manual motor 6090

196
PowerTech Plus 9.0 L 6090HF485 Tier 3/Stage IIIA OEM Diesel Engines OPERATOR'S MANUAL PowerTech Plus 9.0 L 6090HF485 OEM Diesel Engines OMRG36864 Issue 31OCT06 (ENGLISH) CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. If this product contains a gasoline engine: WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. The State of California requires the above two warnings. John Deere Power Systems LITHO IN U.S.A. Multilizer PDF Translator Free version - translation is limited to ~ 3 pages per translation. Multilizer PDF Translator Free version - translation is limited to ~ 3 pages per translation.

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  • PowerTech Plus 9.0 L 6090HF485Tier 3/Stage IIIA

    OEM Diesel Engines

    OPERATOR'S MANUALPowerTech Plus 9.0 L 6090HF485

    OEM Diesel EnginesOMRG36864 Issue 31OCT06 (ENGLISH)

    CALIFORNIAProposition 65 Warning

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

    defects, and other reproductive harm.

    If this product contains a gasoline engine:

    WARNINGThe engine exhaust from this product contains 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.

    Multilizer PDF Translator Free version - translation is limited to ~ 3 pages per translation.

    Multilizer PDF Translator Free version - translation is limited to ~ 3 pages per translation.

  • Introduction

    OURGP12,00000BD 1911OCT061/1

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

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

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

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

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

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

    CERTAIN ENGINE ACCESSORIES such as radiator,air cleaner, and instruments are optional equipment onJohn Deere OEM Engines. These accessories may beprovided by the equipment manufacturer instead ofJohn Deere. This operator's manual applies only to theengine and those options available through the JohnDeere distribution network.

    IMPORTANT: This manual covers John DeerePowerTech Plus 9.0 L OEM dieselengines meeting Tier 3/Stage IIIA 1emission standards.

    NOTE: This operator's manual covers only enginesprovided to OEM (Original EquipmentManufacturers). For engines in Deeremachines, refer to the machine operatorsmanual.

    PowerTech Plus is a trademark of Deere & Company1Emission certified for United States as EPA Tier 3 and for EuropeanUnion as Stage IIIA.

    110306PN=2

    Multilizer PDF Translator Free version - translation is limited to ~ 3 pages per translation.

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  • Introduction

    OURGP11,0000251 1911OCT061/1

    Engine OwnerJohn 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 obliged'avoir recours avotreconcessionnaire John Deere ou au point de service leplus proche pour vous adresser alui. 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 connatre. Il sera lui aussiheureux de faire votre connaissance et de vousproposer ses services le moment venu.

    An Den Besitzer Des John Deere Motors:

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

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

    Proprietario del motore John Deere:

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

    distributore dei motori John Deere o delconcessionario che fornisce 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 garantaodeotro tipo para conocer a su Distribuidor de MotoresJohn Deere o al Concesionario de Servicio. Registresu motor para la garanta en la siguiente direcciondeinternet: http://www.johndeere.com/enginewarranty

    Enterese de quienes,ydonde estasituado. Cuandotenga un momento, vaya a visitarlo. A el le gustaraconocerlo, y saber cuales podran ser susnecesidades.

    Till agare av John Deere motorer:

    Ta reda pavem din aterforsaljare ar och besok honomsasnart 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.

    110306PN=3

    Multilizer PDF Translator Free version - translation is limited to ~ 3 pages per translation.

    Multilizer PDF Translator Free version - translation is limited to ~ 3 pages per translation.

  • Introduction

    OURGP11,000001F 1911OCT061/1

    Identification ViewsJohn Deere Power Tech Plus Tier 3/Stage IIIA 9.0 L OEM DieselEngine

    RG13

    848

    UN

    24JA

    N05

    9.0 L Diesel Engine Right Front View

    RG13

    847

    UN

    24JA

    N05

    9.0 L Diesel Engine Left Front View

    RG13

    850

    UN

    17JA

    N05

    9.0 L Diesel Engine Front View

    RG13

    849

    UN

    24JA

    N05

    9.0 L Diesel Engine Rear View

    NOTE: Engines are Tier 3/Stage IIIAemission-certified.

