man. operat. 4,5-6,8 marino inglese omrg35856 stage 2 (05!05!06)

POWERTECH4045DFM70,4045TFM75,

6068SFM50, 6068TFM75and 6068TFM76Marine Engines

OPERATOR’S MANUALPOWERTECH 4045DFM70,4045TFM75, 6068SFM50,

6068TFM75/76 Marine Engines

OMRG35856 Issue 30Jan04 (ENGLISH)

CALIFORNIAProposition 65 Warning

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

defects, and other reproductive harm.

If this product contains a gasoline engine:

WARNING

The engine exhaust from this product contains chemicalsknown to the State of California to cause cancer, birth

defects or other reproductive harm.

The State of California requires the above two warnings.

John Deere Power SystemsLITHO IN U.S.A.

Introduction

OURGP11,00000E5 –19–03OCT03–1/1

Foreword

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

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

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

RIGHT-HAND AND LEFT-HAND sides are determinedby standing at the drive or flywheel end (rear) of theengine and facing toward the front of the engine.

WRITE ENGINE SERIAL NUMBERS and option codesin the spaces indicated in the Record Keeping Section.Accurately record all the numbers. Your dealer also

needs these numbers when you order parts. File theidentification numbers in a secure place off the engine.

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

CERTAIN ENGINE ACCESSORIES such as aircleaner, and instruments are optional equipment onJohn Deere Marine Engines. These accessories maybe provided by the equipment manufacturer instead ofJohn Deere. This operator’s manual applies only to theengine and those options available through the JohnDeere distribution network.

NOTE: This manual covers POWERTECH Tier 2emission-certified 4.5 and 6.8 L Marine heatexchanger engine models 4045DFM70,4045TFM75, 6068SFM50, 6068TFM75 and6068TFM76. For the earlier non-certifiedmarine engines, refer to OMRG28997.

POWERTECH is a trademark of Deere & Company

013004

PN=2

Introduction

OURGP11,0000251 –19–06NOV03–1/1

Engine Owner

John Deere Engine Owner:

Don’t wait until you need warranty or other service tomeet your local John Deere Engine Distributor orService Dealer. To register your engine for warrantyvia the Internet, use the following URL:http://www.johndeere.com/enginewarranty

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

Aux Utilisateurs De Moteurs John Deere:

N’attendez pas d’etre oblige d’avoir recours a votreconcessionnaire John Deere ou au point de service leplus proche pour vous adresser a lui. Pour enregistrervotre moteur pour la garantie via Internet, utilisezl’adresse suivante:http://www.johndeere.com/enginewarranty

Renseignez-vous des que possible pour l’identifier etle localiser. A la premiere occasion, prenez contactavec lui et faites-vous connaıtre. Il sera lui aussiheureux de faire votre connaissance et de vousproposer ses services le moment venu.

An Den Besitzer Des John Deere Motors:

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

Machen Sie sich bei ihm bekannt und nutzen Sie sein“Service Angebot”.

Proprietario del motore John Deere:

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

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

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

Propietario De Equipo John Deere:

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

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

Till agare av John Deere motorer:

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

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

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Introduction

OURGP11,00000F5 –19–06OCT03–1/1

POWERTECH 4.5 L Marine Engines

RG

1324

8–U

N–0

6OC

T03

4045TFM75 Engine

RG

1324

7–U

N–0

6OC

T03

4045TFM75 Engine

OURGP11,00000F4 –19–06OCT03–1/1

POWERTECH 6.8 L Marine Engines

RG

1325

0–U

N–0

6OC

T03

6068SFM50 Engine

RG

1324

9–U

N–0

6OC

T03

6068SFM50 Engine

013004

PN=4

ContentsPagePage

Using Diagnostic Gauge to Access EngineRecord KeepingInformation . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-7PowerTech Medallion . . . . . . . . . . . . . . . . . . . . . 01-1

Main Menu Navigation . . . . . . . . . . . . . . . . . . . . 15-8Engine Serial Number Plate . . . . . . . . . . . . . . . . 01-1Engine Configuration Data . . . . . . . . . . . . . . . . . 15-9Record Engine Serial Number . . . . . . . . . . . . . . 01-1Accessing Stored Trouble Codes . . . . . . . . . . . 15-11Engine Option Codes . . . . . . . . . . . . . . . . . . . . . 01-2Accessing Active Trouble Codes . . . . . . . . . . . 15-13Engine Option Codes-Continued . . . . . . . . . . . . 01-3Engine Shutdown Codes . . . . . . . . . . . . . . . . . 15-15Record Fuel Injection Pump Model Number . . . . 01-4Adjusting Backlighting. . . . . . . . . . . . . . . . . . . . 15-17Adjusting Contrast . . . . . . . . . . . . . . . . . . . . . . 15-19Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-1Selecting Units Of Measurement . . . . . . . . . . . 15-21Setup 1-Up Display . . . . . . . . . . . . . . . . . . . . . 15-23

Fuels, Lubricants, and Coolant Setup 4-Up Display . . . . . . . . . . . . . . . . . . . . . 15-30Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 Normal Engine Operation . . . . . . . . . . . . . . . . . 15-35Lubricity of Diesel Fuel . . . . . . . . . . . . . . . . . . . . 10-1 Break-In Service. . . . . . . . . . . . . . . . . . . . . . . . 15-35Handling and Storing Diesel Fuel . . . . . . . . . . . . 10-2 Auxiliary Gear Drive Limitations . . . . . . . . . . . . 15-39Dieselscan Fuel Analysis . . . . . . . . . . . . . . . . . . 10-2 Generator Set Power Units. . . . . . . . . . . . . . . . 15-40Bio-Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 Starting the Engine. . . . . . . . . . . . . . . . . . . . . . 15-41Minimizing the Effect of Cold Weather on Emergency Starting Of 6068SFM50 With

Diesel Engines . . . . . . . . . . . . . . . . . . . . . . . . 10-4 Electronic Failure . . . . . . . . . . . . . . . . . . . . . 15-43Diesel Engine Break-In Oil . . . . . . . . . . . . . . . . . 10-5 Warming Engine. . . . . . . . . . . . . . . . . . . . . . . . 15-44Diesel Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . 10-6 Idling Engine . . . . . . . . . . . . . . . . . . . . . . . . . . 15-45Extended Diesel Engine Oil Service Intervals . . . 10-7 Engaging And Disengaging Front PTO (IfMixing of Lubricants . . . . . . . . . . . . . . . . . . . . . . 10-7 Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-45OILSCANand COOLSCAN . . . . . . . . . . . . . . 10-8 Cold Weather Operation. . . . . . . . . . . . . . . . . . 15-46Alternative and Synthetic Lubricants. . . . . . . . . . 10-8 Stopping the Engine . . . . . . . . . . . . . . . . . . . . . 15-47Lubricant Storage . . . . . . . . . . . . . . . . . . . . . . . . 10-9 Using a Booster Battery or Charger . . . . . . . . . 15-49Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9Diesel Engine Coolant . . . . . . . . . . . . . . . . . . . 10-10 Lubrication and MaintenanceDrain Intervals for Diesel Engine Coolant . . . . 10-11 Observe Service Intervals. . . . . . . . . . . . . . . . . . 20-1Supplemental Coolant Additives . . . . . . . . . . . . 10-12 Use Correct Fuels, Lubricants, and Coolant . . . . 20-2Testing Diesel Engine Coolant . . . . . . . . . . . . . 10-12 Lubrication and Maintenance ServiceOperating in Warm Temperature Climates . . . . 10-13 Interval Chart—Propulsion Power Units . . . . . 20-3Disposing of Coolant . . . . . . . . . . . . . . . . . . . . 10-13 Lubrication and Maintenance Service

Interval Chart—Generator Sets . . . . . . . . . . . . 20-5

Engine Operating GuidelinesLubrication & Maintenance/DailyJohn Deere Instrument (Gauge) PanelDaily Prestarting Checks . . . . . . . . . . . . . . . . . . 25-1(Mechanically Controlled 4045DFM70 Engines

Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1John Deere Instrument (Gauge) Panel Lubrication & Maintenance/250 Hour/6 Month

(Electronically Controlled Engines) . . . . . . . . . 15-4 Changing Engine Oil and Replacing Oil Filter. . . 30-1John Deere Instrument (Gauge) Panel Servicing Fire Extinguisher . . . . . . . . . . . . . . . . . 30-3

(Electronically Controlled Engines)Continued on next page(Continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6

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

COPYRIGHT 2004DEERE & COMPANY

Moline, IllinoisAll rights reserved

A John Deere ILLUSTRUCTION Manual

i 013004

PN=1

Contents

Page Page

Servicing Battery . . . . . . . . . . . . . . . . . . . . . . . . 30-4 Replacing Alternator Belt (With ManualTensioner). . . . . . . . . . . . . . . . . . . . . . . . . . . 45-10Inspect and Replacing Zinc Plugs. . . . . . . . . . . . 30-6

Check Front Power Take-Off (PTO) . . . . . . . . . 45-11Checking Belt Wear (Manual Tensioner) . . . . . . 30-7Bleeding the Fuel System—EnginesChecking Engine Mounts . . . . . . . . . . . . . . . . . . 30-8

With Mechanical Fuel Supply Pump . . . . . . . 45-12Bleeding Fuel System—Engines WithLubrication & Maintenance/500 Hour/12 Month

Electric Fuel Supply Pump . . . . . . . . . . . . . . 45-14Replace Crankcase Vent Filter (If Equipped) . . . 35-1Remove and Install Auxiliary GearCleaning Crankcase Vent Tube . . . . . . . . . . . . . 35-1

Driven Sea Water Pump (ExceptChecking Air Intake System . . . . . . . . . . . . . . . . 35-26068SFM50) . . . . . . . . . . . . . . . . . . . . . . . . . 45-16Replacing Final Fuel Filter/Water Separator . . . . 35-3

Remove And Install Sea Water PumpReplacing Primary Fuel Filter Element . . . . . . . . 35-5(6068SFM50) . . . . . . . . . . . . . . . . . . . . . . . . 45-17Checking Belt Tensioner Spring Tension

and Belt Wear (Automatic Tensioner) . . . . . . . 35-6TroubleshootingChecking Cooling System. . . . . . . . . . . . . . . . . . 35-9General Troubleshooting Information . . . . . . . . . 50-1Replenishing Supplemental CoolantPrecautions For Welding On EnginesAdditives (SCAs) Between Coolant

Equipped With Electronic Engine Control UnitChanges . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-10(ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-2Testing Diesel Engine Coolant . . . . . . . . . . . . . 35-12

Propulsion Engine Wiring Harness -Remove, Inspect and Clean Engine HeatMechanically Controlled EngineExchanger Core . . . . . . . . . . . . . . . . . . . . . . 35-13(4045DFM70) . . . . . . . . . . . . . . . . . . . . . . . . . 50-3Install Heat Exchanger Core. . . . . . . . . . . . . . . 35-15

Propulsion Engine Instrument Panel -Remove, Inspect and Clean EngineMechanically Controlled EngineAftercooler Core (6068SFM50) . . . . . . . . . . . 35-17(4045DFM70) . . . . . . . . . . . . . . . . . . . . . . . . . 50-6Install Aftercooler Core (6068SFM50). . . . . . . . 35-18

Electronically Controlled EnginePressure Testing Cooling System. . . . . . . . . . . 35-19Electrical System Layout — 6068SFM50Checking and Adjusting Engine Speeds . . . . . . 35-20Shown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7Checking Engine Electrical Ground

Wiring Diagram for John Deere MainConnections . . . . . . . . . . . . . . . . . . . . . . . . . 35-20Station (Wheel House) InstrumentPanel - Electronically Controlled Engine . . . . . 50-9

Lubrication&Maintenance/2000 Hour/24 Month Wiring Diagram for John Deere MainChecking and Adjusting Engine Valve Station (Wheel House) Instrument

Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1 Panel - Electronically Controlled EngineFlushing And Refilling Cooling System . . . . . . . . 40-4 (Continued) . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10Inspecting Thermostats and Testing Wiring Diagram for John Deere Optional Fly

Opening Temperature . . . . . . . . . . . . . . . . . . . 40-7 Bridge Instrument Panel - Electronically ControlledChecking Crankshaft Vibration Damper Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-11

(6-Cylinder Engine Only). . . . . . . . . . . . . . . . . 40-8 6068SFM50 Marine Electronic ControlInspect and Repair Sea Water Pump System Wiring Diagram . . . . . . . . . . . . . . . . 50-13

(Except 6068SFM50) . . . . . . . . . . . . . . . . . . . 40-8 Engine Coolant and Sea Water Flow ForInspect And Repair Sea Water Pump Heat Exchanger Engines (Except

(6068SFM50) . . . . . . . . . . . . . . . . . . . . . . . . 40-11 6068SFM50) . . . . . . . . . . . . . . . . . . . . . . . . . 50-15Engine Coolant and Sea Water Flow

Service as Required (6068SFM50) . . . . . . . . . . . . . . . . . . . . . . . . 50-17Additional Service Information . . . . . . . . . . . . . . 45-1 Engine Troubleshooting . . . . . . . . . . . . . . . . . . 50-18Do Not Modify Fuel System . . . . . . . . . . . . . . . . 45-1 Electrical Troubleshooting. . . . . . . . . . . . . . . . . 50-25Adding Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . 45-2 Blink Code Method for RetrievingReplacing Dry Air Cleaner Element Diagnostic Trouble Codes . . . . . . . . . . . . . . . 50-27

(Enclosed Element Installations) . . . . . . . . . . . 45-3 Instrument Panel Method for RetrievingServicing Air Cleaner Filter Element . . . . . . . . . . 45-4 Diagnostic Trouble Codes . . . . . . . . . . . . . . . 50-28Replacing Air Cleaner Filter Element . . . . . . . . . 45-8 Listing Of Diagnostic Trouble Codes (DTC) . . . 50-29Replacing Alternator Belt (With Automatic

Continued on next pageTensioner). . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-9

ii 013004

PN=2

Contents

Page

Intermittent Fault Diagnostics . . . . . . . . . . . . . . 50-32Displaying Diagnostic Gauge Software . . . . . . . 50-32

StorageEngine Storage Guidelines . . . . . . . . . . . . . . . . . 55-1Preparing Engine for Long-Term Storage . . . . . . 55-2Removing Engine from Long-Term Storage . . . . 55-3

SpecificationsGeneral Engine Specifications—4.5 L

Engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-1General Engine Specifications—6.8 L

Engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-2Fuel Injection Pump Specifications . . . . . . . . . . . 60-3Engine Crankcase Oil Fill Quantities . . . . . . . . . 60-4Unified Inch Bolt and Screw Torque Values . . . . 60-5Metric Bolt and Screw Torque Values. . . . . . . . . 60-6

Lubrication and Maintenance RecordsUsing Lubrication and Maintenance Records . . . 65-1Daily (Prestarting) Service . . . . . . . . . . . . . . . . . 65-1250 Hour/6 Month Service . . . . . . . . . . . . . . . . . 65-2500 Hour/12 Month Service . . . . . . . . . . . . . . . . 65-32000 Hour Service . . . . . . . . . . . . . . . . . . . . . . . 65-4Service As Required. . . . . . . . . . . . . . . . . . . . . . 65-5

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

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

iii 013004

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Contents

iv 013004

PN=4

Record Keeping

RG,RG34710,5505 –19–11JAN02–1/1

POWERTECH MedallionRG12080 –UN–26FEB02

POWERTECH Medallion

A medallion is located on the rocker arm cover whichidentifies each engine as a John Deere MarinePOWERTECH engine.

OURGP11,000011A –19–20OCT03–1/1

Engine Serial Number Plate

RG

8007

–UN

–15J

AN

99

Engine Serial Number PlateA—Serial Number Plate

Each engine has a 13-digit John Deere engine serialnumber. The first two digits identify the factory thatproduced the engine:

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

Your engine’s serial number plate (A) is located on theright-hand side of cylinder block behind the fuel filter.

OURGP11,00000E8 –19–03OCT03–1/1

Record Engine Serial Number

RG

1325

1–U

N–0

6OC

T03

Serial Number Plate

A—Engine Serial NumberB—Engine Model Number

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

This information is very important for repair parts orwarranty information.

Engine Serial Number (A)

Engine Model Number (B)

01-1 013004

PN=7

Record Keeping

OURGP11,00000E9 –19–03OCT03–1/1

Engine Option Codes

RG

1325

2–1

9–06

OC

T03

Engine Option Codes

A—Engine Base Code

In addition to the serial number plate, marine engineshave an engine option code label affixed to the rockerarm cover. These codes indicate which of the engineoptions were installed on your engine at the factory.When in need of parts or service, furnish yourauthorized servicing dealer or engine distributor withthese numbers.

The engine option code label includes an engine basecode (A). This base code must also be recorded alongwith the option codes. At times it will be necessary tofurnish this base code to differentiate two identicaloption codes for the same engine model.

The first two digits of each code identify a specificgroup, such as alternators. The last two digits of eachcode identify one specific option provided on yourengine, such as a 12-volt, 95-amp alternator.

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

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

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

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

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

01-2 013004

PN=8

Record Keeping

DPSG,OUOD007,20 –19–03JAN02–1/1

Engine Option Codes-Continued

Engine Base Code: ______________________________

Option Codes Description Option Codes Description11 Rocker Arm Cover 50 Oil Pump12 Oil Fill Inlet 51 Cylinder Head With Valves13 Crankshaft Pulley 52 Auxiliary Gear Drive14 Flywheel Housing 53 Fuel Heater15 Flywheel 55 Shipping Stand16 Fuel Injection Pump 56 Paint Option17 Air Inlet 57 Coolant Pump Inlet18 Air Cleaner 59 Oil Cooler19 Oil Pan 60 Add-on Auxiliary Drive Pulley20 Coolant Pump 62 Alternator Mounting Bracket21 Thermostat Cover 63 Low Pressure Fuel Line22 Thermostat 64 Exhaust Elbow23 Belt Drive 65 Turbocharger24 Belt 66 Temperature Switch26 Engine Coolant Heater 67 Electronic Sensors (Base Engine)27 Heat Exchanger 68 Crankshaft Rear Damper28 Exhaust Manifold 69 Engine Serial Number Plate29 Ventilator System 71 Engine Oil Bypass Filter30 Starter Motor 72 Engine Control Unit (ECU) and Software31 Alternator 74 Air Conditioning (Freon) Compressor32 Instrument Panel 75 Air Restriction Indicator33 Tachometer 76 Pressure Switches and Sensors35 Fuel Filters 77 Timing Gear Cover36 Front Plate 79 Engine Certification37 Fuel Transfer Pump 80 Sea Water Pump39 Thermostat Housing 81 Primary Fuel Filter And Water Separator40 Oil Dipstick 84 Electrical Wiring Harness41 Belt-Driven Front Auxiliary Drive 86 Drive Pulley43 Starting Aid 87 Belt Tensioner44 Timing Gear Cover With Gears 88 Oil Filter45 Balancer Shaft 95 Special Equipment (Factory Installed)46 Cylinder Block With Liners and Camshaft 96 Engine Installation Kit47 Crankshaft and Bearings 97 Special Equipment (Field Installed)48 Connecting Rods and Pistons 98 Shipping (Engine Hanger Straps)49 Valve Actuating Mechanism 99 Service Only Items

01-3 013004

PN=9

Record Keeping

OURGP11,00000EA –19–03OCT03–1/1

Record Fuel Injection Pump Model Number

RG

1194

3–U

N–0

6NO

V01

Fuel Injection Pump Model Number

A—Serial Number Plate

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

Model No. RPM

Manufacturer’s No.

Serial No.

01-4 013004

PN=10

Safety

DX,ALERT –19–29SEP98–1/1

Recognize Safety Information

T81

389

–UN

–07D

EC

88

Safety-alert symbol

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

Follow recommended precautions and safe operatingpractices.

DX,SIGNAL –19–03MAR93–1/1

Understand Signal Words

TS

187

–19–

30S

EP

88

Signal Words

A signal word—DANGER, WARNING, or CAUTION—isused with the safety-alert symbol. DANGER identifies themost serious hazards.

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

05-1 013004

PN=11

Safety

DX,READ –19–03MAR93–1/1

Follow Safety Instructions

TS

201

–UN

–23A

UG

88

Safety Messages

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

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

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

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

DX,SIGNS1 –19–04JUN90–1/1

Replace Safety Signs

TS

201

–UN

–23A

UG

88Safety Signs

Replace missing or damaged safety signs. See themachine operator’s manual for correct safety signplacement.

05-2 013004

PN=12

Safety

RG,RG34710,7508 –19–30JUN97–1/1

Prevent Bypass Starting

RG

5419

–UN

–28F

EB

89

Prevent Bypass Starting

Avoid possible injury or death from engine runaway.

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

Start engine only from operator’s station with PTOdisengaged or in neutral.

DX,FIRE1 –19–03MAR93–1/1

Handle Fuel Safely—Avoid Fires

TS

202

–UN

–23A

UG

88

Avoid Fires

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

Always stop engine before refueling machine. Fill fuel tankoutdoors.

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

05-3 013004

PN=13

Safety

DX,FIRE2 –19–03MAR93–1/1

Prepare for Emergencies

TS

291

–UN

–23A

UG

88

First Aid Kit

Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

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

DX,FIRE3 –19–16APR92–1/1

Handle Starting Fluid Safely

TS

1356

–UN

–18M

AR

92

Store Safely

Starting fluid is highly flammable.

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

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

Do not incinerate or puncture a starting fluid container.

05-4 013004

PN=14

Safety

DX,FLAME –19–29SEP98–1/1

Handle Fluids Safely—Avoid Fires

TS

227

–UN

–23A

UG

88

Avoid Fires

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

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

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

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

DX,LOOSE –19–04JUN90–1/1

Service Engines Safely

TS

228

–UN

–23A

UG

88

Moving Parts

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

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

05-5 013004

PN=15

Safety

DX,WEAR –19–10SEP90–1/1

Wear Protective Clothing

TS

206

–UN

–23A

UG

88

Protective Clothing

Wear close fitting clothing and safety equipmentappropriate to the job.

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

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

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

DX,NOISE –19–03MAR93–1/1

Protect Against Noise

TS

207

–UN

–23A

UG

88

Noise Exposure

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

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

05-6 013004

PN=16

Safety

DX,MSDS,NA –19–03MAR93–1/1

Handle Chemical Products Safely

TS

1132

–UN

–26N

OV

90

Material Safety Data Sheet

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

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

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

(See your John Deere dealer for MSDS’s on chemicalproducts used with John Deere equipment.)

OUO1004,0000BD8 –19–03NOV00–1/1

Stay Clear of Rotating Drivelines

TS

1644

–UN

–22A

UG

95Rotating Drivelines

Entanglement in rotating driveline can cause serious injuryor death.

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

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

05-7 013004

PN=17

Safety

DX,SERV –19–17FEB99–1/1

Practice Safe Maintenance

TS

218

–UN

–23A

UG

88

Keep Area Clean

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

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

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

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

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

DX,AIR –19–17FEB99–1/1

Work In Ventilated Area

TS

220

–UN

–23A

UG

88

Engine exhaust fumes

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

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

05-8 013004

PN=18

Safety

DX,FLUID –19–03MAR93–1/1

Avoid High-Pressure Fluids

X98

11–U

N–2

3AU

G88

High-Pressure Fluids

Escaping fluid under pressure can penetrate the skincausing serious injury.

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

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

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

DX,TORCH –19–03MAR93–1/1

Avoid Heating Near Pressurized Fluid Lines

TS

953

–UN

–15M

AY

90Flammable Spray

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

05-9 013004

PN=19

Safety

DX,PAINT –19–24JUL02–1/1

Remove Paint Before Welding or Heating

TS

220

–UN

–23A

UG

88

Avoid potentially toxic fumes and dust.

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

Remove paint before heating:

• Remove paint a minimum of 101 mm (4 in.) from areato be affected by heating. If paint cannot be removed,wear an approved respirator before heating or welding.

• If you sand or grind paint, avoid breathing the dust.Wear an approved respirator.

• If you use solvent or paint stripper, remove stripper withsoap and water before welding. Remove solvent orpaint stripper containers and other flammable materialfrom area. Allow fumes to disperse at least 15 minutesbefore welding or heating.

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

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

Dispose of paint and solvent properly.

DX,RCAP –19–04JUN90–1/1

Service Cooling System Safely

TS

281

–UN

–23A

UG

88

Cooling System

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

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

05-10 013004

PN=20

Safety

OUOD006,000009D –19–04DEC02–1/1

Install Fan Guards

TS

677

–UN

–21S

EP

89

Rotating Fan

Rotating cooling system fans can cause serious injury.

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

OUOD006,000009E –19–04DEC02–1/1

Avoid Hot Parts

TS

271

–UN

–23A

UG

88

Hot Surface

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

External dry exhaust parts become very hot duringoperation. Turbochargers may reach temperatures as highas 500°C (932°F) under full load, and naturally aspiredexhaust manifolds may reach 600°C (1112°F) under fullload. This may ignite paper, cloth or wooden materials.Parts on engines that have been at full load and reducedto no load idle will maintain approximately 150°C (302°F).

05-11 013004

PN=21

Safety

DX,DUST –19–15MAR91–1/1

Avoid Harmful Asbestos Dust

TS

220

–UN

–23A

UG

88

Asbestos Dust

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

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

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

Keep bystanders away from the area.

DX,SPARKS –19–03MAR93–1/1

Prevent Battery Explosions

TS

204

–UN

–23A

UG

88Battery Explosions

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

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

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

05-12 013004

PN=22

Safety

DPSG,OUO1004,2758 –19–11MAY00–1/1

Handling Batteries Safely

TS

204

–UN

–23A

UG

88

Explosion

TS

203

–UN

–23A

UG

88Acid

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 across the posts. Use a voltmeter orhydrometer.

Always remove grounded (—) battery clampfirst and replace it last.

CAUTION: Sulfuric acid in battery electrolyte ispoisonous. It is strong enough to burn skin, eatholes in clothing, and cause blindness ifsplashed into eyes.

Avoid the hazard by:

1. Filling batteries in a well-ventilated area.2. Wearing eye protection and rubber gloves.3. Avoiding breathing fumes when electrolyte is

added.4. Avoiding spilling or dripping electrolyte.5. Using proper jump start procedure.

If you spill acid on yourself:

1. Flush your skin with water.2. Apply baking soda or lime to help neutralize

the acid.3. Flush your eyes with water for 15—30

minutes. Get medical attention immediately.

If acid is swallowed:

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

not exceed 2 L (2 qt.).3. Get medical attention immediately.

WARNING: Battery posts, terminals, and relatedaccessories contain lead and lead compounds, chemicalsknown to the State of California to cause cancer andreproductive harm. Wash hands after handling.

05-13 013004

PN=23

Safety

DX,SPRAY –19–16APR92–1/1

Protect Against High Pressure Spray

TS

1343

–UN

–18M

AR

92

High Pressure Spray

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

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

DX,LIFT –19–04JUN90–1/1

Use Proper Lifting Equipment

TS

226

–UN

–23A

UG

88

Proper Lifting Equipment

Lifting heavy components incorrectly can cause severeinjury or machine damage.

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

05-14 013004

PN=24

Safety

DX,REPAIR –19–17FEB99–1/1

Use Proper Tools

TS

779

–UN

–08N

OV

89

Proper Tools

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

Use power tools only to loosen threaded parts andfasteners.

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

Use only service parts meeting John Deere specifications.

