John Deere 4045 - Manuals

Contents Page Page Record Keeping Using Touch Switches to Display Information . . . . . . . . . . . . . . . . . . . . . . . . . . 16-10 PowerTech Medallion . . . . . . . . . . . . . . . . . . . . . 01-1 Changing Units of Measure (English or Engine Serial Number Plate . . . . . . . . . . . . . . . . ...

Contents Page Page Auxiliary Gear Drive Limitations . . . . . . . . . . . . 19-17 Checking Crankshaft Vibration Damper Generator Set (Standby) Applications . . . . . . . . 19-17 (6-Cylinder Engine Only) . . . . . . . . . . . . . . . . . 35-2 Flushing and Refilling Cooling System . . . . . . . . 35-3...

Contents Page Page Engine Wiring Layout (Electronic Fuel Lubrication and Maintenance RecordsUsing Lubrication and Maintenance Records . . . 60-1 System With Denso High Pressure Common Daily (Prestarting) Service . . . . . . . . . . . . . . . . . 60-1 Rail)(4045HF475,6068HF475). . . . . . . . . . . ....

Record Keeping OURGP11,0000274 –19–04AUG06–1/1 P OWER T ECH  Medallion RG11608 –UN–17OCT01 RG11609 –UN–17OCT01 A medallion is located on the rocker arm cover whichidentifies each engine as a John Deere P OWER T ECH  engine. NOTE: Four-valve head engines also have “16V” or “24V” printed on their me...

Record Keeping OURGP11,0000070 –19–27JUL06–1/1 Record Engine Serial Number RG11949 –UN–07NOV01 Saran Engine Serial Number Plate RG11948 –UN–06NOV01 Torreon Engine Serial Number Plate Record all of the numbers and letters found on yourengine serial number plate in the spaces provided below. This info...

Record Keeping RG,RG34710,5508 –19–27JUL06–1/2 Engine Option Codes RG11946 – UN–06NOV01 A—Engine Base Code In addition to the serial number plate, OEM engineshave an engine option code label affixed to the rockerarm cover. These codes indicate which of the engineoptions were installed on your engine...

Record Keeping OURGP12,00000AD –19–27JUL06–1/1 Record Engine Control Unit (ECU) SerialNumber RG13799 –UN–18NOV04 Record Engine Control Unit (ECU) Serial Number A—Serial Number Label Record the part number and serial number informationfound on the serial number label (A) on the EngineControl Unit (EC...

Safety DX,ALERT –19–29SEP98–1/1 Recognize Safety Information T81389 –UN–07DEC88 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 –19–03MAR93–1/...

Safety DX,SIGNS1 –19–04JUN90–1/1 Replace Safety Signs TS201 –UN–23AUG88 Replace missing or damaged safety signs. See themachine operator’s manual for correct safety signplacement. RG,RG34710,7508 –19–27JUL06–1/1 Prevent Bypass Starting RG5419 –UN–28FEB89 Prevent Bypass Starting Avoid possible injury...

Safety DX,FIRE2 –19–03MAR93–1/1 Prepare for Emergencies TS291 –UN–23AUG88 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 –19–16APR92–1/1 Handle Starting ...

Safety OURGP12,00001DA –19–27JUL06–1/1 Service Engines Safely TS228 –UN–23AUG88 Moving Parts 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 ...

Safety DX,MSDS,NA –19–03MAR93–1/1 Handle Chemical Products Safely TS1132 –UN–26NOV90 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 ...

Safety DX,SERV –19–17FEB99–1/1 Practice Safe Maintenance TS218 –UN–23AUG88 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 operatecon...

Safety DX,FLUID –19–03MAR93–1/1 Avoid High-Pressure Fluids X9811 –UN–23AUG88 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 le...

Safety DX,PAINT –19–24JUL02–1/1 Remove Paint Before Welding or Heating TS220 –UN–23AUG88 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 100 mm (4 in.) from ...

Safety OUOD006,000009D –19–27JUL06–1/1 Install Fan Guards TS677 –UN–21SEP89 Rotating Fan Rotating cooling system fans can cause serious injury. Keep fan guards in place at all times during engineoperation. Wear close fitting clothes. Stop the engine andbe sure fan is stopped before making adjustment...

Safety DX,DUST –19–15MAR91–1/1 Avoid Harmful Asbestos Dust TS220 –UN–23AUG88 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 ...

Safety DX,REPAIR –19–17FEB99–1/1 Use Proper Tools TS779 –UN–08NOV89 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...

Safety DPSG,OUO1004,2758 –19–27JUL06–1/1 Handling Batteries Safely TS204 –UN–23AUG88 Explosion TS203 –UN–23AUG88 Acid CAUTION: Battery gas can explode. Keepsparks and flames away from batteries. Use aflashlight to check battery electrolyte level. Never check battery charge by placing a metalobject a...

Safety DX,SPRAY –19–16APR92–1/1 Protect Against High Pressure Spray TS1343 –UN–18MAR92 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 s...

Fuels, Lubricants, and Coolant DX,FUEL1 –19–17NOV05–1/1 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, Lubricants, and Coolant DX,FUEL4 –19–19DEC03–1/1 Handling and Storing Diesel Fuel CAUTION: Handle fuel carefully. Do not fillthe fuel tank when engine is running. DO NOT smoke while you fill the fuel tank orservice the fuel system. Fill the fuel tank at the end of each day’s operation topreve...

Fuels, Lubricants, and Coolant DX,FUEL7 –19–14NOV05–1/1 Bio-Diesel Fuel Consult your local fuel distributor for properties of thebio-diesel fuel available in your area. Bio-diesel fuels may be used ONLY if the bio-dieselfuel properties meet the latest edition of ASTM D6751,EN 14214, or equivalent sp...

Fuels, Lubricants, and Coolant DX,FUEL10 –19–16DEC05–1/2 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 b...

Fuels, Lubricants, and Coolant DX,FUEL10 –19–16DEC05–2/2 If winterfronts are used, they should never totally closeoff the grill frontal area. Approximately 25% area in thecenter of the grill should remain open at all times. Atno time should the air blockage device be applieddirectly to the radiator ...

Fuels, Lubricants, and Coolant DX,ENOIL7 –19–23NOV05–1/1 Diesel Engine Oil TS1675 –UN–31OCT03 Use oil viscosity base on the expected air temperaturerange during the period between oil changes. John Deere PLUS-50  oil is preferred. Oil meeting one of the following specifications are alsorecommended:...

Fuels, Lubricants, and Coolant OURGP11,0000012 –19–27JUL06–1/3 Diesel Engine Oil and Filter Service Intervals The oil and filter service intervals in the followingcharts should be used as guidelines. Actual serviceintervals depend on operation and maintenancepractices. Use oil analysis to determine ...

Fuels, Lubricants, and Coolant OURGP11,0000012 –19–27JUL06–3/3 6.8 L Engine Oil and Filter Service Intervals in Hours of Operation Oil Pan Option Codes Power Fuel Sulfur Content a 1956 1907, 1908, 1924 19AC 1961 Rating 1909, 1944 Interval Interval Interval Interval Interval kW (hp) Std Prem Std Prem...

Fuels, Lubricants, and Coolant DX,FILT –19–18MAR96–1/1 Oil Filters Filtration of oils is critical to proper operation andlubrication. Always change filters regularly as specified in this manual. Use filters meeting John Deere performancespecifications. DX,OILSCAN –19–02DEC02–1/1 OILSCAN  and COOLSC...

Fuels, Lubricants, and Coolant DX,ALTER –19–15JUN00–1/1 Alternative and Synthetic Lubricants 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. C...

