential Menus .. 15-11

Continued on next page

Original Instructions. All information, illustrations and specifications in this manual are based on the latest information available at the time of publication.

The right is reserved to make changes at any time without notice.

COPYRIGHT © 2018

DEERE & COMPANY

Moline, Illinois All rights reserved.

A John Deere ILLUSTRUCTION ™ Manual Previous Editions

Copyright © 2006, 2008, 2012, 2013, 2014, 2015, 2016, 2017 i 071118

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Main Menu Navigation......................................15-12 Engine Configuration Data ...............................15-13 Accessing Stored Trouble Codes .....................15-15 Accessing Active Trouble Codes......................15-17 Engine Shutdown Codes..................................15-19 Adjusting Backlighting ......................................15-20 Adjusting Contrast ............................................15-22 Selecting Units Of Measurement......................15-24 Setup 1-Up Display...........................................15-26 Setup 4-Up Display...........................................15-31 John Deere PowerSight....................................15-35

Engine Operation Engine Break-In Service.....................................20-1 Starting the Engine.............................................20-3 Normal Engine Operation ...................................20-4 Warming Engine .................................................20-5 Cold Weather Operation.....................................20-6 Using a Booster Battery or Charger ...................20-7 Avoid Excessive Engine Idling............................20-8 Changing Engine Speed.....................................20-9 Stopping The Engine........................................20-10 Auxiliary Gear Drive Limitations ....................... 20-11 Generator Set (Standby) And All Other

OEM Engine Applications ............................ 20-11

Lubrication and Maintenance Required Emission-Related Information.............25-1 Observe Service Intervals ..................................25-1 Use Correct Fuels, Lubricants, and Coolant.......25-1 Lubrication and Maintenance Service

Interval Chart..................................................25-2

Lubrication & Maintenance/Daily Daily Prestarting Checks ....................................30-1

Lubrication & Maintenance/500 Hour/12 Month Servicing Fire Extinguisher.................................35-1 Checking Engine Mounts....................................35-1 Servicing Battery ................................................35-2 Changing Engine Oil and Replacing Filter..........35-4 Checking Crankcase Vent System .....................35-6 Checking Air Intake System ...............................35-7 Replacing Fuel Filter Elements...........................35-8 Checking Belt Tensioner Spring

Tension and Belt Wear (Automatic Tensioner) ......................................................35-9

Checking Engine Electrical Ground Connections .................................................35-10

Checking Cooling System ................................ 35-11 Replenishing Supplemental Coolant

Additives (SCAs) Between Coolant Changes.......................................................35-12

Testing Diesel Engine Coolant..........................35-13 Testing Diesel Engine Coolant..........................35-13 Checking and Adjusting Engine Speeds ..........35-14

Page

Lubrication & Maintenance/1500 Hours Checking Open Crankcase Vent (OCV) .............32-1

Lubrication & Maint./2000 Hour/24 Month Checking Crankshaft Vibration Damper

(6-Cylinder Engine Only)................................40-1 Flushing and Refilling Cooling System...............40-2 Testing Thermostats Opening Temperature .......40-4 Check and Adjust Valve Clearance ....................40-7

Service As Required Additional Service Information............................45-1 Do Not Modify Fuel System................................45-1 Adding Coolant ...................................................45-2 Pre-Start Cleaning Guide ...................................45-3 Replacing Single Stage Air Cleaner ...................45-4 Replacing Axial Seal Air Cleaner Filter

Element ..........................................................45-5 Replacing Radial Seal Air Cleaner

Filter Element .................................................45-7 Replacing Fan and Alternator Belts....................45-8 Checking Fuses..................................................45-8 Checking Air Compressors.................................45-9 Bleed the Fuel System .....................................45-10

Troubleshooting General Troubleshooting Information .................50-1 Precautions For Welding ....................................50-1 Precautions for Electrical System