DX,DRAIN –19–03MAR93–1/1

Dispose of Waste Properly

TS

1133

–UN

–26N

OV

90

Recycle Waste

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

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

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

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

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

05-15 013004

PN=25

Fuels, Lubricants, and Coolant

DX,FUEL1 –19–19DEC03–1/1

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 specified to EN 590 or ASTM D975 arerecommended.

In all cases, the fuel shall meet the followingproperties:

Cetane number of 40 minimum. Cetane numbergreater than 50 is preferred, especially fortemperatures below -20°C (-4°F) or elevations above1500 m (5000 ft).

Cold Filter Plugging Point (CFPP) below theexpected low temperature OR Cloud Point at least5°C (9°F) below the expected low temperature.

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

Sulfur content:

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

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

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

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

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

DX,FUEL5 –19–19DEC03–1/1

Lubricity of Diesel Fuel

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

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

Sulfur content of diesel fuel for highway use is lessthan 0.05% (500 ppm) in the United States andCanada, and less than 0.035% (350 ppm) in theEuropean Union.

Experience shows that some low sulfur diesel fuelsmay have inadequate lubricity and their use mayreduce performance in fuel injection systems due toinadequate lubrication of injection pump components.The lower concentration of aromatic compounds in

these fuels also adversely affects injection pump sealsand may result in leaks.

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

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

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

10-1 013004

PN=26


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 toprevent water condensation and freezing during coldweather.

Keep all storage tanks as full as practicable tominimize condensation.

Ensure that all fuel tank caps and covers are installedproperly to prevent moisture from entering.Monitorwater content of the fuel regularly.

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

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

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

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

DX,FUEL6 –19–06DEC00–1/1

Dieselscan Fuel Analysis

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

DIESELSCAN is a trademark of Deere & Company

10-2 013004

PN=27


DX,FUEL7 –19–05JAN04–1/1

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 specification.

It has been found that bio-diesel fuels may improvelubricity in concentrations up to a 5% blend (alsoknown as B5) in petroleum diesel fuel.

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

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

These oils do not burn completely,and will cause engine failure byleaving deposits on injectors and inthe combustion chamber.

A major environmental benefit of bio-diesel fuel is itsability to biodegrade. This makes proper storage and

handling of bio-diesel fuel especially important. Areasof concern include:

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

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

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

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

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

10-3 013004

PN=28


RG,RG34710,7529 –19–11SEP02–1/2

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 below outlines steps that can minimize theeffect that cold weather may have on starting andoperation of your engine. See your authorized enginedistributor or servicing dealer for additional informationand local availability of cold weather aids.

Use Grade No. 1-D Fuel

When temperatures fall below 5°C (40°F), Grade No.1-D fuel is best suited for cold weather operation.Grade No. 1-D fuel has a lower cloud point and alower pour point.

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

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

Coolant Heaters

Engine block heaters (coolant) are an available optionto aid cold weather starting.

Seasonal Viscosity Oil and Proper CoolantConcentration

Use seasonal grade viscosity engine oil based onexpected air temperature range between oil changes

and a proper concentration of low silicate antifreeze asrecommended. (See DIESEL ENGINE OIL andENGINE COOLANT REQUIREMENTS later in thissection).

Diesel Fuel Flow Additive

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

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

Winterfronts

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

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

Radiator Shutters

If equipped with a thermostatically controlled radiatorshutter system, this system should be regulated insuch a way that the shutters are completely open bythe time the coolant reaches 93°C (200°F) to preventexcessive intake manifold temperatures. Manuallycontrolled systems are not recommended.

10-4 013004

PN=29

Continued on next page


RG,RG34710,7529 –19–11SEP02–2/2

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

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

DX,ENOIL4 –19–07NOV03–1/1

Diesel Engine Break-In Oil

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

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

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

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

• API Service Category CE• API Service Category CD• API Service Category CC• ACEA Oil Sequence E2• ACEA Oil Sequence E1

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

IMPORTANT: Do not use PLUS-50 oil or engine oilsmeeting any of the following during thefirst 100 hours of operation of a new orrebuilt engine:

API CI-4 ACEA E5API CH-4 ACEA E4API CG-4 ACEA E3API CF-4API CF-2API CF

These oils will not allow the engine tobreak-in properly.

PLUS-50 is a trademark of Deere & Company

10-5 013004

PN=30



Diesel Engine Oil

TS

1675

–UN

–31O

CT

03

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

John Deere PLUS-50 oil is preferred.

Oils meeting one of the following specifications are alsorecommended

• ACEA Oil Sequence E5• ACEA Oil Sequence E4

Extended service intervals may apply when John DeerePLUS-50, ACEA E5, or ACEA E4 engine oils are used.Consult your John Deere dealer for more information.

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

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

Multi-viscosity diesel engine oils are preferred.Dieselfuel quality and fuel sulfur content must comply with allexisting emissions regulations for the area in which theengine operates.

If diesel fuel with sulfur content greater than 0.05% (500ppm) is used, reduce the service interval by 100 hours.

If diesel fuel with sulfur content greater than 0.5% (5000ppm) is used, reduce the service interval by 50%.

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

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

10-6 013004

PN=31



Extended Diesel Engine Oil Service Intervals

When John Deere PLUS-50, ACEA E5, or ACEA E4 oilsare used with the specified John Deere filter, the serviceinterval for engine oil and filter changes may be increasedby 50% but not to exceed a maximum of 500 hours.

If John Deere PLUS-50, ACEA E5, or ACEA E4 oils areused with other than the specified John Deere filter,change the engine oil and filter at the normal serviceinterval.

If John Deere TORQ-GARD SUPREME, API CI-4, APICH-4, or ACEA E3 oils are used, change the engine oiland filter at the normal service interval.

DX,LUBMIX –19–18MAR96–1/1

Mixing of Lubricants

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

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

Consult your John Deere dealer to obtain specificinformation and recommendations.

10-7 013004

PN=32


DX,OILSCAN –19–02DEC02–1/1

OILSCANand COOLSCAN

T68

28A

B–U

N–1

5JU

N89

T68

29A

B–U

N–1

8OC

T88

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

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

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

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

DX,ALTER –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.

Consult your John Deere dealer to obtain information andrecommendations.

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

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

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

10-8 013004

PN=33


DX,LUBST –19–18MAR96–1/1

Lubricant Storage

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

Use clean containers to handle all lubricants.

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

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

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

DX,GREA1 –19–14NOV03–1/1

Grease

TS

1667

–UN

–30J

UN

99

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

The following greases are preferred:

• John Deere SD POLYUREA GREASE

The following greases are also recommended:

• John Deere HD MOLY GREASE• John Deere HD LITHIUM COMPLEX GREASE• John Deere HD WATER RESISTANT GREASE• John Deere GREASE-GARD

Other greases may be used if they meet the following:

• NLGI Performance Classification GC-LB

IMPORTANT: Some types of grease thickener are notcompatible with others. Consult yourgrease supplier before mixing differenttypes of grease.

10-9 013004

PN=34


DX,COOL3 –19–19DEC03–1/2

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 your John Deere dealer for recommendations.

John Deere COOL-GARD Prediluted Coolant ispreferred for service.

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

Additional recommended coolants

The following engine coolant is also recommended:

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

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

Other fully formulated coolants

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

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

mixture of concentrate with quality water

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

Coolants requiring supplemental coolant additives

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

• ASTM D4985 ethylene glycol base prediluted (50%)coolant

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

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

Other coolants

If a coolant known to meet the requirements of coolantspecifications shown in this manual is not available,use either:

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

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

The coolant concentrate or prediluted coolant shall beof a quality that provides cavitation protection to castiron and aluminum parts in the cooling system.

Water quality

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

COOL-GARD is a trademark of Deere & Company

10-10 013004

PN=35



DX,COOL3 –19–19DEC03–2/2

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

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

DX,COOL11 –19–19DEC03–1/1

Drain Intervals for Diesel Engine Coolant

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

Subsequent drain intervals are determined by the coolantused for service. At each interval, drain the coolant, flushthe cooling system, and refill with new coolant.

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

If John Deere COOL-GARD is used but the coolant is nottested OR additives are not replenished by adding asupplemental coolant additive, the drain interval is 3 yearsor 3000 hours of operation

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


10-11 013004

PN=36


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 or as determined necessaryby coolant testing.

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

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

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

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

Add the manufacturer’s recommended concentration ofsupplemental coolant additive. DO NOT add more thanthe recommended amount.


DX,COOL9 –19–19DEC03–1/1

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 erosion and pitting.

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

Coolant test strips

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

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

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

COOLSCAN and COOLSCAN PLUS

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

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

10-12 013004

PN=37


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 required.

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

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

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

RG,RG34710,7543 –19–24JAN03–1/1

Disposing of Coolant

TS

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OV

90Recycle Waste

Improperly disposing of engine coolant can threaten theenvironment and ecology.

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

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

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

10-13 013004

PN=38

Engine Operating Guidelines

OURGP11,0000246 –19–05NOV03–1/2

John Deere Instrument (Gauge) Panel (Mechanically Controlled 4045DFM70 Engines Only)

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A—Oil Pressure Gauge E—Alarm Reset Switch K—Water-in-Fuel Warning N—Low Oil Pressure WarningB—Tachometer F—Stop Switch Light LightC—Coolant Temperature G—Hour Meter L—Low Battery Voltage O—Voltmeter

Gauge H—Start Switch Warning LightD—Audible Alarm J—Key Switch M—High Coolant Temperature

Warning Light

NOTE: Instrument panel for all other engines iscovered following this story.

All controls and gauges are optional equipment onJohn Deere Marine Engines. They may be supplied bythe boat builder instead of John Deere. The followinginformation applies only to those controls and gaugesfor mechanically controlled engines provided by JohnDeere. Consult your boat builder for information oninstrumentation other than those supplied by JohnDeere.

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

NOTE: Main station instrument panel shown, fly bridgepanel is similar except it does not have a keyswitch (J) or hour meter (G).

The optional instrument (gauge) panel available fromyour John Deere engine distributor or servicing dealeris recommended for propulsion units only and is notequipped with safety shut-down devices, only audibleand visible warning devices provided.

Following is a brief description of the available optionalgauges and warning devices:

A—Engine Oil Pressure Gauge

15-1 013004

PN=39



OURGP11,0000246 –19–05NOV03–2/2

The oil pressure gauge (A) indicates engine oilpressure. It is connected to an audible alarm (D) and awarning light (N) for warning the operator if engine oilpressure falls below a safe operating pressure.

NOTE: Refer to photo on previous page.

B—Tachometer

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

C—Engine Coolant Temperature Gauge

The engine coolant temperature gauge (C) indicatesthe engine coolant temperature. It is connected to anaudible alarm and a warning light (M) to warn theoperator if coolant temperature rises above the presetsafe operating temperature.

D—Audible Alarm

The audible alarm (D) will sound (and warning light willappear) whenever low oil pressure, high coolanttemperature, low battery voltage, or water-in-fuelcondition exists.

E—Reset (Audible Alarm Override) Switch

The reset switch (E) has a button that silences theaudible alarm for approximately 2-1/2 minutes whendepressed.

F—Stop Switch

The stop switch (F) has a button which whendepressed and held in, will stop the engine with keyswitch at any position. The button must be held in untilengine is completely stopped.

G—Hour Meter

The electric hour meter (G) is used to show theoperating time of an engine while key switch is in the“ON” position. The hour meter records the time intenths of an hour and should be used as a guide forscheduling periodic maintenance.

H—Start Switch

The start switch (H) has a button which whendepressed and held in, operates the starting motor.The engine will only start with key switch in the “ON”position.

J—Key Switch

The two position (ON—OFF) key switch (J) controlsthe engine electrical system, it does not start nor stopthe engine. When the switch is in the “ON” position,the engine may be started or stopped by depressingeach respective button. When the switch is in the”OFF” position, the engine may be stopped but it cannot be started.

K—Water-In-Fuel Warning Light

L—Low Battery Voltage Warning Light

M—High Coolant Temperature Warning Light

N—Low Oil Pressure Warning Light

O—Voltmeter

The voltmeter (O) indicates system battery voltage.

15-2 013004

PN=40


15-3 013004

PN=41


OURGP11,0000247 –19–05NOV03–1/2

John Deere Instrument (Gauge) Panel (Electronically Controlled Engines)

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Instrument Panel (Main Station Panel Shown)

A—Oil Pressure Gauge E—Audible Alarm I—Start Button N—Enter KeyB—Coolant Temperature F—Audible Alarm Override J—Key Switch O—Red “STOP ENGINE”

Gauge Button K—Diagnostic Gauge Indicator LightC—Voltmeter G—Tachometer L—Menu Key P—Amber “WARNING”D—Percent Load Gauge H—Dimmer Switch M—Arrow Keys Indicator Light

Tier 2 John Deere POWERTECH Marine Enginesexcept the 4045DFM70 have an electronic controlsystem, which has the following controls and gaugesas shown. The Tier 2 4045DFM70 Instrument panel isshown on page 15-1. The following information applies

only to those controls and gauges supplied by JohnDeere for electronically controlled engines. Refer toyour engine application manual or boat builder forspecific guidelines if John Deere-sourced controls andinstrumentation are not used.

POWERTECH is a trademark of Deere & Company.

15-4 013004

PN=42



OURGP11,0000247 –19–05NOV03–2/2

NOTE: The standard main station (wheel house)instrument panel is shown. An optionalfly-bridge panel is also available that includesthe same gauges as the standard panel, buthas a stop button in place of the key startswitch.

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

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

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

A—Engine Oil Pressure Gauge

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

B—Engine Coolant Temperature Gauge

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

C—Voltmeter

The voltmeter (C) indicates system battery voltage.The amber “Warning” light (P) will illuminate whenbattery voltage is too low for proper operation of thefuel injection system.

D—Percent Load Gauge

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

E—Audible Alarm

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

F—Audible Alarm Override Button

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

G—Tachometer

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

H—Dimmer Switch

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

I—Start Button

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

15-5 013004

PN=43


OURGP11,0000248 –19–05NOV03–1/1

John Deere Instrument (Gauge) Panel (Electronically Controlled Engines) (Continued)

J—Key Switch

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

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

K—Diagnostic Gauge/Hour Meter

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

L—Menu Key

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

M—Arrow Keys

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

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

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

N—Enter Key

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

O—Red “STOP ENGINE” Indicator Light

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

P—Amber “WARNING” Indicator Light

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

15-6 013004

PN=44


OURGP11,00000A7 –19–03SEP03–1/1

Using Diagnostic Gauge to Access EngineInformation

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Diagnostic Gauge

A—Diagnostic GaugeB—Menu KeyC—Arrow KeysD—Enter KeyE—Red “STOP ENGINE” Indicator LightF—Amber “WARNING” Indicator Light

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

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

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

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

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

15-7 013004

PN=45


OURGP11,00000A9 –19–03SEP03–1/5

Main Menu Navigation

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Menu Key

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

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

OURGP11,00000A9 –19–03SEP03–2/5

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Menu Display

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

OURGP11,00000A9 –19–03SEP03–3/5

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Main Menu Items

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

15-8 013004

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OURGP11,00000A9 –19–03SEP03–4/5

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Last Items On Main Menu

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

OURGP11,00000A9 –19–03SEP03–5/5

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Use Arrow Buttons To Scroll / Quadrant Display

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

OURGP11,00000AB –19–03SEP03–1/6

Engine Configuration Data

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Menu Key

NOTE: The engine configuration data is a read onlyfunction.

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


15-9 013004

PN=47



OURGP11,00000AB –19–03SEP03–2/6

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Select Engine Configuration

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

OURGP11,00000AB –19–03SEP03–3/6

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Enter Key

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

OURGP11,00000AB –19–03SEP03–4/6

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Use Arrow Keys To Scroll

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

OURGP11,00000AB –19–03SEP03–5/6

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Return To Main Menu

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

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PN=48



OURGP11,00000AB –19–03SEP03–6/6

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Exit Main Menu

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

OURGP11,00000AC –19–03SEP03–1/6

Accessing Stored Trouble Codes

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Menu Key


For description of trouble codes, see chart inTroubleshooting Section.


OURGP11,00000AC –19–03SEP03–2/6

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Select Stored Codes

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

15-11 013004

PN=49



OURGP11,00000AC –19–03SEP03–3/6

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Enter Key

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

OURGP11,00000AC –19–03SEP03–4/6

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

OURGP11,00000AC –19–03SEP03–5/6

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Return To Main Menu



15-12 013004

PN=50


OURGP11,00000AC –19–03SEP03–6/6

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Exit Main Menu


OURGP11,00000AD –19–03SEP03–1/7

Accessing Active Trouble Codes

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Normal Operation


For description of trouble codes, see chart inTroubleshooting Section.

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

OURGP11,00000AD –19–03SEP03–2/7

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Active Trouble Codes Displayed

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

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


15-13 013004

PN=51


OURGP11,00000AD –19–03SEP03–3/7

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

OURGP11,00000AD –19–03SEP03–4/7

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Hide Trouble Codes


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

OURGP11,00000AD –19–03SEP03–5/7

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Active Trouble Code Icon

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

OURGP11,00000AD –19–03SEP03–6/7

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Enter Key


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

15-14 013004

PN=52



OURGP11,00000AD –19–03SEP03–7/7

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Active Trouble Code Condition

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

OURGP11,00000AE –19–03SEP03–1/6

Engine Shutdown Codes

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Normal Operation

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

OURGP11,00000AE –19–03SEP03–2/6

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Shutdown Message

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

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

OURGP11,00000AE –19–03SEP03–3/6

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Hide Trouble Code

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

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

15-15 013004

PN=53



OURGP11,00000AE –19–03SEP03–4/6

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Flashing Shutdown Icon

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


OURGP11,00000AE –19–03SEP03–5/6

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Redisplay Trouble Code

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

OURGP11,00000AE –19–03SEP03–6/6

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Shutdown Icon

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


15-16 013004

PN=54


OURGP11,00000AA –19–03SEP03–1/6

Adjusting Backlighting

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Menu Key

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



OURGP11,00000AA –19–03SEP03–2/6

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Select Adjust Backlight

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

OURGP11,00000AA –19–03SEP03–3/6

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Press Enter Key

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


15-17 013004

PN=55


OURGP11,00000AA –19–03SEP03–4/6

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Adjust Backlight Intensity

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

OURGP11,00000AA –19–03SEP03–5/6

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Return To Main Menu


OURGP11,00000AA –19–03SEP03–6/6

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Exit Main Menu


15-18 013004

PN=56


OURGP11,00000AF –19–03SEP03–1/6

Adjusting Contrast

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Menu Key

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

OURGP11,00000AF –19–03SEP03–2/6

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Select Adjust Contrast

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

OURGP11,00000AF –19–03SEP03–3/6

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Press Enter Key

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

15-19 013004

PN=57



OURGP11,00000AF –19–03SEP03–4/6

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Adjust Contrast Intensity

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

OURGP11,00000AF –19–03SEP03–5/6

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Return To Main Menu


OURGP11,00000AF –19–03SEP03–6/6

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Exit Main Menu


15-20 013004

PN=58


OURGP11,00000B0 –19–03SEP03–1/7

Selecting Units Of Measurement

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Menu Key


OURGP11,00000B0 –19–03SEP03–2/7

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Select Units

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

OURGP11,00000B0 –19–03SEP03–3/7

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Press Enter Key

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


15-21 013004

PN=59


OURGP11,00000B0 –19–03SEP03–4/7

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Select Desired Units

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

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

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

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

OURGP11,00000B0 –19–03SEP03–5/7

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Press Enter Key to Select

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

OURGP11,00000B0 –19–03SEP03–6/7

RG

1319

2–U

N–2

6SE

P03

Return To Main Menu


15-22 013004

PN=60



OURGP11,00000B0 –19–03SEP03–7/7

RG

1315

9–U

N–2

6SE

P03

Press Menu Key

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

OURGP11,00000B1 –19–03SEP03–1/18

Setup 1-Up Display

RG

1315

9–U

N–2

6SE

P03

Menu Key

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

OURGP11,00000B1 –19–03SEP03–2/18

RG

1319

3–U

N–0

2OC

T03

Setup 1-Up Display

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


15-23 013004

PN=61


OURGP11,00000B1 –19–03SEP03–3/18

RG

1319

4–U

N–0

2OC

T03

Press Enter Key

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

OURGP11,00000B1 –19–03SEP03–4/18

RG

1319

6–U

N–2

6SE

P03

1-Up Display Options

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

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

b. Custom Setup – This option contains a list ofengine parameters. Engine parameters from this listcan be selected to replace any or all of the defaultparameters. This option can be used to addparameters available for scrolling in the 1-UpDisplay.

c. Automatic Scan – Selecting the scan function willallow the 1-Up Display to scroll through the selectedset of parameters one at a time, momentarilypausing at each.


15-24 013004

PN=62


OURGP11,00000B1 –19–03SEP03–5/18

RG

1319

5–U

N–2

6SE

P03

Select Defaults

5. Use Defaults - To select "Use Defaults" use the Arrowkeys to scroll to and highlight "Use Defaults" in themenu display.

OURGP11,00000B1 –19–03SEP03–6/18

RG

1319

7–U

N–2

9SE

P03

Defaults Selected

6. Press the "Enter" key to activate the "Use Defaults"function.

OURGP11,00000B1 –19–03SEP03–7/18

RG

1314

9–U

N–2

4SE

P03

Restored To Defaults

7. The display parameters are reset to the factorydefaults, then the display will return to the "Setup 1-UpDisplay" menu.

15-25 013004

PN=63



OURGP11,00000B1 –19–03SEP03–8/18

RG

1319

8–U

N–2

6SE

P03

Select Custom Setup

8. Custom Setup - To perform a custom setup of the1-Up Display, use the arrow buttons to scroll to andhighlight "Custom Setup" on the display.

OURGP11,00000B1 –19–03SEP03–9/18

RG

1319

9–U

N–2

6SE

P03

Engine Parameters

9. Press the "Enter" key to display a list of engineparameters.

OURGP11,00000B1 –19–03SEP03–10/18

RG

1315

0–U

N–2

4SE

P03

Select Parameters

10. Use the "Arrow" keys to scroll to and highlight aselected parameter (parameter with a number to rightof it).

15-26 013004

PN=64



OURGP11,00000B1 –19–03SEP03–11/18

RG

1321

9–U

N–2

6SE

P03

Deselect Parameters

11. Press the "Enter" key to deselect the selectedparameter, removing it from the list of parametersbeing displayed on the 1-Up Display.

OURGP11,00000B1 –19–03SEP03–12/18

RG

1315

1–U

N–2

4SE

P03

Select Desired Parameters

12. Use the "Arrow" keys to scroll and highlight thedesired parameter that has not been selected fordisplay (parameter without a number to right of it).

OURGP11,00000B1 –19–03SEP03–13/18

RG

1322

0–U

N–2

6SE

P03

Select Parameters For Display

13. Press the "Enter" key to select the parameter forinclusion in the Single Engine Parameter Display.

14. Continue to scroll through and select additionalparameters for the custom 1-Up Display. Press the"Menu" key at any time to return to the "CustomSetup" menu.

15-27 013004

PN=65



OURGP11,00000B1 –19–03SEP03–14/18

RG

1322

1–U

N–2

6SE

P03

Automatic Scan Off

15. Automatic Scan - Selecting the scan function willallow the 1- Up Display to scroll through the selectedset of parameters one at a time. Use the "Arrow" keysto scroll to the "Automatic Scan" function.

OURGP11,00000B1 –19–03SEP03–15/18

RG

1322

2–U

N–2

6SE

P03

Automatic Scan On

16. Press the "Enter" key to toggle the "Automatic Scan"function on.


15-28 013004

PN=66


OURGP11,00000B1 –19–03SEP03–16/18

RG

1322

3–U

N–2

6SE

P03

Automatic Scan Off

17. Press the "Enter" key again to toggle the "AutomaticScan" function off.

OURGP11,00000B1 –19–03SEP03–17/18

RG

1322

4–U

N–2

6SE

P03

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 –19–03SEP03–18/18

RG

1315

9–U

N–2

6SE

P03

Exit Main Menu

19. Press the "Menu" key to exit the main menu andreturn to the engine parameter display.

15-29 013004

PN=67


OURGP11,00000B2 –19–03SEP03–1/14

Setup 4-Up Display

RG

1315

9–U

N–2

6SE

P03

Menu Key

1. Turn the key switch to the ON position. From the singleor four engine parameter display, press the "Menu"key.

OURGP11,00000B2 –19–03SEP03–2/14

RG

1322

5–U

N–0

2OC

T03

Select Setup 4-Up Display

2. The main menu will be displayed. Use the "Arrow" keysto scroll through the menu until "Setup 4-Up Display" ishighlighted.

OURGP11,00000B2 –19–03SEP03–3/14

RG

1322

6–U

N–0

2OC

T03

Press Enter Key

3. Once the "Setup 4-Up Display" menu item has beenhighlighted, press the "Enter" key to activate the "Setup4-Up Display" menu.

15-30 013004

PN=68



OURGP11,00000B2 –19–03SEP03–4/14

RG

1324

4–U

N–0

2OC

T03

Select Factory Defaults

4. Two options are available for the 4-Up Display.

a. Use Defaults – This option contains the followingengine parameters for display: Engine Speed,Battery Voltage, Coolant Temperature and OilPressure.

b. Custom Setup – This option contains a list ofengine parameters. Engine parameters from this listcan be selected to replace any or all of the defaultparameters.

OURGP11,00000B2 –19–03SEP03–5/14

RG

1314

9–U

N–2

4SE

P03

Restored To Defaults

5. To reset the display parameters to the factory defaults,scroll to and highlight "Use Defaults". Press the "Enter"key to activate the "Use Defaults" function. A messageindicating the display parameters are reset to thefactory defaults will be displayed, then the display willreturn to the "Setup 4-Up Display" menu.

OURGP11,00000B2 –19–03SEP03–6/14

RG

1322

7–U

N–2

6SE

P03

Custom Setup

6. Custom Setup - To perform a custom setup of the4-Up Display, use the arrow buttons to scroll to andhighlight "Custom Setup" on the display.

15-31 013004

PN=69



OURGP11,00000B2 –19–03SEP03–7/14

RG

1322

8–U

N–2

6SE

P03

Select Parameters

7. The quadrant with the highlighted parameter value isthe current selected parameter. Use the "Arrow" keysto highlight the value in the quadrant you wish tochange to a new parameter.

OURGP11,00000B2 –19–03SEP03–8/14

RG

1322

9–U

N–2

6SE

P03

List Of Engine Parameters

8. Press the "Enter" key and a list of engine parameterswill be displayed.

OURGP11,00000B2 –19–03SEP03–9/14

RG

1323

0–U

N–2

6SE

P03

Select Desired Engine Parameter

9. The parameter that is highlighted is the selectedparameter for the screen. Use the "arrow" keys tohighlight the new parameter to be placed in the "4-UpDisplay".