    110306PN=4

  • ContentsPage Page

    Record Keeping Accessing Stored Trouble Codes ............15-9Record Engine Serial Number ..............01-1 Accessing Active Trouble Codes ...........15-11Engine Option Codes .....................01-2 Engine Shutdown Codes .................15-13Record High-Pressure Fuel Pump Model Adjusting Backlighting....................15-14and Serial Numbers ....................01-4 Adjusting Contrast ......................15-16

    Record Rear Power Take-Off (PTO) Selecting Units Of Measurement ...........15-18Serial Number (If Equipped) ..............01-4 Setup 1-Up Display .....................15-21

    Record ECU Serial Number ................01-5 Setup 4-Up Display .....................15-27

    Engine OperationSafety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .05-1Break-In Service.........................20-1Auxiliary Gear Drive Limitations .............20-4Fuels, Lubricants, and Coolant Generator Set (Standby) Applications.........20-4Diesel Fuel .............................10-1 Starting the Engine.......................20-5Lubricity of Diesel Fuel....................10-1 Normal Engine Operation ..................20-8Handling and Storing Diesel Fuel ............10-2 Cold Weather Operation...................20-9Testing Diesel Fuel.......................10-2 Warming Engine........................20-10Bio-Diesel Fuel..........................10-3 Idling Engine ..........................20-11Minimizing the Effect of Cold Weather on Changing Engine Speed..................20-12Diesel Engines ........................10-4 Stopping the Engine.....................20-15Diesel Engine Break-In Oil .................10-5 Using a Booster Battery or Charger .........20-16Diesel Engine Oil ........................10-6

    Diesel Engine Oil and Filter Service Intervals. . . 10-7Lubrication and MaintenanceMixing of Lubricants ......................10-9Observe Service Intervals..................25-1OILSCAN and COOLSCAN ..............10-9Use Correct Fuels, Lubricants, and Coolant ....25-1Alternative and Synthetic Lubricants.........10-10Lubrication and Maintenance ServiceLubricant Storage .......................10-10Interval ChartStandard Industrial Engines . . 25-2Oil Filters .............................10-11

    Lubrication and Maintenance ServiceDiesel Engine Coolant ...................10-12Interval ChartGenerator (Standby)Supplemental Coolant Additives ............10-13Appl icat ions . . . . . . . . . . . . . . . . . . . . . . . . . .25-4Drain Intervals for Diesel Engine Coolant ....10-14

    Additional Information About DieselEngine Coolants and Supplemental Coolant Lubrication & Maintenance/DailyAddit ives . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-15 Daily Prestarting Checks ..................30-1

    Testing Diesel Engine Coolant .............10-16Operating in Warm Temperature Climates ....10-17 Lubrication & Maintenance/500 Hour/12 MonthDisposing of Coolant ....................10-17 Servicing Fire Extinguisher .................35-1

    Servicing Battery ........................35-2Changing Engine Oil and Replacing Oil Filter. . . 35-4Instrument Panels

    Instrument Panels........................15-1 Visually Inspecting Coolant Pump ...........35-8Checking Crankcase Vent Hose and Valve ....35-9Using Diagnostic Gauge to Access Engine

    Informat ion . . . . . . . . . . . . . . . . . . . . . . . . . . .15-4 Checking Air Intake System ...............35-10Main Menu Navigation ....................15-5Engine Configuration Data .................15-7 Continued on next page

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

    COPYRIGHT 2006DEERE & COMPANY

    Moline, IllinoisAll rights reserved

    A John Deere ILLUSTRUCTION ManualPrevious Editions

    Copyright Apr05, Jul05

    i 110306PN=1

  • Contents

    Page Page

    Removing and Installing Fuel Filters.........35-11 Air Intake and Exhaust SystemTroubleshoot ing . . . . . . . . . . . . . . . . . . . . . .50-23Checking Belt Tensioner Spring Tension

    and Belt Wear........................35-14 Precautions for Electrical System WhenSteam Cleaning Engine ................50-24Checking Belt Wear .....................35-14