When Steam Cleaning Engine .......................50-1 Engine Wiring Layout .........................................50-2 Engine Wiring Diagram (With

Full-Featured Electronic Instrument Panel)....50-3 Engine Wiring Diagram (With

Full-Featured Electronic Instrument Panel)—Continued.........................................50-4

Instrument Panel Method for Retrieving Diagnostic Trouble Codes..............................50-5

Displaying Of Diagnostic Trouble Codes (DTCs) ................................................50-5

Listing of Diagnostic Trouble Codes (DTCs) ......50-6 Intermittent Fault Diagnostics (With

Electronic Controls)........................................50-8 Displaying Diagnostic Gauge Software ..............50-8 Engine Troubleshooting....................................50-10

Storage Engine Storage Guidelines.................................55-1 Preparing Engine for Long-Term Storage...........55-1 Removing Engine from Long Term Storage .......55-2

Specifications General OEM Engine Specifications ..................60-1 Engine Power Ratings And Fuel System Specifications .....................................................60-2

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Engine Crankcase Oil Fill Quantities ..................60-4 Unified Inch Bolt and Screw Torque Values........60-5 Metric Bolt and Screw Torque Values.................60-6

Lubrication and Maintenance Records Using Lubrication and Maintenance Records.....65-1 Daily (Prestarting) Service..................................65-1 500 Hour/12 Month Service................................65-1 2000 Hour/24 Month Service..............................65-2 Service as Required ...........................................65-2

Warranty John Deere Warranty in OEM Applications ........70-1 Emissions Control System Certification Label....70-4 EPA Non-road Emissions Control

Warranty Statement—Compression Ignition ..70-5 CARB Non-road Emissions Control

Warranty Statement—Compression Ignition ..70-7

John Deere Service Literature Available Technical Information..........................................75-1 iii 071118

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Record Keeping

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Engine Serial Number Plate Each engine has a John Deere engine serial number. The first two digits identify the factory that produced the engine:

• “CD” = Saran, France

• “PE” = Torreon, Mexico

The engine's serial number plate (A) is located on the right-hand side of cylinder block behind the fuel filter.

A—Serial Number Plate

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Engine Serial Number Plate

Record Engine Serial Number Record all of the numbers and letters found on your engine serial number plate in the spaces provided below.

This information is very important for repair parts or warranty information.

Engine Serial Number (B)

Engine Model Number (C)

NOTE: Engine serial numbers on the 7th digit indicates the Emission Level as follows:

• “B” for non-certified engines

• “C” for Tier 1 / Stage I engines

• “G” for Tier 2 / Stage II engines

• “L” for Tier 3 / Stage IIIA engines

R G U N M

AY

Saran Factory Engine Serial Number Plate

R G U N A U G

Torreon Factory Engine Serial Number Plate

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Engine Option Codes

72F3

6068HFC09 2732F6.8 L

JOHN DEERE

Customer No. OPTION CODES

Number PE6068U000094

A

R G U N A U G

Option Code Label Example

A—Engine Base Code (example)

OEM engines have an engine option code label affixed to the rocker arm cover. These codes indicate which of the engine options were installed on your engine at the factory.

When in need of parts or service, furnish your authorized servicing dealer or engine distributor with these numbers.

The engine option code label includes an engine base code (A). This base code must also be recorded along with the option codes. At times it will be necessary to furnish this base code to differentiate two identical option codes for the same engine model.

The first two digits of each code identify a specific group, such as alternators. The last two digits of each code identify one specific option provided on your engine, such as a 24 volt, 120 amp alternator.

If an engine is ordered without a particular component, the last two digits of that functional group option code will be 99, 00, or XX. The following list shows only the first two digits of the code numbers. For future reference such as ordering repair parts, it is important to have these code numbers available. To ensure this availability, enter the third and fourth digits shown on your engine option code label in the spaces provided on the following page.

An additional option code label may also be delivered (in a plastic bag attached to the engine or inserted in the machine documentation). It is recommended to place this label either on this page of the operators manual or in the Engine Owner's Warranty booklet under Option Codes.