15-32 013004

PN=70


OURGP11,00000B2 –19–03SEP03–10/14

RG

1323

1–U

N–2

6SE

P03

Enter Selected Parameter

10. Press the "Enter" key to change the selectedparameter in the quadrant to the new parameter.

OURGP11,00000B2 –19–03SEP03–11/14

RG

1323

2–U

N–2

6SE

P03

Return To 4-Up Custom Setup

11. Use the "Menu" keys to return to the "4-Up CustomSetup" screen.

OURGP11,00000B2 –19–03SEP03–12/14

RG

1315

3–U

N–2

4SE

P03

4-Up Display

12. The selected quadrant has now changed to the newselected parameter.


15-33 013004

PN=71


OURGP11,00000B2 –19–03SEP03–13/14

RG

1315

4–U

N–2

4SE

P03

Return To Main Menu

13. Repeat the parameter selection process until allspaces are as desired.


OURGP11,00000B2 –19–03SEP03–14/14

RG

1315

5–U

N–0

7OC

T03

Select Remaining Parameters

15. Press the "Menu" key to exit the main menu andreturn to the engine parameter display.

15-34 013004

PN=72


OURGP11,0000142 –19–04DEC03–1/1

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 operating temperature range is80° – 94°C (176° – 202°F). If coolant temperaturerises above 105°C (221°F), reduce load on engine.Unless temperature drops quickly, stop engine anddetermine cause before resuming operation.

Operate the engine under a lighter load and at slowerthan normal speed for first 15 minutes after start-up.DO NOT run engine at slow idle.

Stop engine immediately if there are any signs of partfailure. Symptoms that may be early signs of engineproblems are:

• Sudden drop in oil pressure• Abnormal coolant temperatures• Unusual noise or vibration• Sudden loss of power• Excessive black exhaust• Excessive fuel consumption• Excessive oil consumption• Fluid leaks

OURGP11,00000EC –19–03OCT03–1/5

Break-In Service

RG

8009

–UN

–06J

AN

99

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 and life.DO NOT exceed 100 hours of operation with break-in oil.

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

2. If the engine has significant operating time at idle,constant speeds, and/or light load usage, or makeupoil is required in the first 100 hour period, a longerbreak-in period may be required. In these situations, anadditional 100 hour break-in period is recommendedusing a new change of John Deere Engine Break-In Oiland a new John Deere oil filter.


15-35 013004

PN=73


OURGP11,00000EC –19–03OCT03–2/5

RG8028A –UN–15JAN99

Check Engine Oil

A—Crosshatch Pattern On Dipstick

IMPORTANT: DO NOT add makeup oil until the oillevel is BELOW the ADD mark ondipstick. John Deere Engine Break-InOil (TY22041) should be used to makeup any oil consumed during thebreak-in period.

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

IMPORTANT: DO NOT use PLUS-50 Engine Oilduring the break-in period of a newengine or engine that has had a majoroverhaul. PLUS-50 oil will not allow anew or overhauled engine to properlywear during this break-in period.

DO NOT fill above the crosshatchpattern (A) or the FULL mark, whicheveris present. Oil levels anywhere withinthe crosshatch are considered in theacceptable operating range.

SpecificationEngine1—Oil Pressure at FullLoad Rated Speed 345 ± 103 kPa (3.45 ± 1.03 bar)

(50 ± 15 psi).................................

Minimum Oil Pressure at RatedSpeed 275 (2.75 bar) (40 psi).....................................................................Minimum Oil Pressure at 850 rpm 103 kPa (1.03 bar) (15 psi).................Coolant Temperature Range 80°–94° C (176°–202° F)..............................

PLUS-50 is a trademark of Deere & Company

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


15-36 013004

PN=74


OURGP11,00000EC –19–03OCT03–3/5

RG

9867

–UN

–15J

AN

99

Remove Oil Filter

A—Oil Filter

4. During the first 20 hours, avoid prolonged periods ofengine idling or sustained maximum load operation. Ifengine will idle longer than 5 minutes, stop engine.

5. After the first 100 hours (maximum), change engine oiland replace engine oil filter (A). (See CHANGEENGINE OIL AND FILTER in Lubrication andMaintenance/250 Hour Section.) Fill crankcase withseasonal viscosity grade oil. (See DIESEL ENGINEOIL, in Fuels, Lubricants, and Coolant Section.)

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

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


15-37 013004

PN=75


OURGP11,00000EC –19–03OCT03–4/5R

G60

02–U

N–2

7JA

N92

Coolant Temperature Gauge - Mechanically Controlled Engine

RG

1313

3–U

N–0

7OC

T03

Coolant Temperature Gauge - Electronically Controlled Engine

A—Coolant Temperature Gauge

6. Watch coolant temperature gauge (A) closely. Ifcoolant temperature rises above 112°C (234°F), reduceload on engine. Check sea (raw) water strainer forplugging on heat exchanger engines. Unlesstemperature drops quickly, stop the engine anddetermine the cause before resuming operation.

7. Check poly-vee belt for proper alignment and seatingin pulley grooves.


15-38 013004

PN=76


OURGP11,00000EC –19–03OCT03–5/5

RG

9835

–UN

–05J

AN

99

Zinc Plugs

A—Zinc PlugsB—End Cap

Two zinc plugs (A) are installed in the sea watercooling system to help neutralize the corrosive actionof salt water on internal cavities of marine enginecomponents. The reaction of the zinc, when exposedto the salt water, causes the plugs to deteriorateinstead of critical engine components.

8. After the first 50—100 hours or 2—4 weeks ofoperation, remove zinc plug from each heat exchangerend cap (B) and inspect for corrosion to get an idea ofrate of deterioration in sea water.

If rate of corrosion is slight at 50—100 hours or 2—4weeks initial inspection, zinc plugs should be inspectedat 250 hour intervals thereafter. (See INSPECT ANDREPLACE ZINC PLUGS in Lubrication &Maintenance/250 Hour Section)

RG,RG34710,5555 –19–03JAN02–1/1

Auxiliary Gear Drive Limitations

RG

7634

A–U

N–2

2JA

N99

Auxiliary Gear Drive

A—Auxiliary Gear Drive

IMPORTANT: When attaching a sea water pump orother accessory to be driven by theauxiliary gear drive (A) (engine timinggear train at front of engine), powerrequirements of the accessory must belimited to values listed below:

• 30 kW (40 hp) Continuous Operation• 37 kW (50 hp) Intermittent Operation

15-39 013004

PN=77


RG,RG34710,5556 –19–20MAY96–1/1

Generator Set Power Units

To assure that your engine will deliver efficient generatoroperation when needed, start engine and run at ratedspeed (with 50%—70% load) for 30 minutes every 2weeks. DO NOT allow engine to run extended period oftime with no load.

15-40 013004

PN=78


OURGP11,0000212 –19–09OCT03–1/2

Starting the Engine

TS

220

–UN

–23A

UG

88

Use Proper Ventilation

RG

1323

3–U

N–2

9SE

P03

Wait To Start Screen

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

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

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

1. Perform all prestarting checks outlined in Lubrication &Maintenance/Daily Section later in this manual.

2. Open the fuel supply shut-off valve.

3. Set marine gear control lever in the “NEUTRAL”position on propulsion units.

4. Move the throttle control lever approximately 1/3 of theway off the idle position.

5. For Electronically Controlled Engines

Turn the key switch to the ON position. The "Wait ToStart Preheating" message will be displayed whenambient temperatures require preheating (for engineswith preheating options). The timer will display minutesand seconds, counting down to zero. Once the timerhas reach 0:00 and the "Wait to Start" message is nolonger displayed, you may start the engine.

For Mechanically Controlled Engines

Turn the key switch to the ON position.

15-41 013004

PN=79



OURGP11,0000212 –19–09OCT03–2/2

RG

1329

1–U

N–0

6NO

V03

Start Engine - Mechanically Controlled Engine

RG

1313

4–U

N–0

7OC

T03

Start Engine - Electronically Controlled Engine

A—Key SwitchB—Start ButtonC—Oil Pressure GaugeD—Warning Light

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

If the start switch button is releasedbefore the engine starts, wait until thestarter and the engine stop turningbefore trying again. This will preventpossible damage to the starter and/orflywheel.

NOTE: Key switch (A) on main (standard) instrumentpanel must be in “ON” position to start engineusing fly bridge (optional) instrument panel.

6. Press start button (B) to crank the engine. When theengine starts, release the button.

7. After the engine starts, observe the oil pressure gauge(C) until it reads at least 138 kPa (1.38 bar) (20 psi).

8. For Mechanically Controlled Engines Only: Observethe “Low Voltage” warning light (D) immediately afterengine starts, if light flashes on and off, stop engineand check V-belt tension and alternator output voltage.

9. Warm up the engine at or below 1200 rpm with no loadfor 1-2 minutes. See following guidelines.

10. Check all gauges for normal engine operation. Ifoperation is not normal, stop the engine anddetermine the cause.

11. Check sea water outlet for water flow. Check exhaustpipe for water flow on engines with wet exhaustsystems.

If sea water does not flow within one minute afterengine starts, stop engine and check sea cock, seawater strainer, and sea water pump for restrictions.

15-42 013004

PN=80


OURGP11,0000146 –19–11DEC03–1/1

Emergency Starting Of 6068SFM50 WithElectronic Failure

In the event of an ECU failure, refer to the ElectricalSystem Layout on page 50-7 and plug connector (J) intoconnector (H). The engine will then be in a “limp home”mode. Contact your servicing dealer for repairs.

15-43 013004

PN=81


OURGP11,00000EE –19–03OCT03–1/1

Warming Engine

RG

9836

–UN

–05J

AN

99

Oil Pressure And Coolant Temperature Gauges - MechanicallyControlled Engines

RG

1313

5–U

N–0

7OC

T03

Oil Pressure And Coolant Temperature Gauges - ElectronicallyControlled Engines

A—Oil Pressure GaugeB—Coolant Temperature Gauge

IMPORTANT: To assure proper lubrication, operateengine at or below 1200 rpm with noload for 1–2 minutes. Extend this period2–4 minutes when operating attemperatures below freezing.

Engines used in generator setapplications where the governor islocked at a specified speed may nothave a slow idle function. Operate theseengines at high idle for 1 to 2 minutesbefore applying the load. Thisprocedure does not apply to standbygenerator sets where the engine isloaded immediately upon reaching ratedspeed.

1. Check oil pressure gauge (A) as soon as engine starts.If gauge needle does not rise above minimum oilpressure specification of 105 kPa (1.05 bar) (15.0 psi)within 5 seconds, stop the engine and determine thecause. Normal engine oil pressure is 345 kPa (3.45bar) (50 psi) at rated full load speed (1800–2500 rpm)with oil at normal operating temperature of 115°C(240°F).

NOTE: On certain engines, the oil pressure and coolanttemperature gauges are replaced by indicatorwarning lights. The lights must be "OFF" whenengine is running.

2. Watch coolant temperature gauge (B). Do not placeengine under full load until it is properly warmed up.The normal engine coolant temperature range is 82°–94°C (180°–202°F).

NOTE: It is a good practice to operate the engine under alighter load and at lower speeds than normal forthe first few minutes after start-up.

15-44 013004

PN=82


RG,RG34710,5562 –19–20MAY96–1/1

Idling Engine

Avoid excessive engine idling. Prolonged idling maycause the engine coolant temperature to fall below itsnormal range. This, in turn, causes crankcase oildilution, due to incomplete fuel combustion, andpermits formation of gummy deposits on valves,pistons, and piston rings. It also promotes rapidaccumulation of engine sludge and unburned fuel inthe exhaust system.

Once an engine is warmed to normal operatingtemperatures, engine should be idled at slow idle

speed. Slow idle speed for this engine is 750 rpm atfactory. If an engine will be idling for more than 5minutes, stop and restart later.

NOTE: Generator set applications where the governoris locked at a specified speed may not have aslow idle function. These engines will idle at noload governed speed (high idle).

OURGP11,0000144 –19–08DEC03–1/1

Engaging And Disengaging Front PTO (IfEquipped)

TS

198

–UN

–23A

UG

88

Avoid Entanglement

CAUTION: Entanglement in rotating drivelinecan cause serious injury or death. Keep shieldon PTO driveshaft between clutch housing andthe engine driven equipment at all times duringengine operation. Wear close fitting clothing.Stop the engine and be sure PTO driveline isstopped before making adjustments.

CAUTION: Metal surfaces of PTO housing maybe hot to the touch during operation or atshutdown.

The optional front power take-off (PTO) from John Deeretransfers engine power to auxiliary equipment or movingcomponents.

The PTO clutch is electric and engaged by a switch.Engage the clutch on propulsion engines at enginespeeds below 1200 rpm. Engage Gen-Set engines at noload rpm.

If the power take-off does not work properly, contact yourauthorized servicing dealer or engine distributor.

15-45 013004

PN=83


RG,RG34710,5559 –19–03JAN02–1/1

Cold Weather Operation

TS

1356

–UN

–18M

AR

92

Starting Fluid is Flammable

Additional information on cold weather operation isavailable from your engine distributor or authorizedservicing dealer.

Some engines are equipped with an air intake heaterwhich will make starting the engine easier in cold weather.If equipped, follow steps 1–4 as listed under STARTINGTHE ENGINE, earlier in this section. Switch on the airintake heater for 30 seconds and then proceed to operatethe starter. Follow remaining steps 5–11.

CAUTION: Starting fluid is highly flammable. DONOT use starting fluid on engines equippedwith air intake heaters.

DO NOT use starting fluid near fire, sparks, orflames. DO NOT incinerate or puncture astarting fluid container.

15-46 013004

PN=84


OURGP11,00000C3 –19–08SEP03–1/2

Stopping the Engine

RG

6003

–UN

–27J

AN

92

Stopping The Engine - Mechanically Controlled Engines

RG

1329

0–U

N–0

6NO

V03

Stopping The Engine - Electonically Controlled Engines

A—Key SwitchB—Stop Button - Mechanically Controlled

EnginesC—Diagnostic Gauge/Hour Meter

IMPORTANT: Before stopping an engine that hasbeen operating at working load, idleengine at least 5 minutes at 1000–1200rpm to cool hot engine parts.

Engines in generator set applicationswhere the engine controller (ECU) islocked at a specified speed and no slowidle function is available, run engine forat least 5 minutes at fast idle and noload.

1. Remove load from engine or shift marine gear to“NEUTRAL” and run engine for at least 5 minutes at1000–1200 rpm to allow coolant and oil to carry heataway from the combustion chamber, turbocharger,pistons, and bearings.

2. For Mechanically Controlled Engines - Firmlydepress the “STOP” button (B) until engine stops. Turnkey switch (A) to “OFF” position and remove key fromignition.

By completely stopping the engine before turning thekey switch to “OFF”, tests the alarm and keeps thetachometer working until shutdown.

For Electronically Controlled Engines - Turn keyswitch (A) to “OFF” position and remove key fromignition.

3. If vessel will not be used for several days, close fuelvalves and sea cock.

4. Turn main electrical power switch to “OFF”, ifequipped.

5. Fill the fuel tank to minimize possible watercondensation problems. Filling tanks at end of daydrives out moisture-laden air.

15-47 013004

PN=85



OURGP11,00000C3 –19–08SEP03–2/2

6. For Heat Exchanger Engines: If the engine will besubjected to temperatures at or below 0° C (32° F),open the sea water pump end cover to drain the seawater from the system to prevent freezing. The seawater pump will require priming before starting theengine.

7. Observe the hour meter reading on diagnosticgauge/hour meter (C) to determine if periodicmaintenance is necessary. Make appropriate entries inmaintenance logs. (See LUBRICATION ANDMAINTENANCE RECORDS Section.)

8. Perform required periodic maintenance on all otherequipment, as recommended by the equipmentmanufacturers.

15-48 013004

PN=86


RG,RG34710,5564 –19–03JAN02–1/1

Using a Booster Battery or Charger

TS

204

–UN

–23A

UG

88

Exploding Battery

RG

4678

–UN

–14D

EC

88

12-Volt System

RG

4698

–UN

–14D

EC

88

24-Volt System

A—12-Volt Machine Battery (ies)B—12-Volt Booster Battery (ies)C—Booster CableD—Cable to Starting Motor

A 12-volt booster battery can be connected in parallel withbattery(ies) on the unit to aid in cold weather starting.ALWAYS use heavy duty jumper cables.

CAUTION: Gas given off by battery is explosive.Keep sparks and flames away from battery.Before connecting or disconnecting a batterycharger, turn charger off. Make last connectionand first disconnection at a point away frombattery. Always connect NEGATIVE (–) cablelast and disconnect this cable first.

IMPORTANT: Be sure polarity is correct beforemaking connections. Reversed polaritywill damage electrical system. Alwaysconnect positive to positive andnegative to ground. Always use 12-voltbooster battery for 12-volt electricalsystems and 24-volt booster battery(ies)for 24-volt electrical systems.

1. Connect booster battery or batteries to produce therequired system voltage for your engine application.

NOTE: To avoid sparks, DO NOT allow the free ends ofjumper cables to touch the engine.

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

3. Connect the other end of the jumper cable to thePOSITIVE (+) post of battery connected to starter.

4. Connect one end of the other jumper cable to theNEGATIVE (–) post of the booster battery.

5. ALWAYS complete the hookup by making the lastconnection of the NEGATIVE (–) cable to a goodground on the engine frame and away from thebattery(ies).

6. Start the engine. Disconnect jumper cablesimmediately after engine starts. Disconnect NEGATIVE(–) cable first.

15-49 013004

PN=87

Lubrication and Maintenance

OURGP11,0000249 –19–05NOV03–1/1

Observe Service Intervals

RG

6113

–UN

–29J

AN

92

Hour Meter - Mechanically Controlled Engines

RG

1313

7–U

N–0

7OC

T03

Hour Meter - Electronically Controlled Engines

A—Diagnostic Gauge/Hour Meter

IMPORTANT: Recommended service intervals are fornormal operating conditions. ServiceMORE OFTEN if engine is operatedunder adverse conditions. Neglectingmaintenance can result in failures orpermanent damage to the engine.

Using diagnostic gauge/hour meter (A) as a guide,perform all services at the hourly intervals indicated onfollowing pages. At each scheduled maintenance interval,perform all previous maintenance operations in addition tothe ones specified. Keep a record of hourly intervals andservices performed using charts provided in Lubricationand Maintenance Records Section.

20-1 013004

PN=88


DPSG,OUOE003,20 –19–03JAN02–1/1

Use Correct Fuels, Lubricants, and Coolant

TS

100

–UN

–23A

UG

88

Parts Network

IMPORTANT: Use only fuels, lubricants, and coolantsmeeting specifications outlined inFuels, Lubricants, and Coolant Sectionwhen servicing your John DeereEngine.

Consult your John Deere engine distributor, servicingdealer or your nearest John Deere Parts Network forrecommended fuels, lubricants, and coolant. Alsoavailable are necessary additives for use when operatingengines in tropical arctic, or any other adverse conditions.

20-2 013004

PN=89


OURGP11,00000F0 –19–03OCT03–1/2

Lubrication and Maintenance Service IntervalChart—Propulsion Power Units

Lubrication and Maintenance Service Intervals

250 Hour/6 500 Hour/12 2000 Hour/24 Service AsItem Daily Month Month Month Required

Check Engine Oil Level and Coolant Level •

Check Sea Water Strainer •

Check Air Cleaner Dust Unloader Valve & Restriction •Indicator Gaugea

Visual Walkaround Inspection •

Check Fuel Filter Water Separator Bowl •

Change Engine Oil And Replace Oil Filterb •

Service Fire Extinguisher •

Service Battery •

Inspect and Replace Zinc Plugs •

Check Belt Tension and Wear (Manual Tensioner) •

Check Engine Mounts •

Replace Crankcase Vent Filter (If Equipped) •

Clean Crankcase Ventilation Assembly •

Check Air Intake Hoses, Connections, & System •

Replace Fuel Filter Elements •

Check Automatic Belt Tensioner and Belt Wear •

Check Cooling System •

Coolant Solution Analysis-Add SCAs as required •

Inspect and Clean Heat Exchanger Core and Aftercooler •Core (If Equipped)

Check Engine Speeds •

Check Engine Electrical Ground •

Check Crankshaft Vibration Damper (6-Cylinder) •

Pressure Test Cooling System •

Inspect and Repair Sea Water Pump •

Check and Adjust Engine Valve Clearance •

Flush And Refill Cooling Systemc •

Test Thermostats •

Add Coolant •

Replace Air Cleaner Element •aReplace primary air cleaner element when restriction indicator shows a vacuum of 625 mm (52 in.) H2ObDuring engine break-in, change the oil and filter for the first time before 100 hours of operation. If the recommended engine oils, John DeerePLUS-50 or ACEA E4/E5 and the recommended John Deere filter are used, the oil and filter change interval is extended to every 375 hours.cIf John Deere COOL-GARD is used, the flushing interval may be extended to 3000 hours or 36 months. If John Deere COOL-GARD is usedand the coolant is tested annually AND additives are replenished as needed by adding a supplemental coolant additive, the flushing intervalmay be extended to 5000 hours or 60 months, whichever occurs first.

20-3 013004

PN=90



OURGP11,00000F0 –19–03OCT03–2/2


250 Hour/6 500 Hour/12 2000 Hour/24 Service AsItem Daily Month Month Month Required

Service Dry Air Cleaner Element •

Replace Alternator Drive Belt •

Check Front PTO (If Equipped) •

Bleed Fuel System •

20-4 013004

PN=91


OURGP11,00000F1 –19–03OCT03–1/2

Lubrication and Maintenance Service IntervalChart—Generator Sets


Every 2 350 Hour/6 500 Hour/12 2000 Hour/24 Service AsItem Weeks Month Month Month Required

Operate Engine at Rated Speed and 50%—70% Loadfor a Minimum of 30 Minutes •

Check Engine Oil Level and Coolant Level •

Check Sea Water Strainer •

Check Air Cleaner Dust Unloader Valve & Restriction •Indicator Gaugea

Visual Walkaround Inspection •

Check Fuel Filter Water Separator Bowl •

Change Engine Oil And Replace Oil Filterb •

Service Fire Extinguisher •

Service Battery •

Inspect and Replace Zinc Plugs •

Check Belt Tension and Wear (Manual Tensioner) •

Check Engine Mounts •

Replace Crankcase Vent Filter (If Equipped) •

Clean Crankcase Ventilation Assembly •

Check Air Intake Hoses, Connections, & System •

Replace Fuel Filter Elements •

Check Automatic Belt Tensioner and Belt Wear •

Check Cooling System •

Coolant Solution Analysis-Add SCAs as required •

Inspect and Clean Heat Exchanger Core and Aftercooler •Core (If Equipped)

Check Engine Speeds •

Check Engine Electrical Ground •

Check Crankshaft Vibration Damper (6-Cylinder) •

Pressure Test Cooling System •

Inspect and Repair Sea Water Pump •

Check and Adjust Engine Valve Clearance •

Flush And Refill Cooling Systemc •

Test Thermostats •

Add Coolant •aReplace primary air cleaner element when restriction indicator shows a vacuum of 625 mm (52 in.) H2ObDuring engine break-in, change the oil and filter for the first time before 100 hours of operation. No extended interval is allowed beyond this350 hour interval for gen-sets.cIf John Deere COOL-GARD is used, the flushing interval may be extended to 3000 hours or 36 months. If John Deere COOL-GARD is usedand the coolant is tested annually AND additives are replenished as needed by adding a supplemental coolant additive, the flushing intervalmay be extended to 5000 hours or 60 months, whichever occurs first.

20-5 013004

PN=92



OURGP11,00000F1 –19–03OCT03–2/2


Every 2 350 Hour/6 500 Hour/12 2000 Hour/24 Service AsItem Weeks Month Month Month Required

Replace Air Cleaner Element •

Service Dry Air Cleaner Element •

Replace Alternator Drive Belt •

Check Front PTO (If Equipped) •

Bleed Fuel System •

20-6 013004

PN=93

Lubrication & Maintenance/Daily

OURGP11,00000F2 –19–03OCT03–1/5

Daily Prestarting Checks

RG

9837

–UN

–12J

AN

99

Left Side Oil Filler Cap

RG

9838

–UN

–05J

AN

99

Rocker Arm Cover Filler CapRG8028B –UN–15JAN99

Crosshatch On Oil Dipstick

A—DipstickB—Left Side Oil Filler CapC—Rocker Arm Filler CapD—Crosshatch On Oil Dipstick

Do the following BEFORE STARTING THE ENGINE forthe first time each day:

IMPORTANT: DO NOT add makeup oil until the oillevel is BELOW the add mark.

Depending on application, oil dipstick (A) and oil filler cap(B) may be located on either the left or the right side ofengine. In addition, oil may be added at rocker arm fillercap (C).

1. Check engine oil level on dipstick (A). Add as required,using seasonal viscosity grade oil. (See DIESELENGINE OIL in Fuels, Lubricants, and Coolant Sectionfor oil specifications.)

IMPORTANT: DO NOT fill above the top mark on thedipstick. Oil levels anywhere withincrosshatch (D) are considered in theacceptable operating range.


25-1 013004

PN=94


OURGP11,00000F2 –19–03OCT03–2/5

TS

281

–UN

–23A

UG

88


RG

9839

–UN

–05J

AN

99

Engine Top Tank

A—Engine Top Tank

CAUTION: Explosive release of fluids frompressurized cooling system can cause seriousburns.

Only remove filler cap when engine is cold orwhen cool enough to touch with bare hands.Slowly loosen cap to first stop to relievepressure before removing completely.

2. Check the coolant level in engine top tank (A) whenengine is cold. Coolant level should be at bottom offiller neck. Fill with proper coolant solution if level islow. (See ADDING COOLANT in Service As RequiredSection.) Check overall cooling system for leaks.

NOTE: Refer to your boat operator’s manual forrecommendations for non-John Deere suppliedaccessories.

OURGP11,00000F2 –19–03OCT03–3/5

RG

5993

–UN

–27J

AN

92Sea Water Strainer

IMPORTANT: A restricted or clogged sea waterstrainer will result in hotter than normal(or overheated) engine coolant andmarine gear oil temperatures.

3. The sea water strainer should be checked daily andcleaned as required, depending upon the operatingenvironment.


25-2 013004

PN=95


OURGP11,00000F2 –19–03OCT03–4/5

RG

9874

–UN

–12F

EB

99

Air Intake Restriction Gauge

A—Air Intake Restriction Gauge

4. If equipped with air intake restriction indicator gauge(A), check gauge to determine if air cleaner needs tobe serviced.

IMPORTANT: Maximum air intake restriction is 625mm (25 in. H2O). A clogged air cleanerelement will cause excessive intakerestriction and a reduced air supply tothe engine.

5. Make a thorough inspection of the enginecompartment. Look for oil or coolant leaks, worn drivebelts, loose connections and trash build-up. Removetrash buildup and have repairs made as needed ifleaks are found.

NOTE: Wipe all fittings, caps, and plugs beforeperforming any maintenance to reduce the chanceof system contamination.

Inspect:

• Engine shields and guards for trash build-up.• Air intake system hoses and connections for cracks

and loose clamps.• Alternator drive belt for cracks, breaks or other

damage.• Water pump for coolant leaks.• Coolant system for leaks.

NOTE: It is normal for a small amount of leakage to occuras the engine cools down and parts contract.Excessive coolant leakage may indicate the needto replace the water pump seal. Contact yourengine distributor or servicing dealer for repairs.

6. Turn key switch to “ON” position and checkinstruments for proper operation. Turn key switch“OFF”.

7. Refer to manufacturer’s literature for marine gear andgenerator set daily service recommendations.

25-3 013004

PN=96



OURGP11,00000F2 –19–03OCT03–5/5

RG

1325

3–U

N–0

8DE

C03

Drain Primary Fuel Filter - 6068SFM50 Shown

A—Thumb Screw

8. Check the instrument panel for “water in fuel warning”.If necessary, drain water or debris using the followingsteps.

a. Loosen thumb screw (A) and drain water and debrisinto a suitable container.

b. Dispose of water and debris in an environmentallysafe manner.