Fuels, Lubricants, and Coolant DX,GREA1 –19–07NOV03–1/1 Grease TS1673 –UN–31OCT03 Use grease based on NLGI consistency numbers and theexpected air temperature range during the service interval. John Deere SD POLYUREA GREASE is preferred. The following greases are also recommended • John Deere HD LIT...

Fuels, Lubricants, and Coolant DX,COOL3 –19–27OCT05–1/2 Diesel Engine Coolant The engine cooling system is filled to provideyear-round protection against corrosion and cylinderliner pitting, and winter freeze protection to -37 ° C (-34 ° F). If protection at lower temperatures is required, consult y...

Fuels, Lubricants, and Coolant DX,COOL3 –19–27OCT05–2/2 Water quality is important to the performance of thecooling system. Distilled, deionized, or demineralizedwater is recommended for mixing with ethylene glycoland propylene glycol base engine coolant concentrate. IMPORTANT: Do not use cooling sy...

Fuels, Lubricants, and Coolant DX,COOL4 –19–07NOV03–1/1 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...

Fuels, Lubricants, and Coolant DX,COOL6 –19–18MAR96–1/1 Operating in Warm Temperature Climates 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 requ...

Instrument Panel Identification OURGP11,0000071 –19–27JUL06–1/2 Instrument Panels - Identification RG13343 –UN–24NOV03 Instrument Panel For Earlier Mechanically Controlled “270” Engines (See Section 18) RG13359 –UN–06FEB04 Deluxe Instrument Panel For Later Mechanically Controlled “270” Engines (See ...

Instrument Panel - Elect. Cont. Earlier Engines OURGP11,000027A –19–07AUG06–1/7 Instrument Panel RG11169 –UN–01NOV00 Instrument Panel (Earlier Electronically Controlled Engines) A—Engine Oil Pressure GaugeB—Amber “WARNING” IndicatorC—Red “STOP ENGINE” IndicatorD—Diagnostic Gauge/Hour MeterE—Touch Sw...

Instrument Panel - Elect. Cont. Earlier Engines OURGP11,000027A –19–07AUG06–2/7 RG11169 –UN–01NOV00 Instrument Panel IMPORTANT: Any time an electric gauge or meter does not register correctly, replace witha new one. Do not attempt to repair it.All gauges are plug-in type. Following is a brief descri...

Instrument Panel - Elect. Cont. Earlier Engines OURGP11,000027A –19–07AUG06–3/7 RG11169 –UN–01NOV00 Instrument Panel For Earlier Engines Touch Switches The touch switches are used to change the display on thewindow of the diagnostic gauge to access engineperformance data. Pressing the DOWN switch (E...

Instrument Panel - Elect. Cont. Earlier Engines OURGP11,000027A –19–07AUG06–4/7 RG11169 –UN–01NOV00 Instrument Panel For Earlier Engines Engine Preheater Indicator (Optional) The engine preheater indicator (K) lights up while theengine is being preheated for cold weather starting. Whenthe engine is ...

Instrument Panel - Elect. Cont. Earlier Engines OURGP11,000027A –19–07AUG06–5/7 RG11169 –UN–01NOV00 Instrument Panel For Earlier Engines Bump Speed Enable Rocker Switch This is a three-position switch (O) with the center positionas “OFF” (locked). With this switch in the “OFF” position,the speed sel...

Instrument Panel - Elect. Cont. Earlier Engines OURGP11,000027A –19–07AUG06–6/7 RG11169 –UN–01NOV00 Instrument Panel For Earlier Engines Tachometer The tachometer (R) indicates engine speed in hundreds ofrevolutions per minute (rpm). Percent Load (Optional) The power meter (S) shows percent of avail...

Instrument Panel - Elect. Cont. Earlier Engines DPSG,OUOD007,2841 –19–27JUL06–1/2 Using Touch Switches to Display Information RG9947 –19–09DEC99 Using Touch Switches 16-10 080706 PN=56 Continued on next page

Instrument Panel - Elect. Cont. Earlier Engines DPSG,OUOD007,2841 –19–27JUL06–2/2 The touch switches on the diagnostic gauge allowquick and easy navigation through the menu to find theinformation needed. The diagram on the preceding page is a typical MainMenu of Engine Parameters. The Main Menu has ...

Instrument Panel - Elect. Cont. Earlier Engines DPSG,OUOD007,2842 –19–27JUL06–1/1 Changing Units of Measure (English or Metric) RG10018 –19–28OCT99 Changing Units Of Measure The diagnostic gauge can display engine data in eitherEnglish or Metric units. To toggle between these, the Units Sub-Menu , m...

Instrument Panel - Elect. Cont. Earlier Engines DPSG,OUOD007,2842 –19–27JUL06–2/2 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 switch until the top...

Instrument Panel - Elect. Cont. Earlier Engines DPSG,OUOD002,1928 –19–27JUL06–1/1 Viewing Active Engine Service Codes/Diagnostic Trouble Codes (DTCs) RG11170 –UN–02NOV00 Viewing Active Service Codes/Diagnostic Trouble Codes (DTCs) The diagnostic gauge continuously monitors allmessages broadcast over...

Instrument Panel - Elect. Cont. Earlier Engines OUOD006,000006B –19–27JUL06–1/1 Viewing Stored Service Codes/Diagnostic Trouble Codes (DTCs) in the Engine ECU RG10021 –19–28OCT99 Viewing Stored Service Codes/Diagnostic Trouble Codes (DTCs) The diagnostic gauge can request stored servicecodes (DTCs) ...

Instrument Panel - Elect. Cont. Later Engines OURGP11,0000073 –19–04AUG06–1/3 Instrument Panels RG13276 –UN–28OCT03 Full-Featured Instrument Panel RG13277 –UN–22OCT03 Basic Instrument Panel A—Diagnostic Gauge/Hour F—Key Switch K—Analog Throttle Control O—Arrow Keys Meter G—Override Shutdown Rocker (...

Instrument Panel - Elect. Cont. Later Engines OURGP11,0000074 –19–27JUL06–1/1 Using Diagnostic Gauge to Access EngineInformation RG13132 –UN–09SEP03 Diagnostic Gauge (Later Engines) A—Diagnostic GaugeB—Menu KeyC—Arrow KeysD—Enter KeyE—Red “STOP ENGINE” Indicator LightF—Amber “WARNING” Indicator Ligh...

Instrument Panel - Elect. Cont. Later Engines OURGP11,00000A9 –19–27JUL06–1/5 Main Menu Navigation RG13159 –UN–26SEP03 Menu Key NOTE: The engine does not need to be running to navigate the diagnostic gauge screens. If enginestart up is desired, See Starting The Engine. All ofthe engine values illust...

Instrument Panel - Elect. Cont. Later Engines OURGP11,00000A9 –19–27JUL06–4/5 RG13162 –UN–26SEP03 Last Items On Main Menu 4. Pressing the right arrow key will scroll down to reveal the last items of "Main Menu" screen, highlighting thenext item down. OURGP11,00000A9 –19–27JUL06–5/5 RG13163 –...

Instrument Panel - Elect. Cont. Later Engines OURGP11,00000AB –19–27JUL06–6/6 RG13159 –UN–26SEP03 Exit Main Menu 6. Press the "Menu" key to exit the main menu and return to the engine parameter display. OURGP11,00000AC –19–27JUL06–1/6 Accessing Stored Trouble Codes RG13159 –UN–26SEP03 Menu K...