The machine manufacturer may have placed the label in a specific accessible area (inside the enclosure or close to a maintenance area).

Your engine option code label may not contain all option codes if an option has been added after the engine left the producing factory.

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

Record your engine Base Code (A) in the spaces provided below for easy reference.

Engine Base Code (A):

Option Codes Description Option Codes Description

10 Paint Protection 56 Paint 11 Rocker Arm Cover 57 Water Pump Inlet 12 Oil Filler 58 Power Take Off 13 Crankshaft Pulley 59 Oil Cooler/Oil Filter 14 Flywheel Housing 60 Add-On Fan Drive Pulley 15 Flywheel 61 After Treatment Device/Muffler 16 Fuel Injection System 62 Alternator Mounting 17 Air Inlet 63 Low-Pressure Fuel Lines 18 Air Cleaner 64 Exhaust Elbow 19 Oil Pan 65 Turbocharger 20 Water Pump 66 Temperature Switch 21 Thermostat Cover 67 Engine Sensors 22 Thermostat 68 Damper 23 Fan Drive 69 Engine Serial Number Plate 24 Fan Belt 70 Decomposition Tube (OEM)

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Option Codes Description Option Codes Description 25 Fan 71 SCR (OEM) 26 Block Heater 72 Performance Software and Labels 27 Radiator/Heat Exchanger 7A Performance Software and Labels 28 Exhaust Manifold 73 After Treatment Dosing System 29 Ventilator System 74 Air Conditioning 30 Starting Motor 75 Restriction Indicator 31 Alternator 76 Oil Pressure Switch 32 DEF Lines, Pressure (OEM) 77 Timing Gear Cover (S450/S650 33 DEF Lines, Supply/Return to Tank (OEM) 78 Air Compressor 34 DEF Tank and Header (OEM) 79 Certification 35 Final Fuel Filter 80 Sea Water Pump (Marine) 36 Front Plate and Idler Shafts 81 Primary Fuel Filter/Water Separator 37 Fuel Transfer Pump 82 Ignition System (Natural Gas) 38 Operator Manual 83 Vehicle Performance Software 39 Thermostat Housing 84 Wiring Harness 40 Dipstick and Tube 85 Fuel System (Natural Gas) 41 Belt Driven Auxiliary Drive (Add-On Crank Pulley) 86 Fan Pulley 42 DEF Line, Supply Module to Injector (OEM) 87 Belt Tensioner 43 Starting Aid 88 Oil Filter 44 Timing Gear Cover (S350) 89 EGR System 44 Tachometer Drive Sensors (S450/S650) 90 Trim Software (OEM) 45 Secondary Balancers 91 Engine Installation Kit (S350) 46 Cylinder Block with Camshaft 92 Engine Test Certificate/Engine Accessories (S350) 47 Crankshaft/Main Bearings 92 Engine Installation Kit (S450) 48 Connecting Rods/Pistons/Liners 93 Emission Label 49 Valve Actuating Mechanism 94 Custom Software 50 Oil Pump 95 Parts Installed at Factory 51 Cylinder Head with Valves 96 Engine Installation Kit/Ship With (S450/S650) 52 Gear Driven Auxiliary Drive 96 ECU Wiring Harness (6125/6135) 53 Fuel Heater 97 Field Installed Items 54 Turbo Air Intake 98 Engine Lift Strap 55 Shipping Stand 99 Service Only Parts

NOTE: This is a complete option code list based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice. Your engine will not contain all option codes listed.

Record Engine Control Unit (ECU) Serial Number Record the part number and serial number information found on the serial number label (A) on the Engine Control Unit (ECU) mounted on or near the engine.

Part No.

Serial No.

A—Serial Number Label

R G U N A P R

Record Engine Control Unit (ECU) Serial Number

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Record High-Pressure Fuel Pump Model Number Record the high-pressure fuel pump model and serial number information found on the serial number plate (A).