25-4 013004

PN=97

Lubrication & Maintenance/250 Hour/6 Month

OURGP11,000011B –19–20OCT03–1/4

Changing Engine Oil and Replacing Oil Filter

NOTE: During break-in, change engine oil and filter forthe first time before 100 hours maximum ofoperation.

If John Deere PLUS-50 or ACEA-E4/E5 engine oil and aJohn Deere oil filter are used, the oil and filter changeinterval may be extended by 50 percent or to 375 hours.

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

OILSCAN or OILSCAN PLUSis a John Deere samplingprogram to help you monitor machine performance andidentify potential problems before they cause seriousdamage. OILSCAN and OILSCAN PLUS kits areavailable from your John Deere engine distributor orservicing dealer. Oil samples should be taken prior to theoil change. Refer to instructions provided with kit.

To change engine oil and oil filter:

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

OURGP11,000011B –19–20OCT03–2/4

RG

4881

–UN

–29N

OV

88

Oil Pan Drain Plug

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

2. Remove oil pan drain plug (arrow).

3. Drain crankcase oil from engine while warm.

NOTE: Drain plug location may vary, depending on theapplication.

30-1 013004

PN=98



OURGP11,000011B –19–20OCT03–3/4

RG

1219

6–U

N–1

3MA

R02

Oil Filter

RG

1161

7–U

N–2

4OC

T01

Oil Filter Seals

RG

1161

8–U

N–2

4OC

T01

Oil Filter Mounting Header

A—Oil Filter ElementB—Inner SealC—Outer SealD—Sealing Surface On HeaderE—Sealing Surface On HeaderF—Dust Seal

4. Turn filter element (A) using a suitable filter wrench toremove. Discard oil filter element.

NOTE: Depending on engine application, oil filter may belocated on either side of the engine in a high- orlow-mount location.

IMPORTANT: Filtration of oils is critical to properlubrication. Always change filterregularly. Use filter meeting John Deereperformance specifications.

5. Apply clean engine oil to the new filter at the inner (B)and outer (C) seals and to filter threads.

6. Wipe both sealing surfaces of the header (D, E) with aclean rag. Ensure that the notches in dust seal (F) areproperly installed in the slots of the housing. Replace ifdamaged.

IMPORTANT: When installing filter element, HANDTIGHTEN only. A filter wrench may beused for REMOVAL ONLY.

7. Install and tighten oil filter by hand until firmly againstdust seal (F). DO NOT apply an extra 3/4 to 1-1/4 turnafter gasket contact as done with standard filters.

8. Tighten drain plug to specifications.

SpecificationOil Pan Drain Plug With CopperWasher—Torque 70 N•m (52 lb-ft).............................................................Oil Pan Drain Plug With O-Ring—Torque 50 N•m (37 lb-ft).............................................................................


30-2 013004

PN=99


OURGP11,000011B –19–20OCT03–4/4

RG

1219

7–U

N–1

3MA

R02

Rocker Arm Cover Oil Filler Opening

A—Rocker Arm Cover Oil Filler Opening

9. Fill engine crankcase with correct John Deere engineoil through rocker arm cover opening (A). (See DIESELENGINE OIL in Fuels, Lubricants, and Coolant Sectionfor determining correct engine oil.)

To determine the correct oil fill quantity for your engine,see ENGINE CRANKCASE OIL FILL QUANTITIES inthe Specifications Section of this manual.

IMPORTANT: Immediately after completing any oilchange, crank engine for 30 secondswithout permitting engine to start. Thiswill help insure adequate lubrication toengine components before enginestarts.

NOTE: Crankcase oil capacity may vary slightly.ALWAYS fill crankcase within crosshatch markson dipstick. DO NOT overfill.

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

11. Stop engine and check oil level after 10 minutes. Oillevel reading should be within crosshatch on dipstick.

OURGP11,000015D –19–28JAN04–1/1

Servicing Fire Extinguisher

RW

4918

–UN

–15D

EC

88

Fire Extinguisher

A fire extinguisher (A) is available from your authorizedservicing dealer or engine distributor.

Read and follow the instructions which are packaged withit. The extinguisher should be inspected at least every 250hours of engine operation or every 6 months. Onceextinguisher is operated, no matter how long, it must berecharged. Keep record of inspections on the tag whichcomes with the extinguisher instruction booklet.

30-3 013004

PN=100


RG,RG34710,5568 –19–20MAY96–1/2

Servicing Battery

TS

204

–UN

–23A

UG

88

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 a metalobject across the posts. Use a voltmeter orhydrometer.

Always remove grounded NEGATIVE (–) batteryclamp first and replace it last.

WARNING: Battery posts, terminals, and relatedaccessories contain lead and lead compounds, chemicalsknown to the State of California to cause cancer andreproductive harm. Wash hands after handling.

1. On regular batteries, check electrolyte level. Fill eachcell to bottom of filler neck with distilled water.

NOTE: Low-maintenance or maintenance-free batteriesshould require little additional service. However,electrolyte level can be checked by cutting thecenter section of decal on dash-line, andremoving cell plugs. If necessary, add clean, softwater to bring level to bottom of filler neck.

2. Keep batteries clean by wiping them with a damp cloth.Keep all connections clean and tight. Remove anycorrosion, and wash terminals with a solution of 1 partbaking soda and 4 parts water. Tighten all connectionssecurely.

NOTE: Coat battery terminals and connectors with amixture of petroleum jelly and baking soda toretard corrosion.

3. Keep battery fully charged, especially during coldweather. If a battery charger is used, turn charger offbefore connecting charger to battery(ies). AttachPOSITIVE (+) battery charger lead to POSITIVE (+)battery post. Then attach NEGATIVE (–) batterycharger lead to a good ground.

30-4 013004

PN=101



RG,RG34710,5568 –19–20MAY96–2/2

TS

203

–UN

–23A

UG

88

Sulfuric Acid

CAUTION: Sulfuric acid in battery electrolyte ispoisonous. It is strong enough to burn skin, eatholes in clothing, and cause blindness ifsplashed into eyes.

Avoid the hazard by:

1. Filling batteries in a well-ventilated area.2. Wearing eye protection and rubber gloves.3. Avoiding breathing fumes when electrolyte is

added.4. Avoiding spilling or dripping electrolyte.5. Use proper jump start procedure.

If you spill acid on yourself:

1. Flush your skin with water.2. Apply baking soda or lime to help neutralize

the acid.3. Flush your eyes with water for 10–15

minutes. Get medical attention immediately.

If acid is swallowed:

1. Drink large amounts of water or milk.2. Then drink milk of magnesia, beaten eggs, or

vegetable oil.3. Get medical attention immediately.

In freezing weather, run engine at least 30 minutes toassure thorough mixing after adding water to battery.

If necessary to replace battery(ies), replacements mustmeet or exceed the following recommended capacities at-18°C (0°F):

Specification12 Volt Standard Duty Starter—Cold Cranking Amps 640............................................................................12 Volt Heavy Duty Starter—ColdCranking Amps 800.....................................................................................24 Volt Standard Duty Starter—Cold Cranking Amps 570............................................................................

30-5 013004

PN=102


OURGP11,0000100 –19–07OCT03–1/2

Inspect and Replacing Zinc Plugs

RG

9835

–UN

–05J

AN

99

Inspect Zinc Plugs

A—Zinc PlugsB—End Cap

Two zinc plugs (A) are installed in the sea water coolingsystem to help reduce the corrosive action of salt in thesea water. The reaction of the zinc to sea water causesthe plugs to deteriorate, instead of the more criticalcooling system parts. Therefore, the zinc plugs MUST BEinspected every 250 Hours.

NOTE: Zinc plugs are located in each heat exchangerend cap and are mounted on hex-head pipe plug.

1. Remove zinc rod from each end cap (B) and observecondition of each.

2. Tap the zinc rods lightly with a hammer. If rod flakesapart when tapped, install a new zinc plug.

OURGP11,0000100 –19–07OCT03–2/2

RG

6007

–UN

–27J

AN

92Zinc Plug Erosion

A—Measure Zinc PlugsB—Measure LengthC—Measure Diameter

3. Measure zinc plugs (A) to determine the amount oferosion on length (B) and outer diameter (C).

If length is less than 15.9 mm (0.63 in.) or outer diameteris less than 4.8 mm (0.19 in.) on either plug, replace allzinc plugs.

NOTE: Zinc plug new part dimensions are 31.8 mm (1.25in.) long and 9.5 mm (0.38 in.) outer diameter.

30-6 013004

PN=103


OURGP11,0000143 –19–04DEC03–1/1

Checking Belt Wear (Manual Tensioner)

RG

9872

–UN

–12F

EB

99

Check Belt Tension

RG

9873

–UN

–12F

EB

99

Tensioner ArmA—Belt GuardB—Mounting Cap ScrewsC—Tensioner ArmD—Notched Units

NOTE: While belt is loosened, inspect pulleys andbearings. Rotate and feel for hard turning or anyunusual sounds. If pulleys or bearings needreplacement, see your John Deere dealer.

Inspect belt for cracks, fraying, or stretched-out areas.Replace if necessary. (See REPLACING BELT (MANUALTENSIONER) in Service as Required Section.

NOTE: It is not necessary to remove belt guard (A) tocheck belt wear.

1. Loosen both belt tensioner mounting cap screws (B).

2. Swing tensioner arm (C) to remove all belt slack.

NOTE: Belt adjustment is measured using notched units(D) above the adjusting cap screw slot on thetensioner.

3. Using the notches on tensioner to count units, movethe tensioner arm to stretch belt 1-1/2 units for appropriatetension on new belt. (Move arm one unit for used belt.)

4. Tighten tensioner mounting cap screws (B) to 70 N•m(52 lb-ft).

30-7 013004

PN=104


DPSG,OUOD007,313 –19–04JAN02–1/1

Checking Engine Mounts

RG

9841

–UN

–06J

AN

99

Check Engine Mounts

A—Engine Mounts

Engine mounting is the responsibility of the vessel orgenerator manufacturer. Follow manufacturer’s guidelinesfor mounting specifications. Front engine mounts (A) onlyare available from John Deere.

IMPORTANT: Use only SAE Grade 8 or higher gradeof hardware for engine mounting.

1. Check the engine mounting bolts on support frame andengine block for tightness. Tighten as necessary.

2. Inspect overall condition of vibration isolators, ifequipped. Replace isolators, as necessary, if rubber hasdeteriorated or mounts have collapsed.

30-8 013004

PN=105


OURGP11,000020A –19–08OCT03–1/1

Replace Crankcase Vent Filter (If Equipped)

RG

1328

8–U

N–1

7NO

V03

Replace Crankcase Vent Filter

NOTE: Change closed crankcase vent filter every 500hours or whenever restriction indicator on top ofhousing pops up.

1. Open clips (A) and remove the crankcase vent bowl.

2. Remove old filter and discard.

3. Install new filter in bowl and install bowl.

4. Press restriction indicator (B) down to reset.

RG,RG34710,5574 –19–04JAN02–1/1

Cleaning Crankcase Vent Tube

RG

9842

–UN

–06J

AN

99

Check Crankcase Vent TubeA—Crankcase Vent Tube

If you operate the engine in dusty conditions, clean thetube at shorter intervals.

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

2. Install the vent tube. Be sure the O-ring fits correctly inthe rocker arm cover for elbow adapter. Tighten hoseclamp.

35-1 013004

PN=106


RG,RG34710,5575 –19–04JAN02–1/1

Checking Air Intake System

RG

9869

–UN

–15J

AN

99

Check Clamps

RG

9875

–UN

–12F

EB

99

Air Restriction Indicator

A—ClampsB—Air Restriction Indicator

IMPORTANT: The air intake system must not leak.Any leak, no matter how small, mayresult in engine failure due to abrasivedirt and dust entering the intakesystem.

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

2. Check clamps (A) on piping which connect the aircleaner, engine and, if present, turbocharger. Tightenclamps as necessary. This will help prevent dirt fromentering the air intake system through looseconnections causing internal engine damage.

IMPORTANT: ALWAYS REPLACE primary air cleanerelement when air restriction indicatorshows vacuum of 625 mm (25 in.) H2O,is torn, or visibly dirty.

3. Test air restriction indicator (B) for proper operation.Replace indicator as necessary.

IMPORTANT: If not equipped with air restrictionindicator, replace air cleaner elementsat 500 Hours or 12 Months, whicheveroccurs first.

4. Replace air cleaner element if restriction indicatorshows vacuum of 625 mm (25 in.) H20, is torn or visiblydirty. Service as necessary. (See REPLACING AIRCLEANER in Service As Required Section.)

35-2 013004

PN=107


OURGP11,0000213 –19–09OCT03–1/2

Replacing Final Fuel Filter/Water Separator

RG

1325

4–U

N–0

6OC

T03

Fuel Filter/Water Separator - 6068SFM50 Shown

RG

1334

4–U

N–2

5NO

V03

Fuel Filter/Water Separator - 4045TFM75 Shown

A—Drain PlugB—Air Vent ScrewC—Retaining RingD—Filter Element

CAUTION: Escaping fluid under pressure canpenetrate the skin causing serious injury.Relieve pressure before disconnecting fuel orother lines. Tighten all connections beforeapplying pressure. Keep hands and body awayfrom pinholes and nozzles which eject fluidsunder high pressure. Use a piece of cardboardor paper to search for leaks. Do not use yourhand.

If any fluid is injected into the skin, it must besurgically removed within a few hours by adoctor familiar with this type injury or gangrenemay result. Doctors unfamiliar with this type ofinjury may call the Deere & Company MedicalDepartment in Moline, Illinois, or otherknowledgeable medical source.

1. Close fuel shut-off valve at bottom of fuel tank (notillustrated).

2. Clean entire area surrounding fuel filter assembly tokeep debris from entering fuel system.

3. Loosen drain plug (A) and air vent screw (B). Drain fuelinto a suitable container.

NOTE: Lifting up on retaining ring (C) as it is rotatedhelps to get it past raised locators.

4. Firmly grasp the retaining ring (C) and rotate itclockwise 1/4 turn (when viewed from the top). Removering with filter element (D).

5. Inspect filter mounting base for cleanliness. Clean asrequired.

NOTE: Raised locators on fuel filter canister must beindexed properly with slots in mounting base forcorrect installation.

6. Install new filter element onto mounting base. Be sureelement is properly indexed and firmly seated on base. Itmay be necessary to rotate filter for correct alignment.

35-3 013004

PN=108



OURGP11,0000213 –19–09OCT03–2/2

If equipped with a water separator bowl, remove separatorbowl from filter element. Drain and clean separator bowl.Dry with compressed air. Install bowl onto new filterelement. Tighten securely.

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

8. Install retaining ring onto mounting base making certaindust seal is in place on filter base. Hand tighten ring(about 1/3 turn) until it “snaps” into the detent. DO NOTovertighten retaining ring.

NOTE: The proper installation is indicated when a "click"is heard and a release of the retaining ring is felt.

A plug is provided with the new element forplugging the used element.

9. Open fuel shut-off valve. Whenever the fuel system hasbeen opened up for service (lines disconnected or filtersremoved), it will be necessary to bleed air from thesystem. (See BLEEDING THE FUEL SYSTEM in Serviceas Required Section.)

35-4 013004

PN=109


OURGP11,0000214 –19–09OCT03–1/2

Replacing Primary Fuel Filter Element

RG

1325

5–U

N–0

9DE

C03

Primary Fuel Filter - 6068SFM50 Shown

RG

1334

5–U

N–0

9DE

C03

Primary Fuel Filter - 4045TFM75 Shown

A—Water-In-Fuel Sensor ConnectionB—Retaining RingC—Air Vent ScrewD—Retaining RingE—Filter Element


If any fluid is injected into the skin, it must besurgically removed within a few hours by adoctor familiar with this type injury or gangrenemay result. Doctors unfamiliar with this type ofinjury may call the Deere & Company MedicalDepartment in Moline, Illinois, or otherknowledgeable medical source.

1. Close fuel shut-off valve at bottom of fuel tank (notillustrated).

2. Clean entire area surrounding fuel filter assembly tokeep debris from entering fuel system.

3. Disconnect water in fuel sensor (A).

4. Loosen retaining ring (B) and air vent screw (C). Drainfuel into a suitable container.

NOTE: Lifting up on retaining ring (D) as it is rotatedhelps to get it past raised locators.

5. Firmly grasp the retaining ring (D) and rotate itcounterclockwise 1/4 turn. Remove ring with filter element(E).

6. Inspect filter mounting base for cleanliness. Clean asrequired.


35-5 013004

PN=110


OURGP11,0000214 –19–09OCT03–2/2

NOTE: Raised locators on fuel filter canisters must beindexed properly with slots in mounting base forcorrect installation.

7. Install new filter element onto mounting base. Be sureelement is properly indexed and firmly seated on base. Itmay be necessary to rotate filter for correct alignment.

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

9. Install retaining ring onto mounting base making certaindust seal is in place on filter base. Hand tighten ring(about 1/3 turn) until it “snaps” into the detent. DO NOTovertighten retaining ring.

NOTE: The proper installation is indicated when a "click"is heard and a release of the retaining ring is felt.

A plug is provided with the new element forplugging the used element.

10. Connect water in fuel sensor.

11. Open fuel shut-off valve. Whenever the fuel systemhas been opened up for service (lines disconnected orfilters removed), it will be necessary to bleed air from thesystem. (See BLEEDING THE FUEL SYSTEM in Serviceas Required Section.)

RG,RG34710,5578 –19–25FEB02–1/3

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 maintain proper belt tensionover the life of the belt. If tensioner spring tension is notwithin specification, replace tensioner assembly.


35-6 013004

PN=111


RG,RG34710,5578 –19–25FEB02–2/3

RG

8098

–UN

–18N

OV

97

Cast Stops

A—Cast StopsB—Cast Stop

Checking Belt Wear

The belt tensioner is designed to operate within the limitof arm movement provided by the cast stops (A and B)when correct belt length and geometry is used.

Visually inspect cast stops (A and B) on belt tensionerassembly.

If the tensioner stop on swing arm (A) is hitting the fixedstop (B), check mounting brackets (alternator, belttensioner, idler pulley, etc.) and the belt length. Replacebelt as needed (see REPLACING FAN ANDALTERNATOR BELTS in Service As Required Section).


35-7 013004

PN=112


RG,RG34710,5578 –19–25FEB02–3/3

RG

7977

–UN

–14N

OV

97

Marks on Tensioner

RG

1205

4–U

N–0

8JA

N02

Align Marks

RG

1206

5–U

N–2

8JA

N02

Align Torque Wrench with Pulley and Tensioner

A—Mark On Swing ArmB—Mark On Tensioner Mounting BaseC—Torque Wrench

Checking Tensioner Spring Tension

NOTE: While belt is loosened, inspect pulleys andbearings. Rotate and feel for hard turning or anyunusual sounds. If pulleys or bearings needreplacement, see your John Deere dealer.

A belt tension gauge will not give an accurate measure ofthe belt tension when automatic spring tensioner is used.Measure tensioner spring tension using a torque wrenchand procedure outlined below:

1. Release tension on belt using a breaker bar andsocket on tension arm. Remove belt from pulleys.

2. Release tension on tension arm and remove breakerbar.

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

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

5. Install torque wrench (C) so that it is aligned withcenters of pulley and tensioner. Rotate the swing armusing a torque wrench until marks (A and B) arealigned.

6. Record torque wrench measurement and compare withspecification below. Replace tensioner assembly asrequired.

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

NOTE: Threads on belt tensioner roller cap screw areLEFT-HAND threads

35-8 013004

PN=113


RG,RG34710,5580 –19–20MAY96–1/1

Checking Cooling System

TS

281

–UN

–23A

UG

88



Shut off engine. Only remove filler cap whencool enough to touch with bare hands. Slowlyloosen cap to first stop to relieve pressurebefore removing completely.

IMPORTANT: Air must be expelled from coolingsystem when system is refilled. Loosentemperature sending unit fitting at rearof cylinder head or plug in thermostathousing to allow air to escape whenfilling system. Retighten fitting or plugwhen all the air has been expelled.

1. Check entire cooling system for leaks. Tighten allclamps securely.

2. Thoroughly inspect all cooling system hoses. Replacehoses when hard, flimsy, or cracked.

35-9 013004

PN=114


DPSG,OUOD002,1921 –19–23NOV01–1/2

Replenishing Supplemental CoolantAdditives (SCAs) Between Coolant Changes

RG

6261

–UN

–08D

EC

97

Coolant Check

RG

6262

–UN

–05D

EC

97

JT07298 Coolant/Battery Tester

IMPORTANT: Do not add supplemental coolantadditives when the cooling system isdrained and refilled with John DeereCOOL-GARD

NOTE: If system is to be filled with coolant that does notcontain SCAs, the coolant must be precharged.Determine the total system capacity and premixwith 3% John Deere Coolant Conditioner.

Through time and use, the concentration of coolantadditives is gradually depleted during engine operation.Periodic replenishment of inhibitors is required, even whenJohn Deere COOL-GARD is used. The cooling systemmust be recharged with additional supplemental coolantadditives available in the form of liquid coolant conditioner.

Maintaining the correct coolant conditioner concentration(SCAs) and freeze point is essential in your coolingsystem to protect against rust, liner pitting and corrosion,and freeze-ups due to incorrect coolant dilution.

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

DO NOT mix one brand of SCA with a different brand.

Test the coolant solution at 500 hours or 12 months ofoperation using either John Deere coolant test strips or aCOOLSCAN or COOLSCAN PLUS analysis. If aCOOLSCAN or COOLSCAN PLUS analysis is notavailable, recharge the system per instructions printed onlabel of John Deere Liquid Coolant Conditioner.

COOL-GARD is a registered trademark of Deere & CompanyCOOLSCAN is a registered trademark of Deere & CompanyCOOLSCAN PLUS is a registered trademark of Deere & Company Continued on next page

35-10 013004

PN=115


DPSG,OUOD002,1921 –19–23NOV01–2/2

IMPORTANT: ALWAYS maintain coolant at correctlevel and concentration. DO NOToperate engine without coolant even fora few minutes.

If frequent coolant makeup is required,the glycol concentration should bechecked with JT07298 Coolant/BatteryTester to ensure that the desired freezepoint is maintained. Followmanufacturer’s instructions providedwith Coolant/Battery Tester.

Add the manufacturer’s recommended concentration ofsupplemental coolant additive. DO NOT add more thanthe recommended amount.

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

If other coolants are used, consult the coolant supplierand follow the manufacturer’s recommendation for use ofsupplemental coolant additives.

See DIESEL ENGINE COOLANTS ANDSUPPLEMENTAL ADDITIVE INFORMATION for propermixing of coolant ingredients before adding to the coolingsystem.

35-11 013004

PN=116


OUOD002,0000175 –19–23NOV01–1/1


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

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

Coolant Test Strips

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

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

COOLSCAN Or COOLSCAN PLUS

For a more thorough evaluation of your coolant,perform a COOLSCAN or COOLSCAN PLUS analysis.See your John Deere dealer for information aboutCOOLSCAN or COOLSCAN PLUS.

35-12 013004

PN=117


OURGP11,00000FE –19–07OCT03–1/3

Remove, Inspect and Clean Engine HeatExchanger Core

RG

6063

–UN

–23J

AN

92

Heat Exchanger End Cap

RG

6064

–UN

–23J

AN

92

Remove Heat Exchanger Core

A—ClampB—End CapC—End CapD—Heat Exchanger Core

IMPORTANT: Initially remove and inspect the engineheat exchanger core at 250 hour orthree month service interval on a newengine. Then, remove and clean atevery 500 hour or 12 month intervalthereafter.

1. Close sea cocks and drain the sea water system.

2. Open drain cock on cylinder block and drainapproximately two gallons of engine coolant into a cleancontainer. Close drain cock.

On 4045D Engines Only:

3. Loosen hose clamp (A) and remove hose from rear endcap (B).

4. Remove two end cap mounting cap screws and removeend cap (C) with heat exchanger core (D) from rear ofengine.

OURGP11,00000FE –19–07OCT03–2/3

RG

9847

–UN

–06J

AN

99

Heat Exchanger End Cap

On 4045T, 6068T And 6068SFM50 Engines Only:

3. Loosen hose clamps and remove sea waterpump-to-front end cap connecting hose (A) from heatexchanger end cap.

4. Remove two end cap mounting cap screws (B) andremove end cap with heat exchanger core from front ofengine.

35-13 013004

PN=118



OURGP11,00000FE –19–07OCT03–3/3R

G60

66–U

N–2

3JA

N92

Clean Heat Exchanger

On All Engines:

NOTE: The heat exchanger core may be removed fromhousing when either end cap is removed. It isstrongly recommended that both end caps beremoved for cleaning when cleaning the heatexchanger core.

5. Remove remaining end cap from water manifold/heatexchanger housing. Remove end cap from heatexchanger core.

6. Thoroughly clean all buildup from both end caps andinspect zinc plug in each. Replace plugs as needed. (SeeINSPECT AND REPLACE ZINC PLUGS in 250 HourSection.)

7. Use a 4.76 mm (3/16 in.) diameter brass rod to cleanout any buildup in each heat exchanger tube. Run the rodthe entire length of each tube to push debris out.

8. Flush the heat exchanger tubes with clean water,making sure all tubes are cleared of debris. Clean (withbrass rod) and flush heat exchanger again if necessary toremove any remaining debris from tubes.

If you suspect that your heat exchanger core is defective,have your authorized servicing dealer or engine distributorpressure test for leaks. Replace heat exchanger core asrequired.

9. Remove and thoroughly clean water manifold/heatexchanger housing if needed.

35-14 013004

PN=119


DPSG,OUOD007,322 –19–04JAN02–1/2

Install Heat Exchanger Core

RG

6067

–UN

–23J

AN

92

Inspect Heat Exchanger End Cap

RG

9848

–UN

–06J

AN

99

Install Heat Exchanger

A—O-RingsB—End CapC—Housing

Thoroughly inspect condition of end cap sealing O-rings(A). Sealing O-rings may be reused if not excessivelyworn or damaged during disassembly. Replace sealingrings as necessary.

Lubricate front and rear end cap O-rings with cleanmulti-purpose grease.

On 4045D Engines:

1. Install front end cap, install cap screws and evenlytighten until end cap (B) is about 6.4 mm (0.25 in.) fromhousing (C). Index end cap in same position as removed.

2. Install heat exchanger core from rear of engine. Makesure core is properly seated in front end cap to avoidcutting O-ring.

3. Install rear end cap with heat exchanger core properlyseated in cap and cap properly indexed in same positionas removed.

4. Install and evenly tighten rear end cap screws until capcontacts housing. Evenly tighten front end cap screwsuntil cap contacts housing. Tighten front and rear end capscrews to 24 N•m (18 lb-ft).

5. Connect all water piping and tighten hose clampssecurely. Fill cooling system with the proper amount andconcentration of ethylene-glycol base antifreeze.

6. Open sea cock, start engine and check for leaks.

On 4045T, 6068T and 6068SFM50 Engines:

1. Install rear end cap, install cap screws and evenlytighten until end cap (B) is about 6.4 mm (0.25 in.) fromhousing (C). Index end cap in same position as removed.

2. Install heat exchanger core from front of engine. Makesure core is properly seated in rear end cap to avoidcutting O-ring.

3. Install front end cap with heat exchanger core properlyseated in cap and cap properly indexed in same positionas removed.

35-15 013004

PN=120



DPSG,OUOD007,322 –19–04JAN02–2/2

4. Install and evenly tighten front end cap screws until capcontacts housing. Evenly tighten rear end cap screws untilcap contacts housing. Tighten front and rear end capscrews to 24 N•m (18 lb-ft).