Instrument Panel - Elect. Cont. Later Engines OURGP11,00000AC –19–27JUL06–6/6 RG13159 –UN–26SEP03 Exit Main Menu 6. Press the "Menu" key to exit the main menu and return to the engine parameter display. OURGP11,00000AD –19–27JUL06–1/7 Accessing Active Trouble Codes RG13172 –UN–26SEP03 Normal...

Instrument Panel - Elect. Cont. Later Engines OURGP11,00000AD –19–27JUL06–3/7 RG13241 – UN–30SEP03 Use Arrow Keys To Scroll 3. If the word "Next" appears above the arrow keys, there are more trouble codes that can be viewed by usingthe arrow keys to scroll to the next trouble code. OURGP11,0...

Instrument Panel - Elect. Cont. Later Engines OURGP11,00000AD –19–27JUL06–7/7 RG13243 –UN–01OCT03 Active Trouble Code Condition 7. The single or four parameter screen will display the warning icon until the trouble code condition iscorrected. OURGP11,00000AE –19–27JUL06–1/6 Engine Shutdown Codes RG1...

Instrument Panel - Elect. Cont. Later Engines OURGP11,00000AE –19–27JUL06–4/6 RG13179 –UN–26SEP03 Flashing Shutdown Icon 4. The display will return to the single or four parameter display, but the display will contain the "Shutdown"icon. Pressing the "Enter" key will redisplay the hi...

Instrument Panel - Elect. Cont. Later Engines OURGP11,0000237 –19–27JUL06–5/6 RG13184 –UN–26SEP03 Return To Main Menu 5. Press the "Menu" key to return to the main menu. OURGP11,0000237 –19–27JUL06–6/6 RG13159 –UN–26SEP03 Exit Main Menu 6. Press the "Menu" key to exit the main menu a...

Instrument Panel - Elect. Cont. Later Engines OURGP11,00000AF –19–27JUL06–5/6 RG13187 –UN–26SEP03 Return To Main Menu 5. Press the "Menu" key to return to the main menu. OURGP11,00000AF –19–27JUL06–6/6 RG13159 –UN–26SEP03 Exit Main Menu 6. Press the "Menu" key to exit the main menu a...

Instrument Panel - Elect. Cont. Later Engines OURGP11,00000B0 –19–27JUL06–2/7 RG13188 –UN–02OCT03 Select Units 2. The main menu will be displayed. Use the "Arrow" keys to scroll through the menu until "Select Units" ishighlighted. OURGP11,00000B0 –19–27JUL06–3/7 RG13189 –UN–02OCT03 P...

Instrument Panel - Elect. Cont. Later Engines OURGP11,00000B1 –19–27JUL06–4/18 RG13196 –UN–26SEP03 1-Up Display Options 4. Three options are available for modification of the 1-Up Display. a. Use Defaults – This option contains the following engine parameters for display: Engine Hours,Engine Speed, ...

Instrument Panel - Elect. Cont. Later Engines OURGP11,00000B1 –19–27JUL06–6/18 RG13197 –UN–29SEP03 Defaults Selected 6. Press the "Enter" key to activate the "Use Defaults" function. OURGP11,00000B1 –19–27JUL06–7/18 RG13149 –UN–24SEP03 Restored To Defaults 7. The display parameters a...

Instrument Panel - Elect. Cont. Later Engines OURGP11,00000B1 –19–27JUL06–12/18 RG13151 –UN–24SEP03 Select Desired Parameters 12. Use the "Arrow" keys to scroll and highlight the desired parameter that has not been selected fordisplay (parameter without a number to right of it). OURGP11,0000...

Instrument Panel - Elect. Cont. Later Engines OURGP11,00000B1 –19–27JUL06–17/18 RG13224 –UN–26SEP03 Menu Key 18. Once the "Use Defaults", "Custom Setup" and "Automatic Scan" functions have been set, press the"Menu" key to return to the main menu. OURGP11,00000B1 –19–2...

Instrument Panel - Elect. Cont. Later Engines OURGP11,00000B2 –19–27JUL06–4/14 RG13244 –UN–02OCT03 Select Factory Defaults 4. Two options are available for the 4-Up Display. a. Use Defaults – This option contains the following engine parameters for display: Engine Speed,Battery Voltage, Coolant Temp...

Instrument Panel - Elect. Cont. Later Engines OURGP11,00000B2 –19–27JUL06–7/14 RG13228 –UN–26SEP03 Select Parameters 7. The quadrant with the highlighted parameter value is the current selected parameter. Use the "Arrow" keysto highlight the value in the quadrant you wish tochange to a new p...

Instrument Panel - Elect. Cont. Later Engines OURGP11,00000B2 –19–27JUL06–10/14 RG13231 –UN–26SEP03 Enter Selected Parameter 10. Press the "Enter" key to change the selected parameter in the quadrant to the new parameter. OURGP11,00000B2 –19–27JUL06–11/14 RG13232 –UN–26SEP03 Return To 4-Up C...

Instrument Panel - Elect. Cont. Later Engines OURGP11,00000B2 –19–27JUL06–13/14 RG13154 –UN–24SEP03 Return To Main Menu 13. Repeat the parameter selection process until all spaces are as desired. 14. Press the "Menu" key to return to the main menu. OURGP11,00000B2 –19–27JUL06–14/14 RG13155 –...

Engine Operation - Except 4.5L “270” Engines OURGP11,0000075 –19–27JUL06–1/4 Engine Break-In Service RG8009 –UN–06JAN99 Check Engine Oil The engine is ready for normal operation. However, extracare during the first 100 hours of operation will result inmore satisfactory long-term engine performance a...

Engine Operation - Except 4.5L “270” Engines OURGP11,0000075 –19–27JUL06–2/4 RG8028A –UN–15JAN99 Crosshatch Pattern On Dipstick A—Crosshatch Pattern On Dipstick IMPORTANT: DO NOT add makeup oil until the oil level is BELOW the ADD mark ondipstick. John Deere ENGINE BREAK-INOIL (TY22041) should be us...

Engine Operation - Except 4.5L “270” Engines OURGP11,0000075 –19–27JUL06–3/4 RG11616 –UN–24OCT01 Engine Oil Filter A—Engine Oil Filter 4. During the first 20 hours, avoid prolonged periods of engine idling or sustained maximum load operation. Ifengine will idle longer than 5 minutes, stop engine. 5....

Engine Operation - Except 4.5L “270” Engines OURGP11,0000076 –19–27JUL06–1/3 Starting the Engine TS220 –UN–23AUG88 Use Proper Ventilation The following instructions apply to the optional controlsand instruments available through the John Deere PartsDistribution Network. The controls and instruments ...

Engine Operation - Except 4.5L “270” Engines OURGP11,0000076 –19–27JUL06–2/3 RG13279 –UN–30OCT03 Analog Throttle Control and Speed Select Switch On Earlier Panel (Left) or Later Panel (Right) A—Analog Throttle Control (Optional)B—Speed Select Rocker Switch 4. Set slow idle as follows: Panels with hi...

Engine Operation - Except 4.5L “270” Engines OURGP11,0000076 –19–27JUL06–3/3 RG13280 –UN–30OCT03 Start And Idle Engine On Earlier Panel (Left) or Later Panel (Right) A—Key Start SwitchB—High-Low Speed Select Rocker SwitchC—Bump Speed Enable Rocker SwitchD—Speed Select Rocker SwitchE—Analog Throttle ...

Engine Operation - Except 4.5L “270” Engines OURGP11,0000077 –19–27JUL06–1/1 Normal Engine Operation Observe engine coolant temperature and engine oilpressure. Temperatures and pressures will varybetween engines and with changing operatingconditions, temperatures, and loads. Normal engine coolant op...