Model No. RPM

Manufacturer's No.

Serial No.

A—Serial Number Plate R G U N N O V

Record High-Pressure Fuel Pump Serial Number

Emergency Stationary Engine Rule

R G U N O C T1

Emissions Label Emissions Label

After Tier 4 standards take effect, engine manufacturers of emergency stationary engines that do not meet the standards for non-emergency engines must add to each such emergency engine a permanent label (such as the emission label as shown) which states that the engine is limited to stationary emergency use. On John Deere engines this is stated in the EPA emission label on each engine.

Fuel Requirements

Beginning 01 Oct 10, owners and operators of stationary engines that use diesel fuel must only use diesel fuel meeting the requirements of 40 CFR 80.510 (b), which requires that diesel fuel have a maximum sulfur content of 15 PPM and either a minimum cetane index of 40 or a maximum aromatic content of 35 volume percent.

Operation, Maintenance and Testing

The operation of emergency engines is limited to emergency operations and required maintenance and testing.

There is no time limit on the use of emergency stationary engines in emergency situations.

Maintenance and testing is limited to 100 hours per year. The EPA has also included a provision that allows anyone to petition the Administrator for additional hours, beyond the allowed 100 hours per year, if such additional hours should prove to be necessary for maintenance and testing reasons. The EPA will not require a petition for additional hours if the hours beyond 100 hours per year for maintenance and testing purposes are mandated by regulation such as State or Local requirements.

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Safety

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Recognize Safety Information This is a safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury.

Follow recommended precautions and safe operating practices.

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Understand Signal Words DANGER; The signal word DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING; The signal word WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION; The signal word CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. CAUTION may also be used to alert against unsafe practices associated with events which could lead to personal injury.

A signal word—DANGER, WARNING, or CAUTION—is used with the safety-alert symbol. DANGER identifies the most serious hazards. DANGER or WARNING safety signs are located near specific hazards. General

TS

S E P precautions are listed on CAUTION safety signs.

CAUTION also calls attention to safety messages in this manual.

Follow Safety Instructions Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in good condition. Replace missing or damaged safety signs. Be sure new equipment components and repair parts include the current safety signs. Replacement safety signs are available from your John Deere dealer.

There can be additional safety information contained on parts and components sourced from suppliers that is not reproduced in this operator's manual.

Learn how to operate the machine and how to use controls properly. Do not let anyone operate without instruction.

Keep your machine in proper working condition.

Unauthorized modifications to the machine may impair the function and/or safety and affect machine life.

TS

U N A P R

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

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Replace Safety Signs Replace missing or damaged safety signs. Use this operator’s manual for correct safety sign placement.

There can be additional safety information contained on parts and components sourced from suppliers that is not reproduced in this operator's manual.

TS

U N A P R

California Proposition 65 Warning Diesel engine exhaust, some of its constituents, along with certain machine components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. In addition, certain fluids contained in the machine and certain products of component wear contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Illuminate Work Area Safely Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage.

The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.

TS

U N A U G

Work in Clean Area Before starting a job:

• Clean work area and machine.

• Make sure you have all necessary tools to do your job.

• Have the right parts on hand.

• Read all instructions thoroughly; do not attempt shortcuts.

T6 2E

J U N O C T8

05-2 071118

PN=18

DX,REPAIR -19-17FEB99-1/1

DX,LIVE -19-25SEP92-1/1

DX,BYPAS1 -19-29SEP98-1/1

Use Proper Tools Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards.

Use power tools only to loosen threaded parts and fasteners.

For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches.

Use only service parts meeting John Deere specifications. TS U N N O V

Live With Safety Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields.

TS

O C T8

Prevent Machine Runaway Avoid possible injury or death from machinery runaway.

Do not start engine by shorting across starter terminals.

Machine will start in gear if normal circuitry is bypassed.