5. Connect all water piping and tighten hose clampssecurely. Fill cooling system with the proper amount andconcentration of ethylene-glycol base antifreeze.


35-16 013004

PN=121


OUOD005,000017C –19–18FEB02–1/2

Remove, Inspect and Clean EngineAftercooler Core (6068SFM50)

RG

1219

0–U

N–2

5FE

B02

Remove Clamp And Air Filter Element

RG

1218

2–U

N–2

5FE

B02

Remove Rear Cap

RG

1218

3–U

N–2

5FE

B02

Remove Front Cap

A—ClampB—ClampsC—Mounting BoltD—Cap ScrewsE—ClampsF—Cap Screws

IMPORTANT: Initially remove and inspect theaftercooler core at 250 hour or threemonth service interval on a new engine.Then, remove and clean at every 500hour or 12 month interval thereafter.

1. Close sea cocks and drain the sea water system.

2. Loosen clamp (A) and remove air filter.

3. Loosen clamps (B), remove mounting bolt (C) andremove water line from rear of aftercooler.

4. Remove four cap screws (D) and remove rear cap andO-ring.

5. Remove clamps (E) and remove hoses from front cap.

6. Remove four cap screws (F), front cap and O-ring.

7. Remove aftercooler core from the rear of the engine.


35-17 013004

PN=122


OUOD005,000017C –19–18FEB02–2/2

RG

1218

1–U

N–2

5FE

B02

Clean Aftercooler Core

8. Thoroughly clean all buildup from both end caps.

9. Use a 4.76 mm (3/16 in.) diameter brass rod to cleanout any buildup in each tube. Run the rod the entirelength of each tube to push debris out.

10. Flush the tubes with clean water, making sure alltubes are cleared of debris. Clean (with brass rod) andflush aftercooler core again if necessary to remove anyremaining debris from tubes.

If you suspect that your aftercooler core is defective, haveyour authorized servicing dealer or engine distributorpressure test for leaks. Replace aftercooler core asrequired.

OUOD005,000017D –19–18FEB02–1/1

Install Aftercooler Core (6068SFM50)

RG

1218

4–U

N–2

5FE

B02

End Cap O-Ring

RG

1218

5–U

N–2

5FE

B02

Install Aftercooler Core

A—O-RingB—Aftercooler Core

Thoroughly inspect condition of end cap sealing O-rings(A). Sealing O-rings may be reused if not excessivelyworn or damaged during disassembly. Replace sealingrings as necessary.

Lubricate front and rear end cap O-rings with cleanmulti-purpose grease.

1. Install aftercooler core (B) from rear of engine.

2. Index end cap in same position as removed. InstallO-ring and rear end cap, install cap screws and evenlytighten until snug.

3. Install O-ring and front end cap with aftercooler coreproperly seated in cap and cap properly indexed in sameposition as removed.

4. Install and evenly tighten front cap screws until capcontacts housing. Tighten front and rear end cap screwsto 24 N•m (18 lb-ft).

5. Connect all water piping and tighten waterline-to-cylinder head cap screw to 50 N•m (37 lb-ft).Tighten hose clamps securely. Open sea cocks.

35-18 013004

PN=123


RG,RG34710,5586 –19–20MAY96–1/1

Pressure Testing Cooling System

RG

6557

–UN

–20J

AN

93

RG

9850

–UN

–06J

AN

99

CAUTION: Explosive release of fluids frompressurized cooling system can causeserious burns.

Shut off engine. Only remove filler cap whencool enough to touch with bare hands.Slowly loosen cap to first stop to relievepressure before removing completely.

Test Coolant Filler Cap

1. Remove coolant filler cap and attach to anappropriate tester as shown.

2. Pressurize cap to 70 kPa (0.7 bar) (10 psi). Gaugeshould hold pressure for 10 seconds within thenormal range if cap is acceptable.

If gauge does not hold pressure, replace pressurecap.

3. Remove the cap from gauge, turn it 180°, andretest cap. This will verify that the firstmeasurement was accurate.

Test Cooling System

NOTE: Engine should be warmed up to test overallcooling system.

1. Allow engine to cool, then carefully remove coolantfiller cap.

2. Fill tank with coolant to the normal operating level.

IMPORTANT: DO NOT apply excessive pressure tocooling system, doing so maydamage coolant tank and hoses.

3. Connect gauge and adapter to filler neck.Pressurize system to 70 kPa (0.7 bar) (10 psi).

4. With pressure applied, check all cooling systemhose connections, coolant tank, and overall enginefor leaks.

If leakage is detected, correct as necessary andpressure test system again.

If no leakage is detected, but the gauge indicated adrop in pressure, coolant may be leaking internallywithin the system or at the block-to-head gasket.Have your servicing dealer or distributor correct thisproblem immediately.

35-19 013004

PN=124


OURGP11,00000C5 –19–08SEP03–1/1

Checking and Adjusting Engine Speeds

RG

1313

8–U

N–0

7OC

T03

Observe Tachometer Reading

Observe tachometer reading (A) on the instrument panelto verify engine speeds. (Refer to FUEL SYSTEMSPECIFICATIONS in Specifications Section later in thismanual for engine speed specifications.)

OUOD002,0000169 –19–23NOV01–1/1

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 whenwelding on engine or machine.

35-20 013004

PN=125

Lubrication&Maintenance/2000 Hour/24 Month

RG,RG34710,5589 –19–04JAN02–1/5

Checking and Adjusting Engine ValveClearance

CAUTION: To prevent accidental starting ofengine while performing valve adjustments,always disconnect NEGATIVE (–) batteryterminal.

IMPORTANT: Engine valve clearance MUST BEchecked and adjusted with engineCOLD.

NOTE: If desired, have your authorized servicing dealeror engine distributor adjust the engine valveclearance.

1. Remove rocker arm cover and crankcase ventilatortube.

IMPORTANT: Visually inspect contact surfaces ofvalve tips and rocker arm wear pads.Check all parts for excessive wear,breakage, or cracks. Replace parts thatshow visible damage.

Rocker arms that exhibit excessivevalve clearance should be inspectedmore thoroughly to identify damagedparts.


40-1 013004

PN=126


RG,RG34710,5589 –19–04JAN02–2/5

RG

9854

–UN

–05J

AN

99

Flywheel Housing Timing Holes

A—Timing Holes

2. Remove plastic plugs or cover plate from flywheelhousing timing holes (A).

3. Using either JDG820 or JDE83 Flywheel Turning Tooland JDE81-4 or JDG1571 Timing Pin, rotate engine inrunning direction (clockwise viewed from front) untilNumber 1 (front) cylinder is at Top Dead Center (TDC)Compression stroke. Insert JDE81-4 or JDG1571timing pin in flywheel.

If Number 1 cylinder rocker arms are loose, the engineis at Number 1 "TDC Compression".

If No. 1 cylinder rocker arms are not loose, rotateengine one full revolution (360°) to Number 1 "TDCCompression".

RG,RG34710,5589 –19–04JAN02–3/5

RG

7409

–UN

–06A

UG

96

Adjust Valves

A—Locknut

4. With engine lock-pinned at “TDC” of Number 1 piston’scompression stroke, check valve clearance to followingspecifications, as directed in the procedures (followingpage) for 4 or 6-cylinder engines. If valves needadjusting, loosen the locknut (A) on rocker armadjusting screw. Turn adjusting screw until feelergauge slips with a slight drag. Hold the adjusting screwfrom turning with screwdriver and tighten locknut to 27N•m (20 lb-ft). Recheck clearance again aftertightening locknut. Readjust clearance as necessary.

SpecificationIntake Valve ClearanceAdjustment (Rocker Arm-to-ValveTip) (Engine Cold)—Clearance 0.35 mm (0.014 in.)..................................Exhaust Valve ClearanceAdjustment (Rocker Arm-to-ValveTip) (Engine Cold)—Clearance 0.45 mm (0.018 in.)..................................

5. Replace rocker arm cover and crankcase ventilatortube.


40-2 013004

PN=127


RG,RG34710,5589 –19–04JAN02–4/5

RG

4776

–UN

–31O

CT

97

4-Cylinder Engine Valve Adjustment

A—Front of EngineB—No. 1 Piston at TDC Compression StrokeC—No. 4 Piston at TDC Compression StrokeE—Exhaust ValveI—Intake Valve

4-Cylinder Engine

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

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

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

Rotate flywheel 360°. Lock No. 4 piston at TDCcompression stroke (C).

Adjust valve clearance on No. 2 and 4 exhaust valves andNo. 3 and 4 intake valves.

RG,RG34710,5589 –19–04JAN02–5/5

RG

4777

–UN

–31O

CT

97

6-Cylinder Engine Valve Adjustment

A—Front of EngineB—No. 1 Piston at TDC Compression StrokeC—No. 6 Piston at TDC Compression StrokeE—Exhaust ValveI—Intake Valve

6-Cylinder Engine

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

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

Adjust valve clearance on No. 1, 3, and 5 exhaust valvesand No. 1, 2, and 4 intake valves.

Rotate flywheel 360°. Lock No. 6 piston at TDCcompression stroke (C).

Adjust valve clearance on No. 2, 4, and 6 exhaust valvesand No. 3, 5, and 6 intake valves.

40-3 013004

PN=128


OURGP11,000020B –19–08OCT03–1/3

Flushing And Refilling Cooling System

TS

281

–UN

–23A

UG

88


RG

9839

–UN

–05J

AN

99

Engine Top Tank



NOTE: When John Deere COOL-GARD is used, the draininterval is 3000 hours or 36 months. The draininterval may be extended to 5000 hours or 60months of operation, provided that the coolantis tested annually AND additives arereplenished, as needed, by adding asupplemental coolant additive (SCA).

If COOL-GARD is not used, the flushing interval is2000 hours or 24 months of operation.

Drain old coolant, flush the entire cooling system, testthermostats, and fill with recommended clean coolantusing the following procedure.

1. Pressure test entire cooling system and pressure cap ifnot previously done. (See PRESSURE TESTINGCOOLING SYSTEM, in the Lubrication andMaintenance/500 Hour/12 Month Section.)

2. Slowly open the cap on the top tank (A) or heatexchanger to relieve pressure and allow coolant todrain faster.


40-4 013004

PN=129


OURGP11,000020B –19–08OCT03–2/3

RG

8019

A–U

N–1

9JU

N00

Engine Block Drain Valve

A—Engine Block Drain Valve

3. Open engine block drain valve (A) on left side ofengine. Drain all coolant from engine block.

4. Open heat exchanger or top tank drain valve. Drain allcoolant from heat exchanger or top tank.

5. Remove thermostats at this time, if not previouslydone. Install cover (without thermostats) using oldgasket and tighten cap screws to 47 N•m (35 lb-ft).

6. Test thermostat opening temperature. (See InspectingThermostats And Testing Opening Temperaturefollowing in this section).

7. Close all drain valves after coolant has drained.

CAUTION: Do not run engine longer than 10minutes. Doing so may cause engine tooverheat, causing burns when cooling systemis draining.

8. Fill the cooling system with clean water. Run theengine about 10 minutes to stir up possible rust orsediment.

9. Stop engine, pull off lower cooling system hose andremove heat exchanger or top tank cap. Immediatelydrain the water from system before rust and sedimentsettle.

10. After draining water, close drain valves. Reinstall cap,lower cooling system hose and clamp. Fill the coolingsystem with clean water and a heavy duty coolingsystem cleaner such as Fleetguard RESTORE andRESTORE PLUS.

11. After cleaning the cooling system, drain cleaner andfill with water to flush the system. Run the engineabout 10 minutes, remove heat exchanger or top tankcap and pull off lower cooling system hose to drainout flushing water.

Fleetguard is a trademark of Cummins Engine Company, Inc.RESTORE is a trademark of Fleetguard.RESTORE PLUS is a trademark of Fleetguard.

40-5 013004

PN=130



OURGP11,000020B –19–08OCT03–3/3

12. Close all drain valves. Reinstall hoses and tightenclamps securely. Install thermostats using a newgasket.

IMPORTANT: Air must be expelled from coolingsystem when system is refilled. Loosentemperature sending unit fitting at rearof cylinder head or plug in thermostathousing to allow air to escape whenfilling system. Retighten fitting or plugafter filling cooling system.

13. Refill with fresh coolant until coolant touches bottomof filler neck. (See ADDING COOLANT in Service AsRequired Section.) Install heat exchanger or top tankcap.

14. Run engine until it reaches operating temperature.This mixes the solution uniformly and circulates itthrough the entire system. The normal engine coolanttemperature range is 82°—94°C (180° — 202°F).

15. After running engine, check coolant level and entirecooling system for leaks.

40-6 013004

PN=131


RG,RG34710,20092 –19–31MAR99–1/1

Inspecting Thermostats and Testing OpeningTemperature

RG

5971

–UN

–23N

OV

97

Thermostat And Thermometer In Water

1. Remove thermostats. (See REMOVINGTHERMOSTATS earlier in this section.)

2. Visually inspect thermostats for corrosion or damage.Replace thermostats as a matched set as necessary.

3. Inspect thermostat with wiggle wire in vent notch. Ifwire movement is restricted, replace thermostat ifcleaning does not free movement.

CAUTION: DO NOT allow thermostat orthermometer to rest against the side or bottomof container when heating water. Either mayrupture if overheated.

4. Suspend thermostats and a thermometer in a containerof water.

5. Stir the water as it heats. Observe opening action ofthermostat and compare temperatures withspecification given in chart below.

NOTE: Due to varying tolerances of different supplies,initial opening and full open temperatures mayvary slightly from specified temperatures.

SpecificationThermostat Test—Rating 82°C (180°F)......................................................Initial Opening (Range) 80–84°C (175–182°F)...........................................Full Open (Nominal) 94°C (202°F)..............................................................

6. Remove thermostat and observe its closing action as itcools. In ambient air the thermostat should closecompletely. Closing action should be smooth and slow.

7. If any one thermostat is defective, replace boththermostats.

40-7 013004

PN=132


RG,RG34710,5585 –19–12NOV01–1/1

Checking Crankshaft Vibration Damper(6-Cylinder Engine Only)

RG

8018

–UN

–15J

AN

99

Grasp Vibration Damper

RG

7508

–UN

–23N

OV

97

Check Runout

1. Remove belts (shown removed).

2. Grasp vibration damper with both hands and attempt toturn it in both directions. If rotation is felt, damper isdefective and should be replaced.

IMPORTANT: The vibration damper assembly is notrepairable and should be replaced every4500 hours or 60 months, whicheveroccurs first.

3. Check vibration damper radial runout by positioning adial indicator (A) so probe contacts damper outerdiameter.

4. With engine at operating temperature, rotate crankshaftusing either JDE83 or JDE81-1 Flywheel Turning Tool.

5. Note dial indicator reading. If runout exceedsspecifications given below, replace vibration damper.

SpecificationVibration Damper—MaximumRadial Runout 1.50 mm (0.060 in.).............................................................

OURGP11,00000FF –19–07OCT03–1/3

Inspect and Repair Sea Water Pump (Except6068SFM50)

RG

9852

–UN

–05J

AN

99

Inspect Sea Water Pump

A—Weep Hole

• Inspect pump housing for seal leakage

1. Inspect the sea water pump housing weep hole (A) forevidence of water or oil indicating seal leakage.

If water leakage is evident, order a RE49490 ImpellerRepair Kit and replace impeller and front housing/shaftseal.

If oil leakage is evident, order a RE49491 Major Repair Kitand replace all internal components except shaft. An arborpress and drivers are needed to install this kit. Have anexperienced technician install this kit.

40-8 013004

PN=133



OURGP11,00000FF –19–07OCT03–2/3

RG

9853

–UN

–05J

AN

99

Remove Cover Plate

RG

6243

–UN

–23M

AR

92

Inspect Sea Water Pump Impeller

A—Cover PlateB—Cam Screw

Remove and Inspect Impeller

1. Close sea cock and drain sea water system if notpreviously done.

2. Remove six cover plate cap screws with washers andremove cover plate (A) with O-ring. Remove impeller endcap from end of impeller bore.

NOTE: Normally the impeller can be removed by usingtwo pair of pliers to grip impeller vanes onopposite sides of impeller. Rotating the pumpshaft by hand may help free the impeller.Petroleum based lubricants can cause theimpeller to swell, and are not recommended tofree a stuck impeller.

3. Carefully remove impeller with cam plate. Be carefulnot to damage impeller if in reusable condition. Removekey from shaft keyway.

The impeller must be installed in the same direction asremoved. Mark the impeller to ensure installation in properdirection of rotation if impeller is reused.

4. Inspect impeller for damages such as tears, stresscracks, excess abrasions on vane ends, or chunks ofmaterial missing. Impellers that are run dry will overheatand fail the impeller blades at the root. Impellers that swelland stick, fail the impeller in the middle of the blade. Ifimpeller replacement is necessary, order an impellerrepair kit.

IMPORTANT: If impeller has chunks of materialmissing, the heat exchanger, marinegear oil cooler and any other circuit thatare cooled by raw water should bethoroughly cleaned and flushed.

5. Remove cam screw (B) holding cam plate to impellerhousing bore.

6. Thoroughly clean impeller housing bore and cam plate(if cam plate is reused).

40-9 013004

PN=134



OURGP11,00000FF –19–07OCT03–3/3

RG

9853

–UN

–05J

AN

99

Install Cover Plate

A—Cover PlateB—Cam Screw

Install Impeller

1. Apply LOCTITE 242 (Deere Part No. TY9370) tocurved side of cam plate near threaded hole and installcam plate into impeller housing bore, be sure holes incam plate and housing are aligned. Apply LOCTITE 242to cam screw (B), install, and tighten.

The cam plate should be inspected to insure that none ofthe cam fingers are protruding which could cause impellerdamage. The cam screw should also be inspected toinsure that it does not protrude below the cam plate.Replace cam plate and cam screw or grind screw flush asneeded.

IMPORTANT: Petroleum based lubricants can causethe impeller to swell, and are notrecommended to lubricate the impellerbefore installation.

2. Lubricate impeller blades with a non-petroleum basedlubricant such as silicone or soapy water. Install impellerusing a twisting motion and be sure the impeller bladesare bent in the same direction as they were upon removal.

Be sure impeller is installed in same direction as removedif reusing existing impeller.

3. Rotate impeller to align keyway and slide the key inplace. Install impeller end cap in end of impeller bore.

4. Using a new O-ring, install cover plate (A) onto impellerhousing. Install six screws with washers. Tighten screwsevenly.

5. Reconnect all water piping, if disconnected.

6. Open sea cock and prime sea water pump with water.Start engine and check for leaks.

LOCTITE is a registered trademark of Loctite Corp.

40-10 013004

PN=135


OURGP11,0000252 –19–06NOV03–1/3

Inspect And Repair Sea Water Pump(6068SFM50)

RG

1218

6–U

N–2

5FE

B02

Remove Oil Filter Housing (If Necessary)

RG

1218

7–U

N–2

5FE

B02

Remove Sea Water Pump

A—Cap ScrewsB—Oil TubesC—Sea Water Inlet TubeD—Sea Water Outlet TubeE—Mounting Cap Screws

NOTE: On 6068SFM50 engines, the sea water pumpmust be removed from the engine for inspectionand repair.

If engine is equipped with a remote oil filter, steps2 and 16 are not necessary.

1. Close sea cocks and drain sea water system.

2. Remove two cap screws (A) and remove oil filterhousing and oil tubes (B).

3. Remove flange mount cap screws and remove seawater inlet tube (C) and outlet tube (D).

4. Remove mounting cap screws (E) and remove seawater pump.

5. Clean all gasket material from both mating surfaces.


40-11 013004

PN=136


OURGP11,0000252 –19–06NOV03–2/3

RG

1218

8–U

N–2

5FE

B02

Remove Impeller

RG

1218

9–U

N–2

5FE

B02

Remove and Inspect Components

RG

6243

–UN

–23M

AR

92Inspect Sea Water Pump Impeller

A—Cover PlateB—ImpellerC—Shaft KeyD—O-RingE—Cam Plate

6. Remove cover plate (A) from sea water pump.

NOTE: Normally the impeller can be removed by usingtwo pair of pliers to grip impeller vanes onopposite sides of impeller. Rotating the pumpshaft by hand may help free the impeller.Petroleum based lubricants can cause theimpeller to swell, and are not recommended tofree a stuck impeller.

7. Remove impeller (B) and shaft key (C) from pumphousing.

8. Remove O-ring (D).

9. Inspect cam plate (E) for evidence of heavy pitting orwear. Replace as needed.

10. Inspect impeller for damages such as tears, stresscracks, excess abrasions on vane ends, or chunks ofmaterial missing. Impellers that are run dry willoverheat and fail the impeller blades at the root.Impellers that swell and stick, fail the impeller in themiddle of the blade. If impeller replacement isnecessary, order an impeller repair kit.

IMPORTANT: If impeller has chunks of materialmissing, the heat exchanger,aftercooler, marine gear oil cooler andany other circuit that are cooled by rawwater should be thoroughly cleaned andflushed.

11. Install shaft key (C) on shaft.

IMPORTANT: Petroleum based lubricants can causethe impeller to swell, and are notrecommended to lubricate the impellerbefore installation.

12. Lubricate new impeller blades with a non-petroleumbased lubricant such as silicone or soapy water.Install impeller using a twisting motion and be surethe impeller blades are bent in the same direction asthey were upon removal to prevent damage atstartup. Rotate impeller on shaft to align keyways andslide the impeller onto the shaft.

40-12 013004

PN=137



OURGP11,0000252 –19–06NOV03–3/3

13. Using a new O-ring (D), install cover plate and tightencap screws with washers securely.

14. Install sea water pump and tighten cap screws to 73N•m (54 lb-ft).

15. Connect sea water inlet and outlet tubes. Tightenmounting cap screws evenly until secure.

16. Replace O-rings on oil tubes and install oil filterhousing and oil tubes. Tighten mounting cap screwsto 35 N•m (26 lb-ft).

17. Open sea cocks, start engine and check pumpoperation.

40-13 013004

PN=138

Service as Required

RG,RG34710,5591 –19–20MAY96–1/1

Additional Service Information

RG

4624

–UN

–15D

EC

88

This is not a detailed service manual. If you want moredetailed service information, use the form in the back ofthis manual to order a component technical manual.

OURGP11,0000215 –19–09OCT03–1/1

Do Not Modify Fuel System

RG

1195

3–U

N–2

6NO

V01

Fuel Injection Pump

IMPORTANT: Modification or alteration of theinjection pump (arrow), the injectionpump timing, or the fuel injectors inways not recommended by themanufacturer will terminate thewarranty obligation to the purchaser.

In addition, tampering with fuel systemwhich alters emission-relatedequipment on engines may result infines or other penalties, per EPAregulations or other local emissionlaws.

Do not attempt to service injectionpump or fuel injectors yourself. Specialtraining and special tools are required.(See your authorized servicing dealer orengine distributor.)

45-1 013004

PN=139

Service as Required

RG,RG34710,5593 –19–04JAN02–1/1

Adding Coolant

TS

281

–UN

–23A

UG

88




IMPORTANT: Never pour cold liquid into a hotengine, as it may crack cylinder head orblock. DO NOT operate engine withoutcoolant for even a few minutes.

John Deere TY15161 Cooling SystemSealer may be added to the coolingsystem to stop leaks. DO NOT use anyother stop-leak additives in the coolingsystem.

Air must be expelled from coolingsystem when coolant is added.

1. Loosen temperature sending unit fitting at rear ofcylinder head or plug in side of thermostat housing toallow air to escape when filling system.

IMPORTANT: When adding coolant to the system, usethe appropriate coolant solution. (SeeENGINE COOLANT SPECIFICATIONS inFuels, Lubricants, and Coolant Sectionfor mixing of coolant ingredients beforeadding to cooling system.)

Do not overfill cooling system. Apressurized system needs space forheat expansion without overflowing attop of coolant tank.

2. Fill until coolant level touches bottom of coolant tankfiller neck.

3. Tighten plugs and fittings when air has been expelledfrom system.

45-2 013004

PN=140

Service as Required

RG,RG34710,5594 –19–04JAN02–1/1

Replacing Dry Air Cleaner Element (EnclosedElement Installations)

RG

9874

–UN

–12F

EB

99

Air Restriction Indicator

RG

9912

–UN

–25F

EB

99

Loosen Band Clamp

A—Air Restriction IndicatorB—Band Clamp

IMPORTANT: ALWAYS REPLACE primary air cleanerelement when air restriction indicator(A) shows vacuum of 625 mm (25 in.)H2O, is torn, or visibly dirty.

1. Loosen band clamp (B) securing air cleaner-to-intakeelbow. Remove air cleaner.

IMPORTANT: Tighten all air intake connectionssecurely to prevent ingestion ofabrasive dirt and dust into the system,causing possible engine damage.

2. Install a new air cleaner and tighten band clampsecurely.

45-3 013004

PN=141

Service as Required

DPSG,OUOD007,2907 –19–24DEC02–1/5

Servicing Air Cleaner Filter Element

RG

1274

9–U

N–2

4DE

C02

Air Cleaner Restriction Indicator

RG

9926

–UN

–18N

OV

99

Remove Filter Element

IMPORTANT: Always service primary air cleanerelement when air restriction indicatorshows a vacuum of 625 mm (25 in.)H2O, is torn, or is visibly dirty.

NOTE: This procedure applies to John Deere air cleanerkits. Refer to manufacturers’ instructions forservicing air cleaners not supplied by John Deere.

1. Loosen clamp (A) and remove filter element.

IMPORTANT: Replace filter element after 10cleanings. (See following blocks.)

2. Tap end of filter GENTLY on hard surface to dislodgeloose dirt.

3. Brush dirt side of filter GENTLY with soft bristle brush.

IMPORTANT: Use kit RE504585 to service filterelement. DO NOT clean element withgasoline, solvents, parts cleaners,strong detergents, or caustic cleaningsolutions. DO NOT steam clean or usehigh-pressure washers to cleanelement. These processes will damagefilter media and/or rubber base or endcap.


45-4 013004

PN=142

Service as Required

DPSG,OUOD007,2907 –19–24DEC02–2/5

RG

9943

–UN

–17N

OV

99

Spray Filter with Cleaner

4. Spray air filter cleaner (B) (from kit RE504585) liberallyonto entire element. Let soak into filter media for 10minutes.


45-5 013004

PN=143

Service as Required

DPSG,OUOD007,2907 –19–24DEC02–3/5

RG

9944

–UN

–17N

OV

99

Rinse Filter

5. Rinse filter with low pressure water, flushing oppositethe direction of air flow (from clean side to dirty side).

IMPORTANT: Let element dry at room temperature.Compressed air will damage filtermedia. Heat will shrink filter media andmay damage rubber base or end cap.

6. Shake off excess water and let the element dry atroom temperature.

IMPORTANT: Never put filter in service without oilingit. The filter will not function properlywithout being oiled with oil provided inkit RE504585.

Do not use automatic transmissionfluid, motor oil, diesel fuel, or any typelight-weight spray lubricant. Theseproducts will damage filter or degradeits performance.

NOTE: Red dye is added to oil to show areas of oilapplication.


45-6 013004

PN=144

Service as Required

DPSG,OUOD007,2907 –19–24DEC02–4/5

RG

9945

–UN

–17N

OV

99

Apply Oil To Filter

7. Spray air filter oil from squeeze bottle (C) in kit fromdistance of 25 cm (10 in.) onto a group of pleats untilthe pleats become reddish in color. Respray any areasthat are still white 10 minutes after initial application.