Engine Operation - Except 4.5L “270” Engines OURGP11,0000137 –19–27JUL06–1/1 Warming Engine RG13281 –UN–30OCT03 Oil Pressure and Coolant Temperature Gauges On Earlier Panel (Left) or Later Panel (Right) A—Engine Oil Pressure GaugeB—Engine Coolant Temperature Gauge The electronically-controlled engin...

Engine Operation - Except 4.5L “270” Engines OURGP11,0000078 –19–27JUL06–1/2 Cold Weather Operation TS1356 –UN–18MAR92 Handle Starting Fluid with Care RG11521 –19–10JAN01 Cold Weather Starting Guidelines CAUTION: DO NOT use starting fluid onengines equipped with air intake heaters orglow plugs. Ethe...

Engine Operation - Except 4.5L “270” Engines OURGP11,0000078 –19–27JUL06–2/2 NOTE: Air intake heaters (275 engines) and glow plugs (475 engines) operate automatically through theECU. The Engine Preheater Indicator light onthese engines, located above the key switch,should always illuminate when the ...

Engine Operation - Except 4.5L “270” Engines RG,RG34710,5564 –19–27JUL06–1/2 Using a Booster Battery or Charger TS204 –UN–23AUG88 Exploding Battery RG4678 –UN–14DEC88 12-Volt System RG4698 –UN–14DEC88 24-Volt System A—12-Volt Machine Battery (ies)B—12-Volt Booster Battery (ies)C—Booster CableD—Cable...

Engine Operation - Except 4.5L “270” Engines RG,RG34710,5564 –19–27JUL06–2/2 6. Start the engine. Disconnect jumper cables immediately after engine starts. Disconnect NEGATIVE(–) cable first. RG,RG34710,5562 –19–27JUL06–1/1 Avoid Excessive Engine Idling Prolonged idling may cause the engine coolantt...

Engine Operation - Except 4.5L “270” Engines OURGP11,0000079 –19–27JUL06–1/3 Changing Engine Speed RG13282 –UN–30OCT03 Changing Engine Speed On Earlier Panel (Left) or Later Panel (Right) A—High-Low Speed Select Rocker SwitchB—Bump Speed Enable Rocker SwitchC—Speed Select Rocker SwitchD—Analog Throt...

Engine Operation - Except 4.5L “270” Engines OURGP11,0000079 –19–27JUL06–3/3 RG13289 –UN–30OCT03 Changing Engine Speed With Basic Panel E—High-Low Speed Select Rocker Switch Changing engine speeds on later engines equippedwith the Basic Instrument Panel The basic instrument panel has a “ramp” thrott...

Engine Operation - Except 4.5L “270” Engines OURGP11,0000139 –19–27JUL06–1/1 Stopping The Engine RG13280 –UN–30OCT03 Stopping the Engine On Earlier Panel (Left) or Later Panel (Right) RG9933 –UN–18NOV99 Exhaust Stack Rain Cap A—Key SwitchB—High-Low Speed Select Rocker SwitchC—Bump Speed Enable Switc...

Engine Operation - Except 4.5L “270” Engines RG,RG34710,5555 –19–27JUL06–1/1 Auxiliary Gear Drive Limitations RG7634A –UN–22JAN99 Auxiliary Gear Drive A—Auxiliary Gear Drive IMPORTANT: When attaching an air compressor, hydraulic pump, or other accessory tobe driven by the auxiliary gear drive (A)(en...

Engine Operation- 4.5 L “270” Engines OURGP11,0000169 –19–27JUL06–1/3 Break-In Service RG12692 –UN–07FEB03 Check Engine Oil Level Daily Before starting, fill engine with seasonal viscosity grade oiland with coolant meeting specifications. (See DIESELENGINE OIL and DIESEL ENGINE COOLANTSPECIFICATIONS...

Engine Operation- 4.5 L “270” Engines OURGP11,0000169 –19–27JUL06–3/3 RG11616 –UN–24OCT01 Engine Oil Filter 5. Change engine oil and oil filter after the first 100 hours of use. After break-in period, change oil and filter every500 hours/12 months. (See CHANGE ENGINE OILAND FILTER in Lubrication and...

Engine Operation- 4.5 L “270” Engines RG41183,000002F –19–27JUL06–1/1 Generator Set (Standby) Power Units To assure that your engine will deliver efficient standbyoperation when needed, start engine and run at ratedspeed (with 50%—70% load) for 30 minutes every 2weeks. DO NOT allow engine to run ext...

Engine Operation- 4.5 L “270” Engines OURGP11,000016A –19–27JUL06–2/2 RG6580 –UN–20JAN93 Starting Engine Using Key Switch (Earlier Engines) RG13366 –UN–12FEB04 Starting Engine Using Reset Button and Key Switch (Later Engines) A—Reset ButtonB—Key Switch IMPORTANT: Do not operate the starter for more ...

Engine Operation- 4.5 L “270” Engines OURGP11,000007B –19–27JUL06–1/2 Cold Weather Starting When outside temperatures fall below 0 ° C (32 ° F) it may be necessary to consider using cold weather starting aids. Your PowerTech  Engines may be fitted with a block heater, glow plugs, air intake heater ...

Engine Operation- 4.5 L “270” Engines OURGP11,000007D –19–27JUL06–1/1 Avoid Excessive Engine Idling Avoid excessive engine idling. Prolonged idling may causethe engine coolant temperature to fall below its normalrange. This, in turn, causes crankcase oil dilution, due toincomplete fuel combustion, a...

Engine Operation- 4.5 L “270” Engines OURGP11,0000134 –19–27JUL06–1/2 Stopping the Engine RG6574B –UN–07JAN03 Key Switch on Instrument Panel (Earlier Engines) RG13362 –UN–06FEB04 Key Switch on Instrument Panel (Later Engines) IMPORTANT: Stopping the engine immediately when it has been working under ...

Lubrication and Maintenance OURGP11,0000241 –19–27JUL06–1/1 Observe Service Intervals RG13283 –UN–30OCT03 Hour Meter On Earlier Panel (Left) or Later Panel (Right) (Except 4.5 L “270” Engines) A—Hour Meter Using hour meter (A) on diagnostic gauge as a guide,perform all services at the hourly interva...

Lubrication & Maintenance/Daily OURGP11,000018F –19–27JUL06–1/5 Daily Prestarting Checks RG8009A –UN–16JUN00 Left Side Oil Filler Cap RG8054A –UN–16JUN00 Right Side Oil Filler Cap RG8025B –UN–16JUN00 Rocker Arm Cover Filler Cap RG8028B –UN–15JAN99 Crosshatch on Dipstick A—Left Side Oil Filler Ca...

Lubrication & Maintenance/Daily OURGP11,000018F –19–27JUL06–2/5 TS281 –UN–23AUG88 High-Pressure Fluids RG4675 –UN–14DEC88 Fill Radiator A—Fill Radiator CAUTION: Explosive release of fluids frompressurized cooling system can cause seriousburns. Only remove filler cap when engine is cold orwhen co...

Lubrication & Maintenance/Daily OURGP11,000018F –19–27JUL06–3/5 RG12222 –UN–24MAY02 Drain Final Fuel Filter RG11955 –UN–05DEC01 Drain Primary Fuel Filter (If Equipped) A—Drain PlugB—Air Bleed Plug NOTE: Engine may be equipped with a water sensor at the fuel filter. In this case, an indicator lig...

Lubrication & Maintenance/Daily OURGP11,000018F –19–27JUL06–4/5 RG7332A – UN–22JAN99 Dust Unloader Valve and Indicator Gauge A—Dust Unloader ValveB—Air Restriction Indicator 4. If the air cleaner has an automatic dust unloader valve (A), squeeze the unloader valve on air cleanerassembly to clear...