    Checking Tensioner Spring Tension.........35-15 Engine Wiring Harness Layout .............50-25Precautions for Welding on VehiclesChecking Cooling System.................35-16

    Testing Diesel Engine Coolant .............35-17 Equipped with Electronic Engine Control Unit(ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-26Replenishing Supplemental Coolant

    Additives (SCAs) Between Coolant Engine Wiring Diagram (Engines WithFull-Featured Instrument Panel) ..........50-27Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . .35-18

    Pressure Testing Cooling System...........35-20 Engine Wiring Diagram (Engines WithFull-Featured Instrument Panel)Checking and Adjusting Engine Speeds ......35-21

    Checking Engine Mounts .................35-21 (Cont inued). . . . . . . . . . . . . . . . . . . . . . . . . .50-28Checking Crankshaft Vibration Damper ......35-22Checking Engine Ground Connection........35-23 Storage

    Engine Storage Guidelines .................55-1Preparing Engine for Long Term Storage ......55-2Lubrication&Maintenance/2000Hour/24MonthRemoving Engine from Long Term Storage ....55-3Flushing And Refilling Cooling System ........40-1

    Bleeding Air From Cooling System...........40-4SpecificationsTesting Thermostats......................40-6General OEM Engine Specifications..........60-1Adjusting Valve Clearance .................40-9Engine Power and Speed RatingSpecifications 1 ........................60-3Service As Required

    Engine Crankcase Oil Fill Quantities .........60-4Additional Service Information ..............45-1Unified Inch Bolt and Screw Torque Values ....60-5Do Not Modify Fuel System ................45-1Metric Bolt and Screw Torque Values.........60-6Drain Water From Fuel Filters ..............45-2

    Adding Coolant..........................45-3Lubrication and Maintenance RecordsReplacing Air Cleaner Filter Elements ........45-5Using Lubrication and Maintenance Records . . . 65-1Inspecting Primary Filter Element ............45-6Daily (Prestarting) Service .................65-1Cleaning Primary Filter Element .............45-7500 Hours of Operation/or Every 12 MonthsElement Storage.........................45-8Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65-2Replacing Fan/Alternator Belt...............45-8

    2000 Hours of Operation/or Every 24Checking Fuses .........................45-9Months Service ........................65-3Checking Electrical Wiring And Connections . . . 45-9

    Service as Required ......................65-4Bleeding Fuel System.....................45-9Checking Air Compressors (If Equipped) .....45-10

    Emission System WarrantyChecking Freon (A/C) Compressor (IfU.S. Emissions Control Warranty Statement....70-1Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . .45-10Emissions Control System Certification Label. . . 70-1Checking Rear PTO .....................45-11Service LiteratureTroubleshooting Technical Information .....................80-1General Troubleshooting Information .........50-1

    Instrument Panel Method for RetrievingDiagnostic Trouble Codes................50-2

    Displaying Of Diagnostic Trouble Codes(DTCs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-3

    Listing of Diagnostic Trouble Codes (DTCs)....50-4Intermittent Fault Diagnostics ...............50-8Displaying Diagnostic Gauge Software........50-8Engine Troubleshooting ..................50-10Electrical Troubleshooting.................50-16Lubrication System Troubleshooting.........50-18Cooling System Troubleshooting ...........50-21

    ii 110306PN=2

  • Record Keeping

    OURGP11,0000014 1911OCT061/1

    Record Engine Serial Number

    RG14

    799

    UN

    23JU

    N06

    Engine Serial Number Plate

    RG13

    813

    UN

    11JA

    N05

    Location of Engine Serial Number Plate

    AEngine Serial NumberBEngine Model NumberCSerial Number Plate

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

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

    This information is very important for repair parts orwarranty information.Engine Serial Number (A)

    Engine Model Number (B)

    NOTE: On engine serial number (A) the 7th digit showsthe emission level as follows:

    B for non-certified engines C for Tier 1 / Stage I engines G for Tier 2 / Stage II engines L for Tier 3 / Stage IIIA engines

    01-1 110306PN=7

  • Record Keeping

    OURGP11,0000021 1911OCT061/2

    Engine Option Codes

    RG13

    820

    UN

    11JA

    N05

    Option Code Label

    AEngine Base Code (Shownon Engine Option CodeLabel)