8. Install filter and tighten clamp.

DPSG,OUOD007,2907 –19–24DEC02–5/5

RG

9927

–UN

–18N

OV

99

Air Restriction Indicator ResetButton

IMPORTANT: Whenever the air cleaner has beenserviced, ALWAYS fully depress the airrestriction indicator reset button (ifequipped) to assure accurate readings.

9. If equipped, fully depress air restriction indicator resetbutton (A) and release to reset indicator.

45-7 013004

PN=145

Service as Required

DPSG,OUOD007,2908 –19–24DEC02–1/2

Replacing Air Cleaner Filter Element

RG

9926

–UN

–18N

OV

99

Remove Filter Element

IMPORTANT: Replace the element after 10 cleanings.

1. Loosen clamp (A) and remove filter element.

2. Install new filter element and tighten clamp.

DPSG,OUOD007,2908 –19–24DEC02–2/2

RG

9927

–UN

–18N

OV

99

Air Restriction Indicator ResetButton

IMPORTANT: Whenever the air cleaner has beenserviced, ALWAYS fully depress the airrestriction indicator reset button (ifequipped) to assure accurate readings.

3. If equipped, fully depress air restriction indicator resetbutton (A) and release to reset indicator.

45-8 013004

PN=146

Service as Required

OURGP11,000014B –19–12DEC03–1/1

Replacing Alternator Belt (With AutomaticTensioner)

RG

9856

–UN

–05J

AN

99

Remove Belt Guard

RG

1207

7–U

N–2

6FE

B02

Belt Routing

A—Cap ScrewsALT—AlternatorCSP—Crankshaft PulleyI—Idler PulleyT—TensionerCP—Coolant Pump

Refer to CHECKING BELT TENSIONER SPRINGTENSION AND BELT WEAR in Lubrication andMaintenance/500 Hour/12 Month Section for additionalinformation on the belt tensioner.

CAUTION: Belt guard should be in place at alltimes when engine is running.

NOTE: While belt is removed, inspect pulleys andbearings. Rotate and feel for hard turning or anyunusual sounds. If pulleys or bearings needreplacement, see your John Deere dealer.

1. Remove cap screws (A) and carefully remove beltguard from engine.

2. Release tension on belt using a breaker bar andsocket on tension arm and remove poly-vee belt frompulleys.

3. Inspect belts for cracks, fraying, or stretched out areas.Replace if necessary.

4. Install new belt, making sure belt is correctly seated inall pulley grooves. Refer to belt routing at right.

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

6. Start engine and check belt alignment.

45-9 013004

PN=147

Service as Required

OURGP11,000014C –19–12DEC03–1/1

Replacing Alternator Belt (With ManualTensioner)

RG

9872

–UN

–12F

EB

99

Remove Belt Guard

RG

9873

–UN

–12F

EB

99

Tension With Swing Arm

A—Belt GuardB—Mounting Cap ScrewsC—Tensioner ArmD—Notched Units

Inspect belt for cracks, fraying or stretched-out areas. Ifbelt is worn or damaged, replace it as follows.

NOTE: It is not necessary to remove belt guard (A) toreplace belt.

NOTE: While belt is removed, inspect pulleys andbearings. Rotate and feel for hard turning or anyunusual sounds. If pulleys or bearings needreplacement, see your John Deere dealer.

1. Loosen both belt tensioner mounting cap screws (B).

2. Swing tensioner arm (C) away from belt to loosen belt.

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

4. Install new belt, making sure belt is correctly seated inall pulley grooves.

5. Swing tensioner arm into belt to remove all belt slack.

NOTE: Belt adjustment uses notched units (D) above theadjusting cap screw slot on the tensioner.

6. Using notches on tensioner to count units, movetensioner arm to stretch belt 1-1/2 units (new belt) or oneunit (used belt) for appropriate tension.

7. Tighten tensioner mounting cap screws (B) to 70 N•m(52 lb-ft).

45-10 013004

PN=148

Service as Required

OURGP11,0000145 –19–09DEC03–1/1

Check Front Power Take-Off (PTO)

TS

1644

–UN

–22A

UG

95

Rotating Drivelines

CAUTION: Entanglement in rotating drivelinecan cause serious injury or death. Keep shieldon PTO driveshaft between clutch housing andthe engine driven equipment at all times duringengine operation. Wear close fitting clothing.Stop the engine and be sure PTO driveline isstopped before making adjustments.

CAUTION: Metal surfaces of PTO housing maybe hot to the touch during operation or atshutdown.

The optional front power take-off (PTO) from John Deeretransfers engine power to auxiliary equipment or movingcomponents.

Proper performance of the power take-off unit will berelated to the care it is given. Periodically check for any oilleaks that may occur.

If the power take-off does not work properly, contact yourauthorized servicing dealer or engine distributor.

45-11 013004

PN=149

Service as Required

OURGP11,000020C –19–08OCT03–1/3

Bleeding the Fuel System—Engines WithMechanical Fuel Supply Pump

X98

11–U

N–2

3AU

G88



If ANY fluid is injected into the skin, it must besurgically removed within a few hours by adoctor familiar with this type injury or gangrenemay result. Doctors unfamiliar with this type ofinjury may call the Deere & Company MedicalDepartment in Moline, Illinois, or otherknowledgeable medical source.

IMPORTANT: Do not operate the engine at highspeeds or full loads just beforebleeding the fuel system. Doing so maycause an injection pump failure.

Bleed the fuel system anytime the system has beenopened. This includes:

• After fuel filter changes.• Anytime fuel lines have been disconnected.• After engine has run out of fuel.• After pump or nozzle replacement.


45-12 013004

PN=150

Service as Required

OURGP11,000020C –19–08OCT03–2/3

RG

1334

6–U

N–2

5NO

V03

Bleed Fuel System At Filter

A—Bleed Vent ScrewB—Primer Lever

Bleeding Fuel System At Filter

1. Loosen the air bleed vent screw (A) two full turns byhand on fuel filter base.

2. Operate supply pump primer lever (B) until fuel flow isfree from air bubbles.

3. Tighten bleed plug securely, continue operating handprimer until pumping action is not felt. Leave hand primerin the up position, away from the cylinder block.

4. Start engine and check for leaks.

If engine will not start, it may be necessary to bleed airfrom fuel system at fuel injection pump or injectionnozzles as explained next.

OURGP11,000020C –19–08OCT03–3/3

RG

1180

7–U

N–2

5OC

T01

Bleed Fuel At Injection Pump

A—Fuel Return Line

Bleeding Fuel System at Fuel Injection Pump

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

2. Operate fuel supply pump primer until fuel, without airbubbles, flows from fuel return line connection.

3. As soon as fuel flow is free from air bubbles, tightenfuel return line to specifications. Primer lever isspring-loaded and will return to normal position.

SpecificationFuel Injection Pump ReturnLine—Torque 27 N•m (20 lb-ft)...................................................................

45-13 013004

PN=151

Service as Required

OURGP11,00000F6 –19–06OCT03–1/3

Bleeding Fuel System—Engines With ElectricFuel Supply Pump

X98

11–U

N–2

3AU

G88



If ANY fluid is injected into the skin, it must besurgically removed within a few hours by adoctor familiar with this type injury or gangrenemay result. Doctors unfamiliar with this type ofinjury may call the Deere & Company MedicalDepartment in Moline, Illinois, or otherknowledgeable medical source.

Whenever the fuel system has been opened up forservice (lines disconnected or filters removed), it will benecessary to bleed air from the system.

This fuel system can only be bled by the electronictransfer pump or at the injection nozzles. BLEEDINGSHOULD NOT BE PERFORMED at any location on theBosch VP44 injection pump.


45-14 013004

PN=152

Service as Required

OURGP11,00000F6 –19–06OCT03–2/3

RG

1219

2–U

N–2

6FE

B02

Bleed Fuel System

A—Bleed Orifice in Final Fuel Filter BaseB—Fuel Return Line

Bleed Using Electronic Transfer Pump

The bleed is automatically performed by a small orifice (A)inside the final fuel filter base connected to the overflowvalve on injection pump. The system allows air to escapecontinually through the fuel return line (B) when ignition isON.

1. Ignition ON.

2. Allow 40 seconds for electronic transfer pump tocomplete priming.

3. If additional system bleeding is required, bleed thecircuit by loosening fuel line connections at injectionnozzles. See the next procedure, Bleed Fuel System AtFuel Injection Nozzles.

OURGP11,00000F6 –19–06OCT03–3/3

RG

7725

–UN

–08J

AN

97

Bleed At Fuel Injection Nozzles

Bleed Fuel System at Fuel Injection Nozzles

IMPORTANT: Always use a backup wrench whenloosening or tightening fuel lines atnozzles and/or injection pump to avoiddamage.

1. Using two open-end wrenches, loosen two fuel lineconnections at injection nozzles.

2. Crank engine over with starter motor for 15 seconds(but do not start engine) until fuel free from bubblesflows out of loosened connection. Retighten connectionto specifications.

SpecificationFuel Injection Nozzle DeliveryLine—Torque 27 N•m (20 lb-ft)...................................................................

3. Repeat procedure for remaining injection nozzles (ifnecessary) until all air has been removed from fuelsystem.

45-15 013004

PN=153

Service as Required

DPSG,OUOD007,330 –19–19JAN99–1/1

Remove and Install Auxiliary Gear DrivenSea Water Pump (Except 6068SFM50)

RG

9861

–UN

–06J

AN

99


RG

9864

–UN

–06J

AN

99

Install Sea Water Pump

A—Outlet TubeB—Mounting ScrewsC—Splined ShaftD—Drive Gear Splined ID

• Remove Sea Water Pump:

1. Close sea cock and drain sea water system, if notpreviously done.

2. Remove water inlet tube (shown removed) and outlettube (A) from sea water pump.

3. Remove two cap screws (B) attaching sea water pumpto gear housing. Withdraw pump from housing untilsplined shaft (C) is free from splined drive gear ID (D).


• Install Sea Water Pump:

1. Position a new gasket on water pump mounting flange.Install splined pump shaft in splined ID of drive gear.

2. Align mounting holes in water pump flange and gasketwith threaded holes in gear housing. Install cap screwswith washers and tighten cap screws to 47 N•m (35 lb-ft).

3. Connect water piping and tighten clamps.

4. Open sea cock, start engine, and check for leaks.

45-16 013004

PN=154

Service as Required

DPSG,OUOD005,3476 –19–20MAR00–1/1

Remove And Install Sea Water Pump(6068SFM50)

RG

1218

6–U

N–2

5FE

B02

Remove Oil Filter Housing (If Necessary)

RG

1218

7–U

N–2

5FE

B02


A—Cap ScrewsB—Oil TubesC—Sea Water InletD—Sea Water OutletE—Cap Screws

NOTE: If engine is equipped with a remote oil filter, steps2 and 10 are not necessary.

1. Close sea cock and drain sea water system.

2. Remove two cap screws (A) and remove oil filterhousing and tubes (B).

3. Remove four flange mount cap screws and removesea water inlet tube (C) and outlet tube (D).

4. Remove two cap screws (E) and remove sea waterpump.


6. Position a new gasket on sea water pump mountingflange. Install splined pump shaft in splined ID of drivegear.

7. Align mounting holes in water pump mounting flangeand gasket with threaded holes in drive gear housing.Install cap screws with washers and tighten cap screwsto 73 N•m (54 lb-ft) of torque.

8. Inspect condition of O-ring in sea water pump inlet andoutlet tubes determine if they are reusable. ReplaceO-rings as needed.

9. Connect sea water inlet and outlet tubes and installand tighten cap screws evenly until secure. Tightenhose clamps.

10. Replace O-rings on oil tubes and install oil tubes andoil filter housing. Tighten mounting cap screws to 35N•m (26 lb-ft).


45-17 013004

PN=155

Troubleshooting

OURGP11,000024A –19–05NOV03–1/2

General Troubleshooting Information

RG

1314

0–U

N–0

7OC

T03

Diagnostic Gauge

A—Diagnostic Gauge - Electronically ControlledEngine

Troubleshooting engine problems can be difficult. Enginewiring diagrams are provided in this section to help isolateelectrical problems on engines using John Deere wiringharness and instrument (gauge) panel.

Later in this section is a list of possible engine problemsthat may be encountered, accompanied by possiblecauses and corrections. The illustrated diagrams andtroubleshooting information are of a general nature; finaldesign of the overall system for your engine applicationmay be different. See your engine distributor or servicingdealer if you are in doubt.

For Electronically Controlled Engines: The EngineControl Unit (ECU) has the ability to detect problemsinternally and in the electronic control system. Thisincludes determining if any of the sensor input voltagesare too high or too low, if the camshaft and crankshaftposition sensor inputs are valid, and if the unit injectorsolenoids are responding properly.

If the ECU detects a problem with the electronic controlsystem a Diagnostic Trouble Code (DTC) specific to thefailed system will be stored in the ECU’s memory.

There are two types of DTCs:

• Active• Inactive (Stored)

Active or stored DTCs indicate that the failure is occurring.These type of failures are sometimes called “hard”failures. They can be accessed on the diagnostic gauge(A) on the instrument panel.

Inactive DTCs indicate that a failure has occurred in thepast, but is not currently occurring. This type of “stored”DTC can be caused by an “intermittent” failure. Thesecould be problems such as a bad connection or a wireintermittently shorting to ground.

To access DTC’s with the diagnostic gauge (A), seesection 15 of this manual.

50-1 013004

PN=156


Troubleshooting

OURGP11,000024A –19–05NOV03–2/2

If a sensor or wiring fails and a DTC is active for thesensor, the ECU will use a substitute “limp home” value inits calculations to continue engine operation.

A list of DTCs is given later in this section with adescription of each. Contact your engine servicing dealerto correct any DTCs which are displayed on theinstrument panel.

OUOD002,000016B –19–08OCT01–1/1

Precautions For Welding On EnginesEquipped With Electronic Engine ControlUnit (ECU)

IMPORTANT: ALWAYS disconnect Electronic ControlUnit (ECU) connectors and enginecontrol system-to-machine groundbefore welding on engine or machine.High currents or electro-staticdischarge in electronic componentsfrom welding may cause permanentdamage.

1. Remove the ground connection for the engine controlsystem-to-machine frame.

2. Disconnect the connectors from the ECU.

3. Connect the welder ground close to the welding pointand be sure ECU or other electronic components are notin the ground path.

50-2 013004

PN=157

Troubleshooting

OURGP11,000024B –19–05NOV03–1/2

Propulsion Engine Wiring Harness - Mechanically Controlled Engine (4045DFM70)

RG

6728

–UN

–14A

PR

93

50-3 013004

PN=158


Troubleshooting

OURGP11,000024B –19–05NOV03–2/2

A—10-Way Molded Connector G—14 Ga. Black (Start Circuit M—14 Ga. Black (Oil Sender) S—14 Ga. Gray (TachometerB—6 Ga. Red (Alternator) Relay) N—14 Ga. Red (Starting Motor) Pick-Up)C—6 Ga. Black (Alternator) H—12 Ga. Red (Start Circuit O—6 Ga. Red (Starting Motor) T—14 Ga. Black (TachometerD—14 Ga. Yellow and Red Relay) P—12 Ga. Red (Starting Motor) Pick-Up)

(Alternator) J—14 Ga. Red (Fuse Holder) Q—14 Ga. Black/Yellow (Fuel U—14 Ga. Tan (CoolantE—14 Ga. Pink/Black and K—6 Ga. and 12 Ga. Black Shut-Off Solenoid) Temperature Sender)

Black (Fuel Filter/Water (Ground) R—14 Ga. Black (Fuel Shut-Off V—14 Ga. Black (CoolantSeparator) L—14 Ga. Lt. Blue (Oil Sender) Solenoid) Temperature Sender)

F—14 Ga. Yellow/Red (StartCircuit Relay)

50-4 013004

PN=159

Troubleshooting

OURGP11,000024C –19–05NOV03–1/1

Propulsion Engine Wiring Harness - Mechanically Controlled Engine (4045DFM70)

RG

9862

–UN

–06J

AN

99

A—Alternator G—Battery L—10-Way Molded Connector Q—RedB—20-Amp Fuse with Holder H—Tachometer Pick-up M—White R—Black/YellowC—Start Circuit Relay I—Coolant Temperature N—Lt. Blue S—BlackD—Fuel Filter/Water Separator Sensor O—Tan T—Yellow/RedE—Starting Motor J—Engine Oil Pressure Sensor P—Gray U—PurpleF—Fuel Shut-Off Solenoid K—Spare Sensor

50-5 013004

PN=160

Troubleshooting

OURGP11,000024D –19–05NOV03–1/1

Propulsion Engine Instrument Panel - Mechanically Controlled Engine (4045DFM70)

RG

6121

–UN

–03F

EB

92

A—Coolant Temperature E—Hourmeter J—Start Switch N—High Coolant TemperatureGauge F—Voltmeter K—Key Switch Warning Light

B—Audible Alarm G—Alarm Circuit Board L—Water-in-Fuel Warning O—Low Oil Pressure WarningC—Tachometer H—10-Way Molded Connector Light LightD—Oil Pressure Gauge I—Stop Switch M—Low Battery Voltage

Warning Light

50-6 013004

PN=161

Troubleshooting

OURGP11,0000101 –19–08OCT03–1/2

Electronically Controlled Engine Electrical System Layout — 6068SFM50 Shown

RG

P97

85–U

N–1

9AU

G03


50-7 013004

PN=162

Troubleshooting

OURGP11,0000101 –19–08OCT03–2/2

A—Analog Throttle O—Performance Program X—Ground Connector II—Starter/Air Heater/AlternatorB—Throttle Emulator Connector (PPC) Y—Oil Pressure Sensor HarnessC—Secondary Analog Throttle P—Performance Program Z—Fuel Supply Pump Relay JJ—Air Heater HarnessD—Engine Harness Connector (PPC) Jumper AA—Air Heater Control Relay KK—Air Heater Coil 1E—Engine Control Unit (ECU) Wire BB—Crankshaft Speed Sensor LL—Air Heater Coil 2F—Ground Q—Transient Voltage CC—Fuel Pump Connector MM—Air Heater DiagnosticG—CAN Terminator Protection (TVP) DD—Fuel Pump Event Sensor NN—Fuel HeaterH—PSG Home Speed Enable R—CAN Diagnostic Connector EE—Coolant Temperature OO—Water In Fuel SensorI—Power Fuse S—External Shutdown Sensor PP—Fuel Transfer PumpJ—Home Speed Select T—Single Point Ground (SPG) FF—Alternator Connector ConnectorsK—Kickback Starter Relay U—Battery Power GG—Loss Of Coolant Sensor QQ—Fuel Transfer PumpL—Fuse V—Fuse HH—Manifold Air Temperature HarnessM—CAN Interconnect W—Starter Relay Solenoid Sensor (MAT) RR—Fuel Pressure SensorN—Throttle Bumps

50-8 013004

PN=163

Troubleshooting

OURGP11,000024E –19–05NOV03–1/1

Wiring Diagram for John Deere Main Station (Wheel House) Instrument Panel -Electronically Controlled Engine

RG

1314

4–U

N–2

5SE

P03

50-9 013004

PN=164

Troubleshooting

OURGP11,000024F –19–05NOV03–1/1

Wiring Diagram for John Deere Main Station (Wheel House) Instrument Panel -Electronically Controlled Engine (Continued)

RG

1314

5–U

N–2

5SE

P03

50-10 013004

PN=165

Troubleshooting

OURGP11,0000250 –19–05NOV03–1/1

Wiring Diagram for John Deere Optional Fly Bridge Instrument Panel - ElectronicallyControlled Engine

RG

1314

7–U

N–2

5SE

P03

50-11 013004

PN=166

Troubleshooting

50-12 013004

PN=167

Troubleshooting

OURGP11,0000211 –19–08OCT03–1/2

6068SFM50 Marine Electronic Control System Wiring Diagram

RG

1334

7–U

N–0

3DE

C03


50-13 013004

PN=168

Troubleshooting

OURGP11,0000211 –19–08OCT03–2/2

RG

1334

8–U

N–0

3DE

C03

50-14 013004

PN=169

Troubleshooting

DPSG,OUOD007,334 –19–19JAN99–1/2

Engine Coolant and Sea Water Flow For Heat Exchanger Engines (Except 6068SFM50)

RG

9865

–UN

–20J

AN

99

50-15 013004

PN=170


Troubleshooting

DPSG,OUOD007,334 –19–19JAN99–2/2

A—Coolant Pump G—Block Deck Passages L—Coolant Outlet Hose P—Sea Water InletB—Coolant Passage Adapter H—Passages M—Sea Water Pump Q—Sea Water OutletC—Oil Cooler Drain Plug I—Thermostat(s) N—Drain Valve (Coolant) R—High-Temperature CoolantD—Oil Cooler Plates J—Heat Exchanger/Thermostat O—Coolant Inlet to Water S—Low-Temperature CoolantE—Main Coolant Gallery Housing Pump T—Sea WaterF—Coolant Jacket K—Heat Exchanger Core

Coolant is circulated from the coolant pump (A) intothe coolant passage adapter (B) and circulates aroundthe oil cooler plates (D). From the oil cooler, coolantflows into the main coolant gallery (E). From thegallery, coolant flows into the coolant jacket (F),around the cylinder liners, up through the block deckpassages (G), and into the cylinder head. In thecylinder head, the coolant flows through passages (H)around the intake and exhaust ports, valve seats, andinjection nozzles. Coolant flows toward the front end ofthe cylinder head and exits into the heatexchanger/thermostat housing (J).

During the warm-up period, thermostats (I) are closedand coolant bypasses heat exchanger core (K), exitingthrough hose (L) into the coolant inlet side (O) of thecoolant pump. The coolant continues circulatingthrough the cylinder block, cylinder head, heat

exchanger and coolant pump to provide a uniform andfast warm-up period.

Once the engine has reached operating temperature,the thermostats open and allow high-temperaturecoolant to flow around tubes in the heat exchangercore (K), dissipating heat. Low-temperature coolantflows out coolant outlet hose (L) and into coolant inletside (O) of the coolant pump. Coolant continuesflowing through the engine and heat exchanger circuituntil the coolant temperature drops below thethermostat opening temperature.

Sea water flows into sea water pump (M) at inlet (P).Water then flows through tubing in the heat exchangercore (K). It absorbs heat from high-temperature coolantflowing around the tubing and exits through the seawater outlet (Q), or is discharged overboard.

50-16 013004

PN=171

Troubleshooting

DPSG,OUOD007,334 –19–19JAN99–1/2

Engine Coolant and Sea Water Flow (6068SFM50)

RG

1207

9–U

N–0

7MA

R02

Engine Coolant And Sea Water Flow

A—Coolant Pump D—Heat Exchanger Core G—Sea Water Inlet J—Low-Temperature CoolantB—Oil Cooler E—Coolant Outlet Hose H—Aftercooler Core K—Sea WaterC—Heat F—Sea Water Pump I—High-Temperature Coolant

Exchanger/ThermostatHousing

Coolant is circulated from the coolant pump (A) intothe oil cooler (B) and circulates around the oil coolerplates. From the oil cooler, coolant flows into the maincoolant gallery. From the gallery, coolant flows into thecoolant jacket, around the cylinder liners, up throughthe block deck passages, and into the cylinder head.

In the cylinder head, the coolant flows throughpassages around the intake and exhaust ports, valveseats, and injection nozzles. Coolant flows from thecylinder head and exits into the heatexchanger/thermostat housing (C).

50-17 013004

PN=172


Troubleshooting

DPSG,OUOD007,334 –19–19JAN99–2/2

During the warm-up period, thermostats are closedand coolant bypasses heat exchanger core, exitingthrough hose (E) into the coolant inlet side of the waterpump. The coolant continues circulating through thecylinder block, cylinder head, heat exchanger andcoolant pump to provide a uniform and fast warm-upperiod.

Once the engine has reached operating temperature,the thermostats open and allow high-temperaturecoolant (I) to flow around tubes in the heat exchangercore (D), dissipating heat. Low-temperature coolant (J)flows out coolant outlet hose (E) and into coolant inletside of the coolant pump. Coolant continues flowingthrough the engine and heat exchanger circuit until the

coolant temperature drops below the thermostatopening temperature.

Sea water (K) flows into sea water pump (F) at inlet(G). Sea water then flows into the aftercooler core (H)and into the heat exchanger core (D). In theaftercooler core, the sea water flowing through theaftercooler core tubes absorbs heat from theturbocharged air passing around the core, and exitsthrough the sea water outlet on the turbocharger. Inthe heat exchanger core (C), sea water (K) flowingthrough the heat exchanger core absorbs heat fromhigh-temperature coolant (I) flowing around the coreand exits through the sea water outlet on theturbocharger.

OURGP11,00000F8 –19–06OCT03–1/7

Engine Troubleshooting

Symptom Problem Solution

Engine cranks but will not start Incorrect starting procedure. Verify correct starting procedure.

No fuel. Check fuel in tank and manualshut-off valve.

Exhaust restricted. Check and correct exhaustrestriction.

Fuel filter plugged or full of water. Replace fuel filter or drain waterfrom filter.

Injection pump not getting fuel or air Check fuel flow at supply pump orin fuel system. bleed fuel system.

Faulty injection pump or nozzles. Consult authorized diesel repairstation for repair or replacement.


50-18 013004

PN=173

Troubleshooting

OURGP11,00000F8 –19–06OCT03–2/7


Engine hard to start or will not Engine starting under load. Disengage PTO (if equipped).start

Improper starting procedure. Review starting procedure.

No fuel. Check fuel tank.

Air in fuel line. Bleed fuel line.

Cold weather. Use cold weather starting aids.

Slow starter speed. See “Starter Cranks Slowly”.

Crankcase oil too heavy. Use oil of proper viscosity.

Improper type of fuel. Consult fuel supplier; use propertype fuel for operating conditions.

Water, dirt, or air in fuel system. Drain, flush, fill, and bleed system.

Clogged fuel filter. Replace filter element.

Dirty or faulty injection nozzles. Have authorized servicing dealer orengine distributor check injectors.

Electronic fuel system problem See your authorized servicing dealer

Injection pump shut-off not reset. Turn key switch to “OFF” then to“ON”.

Engine knocks Low engine oil level. Add oil to engine crankcase.

Injection pump out of time. See your authorized servicing dealeror engine distributor.

Low coolant temperature. Remove and check thermostat.

Engine overheating. See “Engine Overheats”.


50-19 013004

PN=174

Troubleshooting

OURGP11,00000F8 –19–06OCT03–3/7


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.



Below normal engine Defective thermostat. Remove and check thermostat.temperature

Defective temperature gauge or Check gauge, sender, andsender. connections.


50-20 013004

PN=175

Troubleshooting

OURGP11,00000F8 –19–06OCT03–4/7


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 normal engine temperature. Remove and check thermostat.

Improper valve clearance. See your authorized servicing dealeror engine distributor.


Injection pump out of time. See your authorized servicing dealeror engine distributor.

Turbocharger not functioning. See your authorized servicing dealer(Turbocharger engines only.) or engine distributor.

Leaking exhaust manifold gasket. See your authorized servicing dealeror engine distributor.

Defective aneroid control line. See your authorized servicing dealeror engine distributor.

Restricted fuel hose. Clean or replace fuel hose.

Low fast idle speed. See your authorized servicing dealeror engine distributor.

Damaged propeller Have propeller checked.