NEVER start engine while standing on ground. Start engine only from operator’s seat, with transmission in neutral or park.

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U N

JA

N

05-3 071118

PN=19

DX,FIRE1 -19-12OCT11-1/1

DX,FIRE2 -19-03MAR93-1/1

DX,FIRE3 -19-14MAR14-1/1

Handle Fuel Safely—Avoid Fires Handle fuel with care: it is highly flammable. Do not refuel the machine while smoking or when near open flame or sparks.

Always stop engine before refueling machine. Fill fuel tank outdoors.

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

Use only an approved fuel container for transporting flammable liquids.

Never fill fuel container in pickup truck with plastic bed liner. Always place fuel container on ground before refueling. Touch fuel container with fuel dispenser nozzle before removing can lid. Keep fuel dispenser nozzle in contact with fuel container inlet when filling.

TS

U N A U G

Do not store fuel container where there is an open flame, spark, or pilot light such as within a water heater or other appliance.

Prepare for Emergencies Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

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

TS

U N A P R

Handle Starting Fluid Safely Starting fluid is highly flammable.

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

To prevent accidental discharge when storing the pressurized can, keep the cap on the container, and store in a cool, protected location.

Do not incinerate or puncture a starting fluid container.

Do not use starting fluid on an engine equipped with glow plugs or an air intake heater. TS

U N M A R

05-4 071118

PN=20

DX,FIRE4 -19-22AUG13-1/1

DX,FLAME -19-29SEP98-1/1

In Case of Fire

CAUTION: Avoid personal injury.

Stop machine immediately at the first sign of fire. Fire may be identified by the smell of smoke or sight of flames.

Because fire grows and spreads rapidly, get off the machine immediately and move safely away from the fire.

Do not return to the machine! The number one priority is safety.

Call the fire department. A portable fire extinguisher can put out a small fire or contain it until the fire department arrives; but portable extinguishers have limitations.

Always put the safety of the operator and bystanders first.

If attempting to extinguish a fire, keep your back to the wind with an unobstructed escape path so you can move away quickly if the fire cannot be extinguished.

Read the fire extinguisher instructions and become familiar with their location, parts, and operation before a fire starts.

Local fire departments or fire equipment distributors may offer fire extinguisher training and recommendations.

If your extinguisher does not have instructions, follow these general guidelines:

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U N A P R

1. Pull the pin. Hold the extinguisher with the nozzle pointing away from you, and release the locking mechanism.

2. Aim low. Point the extinguisher at the base of the fire.

3. Squeeze the lever slowly and evenly.

4. Sweep the nozzle from side-to-side.

Handle Fluids Safely—Avoid Fires When you work around fuel, do not smoke or work near heaters or other fire hazards.

Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers.

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

Do not store oily rags; they can ignite and burn spontaneously.

TS

U N A P R

05-5 071118

PN=21

DX,FUEL,STATIC,ELEC -19-12JUL13-1/1

DX,LOOSE -19-04JUN90-1/1

DX,WEAR2 -19-03MAR93-1/1

Avoid Static Electricity Risk When Refueling The removal of sulfur and other compounds in Ultra-Low Sulfur Diesel (ULSD) fuel decreases its conductivity and increases its ability to store a static charge.

Refineries may have treated the fuel with a static dissipating additive. However, there are many factors that can reduce the effectiveness of the additive over time.

Static charges can build up in ULSD fuel while it is flowing through fuel delivery systems. Static electricity discharge when combustible vapors are present could result in a fire or explosion.

Therefore, it is important to ensure that the entire system used to refuel your machine (fuel supply tank, transfer pump, transfer hose, nozzle, and others) is properly grounded and bonded. Consult with your fuel or fuel system supplier to ensure that the delivery system is in compliance with fueling standards for proper grounding and bonding practices.

R G U N M A R

R G U N A U G

Service Machines Safely Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result.