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

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

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

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

    01-2 110306PN=8

    Continued on next page

  • Record Keeping

    OURGP11,0000021 1911OCT062/2

    Engine Option CodesContinued

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

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

    Option Codes Description Option Codes Description

    11 Rocker Arm Cover 51 Cylinder Head With Valves12 Oil Filter Inlet 52 Auxiliary Gear Drive13 Crankshaft Pulley/Damper 53 Fuel Heater14 Flywheel Housing 55 Shipping Stand15 Flywheel 56 Paint Option16 Fuel Injection System 57 Coolant Pump Inlet17 Air Intake 59 Oil Cooler and Filter18 Air Cleaner 60 Add-0n Auxiliary Drive Pulley19 Oil Pan 62 Alternator Mounting Bracket20 Coolant Pump 63 Low Pressure Fuel Line21 Thermostat Cover 64 Exhaust Elbow22 Thermostats 65 Turbocharger23 Fan Drive 66 Temperature Switch24 Fan Belts 67 Electronic Sensors (Base Engine)25 Fan 68 Crankshaft Rear Damper26 Engine Coolant Heater 69 Engine Serial Number Plate27 Radiator 71 Engine Oil Bypass Filter28 Exhaust System 72 Electronic Software Option29 Ventilator System 74 Air Conditioning (A/C) Compressor (Optional)30 Starter Motor 75 Air Restriction Indicator31 Alternator 76 Switches and Sensors32 Instrument Panel 77 Timing Gear Cover33 Tachometer 78 Air Compressor (Optional)35 Fuel Filter 79 Engine Certification36 Front Plate 81 Primary Fuel Filter and Water Separator37 Fuel Transfer Pump 83 Electronic Software (Vehicle Option)38 Operator's Manual 84 Electrical Wiring Harness39 Outlet Manifold 86 Fan Pulley40 Oil Dipstick 87 Belt Tensioner41 Belt-Driven Front Auxiliary Drive 88 Oil Filter43 Starting Aid 89 Exhaust Gas Recirculating (EGR) System44 Timing Gear Cover With Gears 92 Accessories (Factory Installed)(Rear PTO)46 Cylinder Block 93 Emissions Label47 Crankshaft And Bearings 95 Special Equipment (Factory Installed)48 Connecting Rods and Pistons 96 Engine Installation Kit49 Valve Actuating Mechanism 97 Special Equipment (Field Installed)50 Oil Pump 98 Shipping (Engine Hanger Straps)

    99 Service Only Items

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

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

    01-3 110306PN=9

  • Record Keeping

    OURGP11,0000022 1911OCT061/1

    Record High-Pressure Fuel Pump Model andSerial Numbers

    RG13

    851

    UN

    17JA

    N05

    High Pressure Fuel Pump Serial Number Plate

    ASerial Number Plate

    Record the fuel transfer pump model and serialinformation found on the serial number plate (A).Model No. RPM

    Manufacturer's No.

    Serial No.

    RG,RG34710,4004 1911OCT061/1

    Record Rear Power Take-Off (PTO) SerialNumber (If Equipped)

    RG12

    594

    UN

    24SE

    P02

    Rear PTO Serial Number Plate

    Record the rear power take-off (PTO) serial number foundon rear PTO serial number plate (A) (if equipped).Rear PTO Serial Number

    01-4 110306PN=10

  • Record Keeping

    OURGP11,000003B 1911OCT061/1

    Record ECU Serial Number

    RG13

    853

    UN

    17JA

    N05

    Record Engine Control Unit (ECU) Serial Number

    ASerial Number Label

    Record the part number and serial number informationfound on the serial number label on the Engine ControlUnit (ECU) (A) mounted on or near the engine.Part No.

    Serial No.

    01-5 110306PN=11

  • Safety

    DX,ALERT 1929SEP981/1

    Recognize Safety Information

    T813

    89U

    N07

    DEC8

    8

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

    Follow recommended precautions and safe operatingpractices.