Lubrication & Maintenance/500 Hour/12 Month OURGP11,000015F –19–27JUL06–1/1 Servicing Fire Extinguisher RW4918 –UN–15DEC88 Fire Extinguisher A—Fire Extinguisher A fire extinguisher (A) is available from your authorizedservicing dealer or engine distributor. Read and follow the instructions which...

Lubrication & Maintenance/500 Hour/12 Month RG,RG34710,5568 –19–27JUL06–1/2 Servicing Battery TS204 –UN–23AUG88 Exploding Battery CAUTION: Battery gas can explode. Keepsparks and flames away from batteries. Use aflashlight to check battery electrolyte level. Never check battery charge by placing...

Lubrication & Maintenance/500 Hour/12 Month DPSG,RG41165,128 –19–27JUL06–1/1 Manual Belt Tensioner Adjustment RG10556 –UN–21DEC99 Check Belt Tension RG10557 –UN–21DEC99 Adjust Belt Tension A—Belt Tension GaugeB—Cap ScrewC—Cap ScrewD—Tensioner Bracket NOTE: Two types of manual tensioners shown. N...

Lubrication & Maintenance/500 Hour/12 Month OUOD002,000016D –19–27JUL06–1/2 Manual Belt Tensioner Adjustment UsingBelt Tension Tool (Alternate Method ForEngines Without Auxiliary Drive) RG11812 –UN–31OCT01 Alternator Bracket and Cap Screws RG11813 –UN–31OCT01 Belt Tension Tool A—Upper Alternator...

Lubrication & Maintenance/500 Hour/12 Month OUOD002,000016D –19–27JUL06–2/2 RG11814 –UN–31OCT01 Belt Tension Tool and Torque Wrench RG11815 –UN–31OCT01 Scribe Reference Mark A—AlternatorB—Belt Tensioning ToolC—Torque WrenchD—Reference MarkE—Alternator Upper Bracket Notch 3. Place torque wrench (...

Lubrication & Maintenance/500 Hour/12 Month OURGP11,000008C –19–27JUL06–1/4 Changing Engine Oil and Replacing Filter RG11616 –UN–24OCT01 Special Oil Filter RG4881 –UN–29NOV88 Oil Pan Drain Plug A—Oil Filter Element IMPORTANT: 6-Cylinder engines with oil pan option codes 1907, 1908, and 1909 requ...

Lubrication & Maintenance/500 Hour/12 Month OURGP11,000008C –19–27JUL06–2/4 3. Drain crankcase oil from engine while warm. NOTE: Drain plug location may vary, depending on the application. OURGP11,000008C –19–27JUL06–3/4 RG11616 – UN–24OCT01 Oil Filter And Mounting Header RG11617 –UN–24OCT01 Oil...

Lubrication & Maintenance/500 Hour/12 Month OURGP11,000008C –19–27JUL06–4/4 RG11619 –UN–24OCT01 Rocker Arm Cover Oil Filler Opening RG11942 –UN–24OCT01 Oil Filler At Side Of Engine A—Rocker Arm Cover Oil Filler OpeningB—Oil Filler At Side Of Engine 9. Fill engine crankcase with correct John Deer...

Lubrication & Maintenance/500 Hour/12 Month OURGP11,000014F –19–27JUL06–2/2 RG12426 –UN–20NOV03 Closed Crankcase Vent RG12427 –UN–03FEB04 Closed Crankcase Vent A—Closed Crankcase Ventilation (CCV) ValveB—Hose, CCV Valve to Intake ManifoldC—Hose, Valve Cover to CCV ValveD—Valve Cover Vent Fitting...

Lubrication & Maintenance/500 Hour/12 Month RG,RG34710,5575 –19–27JUL06–1/1 Checking Air Intake System RG4689 –UN–20DEC88 Check Clamps RG7332B –UN–22JAN99 Underloader Valve and Air Restriction Indicator A—ClampsB—Dust Unloader ValveC—Air Restriction Indicator IMPORTANT: The air intake system mus...

Lubrication & Maintenance/500 Hour/12 Month OURGP11,000021F –19–27JUL06–1/2 Replacing Fuel Filter Elements X9811 –UN–23AUG88 High-Pressure Fluids RG7721 –UN–15JAN99 Final Fuel Filter RG11954 –UN–05DEC01 Primary Fuel Filter (or Pre-Filter, If Equipped) A—Retaining RingB—Filter ElementC—Drain Plug...

Lubrication & Maintenance/500 Hour/12 Month OURGP11,000021F –19–27JUL06–2/2 NOTE: Raised locators on fuel filter canisters must be indexed properly with slots in mounting base forcorrect installation. 7. Install new filter elements onto mounting bases. Be sure elements are properly indexed and f...

Lubrication & Maintenance/500 Hour/12 Month OURGP11,0000080 –19–27JUL06–1/3 Checking Belt Tensioner Spring Tension andBelt Wear (Automatic Tensioner) Belt drive systems equipped with automatic (spring) belttensioners cannot be adjusted or repaired. The automaticbelt tensioner is designed to main...

Lubrication & Maintenance/500 Hour/12 Month OURGP11,0000080 –19–27JUL06–3/3 RG7977 –UN–14NOV97 Marks on Tensioner RG8037C –UN–11SEP00 Align Marks RG12065 –UN–28JAN02 Align Torque Wrench With Pulley and Tensioner A—Mark On Swing ArmB—Mark On Tensioner Mounting BaseC—Torque Wrench Checking Tension...

Lubrication & Maintenance/500 Hour/12 Month OUOD002,0000169 –19–27JUL06–1/1 Checking Engine Electrical GroundConnections Keep all engine ground connections clean and tight toprevent electrical arcing which can damage electroniccomponents. Also see precautions in Troubleshooting Section whenweldi...

Lubrication & Maintenance/500 Hour/12 Month DPSG,OUOD002,1921 –19–27JUL06–1/2 Replenishing Supplemental CoolantAdditives (SCAs) Between Coolant Changes RG6261 –UN–08DEC97 Radiator Coolant Check RG6262 –UN–05DEC97 JT07298 Coolant/Battery Tester IMPORTANT: Do not add supplemental coolant additives...

Lubrication & Maintenance/500 Hour/12 Month DPSG,OUOD002,1921 –19–27JUL06–2/2 IMPORTANT: ALWAYS maintain coolant at correct level and concentration. DO NOToperate engine without coolant even fora few minutes. If frequent coolant makeup is required,the glycol concentration should bechecked with J...

Lubrication & Maintenance/500 Hour/12 Month OUOD002,0000175 –19–27JUL06–1/1 Testing Diesel Engine Coolant Maintaining adequate concentrations of glycol andinhibiting additives in the coolant is critical to protectthe engine and cooling system against freezing,corrosion, and cylinder liner erosio...

Lubrication & Maintenance/500 Hour/12 Month OURGP11,0000220 –19–27JUL06–1/1 Pressure Testing Cooling System RG6557 –UN–20JAN93 Test Radiator Cap RG6558 –UN–20JAN93 Test Cooling System CAUTION: Explosive release of fluids frompressurized cooling system can causeserious burns. Shut off engine. Onl...

Lubrication & Maintenance/500 Hour/12 Month OURGP12,00001DB –19–27JUL06–1/1 Checking and Adjusting Engine Speeds RG12607 –UN–24OCT02 Using Tachometer to Check Engine Speeds A—Tachometer If equipped with a tachometer (A) on the instrument panel,observe tachometer reading to verify engine speeds.(...