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

TS

U N A U G

Wear Protective Clothing Wear close fitting clothing and safety equipment appropriate to the job.

Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine.

TS

U N A P R

05-6 071118

PN=22

DX,NOISE -19-03OCT17-1/1

DX,WW,BATTERIES -19-02DEC10-1/1

Protect Against Noise There are many variables that affect the sound level range, including machine configuration, condition and maintenance level of the machine, ground surface, operating environmental, duty cycles, ambient noise, and attachments.

Exposure to loud noise can cause impairment or loss of hearing.

Always wear hearing protection. Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.

TS

U N A U G

Handling Batteries Safely Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check battery electrolyte level.

Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.

Always remove grounded (-) battery clamp first and replace grounded clamp last.

Sulfuric acid in battery electrolyte is poisonous and strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.

Avoid hazards by:

• Filling batteries in a well-ventilated area

• Wearing eye protection and rubber gloves

• Avoiding use of air pressure to clean batteries

• Avoiding breathing fumes when electrolyte is added

• Avoiding spilling or dripping electrolyte

• Using correct battery booster or charger procedure.

If acid is spilled on skin or in eyes:

1. Flush skin with water.

2. Apply baking soda or lime to help neutralize the acid.

3. Flush eyes with water for 15—30 minutes. Get medical attention immediately.

If acid is swallowed:

1. Do not induce vomiting.

2. Drink large amounts of water or milk, but do not exceed 2 L (2 qt.).

3. Get medical attention immediately.

WARNING: Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.

TS

U N A P R

TS

U N A U G

05-7 071118

PN=23

DX,POISON -19-21APR93-1/1

DX,ROTATING -19-18AUG09-1/1

Prevent Acid Burns Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.

Avoid the hazard by:

1. Filling batteries in a well-ventilated area.

2. Wearing eye protection and rubber gloves.

3. Avoiding breathing fumes when electrolyte is added.

4. Avoiding spilling or dripping electrolyte.

5. Use proper jump start procedure.

If you spill acid on yourself:

1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize the acid.

3. Flush your eyes with water for 15—30 minutes. Get medical attention immediately.

If acid is swallowed:

1. Do not induce vomiting.

2. Drink large amounts of water or milk, but do not exceed 2 L (2 quarts).

3. Get medical attention immediately.

TS

U N A U G

Stay Clear of Rotating Drivelines Entanglement in rotating driveline can cause serious injury or death.

Keep all shields in place at all times. Make sure rotating shields turn freely.

Wear close-fitting clothing. Stop the engine and be sure that all rotating parts and drivelines are stopped before making adjustments, connections, or performing any type of service on engine or machine driven equipment.

TS

U N A U G

05-8 071118

PN=24

DX,GUARDS -19-18AUG09-1/1

DX,SERV -19-28FEB17-1/1

Install All Guards Rotating cooling system fans, belts, pulleys, and drives can cause serious injury.

Keep all guards in place at all times during engine operation.

Wear close-fitting clothes. Stop the engine and be sure fans, belts, pulleys, and drives are stopped before making adjustments, connections, or cleaning near fans and their drive components.

TS

U N S E P

Practice Safe Maintenance Understand service procedure before doing work. Keep area clean and dry.

Never lubricate, service, or adjust machine while it is moving. Keep hands, feet, and clothing away from power-driven parts. Disengage all power and operate controls to relieve pressure. Lower equipment to the ground. Stop the engine. Remove the key. Allow machine to cool.

Securely support any machine elements that must be raised for service work.

Keep all parts in good condition and properly installed.

Fix damage immediately. Replace worn or broken parts.

Remove any buildup of grease, oil, or debris.

On self-propelled equipment, disconnect battery ground cable (-) before making adjustments on electrical systems or welding on machine.

On towed implements, disconnect wiring harnesses from tractor before servicing electrical system components or welding on machine.