Marine growth Clean hull.

Low oil pressure Low oil level. Add oil.

Improper type of oil. Drain, fill crankcase with oil of properviscosity and quality.

50-21 013004

PN=176


Troubleshooting

OURGP11,00000F8 –19–06OCT03–5/7


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 (if equipped). See your authorized servicing dealeror engine distributor.

Engine emits white smoke Improper type of fuel. Use proper fuel.

Low engine temperature. Warm up engine to normal operatingtemperature.

Defective thermostat. Remove and check thermostat.

Defective injection nozzles. See your authorized servicing dealeror engine distributor.

Engine out of time. See your authorized servicing dealeror engine distributor.

Engine emits black or gray Improper type of fuel. Use proper fuel.exhaust smoke

Clogged or dirty air cleaner. Service air cleaner.

Engine overloaded. Reduce load.

Injection nozzles dirty. See your authorized servicing dealeror engine distributor.


Turbocharger not functioning. See your authorized servicing dealeror engine distributor.



50-22 013004

PN=177

Troubleshooting

OURGP11,00000F8 –19–06OCT03–6/7


Engine overheats Engine overloaded. Reduce load.

Low coolant level. Fill coolant tank to proper level,check coolant tank and hoses forloose connections or leaks.

Faulty coolant tank cap. Have serviceman check.

Stretched poly-vee belt or defective Check automatic belt tensioner andbelt tensioner. check belts for stretching. Replace

as required.

Faulty sea (raw) water pump. Check/replace impeller/pump.

Low engine oil level. Check oil level. Add oil as required.

Cooling system needs flushing. Flush cooling system.

Defective thermostat. Remove and check thermostat.

Defective temperature gauge or Check water temperature withsender. thermometer and replace, if

necessary.


Incorrect grade of fuel. Use correct grade of fuel.

Plugged heat exchanger. Clean heat exchanger and core.

Plugged keel cooler. Flush and clean keel cooler. Checkfor marine growth on O.D. of keelcooler tubes.

Trash or debris in engine Clean engine compartment.compartment.


50-23 013004

PN=178

Troubleshooting

OURGP11,00000F8 –19–06OCT03–7/7


High fuel consumption Improper type of fuel. Use proper type of fuel.

Clogged or dirty air cleaner. Service air cleaner.

Engine overloaded. Reduce load.

Improper valve clearance. See your authorized servicing dealeror engine distributor.

Injection nozzles dirty. See your authorized servicing dealeror engine distributor.


Defective turbocharger. See your authorized servicing dealeror engine distributor.

Low engine temperature. Check thermostat.

50-24 013004

PN=179

Troubleshooting

DPSG,OUOD007,335 –19–04JAN02–1/2

Electrical Troubleshooting


Undercharged electrical system Excessive electrical load from added Remove accessories or install higheraccessories. output alternator.

Excessive engine idling. Increase engine rpm when heavyelectrical load is used.

Poor electrical connections on Inspect and clean as necessary.battery, ground strap, starter, oralternator.

Defective battery. Test battery.

Defective alternator. Test charging system.

Battery uses too much water Cracked battery case. Check for moisture and replace asnecessary.

Defective battery. Test battery.

Battery charging rate too high. Test charging system.

Batteries will not charge Loose or corroded connections. Clean and tighten connections.

Sulfated or worn-out batteries. See your authorized servicing dealeror engine distributor.

Stretched poly-vee belt or defective Adjust belt tension or replace belt.belt tensioner.

Starter will not crank PTO engaged (if equipped). Disengage PTO.

Marine gear control engaged. Disengage marine gear.

Loose or corroded connections. Clean and tighten loose connections.

Low battery output voltage. See your authorized servicing dealeror engine distributor.

Faulty start circuit relay. See your authorized servicing dealeror engine distributor.

Blown main system fuse. Replace fuse.

50-25 013004

PN=180


Troubleshooting

DPSG,OUOD007,335 –19–04JAN02–2/2


Starter cranks slowly Low battery output. See your authorized servicing dealeror engine distributor.

Crankcase oil too heavy. Use proper viscosity oil.

Loose or corroded connections. Clean and tighten loose connections.

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

Sulfated or worn-out batteries. See your authorized servicing dealeror engine distributor.

Blown main system fuse. Replace fuse.

50-26 013004

PN=181

Troubleshooting

OURGP11,00000BA –19–05SEP03–1/1

Blink Code Method for Retrieving Diagnostic Trouble Codes

NOTE: If engine has an electronic instrument panelwith diagnostic gauge, refer to “InstrumentPanel Method for Retrieving DiagnosticTrouble Codes” later in this section.

On marine applications that have a Fault Lamp, theECU has the ability to display DTCs using blinkingsequence of the fault lamp. To retrieve DTCs from theECU using the “blink code” method:

NOTE: The ECU blinks the codes in 2-digit codesonly. See LISTING OF DIAGNOSTICTROUBLE CODES (DTCS) later in this Group.

1. Turn the ignition switch “ON”.

2. Press down Override Shutdown Switch (ifequipped) for a few seconds.

3. The Fault Lamp will begin to flash a code number.For example, flash three times...short pause...flashtwo times...long pause. This example is code 32.

4. The ECU begins the flashing sequence by flashinga code 32, this indicates the start of blinking active

codes. If there are any active DTCs, the ECU willflash it’s 2–digit number. If there is more than oneactive DTC, the ECU will flash each code innumerical order. If there are no active DTCs, theFault Lamp will flash a code 88.

5. Following the active codes, the Fault Lamp willflash a code 33. This indicates the start of blinkingstored codes. If there are any stored DTCs, theFault Lamp will flash its 2–digit number. If there ismore than one stored DTC, the ECU will flash eachcode in numerical order. If there are no storedDTCs, the Fault Lamp will flash a code 88.

6. Once complete, this sequence will repeat.

7. When complete, turn ignition “OFF”.

As an example, if an engine had an active DTC 18and stored DTC 53, the flashing sequence would be:flash three times...short pause...flash two times...longpause...flash one time...short pause...flash eighttimes...long pause...flash three times...shortpause...flash three times...long pause...flash fivetimes...short pause...flash three times.

50-27 013004

PN=182

Troubleshooting

OURGP11,00000BB –19–05SEP03–1/2

Instrument Panel Method for RetrievingDiagnostic Trouble Codes

IMPORTANT: Care should be used during diagnosticprocedures to avoid damaging theterminals of connectors, sensors, andactuators. Probes should not be pokedinto or around the terminals or damagewill result. Probes should only betouched against the terminals to makemeasurements.

Diagnosis of the electronic control system should beperformed according to the following procedure:

1. Make sure all engine mechanical and other systemsnot related to the electronic control system areoperating properly.

OURGP11,00000BB –19–05SEP03–2/2

RG

1314

0–U

N–0

7OC

T03

Diagnostic Gauge

A—Diagnostic Gauge

2. Read and record diagnostic trouble codes (DTCs)displayed on the diagnostic gauge (A). To accesstrouble codes on diagnostic gauge (A), see Section 15of this manual.

3. Go to the LISTING OF DIAGNOSTIC TROUBLECODES (DTCs) later in this section, to interpret theDTCs present.

4. Contact your nearest engine distributor or servicingdealer with a list of DTC codes that are displayed sonecessary repairs can be made.

50-28 013004

PN=183

Troubleshooting

OURGP11,0000205 –19–07OCT03–1/3

Listing Of Diagnostic Trouble Codes (DTC)

The Diagnostic Trouble Codes (DTCs) are output on thediagnostic gauge according to the J1939 standard as atwo-part code. The first part is a two to four-digit SuspectParameter Number (SPN) followed by a one or two-digitFailure Mode Identifier (FMI) code.

Following is a list of SPNs, FMIs, Blink Codes anddescription of the diagnostic trouble codes that can occurin the various engine systems. Not all of these codes willbe present in all engine applications.

When trouble codes appear on the diagnostic gauge, seeyour engine dealer for repairs as soon as possible.


50-29 013004

PN=184

Troubleshooting

OURGP11,0000205 –19–07OCT03–2/3

Listing Of Diagnostic Trouble Codes—Continued

SPN FMI Blink Code Definition

28 ............... 03 ............... 03 ............... Analog Throttle (A) No. 3 Voltage High28 ............... 04 ............... 14 ............... Analog Throttle (A) No. 3 Voltage Low29 ............... 03 ............... 15 ............... Analog Throttle (B) No. 2 Voltage High29 ............... 04 ............... 16 ............... Analog Throttle (B) No. 2 Voltage Low84 ............... 02 ............... 91 ............... Vehicle Speed Mismatch91 ............... 03 ............... 11 ............... Multistate Throttle Input High91 ............... 04 ............... 12 ............... Multistate Throttle Input Low91 ............... 09 ............... ................... Throttle Invalid94 ............... 01 ............... 58 ............... Fuel Supply Pressure Extremely Low94 ............... 03 ............... 27 ............... Fuel Supply Pressure Input Voltage High94 ............... 04 ............... 28 ............... Fuel Supply Pressure Input Voltage Low94 ............... 18 ............... 57 ............... Fuel Supply Pressure Moderately Low100 ............. 01 ............... 75 ............... Engine Oil Pressure Extremely Low100 ............. 03 ............... 23 ............... Engine Oil Pressure Input Voltage High100 ............. 04 ............... 24 ............... Engine Oil Pressure Input Voltage Low100 ............. 18 ............... 74 ............... Engine Oil Pressure Moderately Low105 ............. 00 ............... ................... Manifold Air Temperature Extremely High105 ............. 03 ............... ................... Manifold Air Temperature Input Voltage High105 ............. 04 ............... ................... Manifold Air Temperature Input Voltage Low105 ............. 16 ............... ................... Manifold Air Temperature Moderately High107 ............. 00 ............... ................... Air Filter Differential Pressure110 ............. 00 ............... 63 ............... Engine Coolant Temperature Extremely High110 ............. 03 ............... 18 ............... Engine Coolant Temperature Input Voltage High110 ............. 04 ............... 19 ............... Engine Coolant Temperature Input Voltage Low110 ............. 15 ............... 62 ............... Engine Coolant Temperature High Least Severe110 ............. 16 ............... 63 ............... Engine Coolant Temperature Moderately High111 ............. 01 ............... 61 ............... Engine Coolant Level Low158 ............. 17 ............... 54 ............... ECU Power Down Error174 ............. 00 ............... 67 ............... Fuel Temperature High-Most Severe174 ............. 15 ............... 33/53 .......... Fuel Temperature High-Least Severe174 ............. 16 ............... 71 ............... Fuel Temperature High-Moderately Severe174 ............. 31 ............... 98 ............... Fuel Temperature Sensor Faulty189 ............. 00 ............... ................... Fuel temperature Sender Faulty189 ............. 31 ............... 48 ............... Engine Speed Derate190 ............. 00 ............... 42 ............... Engine Overspeed Extreme190 ............. 16 ............... 42 ............... Engine Overspeed Moderate620 ............. 03 ............... ................... Sensor Supply Voltage High620 ............. 04 ............... ................... Sensor Supply Voltage Low627 ............. 04 ............... 76 ............... ECU Unswitched, Power Missing629 ............. 13 ............... ................... ECU Error629 ............. 19 ............... 34 ............... ECU to Pump Communication Error632 ............. 02 ............... 37 ............... Fuel Shutoff Error632 ............. 05 ............... 86 ............... Fuel Shutoff Not Functioning636 ............. 02 ............... 44 ............... Pump Position Sensor Input Noise636 ............. 08 ............... 43 ............... Pump Position Sensor Input Missing636 ............. 10 ............... 44 ............... Pump Position Sensor Input Pattern Error637 ............. 02 ............... 39 ............... Crankshaft Position Input Noise637 ............. 08 ............... 38 ............... Crankshaft Position Input Missing637 ............. 10 ............... 39 ............... Crankshaft Position Input Pattern Error729 ............. 03 ............... ................... Inlet Air Heater Signal High729 ............. 05 ............... ................... Inlet Air Heater Signal Low

50-30 013004

PN=185


Troubleshooting

OURGP11,0000205 –19–07OCT03–3/3

SPN FMI Blink Code Definition

810 ............. 02 ............... 92 ............... Calculated Vehicle Speed Input Noise898 ............. 09 ............... 77 ............... Vehicle Speed Invalid/Missing970 ............. 02 ............... ................... Auxiliary Engine Shutdown Switch Signal Invalid970 ............. 31 ............... ................... Auxiliary Engine Shutdown Switch Active971 ............. 31 ............... ................... External Engine Derate Switch Active1076 ........... 02 ............... 66 ............... Injection Pump Detected Defect1077 ........... 07 ............... 35 ............... Attempting to Fuel Without Command1077 ........... 11 ............... 68 ............... Pump Supply Voltage Out of Range1077 ........... 12 ............... 97 ............... Pump Self Test Error1077 ........... 19 ............... 96 ............... Pump Detected Communication Error1077 ........... 31 ............... 36 ............... Pump Initiated Engine Protection1078 ........... 07 ............... 95 ............... ECU/Pump Timing Moderately Out of Sync1078 ........... 11 ............... 87 ............... ECU/Pump Speed Out of Sync1078 ........... 31 ............... 94 ............... ECU/Pump Timing Extremely Out of Sync1079 ........... 03 ............... 21 ............... Sensor Supply 1 Voltage High1079 ........... 04 ............... 22 ............... Sensor Supply 1 Voltage Low1080 ........... 03 ............... 31 ............... Sensor Supply 2 Voltage High1080 ........... 04 ............... 32 ............... Sensor Supply 2 Voltage Low1109 ........... 31 ............... ................... Engine Shutdown Warning1110 ........... 31 ............... ................... Engine Shutdown1485 ........... 02 ............... 89 .............. Pump Power Relay Fault1569 ........... 31 ............... 47 .............. Fuel Derate2000 ........... 13 ............... ................... Security Violation

NOTE: The Diagnostic Gauge on the electronicinstrument panel can have communicationproblems that result in Error Codes being shownon its LCD display window. The following ErrorCodes all indicate that there is a DiagnosticGauge communication error with the ECU.Contact your servicing dealer for help in correctingthese codes:

50-31 013004

PN=186

Troubleshooting

OURGP11,0000206 –19–07OCT03–1/1

Intermittent Fault Diagnostics

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 faults may be set only under certainoperating conditions such as heavy load, extended idleetc. When diagnosing intermittent faults, take specialnote of the condition of wiring and connectors since ahigh percentage of intermittent problems originatehere. Check for loose, dirty or disconnectedconnectors. Inspect the wiring routing looking forpossible shorts caused by contact with external parts(for example, rubbing against sharp sheet metaledges). Inspect the connector vicinity looking for wiresthat have pulled out of connector terminals, damagedconnectors, poorly positioned terminals, and corrodedor damaged terminals. Look for broken wires,damaged splices, and wire-to-wire shorts. Use goodjudgement if component replacement is thought to berequired.

NOTE: The Engine Control Unit (ECU) is thecomponent LEAST likely to fail.

Suggestions for diagnosing intermittent faults:

If the problem is intermittent, try to reproduce theoperating conditions that were present when theDiagnostic Trouble Code (DTC) set.

If a faulty connection or wire is suspected to be thecause of the intermittent problem: clear DTCs, thencheck the connection or wire by wiggling it whilewatching the diagnostic gauge to see if the faultresets.

Possible Causes of Intermittent Faults:

1. Faulty connection between sensor or actuator andharness.

2. Faulty contact between terminals in connector.3. Faulty terminal/wire connection.

Electromagnetic interference (EMI) from an improperlyinstalled 2-way radio, etc. can cause faulty signals tobe sent to the ECU.

NOTE: Refer to wiring diagram foldouts earlier in thissection as a guide to connections and wires.

OURGP11,00000E3 –19–29SEP03–1/4

Displaying Diagnostic Gauge Software

RG

1315

9–U

N–2

6SE

P03

Menu Key

NOTE: The following steps can be used to display thesoftware version of the diagnostic gauge if neededby your dealer for troubleshooting. This is a readonly function.

1. Starting at the single or four engine parameter display,press the "Menu" key.


50-32 013004

PN=187

Troubleshooting

OURGP11,00000E3 –19–29SEP03–2/4

RG

1323

4–U

N–2

2OC

T03

Select Utilities

2. The main menu will be displayed. Use the "Arrow" keyto scroll through the menu until "Utilities" is highlighted.

OURGP11,00000E3 –19–29SEP03–3/4

RG

1323

7–U

N–2

2OC

T03

Select Utilities

3. Once "Utilities" is highlighted, press "Enter" to activatethe utilities function.

OURGP11,00000E3 –19–29SEP03–4/4

RG

1323

6–U

N–1

3OC

T03

Software Version

4. Scroll to the "Software Version". Press "Enter" to viewthe software version. Press the menu button twice toreturn to the main menu.

50-33 013004

PN=188

Storage

RG,RG34710,5610 –19–23NOV01–1/1

Engine Storage Guidelines

1. John Deere engines can be stored outside for up tothree (3) months with no long term preparation IFCOVERED BY WATERPROOF COVERING.

2. John Deere engines can be stored in a standardoverseas shipping container for up to three (3)months with no long term preparation.

3. John Deere engines can be stored inside,warehoused, for up to six (6) months with no longterm preparation.

4. John Deere engines expected to be stored morethan six (6) months, long term storage preparationMUST BE taken. (See PREPARING ENGINE FORLONG TERM STORAGE, later in this section.)

55-1 013004

PN=189

Storage

RG,RG34710,5612 –19–20MAY96–1/1

Preparing Engine for Long-Term Storage

The following storage preparations are good 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 not beused for over six (6) months, thefollowing recommendations forstoring it and removing it fromstorage will help to minimizecorrosion and deterioration.

1. Change engine oil and replace filter. Used oil willnot give adequate protection. (See CHANGEENGINE OIL AND FILTER in Lubrication andMaintenance/500 Hour Section.)

2. Service air cleaner. (See REPLACING AIRCLEANER FILTER ELEMENTS in Service AsRequired Section.)

3. Draining and flushing of cooling system is notnecessary if engine is to be stored only for severalmonths. However, for extended storage periods of ayear or longer, it is recommended that the coolingsystem be drained, flushed, and refilled. Refill withappropriate coolant. (See RECOMMENDEDENGINE COOLANT in Fuels, Lubricants, andCoolant Section and ADDING COOLANT in ServiceAs Required Section.)

4. Drain and completely clean the sea water strainer.Close sea water drain cock and fill the sea watersystem with (premixed) RV antifreeze.

5. Crank the engine several revolutions with starter(do not allow the engine to start).

6. Loosen alternator poly-vee belt. Remove, if desired.

7. Remove and clean batteries. Store them in a cool,dry place and keep them fully charged.

8. Disengage the PTO clutch (if equipped).

9. Clean the exterior of the engine with salt-free waterand touch up any scratched or chipped paintedsurfaces with a good quality paint.

10. Coat all exposed (machined) metal surfaces withgrease or corrosion inhibitor if not feasible to paint.

11. Seal all openings on engine with plastic bags.

12. Store the engine in a dry protected place. Ifengine must be stored outside, cover it with awaterproof canvas or other suitable protectivematerial and use a strong waterproof tape.

55-2 013004

PN=190

Storage

RG,RG34710,5613 –19–20MAY96–1/1

Removing Engine from Long-Term Storage

Refer to the appropriate section for detailed serviceslisted below or have your authorized servicing dealeror engine distributor perform services that you may notbe familiar with.

1. Remove all protective coverings from engine.Unseal all openings in engine and remove coveringfrom electrical systems.

2. Remove the batteries from storage. Install batteries(fully charged) and connect the terminals.

3. Install alternator poly-vee belt if removed. Adjustbelt tension. (See CHECKING BELT TENSIONERSPRING TENSION AND BELT WEAR inLubrication and Maintenance/500 Hour/12 MonthSection.) Install belt guard.

4. Perform all appropriate prestarting checks. (SeeDAILY PRESTARTING CHECKS in Lubrication andMaintenance/Daily Section.)

5. Open sea water valve and prime the sea watersystem.

6. Open fuel valve, fill fuel filter/water separator withclean fuel and bleed the fuel system. (SeeBLEEDING THE FUEL SYSTEM in Service asRequired Section.)

IMPORTANT: DO NOT operate starter more than30 seconds at a time. Wait at least 2minutes for starter to cool beforetrying again.

7. Crank engine for 20 seconds with starter (do notallow the engine to start). Wait 2 minutes and crankengine an additional 20 seconds to assure bearingsurfaces are adequately lubricated.

8. Start engine and run at low idle and no load forseveral minutes. Warm up carefully and check allgauges before placing engine under load.

9. On the first day of operation after storage, checkoverall engine for leaks and check all gauges forcorrect operation.

55-3 013004

PN=191

Specifications

OURGP11,0000207 –19–07OCT03–1/1

General Engine Specifications—4.5 LEngines

ITEM UNIT OF MEASURE 4045DFM70 4045TFM75

Number of Cylinders — 4 4

Fuel — Diesel Diesel

Bore mm 106 106(in.) (4.19) (4.19)

Stroke mm 127 127(in.) (5.00) (5.00)

Displacement L 4.5 4.5(cu in.) (276) (276)

Compression Ratio — 17.6:1 17.6:1

Rated Speed:Std. Governor RPM 2500 2500-26003—5% Governor

Fast Idle Speed (Std. Governor) RPM 2700 2675

Slow Idle Speed:Propulsion Engines RPM 700 650Gen-Set Engines RPM — —

Oil Pressure @ Rated Speed kPa (psi) 345 (50) 345 (50)

Flywheel and Housing SAE No. 2,3,4 2,3,4

Injection Nozzles mm 9.5 9.5

Coolant Capacity (Including Heat Exchanger) L (qt) 14 L (15 qt) 14 L (15 qt)

Physical Dimensions:Width mm (in.) 713 (28.1) 713 (28.1)Height mm (in.) 902 (35.5) 912 (35.9)Length mm (in.) 885 (34.8) 885 (34.8)Basic Dry Weight kg (lb) 437 (961) 462 (1019)

60-1 013004

PN=192

Specifications

OURGP11,0000208 –19–07OCT03–1/1

General Engine Specifications—6.8 LEngines

ITEM UNIT OF 6068SFM50 6068TFM75 6068TFM76MEASURE

Number of Cylinders — 6 6 6

Fuel — Diesel Diesel Diesel

Bore mm (in.) 106.5 (4.19) 106.5 (4.19) 106.5 (4.19)

Stroke mm (in.) 127 (5.00) 127 (5.00) 127 (5.00)

Displacement L (cu in.) 6.8 (414) 6.8 (414) 6.8 (414)

Compression Ratio — 17.0:1 17.0:1 17.0:1

Rated Speed:Std. Governor RPM 2400—2600 2400—2600 1500 or 18003—5% Governor RPM — — —

Fast Idle Speed RPM 2675 2675 1560 or 1890

Slow Idle Speed:Propulsion Engines RPM 650 650 —Gen-Set Engines RPM — — —

Oil Pressure @ Rated Speed kPa (psi) 345 (50) 345 (50) 345 (50)

Flywheel and Housing SAE No. 2,3 2,3 2,3

Injection Nozzles mm 9.5 9.5 9.5

Coolant Capacity (Including L (qt) 28 L (30 qt) 28 L (30 qt) 28 L (30 qt)Heat Exchanger)

Physical Dimensions:Width mm (in.) 829 (32.6) 712 (28.0) 712 (28.0)Height mm (in.) 941 (37.0) 881 (34.7) 881 (34.7)Length mm (in.) 1183 (46.6) 1141 (44.9) 1141 (44.9)Basic Dry Weight kg (lb) 636 (1399) 590 (1298) 590 (1298)

60-2 013004

PN=193

Specifications

OURGP11,0000209 –19–07OCT03–1/1

Engine Power And Speed Specifications1

Engine Model Application Rating Power Rating @ Rated Speeda (rpm) Slow Idle Fast Idleb(rpm)Rated Speed (rpm)Without Fan kW (hp)

4045DFM70 M2 60 (80) 2500 700 2700Gen-Set 60 Hz 46 (61) 1800 1400 1890Gen-Set 50 Hz 40 (54) 1500 1400 1605

4045TFM75 M1 79 (106) 2400 650 2520

M2 90 (121) 2500 650 2620

M3 101 (135) 2600 650 2720

Gen-Set 60 Hz 73 (97) 1800 1400 1890

Gen-Set 50 Hz 55 (74) 1500 1400 1575

6068SFM50 M1 136 (182) 2200 650 2320

M2 155 (208) 2300 650 2420

M3 176 (236) 2400 650 2520

M4) 199 (267) 2500 650 2620

M5 224 (300) 2600 650 2720

6068TFM75 M1 118 (158) 2400 650 2520

M2 133 (178) 2500 650 2620

M3 150 (201) 2600 650 2720

6068TFM76 Gen-Set 60 Hz 110 (147) 1800 1400 1890

Gen-Set 50 Hz 89 (119) 1500 1400 1575aGenerator set engines (3-5% governor) usually run at 1500 rpm (50 Hz) or 1800 (60 Hz) when operating under load depending on cycles ofAC current.bFor engines with standard governor, fast idle is 7-10% above rated speed. For engines with generator set governors, fast idle is 3-5% aboverated speed.

1Engine speeds listed are preset to factory specification. Slow idle speedmay be reset depending upon specific boat application requirements.Refer to your boat operator’s manual for engine speeds that are differentfrom those preset at the factory.

60-3 013004

PN=194

Specifications

OURGP11,00000F9 –19–07OCT03–1/1

Engine Crankcase Oil Fill Quantities

RG

1325

2–1

9–06

OC

T03

Option Code Label

A—Engine Base Code

Each engine has a 13-digit John Deere engine serialnumber. The first two digits identify the factory thatproduced the engine:

“T0” indicates the engine was built in Dubuque, Iowa,while “CD” indicates that the engine was built in Saran,France and “PE” indicates Torreon, Mexico

In addition to the serial number plate, Marine engineshave an engine option code label affixed to the rockerarm cover. These codes indicate which of the engineoptions were installed on your engine at the factory.When in need of parts or service, furnish yourauthorized servicing dealer or engine distributor withthese numbers.

The engine option code label includes an engine basecode (A). At times it will be necessary to furnish thisbase code to differentiate two identical option codesfor the same engine model.

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 (40) identify the dipstick tube group. The lasttwo digits of each code identify the specific dipstickand tube assembly on your engine.

Listed below are engine crankcase oil fill quantities:

Engine Model Oil Pan Option Code (s) Crankcase Oil Capacity4045DFM70 .................................................................. 1901 ......................................................... 8.5 L (9.0 qt.)

1902 ......................................................... 8.5 L (9.0 qt.)1903 ......................................................... 12.0 L (12.7 qt.)1923 ......................................................... 15.0 L (15.9 qt.)19AE ........................................................ 14.7 L (15.5 qt.)

4045TFM75 .................................................................. 1954 ......................................................... 13.0 L (13.7 qt.)6068SFM50 .................................................................. 1987 ......................................................... 31.5 L (33.3 qt.)

1996 ......................................................... 32.5 L (34.4 qt)6068TFM75 .................................................................. 1945 ......................................................... 20.0 L (21.1 qt)

1955 ......................................................... 19.5 L (20.6 qt)6068TFM76 .................................................................. 1945 ......................................................... 20.5 L (21.1 qt)

1955 ......................................................... 19.5 L (20.6 qt)

NOTE: Crankcase oil capacity may vary slightly fromamount shown. ALWAYS fill crankcase to full

mark or between arrows on dipstick, whicheveris present. DO NOT overfill.