Lubrication & Maint./2000 Hour/24 Month OURGP12,00001ED –19–27JUL06–1/1 Adjusting Variable Speed (Droop) — 4.5 L“270” Generator Set Engines Only RG12066 –UN–29JAN02 Droop Adjustment Screw A—Adjustment ScrewB—Fast Idle AdjustmentC—Slow Idle Adjustment 1. Warm engine to normal operating temperatur...

Lubrication & Maint./2000 Hour/24 Month RG,RG34710,5585 –19–27JUL06–1/1 Checking Crankshaft Vibration Damper(6-Cylinder Engine Only) RG8018 –UN–15JAN99 Grasp Vibration Damper RG7508 –UN–23NOV97 Check Runout 1. Remove belts (shown removed). 2. Grasp vibration damper with both hands and attempt to...

Lubrication & Maint./2000 Hour/24 Month OURGP11,0000081 –19–27JUL06–1/4 Flushing and Refilling Cooling System TS281 –UN–23AUG88 High-Pressure Fluids RG12833 –UN–13FEB03 Radiator Cap CAUTION: Explosive release of fluids frompressurized cooling system can cause seriousburns. Shut off engine. Only ...

Lubrication & Maint./2000 Hour/24 Month OURGP11,0000081 –19–27JUL06–2/4 RG8019A –UN–19JUN00 Engine Block Drain Valve- Except 475 Engines RG12223 –UN–11JUN02 Engine Block Coolant Drain Plug- 475 Engines A—Engine Block Drain ValveB—Engine Block Drain PlugC—Engine Block Drain Plug 3. All Except 404...

Lubrication & Maint./2000 Hour/24 Month OURGP11,0000081 –19–27JUL06–4/4 16. Inspect the fan belt for wear and check belt tension. (See Checking Belt Tensioner Spring Tension andBelt Wear in Lubrication and Maintenance 500Hour/12 Month section. DPSG,RG34710,112 –19–27JUL06–1/5 Testing Thermostats...

Lubrication & Maint./2000 Hour/24 Month DPSG,RG34710,112 –19–27JUL06–3/5 RG5971 –UN–23NOV97 Testing Thermostat Opening Temperature Testing Thermostats Opening Temperature 1. Remove thermostat(s). 2. Visually inspect thermostat(s) for corrosion or damage. If dual thermostats, replace as a matched...

Lubrication & Maint./2000 Hour/24 Month DPSG,RG34710,112 –19–27JUL06–4/5 RG7614A –UN–06NOV97 Installing Thermostat Cover RG7921B –UN–13NOV97 Thermostat Cover Seal A—Guide StudsB—Seal To Install Thermostats IMPORTANT: Install manifold gasket so that smaller (round) holes are at lower left anduppe...

Lubrication & Maint./2000 Hour/24 Month DPSG,RG41165,137 –19–27JUL06–1/5 Check and Adjust Valve Clearance (AllEngines Except 4045HF475 And 6068HF475) RG7408 –UN–06AUG96 Flywheel Housing Timing Holes A—Timing/Rotation HoleB—Timing Pin Hole CAUTION: To prevent accidental starting ofengine while pe...

Lubrication & Maint./2000 Hour/24 Month DPSG,RG41165,137 –19–27JUL06–2/5 4. With engine lock-pinned at TDC of No. 1 piston’s compression stroke, check valve clearance to followingspecifications. (Use sequence for 4-cylinder or6-cylinder engines as outlined on next page.) Specification Intake Val...

Lubrication & Maint./2000 Hour/24 Month DPSG,RG41165,137 –19–27JUL06–4/5 RG4776 –UN–31OCT97 4-Cylinder Engine Valve Adjustment A—Front of EngineB—No. 1 Piston TDC CompressionC—No. 4 Piston TDC CompressionE—Exhaust ValveI—Intake Valve 4-Cylinder Engine: NOTE: Firing order is 1-3-4-2. 1. Using JDE...

Lubrication & Maint./2000 Hour/24 Month OUO1089,0000208 –19–27JUL06–1/5 Check and Adjust Valve Clearance(4045HF475 And 6068HF475 Engines) RG12168 –UN–03JUL02 Flywheel Housing Timing Holes A—Timing/Rotation HoleB—Timing Pin Hole CAUTION: To prevent accidental starting ofengine while performing va...

Lubrication & Maint./2000 Hour/24 Month OUO1089,0000208 –19–27JUL06–2/5 4. With engine lock-pinned at TDC of No. 1 piston’s compression stroke, check valve clearance to followingspecifications. (Use sequence for 4-cylinder or6-cylinder engines as outlined on next page.) Specification Intake Valv...

Lubrication & Maint./2000 Hour/24 Month OURGP11,0000082 –19–27JUL06–1/1 Test Glow Plugs for Continuity (4045HF475And 6068HF475 Engines) RG13802 –UN–18NOV04 Test Glow Plugs for Continuity A—Glow Plug CAUTION: To prevent accidental starting ofengine while performing this test, alwaysdisconnect NEG...

Service as Required RG,RG34710,5591 –19–27JUL06–1/1 Additional Service Information RG4624 –UN–15DEC88 Component Technical Manual This is not a detailed service manual. If you want moredetailed service information, use the PublicationsInformation in the back of this manual to order acomponent technic...

Service as Required OURGP11,0000083 –19–27JUL06–1/1 Do Not Modify Fuel System TS1343 –UN–18MAR92 High-Pressure Fuel Lines RG11953 –UN–26NOV01 Fuel Injection Pump CAUTION: Do not open high-pressure fuelsystem. High-pressure fluid remaining in fuel lines cancause serious injury. Do not disconnect orat...

Service as Required OURGP11,0000222 –19–27JUL06–1/2 Adding Coolant TS281 –UN–23AUG88 High-Pressure Fluids RG13295 –UN–20NOV03 Radiator and Coolant A—Radiator Filler NeckB—Radiator CAUTION: Explosive release of fluids frompressurized cooling system can cause seriousburns. Shut off engine. Only remove...

Service as Required OURGP11,0000222 –19–27JUL06–2/2 3. Tighten plugs and fittings when air has been expelled from system. 4. Run engine until it reaches operating temperature. 40-4 080706 PN=177

Service as Required RG,RG34710,5594 –19–27JUL06–1/1 Replacing Single Stage Air Cleaner RG11319A –UN–06SEP00 Single Stage Air Filter RG11320 –UN–07SEP00 Installation of Single Stage Air Cleaner A—Outlet Neck ClampB—Filter to Engine Overlap IMPORTANT: ALWAYS REPLACE air cleaner when air restriction in...

Service as Required OURGP11,000013A –19–27JUL06–1/2 Replacing Axial Seal Air Cleaner FilterElement RG8719B –UN–03SEP99 Air restriction Indicator IMPORTANT: ALWAYS REPLACE primary air cleaner element when air restriction indicator(A) shows a vacuum of 625 mm (25 in.)H 2 O, is torn, or visibly dirty. ...

Service as Required OURGP11,000013A –19–27JUL06–2/2 RG4686 –UN–20DEC88 Wing Nut and Primary Element RG4687 –UN–20DEC88 Dust Unloader Valve and Restriction Indicator RG11068 –UN–26JUN00 Retaining Nut and Secondary Element A—Wing NutB—Primary ElementC—Dust Unloader ValveD—Retaining NutE—Secondary Elem...

Service as Required RG41165,000008B –19–27JUL06–1/2 Replacing Radial Seal Air Cleaner FilterElement RG11321A –UN–08SEP00 Dust Cup/Cover RG11322A –UN–08SEP00 Primary Filter Element RG11327A –UN–08SEP00 Secondary Filter Element A—Dust Cap/CoverB—Primary Filter ElementC—Secondary Filter Element IMPORTA...