Falling while cleaning or working at height can cause serious injury. Use a ladder or platform to easily reach each location. Use sturdy and secure footholds and handholds. TS

U N A U G

05-9 071118

PN=25

DX,PAINT -19-24JUL02-1/1

DX,TORCH -19-10DEC04-1/1

DX,FLUID -19-12OCT11-1/1

Remove Paint Before Welding or Heating Avoid potentially toxic fumes and dust.

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

Remove paint before heating:

• Remove paint a minimum of 100 mm (4 in.) from area to be affected by heating. If paint cannot be removed, wear an approved respirator before heating or welding.

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

Wear an approved respirator.

• If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

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

TS

U N A P R

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

Dispose of paint and solvent properly.

Avoid Heating Near Pressurized Fluid Lines Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can accidentally burst when heat goes beyond the immediate flame area.

TS

U N M

AY

Avoid High-Pressure Fluids Inspect hydraulic hoses periodically – at least once per year – for leakage, kinking, cuts, cracks, abrasion, blisters, corrosion, exposed wire braid or any other signs of wear or damage.

Replace worn or damaged hose assemblies immediately with John Deere approved replacement parts.

Escaping fluid under pressure can penetrate the skin causing serious injury.

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids.

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within

X

U N A U G a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available in English from Deere & Company Medical Department in Moline, Illinois, U.S.A., by calling 1-800-822-8262 or +1 309-748-5636.

05-10 071118

PN=26

DX,WW,HPCR1 -19-07JAN03-1/1

DX,SPRAY -19-16APR92-1/1

DX,SPARKS -19-03MAR93-1/1

Do Not Open High-Pressure Fuel System High-pressure fluid remaining in fuel lines can cause serious injury. Do not disconnect or attempt repair of fuel lines, sensors, or any other components between the high-pressure fuel pump and nozzles on engines with High Pressure Common Rail (HPCR) fuel system.

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

TS

U N M A R

Protect Against High Pressure Spray Spray from high pressure nozzles can penetrate the skin and cause serious injury. Keep spray from contacting hands or body.

If an accident occurs, see a doctor immediately. Any high pressure spray injected into the skin must be surgically removed within a few hours or gangrene may result.

Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A.

TS

U N M A R

Prevent Battery Explosions Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode.

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

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

TS

U N A P R

05-11 071118

PN=27

DX,EXHAUST -19-20AUG09-1/1

DX,AIR -19-17FEB99-1/1

DX,WW,COOLING -19-19AUG09-1/1

Avoid Hot Exhaust Servicing machine or attachments with engine running can result in serious personal injury. Avoid exposure and skin contact with hot exhaust gases and components.

Exhaust parts and streams become very hot during operation. Exhaust gases and components reach temperatures hot enough to burn people, ignite, or melt common materials.

R G U N A U G

Work In Ventilated Area Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension.

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

TS

U N A P R

Service Cooling System Safely Explosive release of fluids from pressurized cooling system can cause serious burns.

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

TS

U N A P R

05-12 071118

PN=28

DX,DRAIN -19-01JUN15-1/1

Decommissioning — Proper Recycling and Disposal of Fluids and Components Safety and environmental stewardship measures must be taken into account when decommissioning a machine and/or component. These measures include the following:

• Use appropriate tools and personal protective equipment such as clothing, gloves, face shields or glasses, during the removal or handling of objects and materials.

• Follow instructions for specialized components.

• Release stored energy by lowering suspended machine elements, relaxing springs, disconnecting the battery or other electrical power, and releasing pressure in hydraulic components, accumulators, and other similar systems.

• Minimize exposure to components which may have residue from agricultural chemicals, such as fertilizers and pesticides. Handle and dispose of these components appropriately.

• Carefully drain engines, fuel tanks, radiators, hydraulic cylinders, reservoirs, and lines before recycling components. Use leak-proof containers when draining fluids. Do not use food or beverage containers.

• Do not pour waste fluids onto the ground, down a drain, or into any water source.

• Observe all national, state, and local laws, regulations, or ordinances…