60-4 013004

PN=195

Specifications

TORQ1 –19–24APR03–1/1

Unified Inch Bolt and Screw Torque ValuesTS1671 –UN–01MAY03

Bolt or SAE Grade 1 SAE Grade 2a SAE Grade 5, 5.1 or 5.2 SAE Grade 8 or 8.2

Screw Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc

Size N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in

1/4 3.7 33 4.7 42 6 53 7.5 66 9.5 84 12 106 13.5 120 17 150

N•m lb-ft N•m lb-ft

5/16 7.7 68 9.8 86 12 106 15.5 137 19.5 172 25 221 28 20.5 35 26

N•m lb-ft N•m lb-ft

3/8 13.5 120 17.5 155 22 194 27 240 35 26 44 32.5 49 36 63 46

N•m lb-ft N•m lb-ft N•m lb-ft

7/16 22 194 28 20.5 35 26 44 32.5 56 41 70 52 80 59 100 74

N•m lb-ft

1/2 34 25 42 31 53 39 67 49 85 63 110 80 120 88 155 115

9/16 48 35.5 60 45 76 56 95 70 125 92 155 115 175 130 220 165

5/8 67 49 85 63 105 77 135 100 170 125 215 160 240 175 305 225

3/4 120 88 150 110 190 140 240 175 300 220 380 280 425 315 540 400

7/8 190 140 240 175 190 140 240 175 490 360 615 455 690 510 870 640

1 285 210 360 265 285 210 360 265 730 540 920 680 1030 760 1300 960

1-1/8 400 300 510 375 400 300 510 375 910 670 1150 850 1450 1075 1850 1350

1-1/4 570 420 725 535 570 420 725 535 1280 945 1630 1200 2050 1500 2600 1920

1-3/8 750 550 950 700 750 550 950 700 1700 1250 2140 1580 2700 2000 3400 2500

1-1/2 990 730 1250 930 990 730 1250 930 2250 1650 2850 2100 3600 2650 4550 3350

Torque values listed are for general use only, based on the strength of the Replace fasteners with the same or higher grade. If higherbolt or screw. DO NOT use these values if a different torque value or grade fasteners are used, tighten these to the strength of thetightening procedure is given for a specific application. For plastic insert or original. Make sure fastener threads are clean and that youcrimped steel type lock nuts, for stainless steel fasteners, or for nuts on properly start thread engagement. When possible, lubricateU-bolts, see the tightening instructions for the specific application. Shear plain or zinc plated fasteners other than lock nuts, wheel boltsbolts are designed to fail under predetermined loads. Always replace shear or wheel nuts, unless different instructions are given for thebolts with identical grade. specific application.aGrade 2 applies for hex cap screws (not hex bolts) up to 6. in (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long,and for all other types of bolts and screws of any length.b“Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or 7/8 in. and larger fasteners withJDM F13C zinc flake coating.c“Dry” means plain or zinc plated without any lubrication, or 1/4 to 3/4 in. fasteners with JDM F13B zinc flake coating.

60-5 013004

PN=196

Specifications

DX,TORQ2 –19–24APR03–1/1

Metric Bolt and Screw Torque Values

4.84.8 8.8 9.8 10.9 12.9 12.9

12.912.910.99.88.84.8

TS

1670

–UN

–01M

AY

03

Bolt or Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9

Screw Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb

Size N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in

M6 4.7 42 6 53 8.9 79 11.3 100 13 115 16.5 146 15.5 137 19.5 172

N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft

M8 11.5 102 14.5 128 22 194 27.5 243 32 23.5 40 29.5 37 27.5 47 35

N•m lb-ft N•m lb-ft N•m lb-ft

M10 23 204 29 21 43 32 55 40 63 46 80 59 75 55 95 70

N•m lb-ft

M12 40 29.5 50 37 75 55 95 70 110 80 140 105 130 95 165 120

M14 63 46 80 59 120 88 150 110 175 130 220 165 205 150 260 190

M16 100 74 125 92 190 140 240 175 275 200 350 255 320 235 400 300

M18 135 100 170 125 265 195 330 245 375 275 475 350 440 325 560 410

M20 190 140 245 180 375 275 475 350 530 390 675 500 625 460 790 580

M22 265 195 330 245 510 375 650 480 725 535 920 680 850 625 1080 800

M24 330 245 425 315 650 480 820 600 920 680 1150 850 1080 800 1350 1000

M27 490 360 625 460 950 700 1200 885 1350 1000 1700 1250 1580 1160 2000 1475

M30 660 490 850 625 1290 950 1630 1200 1850 1350 2300 1700 2140 1580 2700 2000

M33 900 665 1150 850 1750 1300 2200 1625 2500 1850 3150 2325 2900 2150 3700 2730

M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2770 4750 3500

Torque values listed are for general use only, based on the strength Shear bolts are designed to fail under predetermined loads. Alwaysof the bolt or screw. DO NOT use these values if a different torque replace shear bolts with identical property class. Replace fastenersvalue or tightening procedure is given for a specific application. For with the same or higher property class. If higher property classstainless steel fasteners or for nuts on U-bolts, see the tightening fasteners are used, tighten these to the strength of the original. Makeinstructions for the specific application. Tighten plastic insert or sure fastener threads are clean and that you properly start threadcrimped steel type lock nuts by turning the nut to the dry torque engagement. When possible, lubricate plain or zinc plated fastenersshown in the chart, unless different instructions are given for the other than lock nuts, wheel bolts or wheel nuts, unless differentspecific application. instructions are given for the specific application.a“Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or M20 and larger fasteners withJDM F13C zinc flake coating.b“Dry” means plain or zinc plated without any lubrication, or M6 to M18 fasteners with JDM F13B zinc flake coating.

60-6 013004

PN=197

Lubrication and Maintenance Records

OURGP11,0000159 –19–28JAN04–1/1

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 operateyour engine by regular observation of hour meter.

2. Check your record regularly to learn when yourengine needs service.

3. DO ALL the services within an interval section.Write the number of hours (from your servicerecords) and the date in the spaces provided. For a

complete listing of all items to be performed and theservice intervals required, refer to thequick-reference chart near the front of theLubrication and Maintenance Section.

IMPORTANT: The service recommendationscovered in this manual are for theaccessories that are provided byJohn Deere. Follow manufacturer’sservice recommendations forservicing engine driven equipmentnot supplied by Deere.

RG,RG34710,5621 –19–25MAR02–1/1

Daily (Prestarting) Service

• Check engine oil level.• Check coolant level.• Check fuel filter water separator bowl.• Check sea water strainer.• Check air cleaner dust unloader valve and air restriction

indicator, if equipped.• Visual walkaround inspection.

65-1 013004

PN=198


OURGP11,00000FA –19–07OCT03–1/1

250 Hour/6 Month Service

• Change engine oil and filter.• Service fire extinguisher.• Service battery.• Inspect zinc plugs.• Check belt tension and wear.• Check engine mounts.• Check engine electrical ground connections

Hours

Date

Hours

Date

Hours

Date

Hours

Date

Hours

Date

Hours

Date

Hours

Date

Hours

Date

65-2 013004

PN=199


OURGP11,00000FB –19–07OCT03–1/1

500 Hour/12 Month Service

• Clean crankcase vent tube.• Check air intake hoses, connections, and system.• Replace fuel filter element.• Check automatic belt tensioner and belt wear.• Check cooling system.• Coolant solution analysis – add SCAs as needed.• Inspect and clean heat exchanger and aftercooler core.• Check engine speeds.• Check engine electrical ground.• Replace crankcase vent filter (if equipped).• Pressure test cooling system.

Hours

Date

Hours

Date

Hours

Date

Hours

Date

Hours

Date

Hours

Date

Hours

Date

Hours

Date

65-3 013004

PN=200


OURGP11,00000FC –19–07OCT03–1/1

2000 Hour Service

• Check crankshaft vibration damper.• Inspect and repair sea water pump.• Test thermostats.• Have your authorized servicing dealer or engine

distributor adjust valve clearance.• Flush and refill cooling system.1

Hours

Date

Hours

Date

Hours

Date

Hours

Date

Hours

Date

Hours

Date

Hours

Date

Hours

Date

1If John Deere Cool-Gard is used, the flushing interval may be extendedto 5000 hours or 60 months, whichever occurs first, provided the coolantis tested annually AND additives are replenished by addingsupplemental coolant additives (SCAs).

65-4 013004

PN=201


RG,RG34710,5627 –19–25MAR02–1/1

Service As Required

• Adding coolant.• Replace dry air cleaner element (Enclosed element

installations).• Service dry air cleaner element (Open element

installations).• Replace dry air cleaner element (Open element

installations).• Replace poly-vee belt.• Inspect driveline.• Bleed fuel system.• Remove and install sea water pump.

Hours

Date

Hours

Date

Hours

Date

Hours

Date

Hours

Date

Hours

Date

Hours

Date

Hours

Date

65-5 013004

PN=202

Emission System Warranty

OURGP11,000012D –19–03NOV03–1/1

Emissions Control System Certification Label

RG

1334

9–U

N–1

0DE

C03

Emission Label

CAUTION: Statutes providing severe penaltiesfor tampering with emissions controls mayapply at the user’s location.

The emissions warranty described below applies only tothose engines marketed by John Deere that have beencertified by the United States Environmental protectionAgency (EPA) and used in the United States. EPA’semission regulations, and thus this emissions warranty,does not apply to recreational marine engines as definedin 40 CFR 94.2.

The presence of an emissions label like the one shownsignifies that the engine has been certified with the EPA.The EPA warranty applies only to new engines having thecertification label affixed to the engine and sold in theabove-stated geographic area.

NOTE: The kW rating on the engine emissionscertification label specifies the gross engine kW,which is flywheel power without fan. In someapplications this will not be the same power asstated on the above emissions label.

OURGP11,000012E –19–03NOV03–1/1

U.S. EPA Emissions Control Warranty Statement

Emissions control-related parts and components arewarranted by John Deere for five years or 5000 hoursof operation, whichever occurs first. John Deere furtherwarrants that the engine covered by this warranty wasdesigned, built, and equipped so as to conform at thetime of sale with all U.S. emissions standards at thetime of manufacture, and that it is free of defects inmaterials and workmanship which would cause it notto meet these standards within the period of five yearsor 5000 hours of operation, whichever occurs first.

Warranties stated in this manual refer only toemissions-related parts and components of yourengine. The complete engine warranty, lessemissions-related parts and components, is providedseparately as the “John Deere New Marine EngineWarranty”.

70-1 013004

PN=203

John Deere Service Literature Available

DX,SERVLIT –19–11NOV97–1/1

Technical Information

TS

189

–UN

–17J

AN

89T

S19

1–U

N–0

2DE

C88

TS

224

–UN

–17J

AN

89T

S16

63–U

N–1

0OC

T97

Technical information is available from John Deere. Someof this information is available in electronic as well asprinted form. Order from your John Deere dealer or call1-800-522-7448. Please have available the modelnumber, serial number, and name of the product.

Available information includes:

• PARTS CATALOGS list service parts available for yourmachine with exploded view illustrations to help youidentify the correct parts. It is also useful in assemblingand disassembling.

• OPERATOR’S MANUALS providing safety, operating,maintenance, and service information. These manualsand safety signs on your machine may also be availablein other languages.

• OPERATOR’S VIDEO TAPES showing highlights ofsafety, operating, maintenance, and service information.These tapes may be available in multiple languagesand formats.

• TECHNICAL MANUALS outlining service information foryour machine. Included are specifications, illustratedassembly and disassembly procedures, hydraulic oilflow diagrams, and wiring diagrams. Some productshave separate manuals for repair and diagnosticinformation. Some components, such as engines, areavailable in separate component technical manuals

• FUNDAMENTAL MANUALS detailing basic informationregardless of manufacturer:– Agricultural Primer series covers technology in

farming and ranching, featuring subjects likecomputers, the Internet, and precision farming.

– Farm Business Management series examines“real-world” problems and offers practical solutions inthe areas of marketing, financing, equipmentselection, and compliance.

– Fundamentals of Services manuals show you how torepair and maintain off-road equipment.

– Fundamentals of Machine Operation manuals explainmachine capacities and adjustments, how to improvemachine performance, and how to eliminateunnecessary field operations.

013004

PN=204

John Deere Service Literature Available

OURGP11,00000FD –19–07OCT03–1/1

Publications For This Engine

Technical information is available from John Deere insupport of our products. Some of this information isavailable in electronic media as well as printed form.Order from your John Deere dealer, search online fromhttp://www.JohnDeere.com or call 1-800-522-7448 toorder using a credit card. Please have available the modelnumber, serial number and name of the product.

Title Order Number

POWERTECH 4.5 L and 6.8L Marine Engines (Tier2)

Operation and Service Manual (English) OMRG35856

Parts Catalogs:

POWERTECH 4.5 L Marine (Tier 2) PC2480

POWERTECH 6.8 L Marine (Tier 2) PC2481

Component Technical Manuals (English)

Base Engine CTM104

Mechanical Fuel Systems CTM207

Electronic Fuel Systems (Level 12 w/DE10 Pump) CTM331

Electronic Fuel Systems (Level 4 w/VP44 Pump) CTM170

OEM Engine Accessories (English Only) CTM67

Alternators and Starter Motors (English) CTM77

013004

PN=205

John Deere Service Keeps You On The Job

DX,IBC,A –19–04JUN90–1/1

John Deere Parts

TS

100

–UN

–23A

UG

88

We help minimize downtime by putting genuine JohnDeere parts in your hands in a hurry.

That’s why we maintain a large and varied inventory—tostay a jump ahead of your needs.

DX,IBC,B –19–04JUN90–1/1

The Right Tools

TS

101

–UN

–23A

UG

88

Precision tools and testing equipment enable our ServiceDepartment to locate and correct troubles quickly . . . tosave you time and money.

DX,IBC,C –19–04JUN90–1/1

Well-Trained Technicians

TS

102

–UN

–23A

UG

88

School is never out for John Deere service technicians.

Training schools are held regularly to be sure ourpersonnel know your equipment and how to maintain it.

Result?

Experience you can count on!

DPSG,OUOD007,38 –19–02MAR99–1/1

Prompt Service

TS

103

–UN

–23A

UG

88

Our goal is to provide prompt, efficient care when youwant it and where you want it. We can make repairs atyour place or at ours; see us, depend on us.

JOHN DEERE SERVICE SUPERIORITY: We’ll be aroundwhen you need us.

013004

PN=206

IndexPage Page

A Testing . . . . . . . . . . . . . . . . . . . . . . . .10-12, 35-12Warm temperature climates . . . . . . . . . . . . . 10-13

Coolant temperature gauge . . . . . . . . . . . . . . . . 15-1Acid burns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4Cooling systemAftercooler core,

Adding coolant . . . . . . . . . . . . . . . . . . . . . . . . 45-2inspect and clean . . . . . . . . . . . . . . . . . . . . . 35-17Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-9Aftercooler core, install . . . . . . . . . . . . . . . . . . . 35-18Flush. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-4Air cleanerPressure test. . . . . . . . . . . . . . . . . . . . . . . . . 35-19Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-8Pressure test filler cap . . . . . . . . . . . . . . . . . 35-19Servicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-4

Crankcase vent filter, replace . . . . . . . . . . . . . . . 35-1Air FilterCrankcase vent tube, clean . . . . . . . . . . . . . . . . 35-1Replace element (enclosed) . . . . . . . . . . . . . . 45-3Crankshaft vibration damper. . . . . . . . . . . . . . . . 40-8Air intake system, check. . . . . . . . . . . . . . . . . . . 35-2

Alarm, audible . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4Override switch . . . . . . . . . . . . . . . . . . . . . . . . 15-4

Alternator belt . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-9 DAmmeter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1Auxiliary gear drive, limitations . . . . . . . . . . . . . 15-39

Damper, checking. . . . . . . . . . . . . . . . . . . . . . . . 40-8Diagnostic gauge . . . . . . . . . . . . . . . . . . . . . . . . 15-4

Accessing active codes. . . . . . . . . . . . . . . . . 15-13B Accessing stored codes . . . . . . . . . . . . . . . . 15-11

Adjust backlighting . . . . . . . . . . . . . . . . . . . . 15-17Adjust contrast . . . . . . . . . . . . . . . . . . . . . . . 15-19BatteriesEngine configuration data . . . . . . . . . . . . . . . . 15-9Charge/Boost . . . . . . . . . . . . . . . . . . . . . . . . 15-49Main menu navigation. . . . . . . . . . . . . . . . . . . 15-8Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-7Battery acid burns . . . . . . . . . . . . . . . . . . . . . . . 30-4Select units of measurement. . . . . . . . . . . . . 15-21Battery explosion . . . . . . . . . . . . . . . . . . . . . . . . 30-4Setup 1-up display . . . . . . . . . . . . . . . . . . . . 15-23Belt tensioner, automatic . . . . . . . . . . . . . . . . . . 35-6Setup 4-up display . . . . . . . . . . . . . . . . . . . . 15-30Belt, alternatorShutdown codes . . . . . . . . . . . . . . . . . . . . . . 15-15Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-9Software version . . . . . . . . . . . . . . . . . . . . . . 50-32Wear (manual tensioner). . . . . . . . . . . . . . . . . 30-7

Diagnostic procedureBleeding fuel system . . . . . . . . . . . . . . . . . . . . 45-12Retrieving trouble codes . . . . . . . . . . .50-27, 50-28Break-in engine oil . . . . . . . . . . . . . . . . . . . . . . . 10-5

Diagnostic Trouble Codes (DFCs)Break-in, engine . . . . . . . . . . . . . . . . . . . . . . . . 15-35Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-29

Diagnostic Trouble Codes (DTCs)Diagnosing intermittent faults . . . . . . . . . . . . 50-32

C Diagnostic procedure . . . . . . . . . . . . .50-27, 50-28Diesel engine oil . . . . . . . . . . . . . . . . . . . . . . . . . 10-6

Chart, service interval. . . . . . . . . . . . . . . . .20-3, 20-5 Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . .10-1, 10-3Check engine electrical ground. . . . . . . . . . . . . 35-20 Dimmer switch . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4Clearance, valve. . . . . . . . . . . . . . . . . . . . . . . . . 40-1Cold weather aids. . . . . . . . . . . . . . . . . . .10-4, 15-46Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1

ECoolantAdding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-2Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . 10-10 Emissions

EPA Statement . . . . . . . . . . . . . . . . . . . . . . . . 70-1Disposing . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13Flow diagram (Except 6068SFM50) . . . . . . . 50-15 Engine

Break-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-35Flow diagram (6068SFM50) . . . . . . . . . . . . . 50-17Replenishing supplemental additives. . . . . . . 35-10 Check electrical ground. . . . . . . . . . . . . . . . . 35-20

Idling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-45Supplemental additives . . . . . . . . . . . . . . . . . 10-12Temperature gauge. . . . . . . . . . . . . . . . . . . . . 15-4 Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-8

Index-1 013004

PN=1

Index

Page Page

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-35 GOption codes. . . . . . . . . . . . . . . . . . . . . . . . . . 01-2

Gauge panel. . . . . . . . . . . . . . . . . . . . . . . .15-1, 15-4Serial number . . . . . . . . . . . . . . . . . . . . . . . . . 01-1Gauges . . . . . . . . . . . . . . . . . . . . . . . . . .15-1, 15-44Speed, check and adjust. . . . . . . . . . . . . . . . 35-20Generator set enginesStarting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-41

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-40Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-47GreaseTroubleshooting . . . . . . . . . . . . . . . . . . . . . . 50-18

Extreme pressure and multipurpose . . . . . . . . 10-9Valve clearance, adjust . . . . . . . . . . . . . . . . . . 40-1Warming . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-44Wiring harness (except 6068SFM50) . . . . . . . 50-3

Engine coolant HAdding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-2Disposing of . . . . . . . . . . . . . . . . . . . . . . . . . 10-13 Hand throttle. . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1

Engine oil Heat exchanger coreBreak-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5 Inspect and clean . . . . . . . . . . . . . . . . . . . . . 35-13Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1 Install . . . . . . . . . . . . . . . . . . . . . . . . .35-13, 35-15Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6 Hour meter . . . . . . . . . . . . . . . . . . . . 15-1, 15-4, 20-1

Engine OilExtended Service Intervals . . . . . . . . . . . . . . . 10-7

Engine oilIOil filter, change . . . . . . . . . . . . . . . . . . . . . . . 30-1

Engine wiring diagramIdling engine. . . . . . . . . . . . . . . . . . . . . . . . . . . 15-45Electronic controls. . . . . . . . . . . . . . . . . . . . . 50-13Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IBC-1

Flybridge instrument panel . . . . . . . . . . . . . . 50-11Instrument panel. . . . . . . . . . . . . . . . . . . . .15-1, 15-4

Main instrument panel. . . . . . . . . . . . . . . . . . . 50-9 Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . 50-9Intermittent fault diagnostics . . . . . . . . . . . . . . . 50-32

FK

Fan belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-9Key switch . . . . . . . . . . . . . . . . . . . . . . . . .15-1, 15-4

FilterAir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-4Air, service (enclosed). . . . . . . . . . . . . . . . . . . 45-3

LFilter, replaceCrankcase vent . . . . . . . . . . . . . . . . . . . . . . . . 35-1

LubricantOil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1Mixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7Front Power Take-Off (PTO) . . . . . . . . . . . . . . 45-11Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9Fuel

Lubrication and maintenanceDiesel . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1, 10-3Service interval chart - generators . . . . . . . . . 20-5Handling and storing . . . . . . . . . . . . . . . . . . . . 10-2Service interval chart - standard . . . . . . . . . . . 20-3Lubricity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

Lubrication and Maintenance records . . . . . . . . . 65-1Fuel injection pump model number. . . . . . . . . . . 01-4Lubricity of diesel fuel. . . . . . . . . . . . . . . . . . . . . 10-1Fuel injection pump specifications . . . . . . . . . . . 60-3

Fuel systemDo not modify . . . . . . . . . . . . . . . . . . . . . . . . . 45-1

Fuel system, MBleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-14Bleeding, 6.8 L engine . . . . . . . . . . . . . . . . . 45-14 Maintenance interval chart . . . . . . . . . . . . .20-3, 20-5

Mixing lubricants. . . . . . . . . . . . . . . . . . . . . . . . . 10-7Fuel system, bleeding. . . . . . . . . . . . . . . . . . . . 45-12

Index-2 013004

PN=2

Index

Page Page

Mounts, engine. . . . . . . . . . . . . . . . . . . . . . . . . . 30-8 Remove and install (Except 6068SFM50) . . . 45-16Sea Water Pump

Remove (6068SFM50) . . . . . . . . . . . . . . . . . 45-17Serial numberO Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1

Fuel injection pump. . . . . . . . . . . . . . . . . . . . . 01-4Oil Service

Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4Fill quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-4 Intervals . . . . . . . . . . . . . . . . . . . . . . . . .20-3, 20-5

Oil filter, change . . . . . . . . . . . . . . . . . . . . . . . . . 30-1 250 Hour/6 Month . . . . . . . . . . . . . . . . . . . . . . 30-3Oil pressure gauge . . . . . . . . . . . . . . . . . . .15-1, 15-4 Service InternalsOperating engine Extended Diesel Engine Oil . . . . . . . . . . . . . . 10-7

Break-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-35 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-1Cold weather. . . . . . . . . . . . . . . . . . . . .10-4, 15-46 Battery capabilities . . . . . . . . . . . . . . . . . . . . . 30-4Normal operation . . . . . . . . . . . . . . . . . . . . . 15-35 Belt tensioner . . . . . . . . . . . . . . . . . . . . . . . . . 35-6

Option codes . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2 Damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-8Engine crankcase oil fill . . . . . . . . . . . . . . . . . 60-4Fuel injection pump. . . . . . . . . . . . . . . . . . . . . 60-3General, 4.5 L Engine. . . . . . . . . . . . . . . . . . . 60-1PGeneral, 6.8 L engine . . . . . . . . . . . . . . . . . . . 60-2Thermostats . . . . . . . . . . . . . . . . . . . . . . . . . . 40-7Percent load . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4

Starting engine . . . . . . . . . . . . . . . . . . . . . . . . . 15-41Poly-vee beltStopping engine . . . . . . . . . . . . . . . . . . . . . . . . 15-47Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-9StoragePower Take-Off (PTO), Front . . . . . . . . . . . . . . 45-11

Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-1Precautions for welding on engines equippedStoring fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2w/ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-2Storing lubricants . . . . . . . . . . . . . . . . . . . . . . . . 10-9Pressure test cooling system . . . . . . . . . . . . . . 35-19Supplemental coolant additivesPump, sea water . . . . . . . . . . . . . . . . . . . . . . . 45-16

Replenishing . . . . . . . . . . . . . . . . . . . . . . . . . 35-10Pump, sea water (Except 6068SFM50) . . . . . . . 40-8Pump, sea water (6068SFM50) . . . . . . . . . . . . 40-11

T

Tachometer . . . . . . . . . . . . . . . . . . . . . . . .15-1, 15-4RTemperature gauge . . . . . . . . . . . . . . . . . . . . . . 15-4Temperature gauge (coolant) . . . . . . . . . . . . . . . 15-1Radiator shutters . . . . . . . . . . . . . . . . . . . . . . . . 10-4Tensioner, beltRecordkeeping

Automatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-6Engine option codes . . . . . . . . . . . . . . . . . . . . 01-2ThermostatsEngine serial number . . . . . . . . . . . . . . . . . . . 01-1

Inspect and test . . . . . . . . . . . . . . . . . . . . . . . 40-7Injection pump model number . . . . . . . . . . . . . 01-4Touch switches. . . . . . . . . . . . . . . . . . . . . . . . . . 15-4Lubrication and Maintenance . . . . . . . . . . . . . 65-1Trouble codesRetrieving diagnostic trouble codes . . . .50-27, 50-28

Diagnostic procedure . . . . . . . . . . . . . . . . . . 50-28Intermittent . . . . . . . . . . . . . . . . . . . . . . . . . . 50-32Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-29

S TroubleshootingGeneral information. . . . . . . . . . . . . . . . . . . . . 50-1

Sea water flow diagram (Except General, engine . . . . . . . . . . . . . . . . . . . . . . 50-186068SFM50) . . . . . . . . . . . . . . . . . . . . . . . . . 50-15

Sea water flow diagram (6068SFM50) . . . . . . . 50-17Sea water pump V

Inspect and repair (Except 6068SFM50) . . . . . 40-8Inspect and repair (6068SFM50). . . . . . . . . . 40-11 Valve clearance, adjust . . . . . . . . . . . . . . . . . . . 40-1

Index-3 013004

PN=3

Index

Page

Vent tube, crankcase . . . . . . . . . . . . . . . . . . . . . 35-1Vibration damper . . . . . . . . . . . . . . . . . . . . . . . . 40-8Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4

W

Warming engine . . . . . . . . . . . . . . . . . . . . . . . . 15-44Warning indicators . . . . . . . . . . . . . . . . . . . . . . . 15-4Warranty

Emission System . . . . . . . . . . . . . . . . . . . . . . 70-1Winterfronts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 50-5

layout - 6068SFM50 . . . . . . . . . . . . . . . . . . . . 50-7Wiring harness (except 6068SFM50) . . . . . . . . . 50-3

Z

Zinc plugs. . . . . . . . . . . . . . . . . . . . . . . . .15-35, 30-6

Index-4 013004

PN=4

man. operat. 4,5-6,8 marino inglese omrg35856 stage 2 (05!05!06)

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