Service as Required RG41165,000008B –19–27JUL06–2/2 IMPORTANT: Whenever the air cleaner has been serviced or cover has been removed,ALWAYS fully depress the airrestriction indicator reset button (ifequipped) to assure accurate readings. 8. If equipped, fully depress air restriction indicator reset b...

Service as Required OURGP11,000013B –19–27JUL06–1/1 Replacing Fan and Alternator Belts RG11950 –UN–07NOV01 290 mm (11.4 in.) Fan Height and Lower* RG11951 –UN–07NOV01 338 mm (13.3 in.) Fan Height and Higher Without Freon Compressor* RG11952 –UN–07NOV01 402 mm (15.8 in.) Fan Height With Freon Compres...

Service as Required OURGP11,000013C –19–27JUL06–1/1 Checking Fuses RG11938 –UN–06NOV01 Early Engines with Electronic Instrument Panel A—5 Amp Fuse NOTE: The instrument panels for later electronically controlled engines as described in Section 17 donot have this fuse. Check fuse (A) located in fuse h...

Service as Required OURGP11,000000E –19–27JUL06–1/3 Bleeding the Fuel System (Engines WithElectronic Fuel Systems And Bosch VP44Pump) X9811 –UN–23AUG88 High-Pressure Fluids CAUTION: Escaping fluid under pressure canpenetrate the skin causing serious injury.Relieve pressure before disconnecting fuel ...

Service as Required OURGP11,000000E –19–27JUL06–2/3 RG11719A –UN–20JUN01 Bleed Fuel System A—Bleed Orifice in Final Fuel Filter BaseB—Fuel Return Line IMPORTANT: NEVER pressurize the fuel tank to prime the fuel system as it could rupture sealsin the injection pump. Bleed Using Electronic Transfer Pu...

Service as Required OUOD002,000016F –19–27JUL06–2/5 RG11805 –UN–25OCT01 Final Fuel Filter Bleed Vent Screw A—Bleed Vent Screw 1. Loosen the air bleed vent screw (A) two full turns by hand on fuel filter base. OUOD002,000016F –19–27JUL06–3/5 RG11806 –UN–25OCT01 Fuel Supply Pump Primer Lever B—Primer ...

Service as Required OUOD002,000016F –19–27JUL06–4/5 RG11807 –UN–25OCT01 Fuel Injection Pump Return Line A—Fuel Return Line At Fuel Injection Pump 1. Loosen fuel return line (A) at fuel injection pump. 2. Operate fuel supply pump primer lever or primer button on fuel filter base (if equipped). 3. As ...

Service as Required OURGP11,000000F –19–27JUL06–2/3 RG12220 –UN–24MAY02 Final Fuel Filter Bleed Vent Screw A—Bleed Vent Screw IMPORTANT: NEVER pressurize the fuel tank to prime the fuel system as it could rupture sealsin the injection pump. NOTE: These are the 4-valve cylinder head 4.5 L and 6.8 L “...

Service as Required OURGP11,0000010 –19–27JUL06–2/5 RG7947 –UN–13NOV97 Air Bleed Vent Screw A—Vent Screw IMPORTANT: NEVER pressurize the fuel tank to prime the fuel system as it could rupture sealsin the injection pump. 1. Loosen the air bleed vent screw (A) two full turns by hand on fuel filter bas...

Service as Required OURGP11,0000010 –19–27JUL06–4/5 RG6264 –UN–03NOV97 Stanadyne Rotary Fuel Injection Pump A—Fuel Return Line Connector At Fuel Injection Pump 1. Slightly loosen fuel return line connector (A) at fuel injection pump. 2. Operate fuel supply pump primer lever until fuel, without air b...

Troubleshooting RG,RG34710,5605 –19–27JUL06–1/1 General Troubleshooting Information Troubleshooting engine problems can be difficult. Anengine wiring diagram is provided in this section tohelp isolate electrical problems on power units usingJohn Deere wiring harness and instrument (gauge)panel. Wiri...

Troubleshooting OUOD002,000016B –19–27JUL06–1/1 Precautions For Welding On EnginesEquipped With Electronic Engine ControlUnit (ECU) IMPORTANT: ALWAYS disconnect Electronic Control Unit (ECU) connectors and enginecontrol system-to-machine groundbefore welding on engine or machine.High currents or ele...

Troubleshooting OURGP11,000026F –19–27JUL06–1/1 Engine Wiring Diagram (With Earlier Electronic Instrument Panel) 414 BAT B B A B A X6 REMOTE ON/OFFPLUG 022 032 032 022 A B C 905 CAN L 012 IGN +12V OR +24V 412 ACC 422 STARTER RELAY SOLENOID 002 BAT 904 CAN H 020 CAN SHIELD 464 SENSOR RETURN 2 911 915...

Troubleshooting RG,RG34710,5608 –19–27JUL06–1/8 Engine Troubleshooting Symptom Problem Solution Engine cranks but will not start Incorrect starting procedure. Verify correct starting procedure. No fuel. Check fuel in tank. Exhaust restricted. Check and correct exhaustrestriction. Fuel filter plugged...

Troubleshooting RG,RG34710,5608 –19–27JUL06–2/8 Symptom Problem Solution Engine hard to start or will not Engine starting under load. Disengage PTO. start Improper starting procedure. Review starting procedure. No fuel. Check fuel tank. Air in fuel line. Bleed fuel line. Cold weather. Use cold weath...

Troubleshooting RG,RG34710,5608 –19–27JUL06–3/8 Symptom Problem Solution Engine runs irregularly or stalls Low coolant temperature. Remove and check thermostat. frequently Clogged fuel filter. Replace fuel filter element. Water, dirt, or air in fuel system. Drain, flush, fill, and bleed system. Dirt...

Troubleshooting RG,RG34710,5608 –19–27JUL06–4/8 Symptom Problem Solution Lack of power Engine overloaded. Reduce load. Intake air restriction. Service air cleaner. Clogged fuel filter. Replace filter elements. Improper type of fuel. Use proper fuel. Overheated engine. See “Engine Overheats”. Below n...

Troubleshooting RG,RG34710,5608 –19–27JUL06–5/8 Symptom Problem Solution High oil consumption Crankcase oil too light. Use proper viscosity oil. Oil leaks. Check for leaks in lines, gaskets,and drain plug. Restricted crankcase vent tube. Clean vent tube. Defective turbocharger. See your authorized s...

Troubleshooting RG,RG34710,5608 –19–27JUL06–6/8 Symptom Problem Solution Engine overheats Engine overloaded. Reduce load. Low coolant level. Fill radiator to proper level, checkradiator and hoses for looseconnections or leaks. Faulty radiator cap. Have technician check. Stretched poly-vee belt or de...

Troubleshooting RG,RG34710,5608 –19–27JUL06–7/8 Symptom Problem Solution Undercharged electrical system Excessive electrical load from added Remove accessories or install higher accessories. output alternator. Excessive engine idling. Increase engine rpm when heavyelectrical load is used. Poor elect...

Troubleshooting RG,RG34710,5608 –19–27JUL06–8/8 Symptom Problem Solution Starter and hour meter functions; Blown fuse on magnetic switch. Replace fuse. rest of electrical system does notfunction Entire electrical system does not Faulty battery connection. Clean and tighten connections. function Sulf...

Troubleshooting OURGP12,00001EA –19–27JUL06–1/2 Blink Code Method for Retrieving DiagnosticTrouble Codes (Early VP44 Pump EnginesOnly) RG11754A –UN–13JUL01 Diagnostic Blink Code Connector A—Diagnostic Blink Code ConnectorB—Diagnostic ConnectorC—ECU On OEM applications that have a Fault Lamp, the ECU...

Troubleshooting OURGP12,00001EA –19–27JUL06–2/2 8. When complete, turn ignition “OFF”, remove jumper wire, and recap the diagnostic reader connector. As an example, if an engine had an active DTC 18 andstored DTC 53, the flashing sequence would be: flashthree times...short pause...flash two times......

Troubleshooting OURGP11,0000279 –19–27JUL06–1/1 Instrument Panel Method for RetrievingDiagnostic Trouble Codes RG13287 –UN–30OCT03 Trouble Code Display On Earlier Panel (Left) or Later Panel (Right) A—Diagnostic Gauge IMPORTANT: Care should be used during diagnostic procedures to avoid damaging thet...

Troubleshooting DPSG,OUOD002,1591 –19–27JUL06–1/1 Displaying Of Diagnostic Trouble Codes (DTCs) There are several different methods for displaying bothstored and active DTCs from the ECU via a fault lampor a diagnostic gauge on the electronic instrumentpanel. 2-DIGIT CODES Some engines display Servi...

Troubleshooting OURGP11,0000088 –19–27JUL06–3/3 SPN FMI Blink Code Description of Fault 002000 13 — Security Violation N/A N/A 32 When reading blink codes, signifies the start of active codes. N/A N/A 33 When reading blink codes, signifies the start of stored codes. N/A N/A 88 When reading blink cod...

Troubleshooting OUOD007,0000036 –19–27JUL06–1/1 Intermittent Fault Diagnostics (With Electronic Controls) Intermittent faults are problems that periodically “goaway”. A problem such as a terminal that intermittentlydoesn’t make contact can cause an intermittent fault.Other intermittent may be set on...

Troubleshooting OURGP11,000012B –19–27JUL06–2/4 RG13234 –UN–22OCT03 Select Utilities 2. The main menu will be displayed. Use the "Arrow" key to scroll through the menu until "Utilities" is highlighted. OURGP11,000012B –19–27JUL06–3/4 RG13237 –UN–22OCT03 Select Utilities 3. Once "...

Storage OURGP12,00000DF –19–27JUL06–1/1 Engine Storage Guidelines 1. John Deere engines can be stored outside for up to three (3) months with no long term preparation IFCOVERED BY WATERPROOF COVERING. Nooutside storage is recommended without awaterproof covering. 2. John Deere engines can be stored ...

Storage OURGP11,000006C –19–27JUL06–1/2 Preparing Engine for Long Term Storage The following storage preparations are used for longterm engine storage up to one year. After that, theengine should be started, warmed up, and retreatedfor an extended storage period. IMPORTANT: Any time your engine will...

Storage OURGP11,000006C –19–27JUL06–2/2 15. Store the engine in a dry protected place. If engine must be stored outside, cover it with a waterproof canvas or other suitable protectivematerial and use a strong waterproof tape. RG,RG34710,5613 –19–27JUL06–1/1 Removing Engine from Long Term Storage Ref...

Specifications OURGP11,0000089 –19–27JUL06–1/2 General OEM Engine Specifications ITEM 4045DF270 4045TF270 4045TF/HF275 4045HF475 6068TF/HF275 6068HF475 Number of Cylinders 4 4 4 4 6 6 Bore 106 mm 106 mm 106 mm 106 mm 106 mm 106 mm (4.19 in.) (4.19 in.) (4.19 in.) (4.19 in.) (4.19 in.) (4.19 in.) Str...

Specifications OURGP11,000008A –19–27JUL06–1/3 Engine Power Ratings 1 And Fuel System Specifications 2 Engine Fuel System Electronic Software System Power Rated Slow Idle Fast Idle Model Option Codes Option Codes Voltage Rating @ Speed (rpm) (rpm) Rated Speed (rpm) kW (hp) 4045DF270 164J ..............

Specifications OURGP11,000008B –19–27JUL06–1/1 Engine Crankcase Oil Fill Quantities To determine the option code for the oil fill quantity ofyour engine, refer to the engine option code labelaffixed to the rocker arm cover. The first two digits ofthe code (19) identify the oil pan option group. The ...

Specifications TORQ1 –19–24APR03–1/1 Unified Inch Bolt and Screw Torque Values TS1671 –UN–01MAY03 Bolt or SAE Grade 1 SAE Grade 2 a SAE Grade 5, 5.1 or 5.2 SAE Grade 8 or 8.2 Screw Lubricated b Dry c Lubricated b Dry c Lubricated b Dry c Lubricated b Dry c Size N•m lb-in N•m lb-in N•m lb-in N•m lb-i...

Specifications DX,TORQ2 –19–24APR03–1/1 Metric Bolt and Screw Torque Values 4.8 4.8 8.8 9.8 10.9 12.9 12.9 12.9 12.9 10.9 9.8 8.8 4.8 TS1670 –UN–01MAY03 Bolt or Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9 Screw Lubricated a Dry b Lubricated a Dry b Lubricated a Dry b Lubricated a Dry b Size N•m...

Lubrication and Maintenance Records RG,RG34710,5620 –19–27JUL06–1/1 Using Lubrication and Maintenance Records Refer to specific Lubrication and Maintenance Sectionfor detailed service procedures. 1. Keep a record of the number of hours you operate your engine by regular observation of hour meter. 2....

Lubrication and Maintenance Records RG,RG34710,5625 –19–27JUL06–1/1 2000 Hour/24 Month Service • Check crankshaft vibration damper (6-cylinder only). • Flush and refill cooling system. 1 • Test thermostats. • Check and adjust valve clearance. • Test glow plugs (4045HF475, 6068HF475) Hours Date Hours...

Lubrication and Maintenance Records RG,RG34710,5627 –19–27JUL06–1/1 Service as Required • Add coolant • Service air cleaner. • Replace poly-vee belts. • Check fuses • Check air compressor (if equipped) • Bleed fuel system Hours Date Hours Date Hours Date Hours Date Hours Date Hours Date Hours Date H...

Emission System Warranty RG,RG34710,7629 –19–27JUL06–1/1 U.S. EPA Emissions Control Warranty Statement Emissions control-related parts and components arewarranted by John Deere for five years or 3000 hoursof operation, whichever occurs first. John Deere furtherwarrants that the engine covered by thi...

Emission System Warranty DPSG,RG41165,133 –19–27JUL06–1/1 Emissions Control System Certification Label RG11947 –UN–06NOV01 Emissions Label CAUTION: Statutes providing severepenalties for tampering with emissionscontrols may apply to the user or dealer. The emissions warranty described below applies ...

John Deere Service Literature Available DX,SERVLIT –19–31JUL03–1/2 Technical Information TS189 – UN–17JAN89 TS191 –UN–02DEC88 TS224 –UN–17JAN89 TS1663 –UN–10OCT97 Technical information can be purchased from John Deere.Some of this information is available in electronic media,such as CD-ROM disks, an...

John Deere Service Literature Available DX,SERVLIT –19–31JUL03–2/2 – Fundamentals of Machine Operation manuals explain machine capacities and adjustments, how to improvemachine performance, and how to eliminateunnecessary field operations. 70-2 080706 PN=243

Index Page Page A Cold weather aids. . . . . . . . . . . . . . . . . . . . . . . 35-15 Except 4045DF,TF270 . . . . . . . . . . . . . . . . . . 19-9 Acid burns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-2 4045DF,TF270 . . . . . . . . . . . . . . . . . . . . . . . . 20-6 Adjust Compr...