    DX,SIGNAL 1903MAR931/1

    Understand Signal Words

    TS18

    71

    930

    SEP8

    8

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

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

    DX,READ 1903MAR931/1

    Follow Safety Instructions

    TS20

    1U

    N23

    AUG8

    8

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

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

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

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

    05-1 110306PN=12

  • Safety

    DX,SIGNS1 1904JUN901/1

    Replace Safety Signs

    TS20

    1U

    N23

    AUG8

    8

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

    DX,BYPAS1 1929SEP981/1

    Prevent Machine Runaway

    TS17

    7U

    N11

    JAN8

    9

    Avoid possible injury or death from machinery runaway.

    Do not start engine by shorting across starter terminals.Machine will start in gear if normal circuitry is bypassed.

    NEVER start engine while standing on ground. Startengine only from operator's seat, with transmission inneutral or park.

    DX,FIRE1 1903MAR931/1

    Handle Fuel SafelyAvoid Fires

    TS20

    2U

    N23

    AUG8

    8

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

    Always stop engine before refueling machine. Fill fuel tankoutdoors.

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

    05-2 110306PN=13

  • Safety

    DX,FIRE2 1903MAR931/1

    Prepare for Emergencies

    TS29

    1U

    N23

    AUG8

    8

    Be prepared if a fire starts.

    Keep a first aid kit and fire extinguisher handy.

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

    DX,FIRE3 1916APR921/1

    Handle Starting Fluid Safely

    TS13

    56U

    N18

    MAR9

    2

    Starting fluid is highly flammable.

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

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

    Do not incinerate or puncture a starting fluid container.

    DX,FLAME 1929SEP981/1

    Handle Fluids SafelyAvoid Fires

    TS22

    7U

    N23

    AUG8

    8

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

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

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

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

    05-3 110306PN=14

  • Safety

    DX,LOOSE 1904JUN901/1

    Service Machines Safely

    TS22

    8U

    N23

    AUG8

    8

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

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

    DX,WEAR 1910SEP901/1

    Wear Protective Clothing

    TS20

    6U

    N23

    AUG8

    8

    Wear close fitting clothing and safety equipmentappropriate to the job.

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

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

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

    DX,NOISE 1903MAR931/1

    Protect Against Noise

    TS20

    7U

    N23

    AUG8

    8

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

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

    05-4 110306PN=15

  • Safety

    DX,MSDS,NA 1903MAR931/1

    Handle Chemical Products Safely

    TS11

    32U

    N26

    NOV9

    0

    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 1911OCT061/1

    Stay Clear of Rotating Drivelines

    TS16

    44U

    N22

    AUG9

    5Rotating 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.

    05-5 110306PN=16

  • Safety

    DX,SERV 1917FEB991/1

    Practice Safe Maintenance

    TS21

    8U

    N23

    AUG8

    8

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

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

    Securely support any machine elements that must beraised for service work.

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

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

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

    DX,AIR 1917FEB991/1

    Work In Ventilated Area

    TS22

    0U

    N23

    AUG8

    8

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

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

    05-6 110306PN=17

  • Safety

    DX,FLUID 1903MAR931/1

    Avoid High-Pressure Fluids

    X981

    1U

    N23

    AUG8

    8

    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 1910DEC041/1

    Avoid Heating Near Pressurized Fluid Lines

    TS95

    3U

    N15

    MAY9

    0

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

    DX,WW,HPCR1 1907JAN031/1

    Do Not Open High-Pressure Fuel System

    TS13

    43U

    N18

    MAR9

    2

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

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

    05-7 110306PN=18

  • Safety

    DX,PAINT 1924JUL021/1

    Remove Paint Before Welding or Heating

    TS22

    0U

    N23

    AUG8

    8

    Avoid potentially toxic fumes and dust.

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

    Remove paint before heating:

    Remove paint a minimum of 100 mm (4 in.) from 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 1904JUN901/1

    Service Cooling System Safely

    TS28

    1U

    N23

    AUG8

    8

    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.

    05-8 110306PN=19

  • Safety

    OUOD006,000009D 1911OCT061/1

    Install Fan Guards

    TS67

    7U

    N21

    SEP8

    9

    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.

    OURGP12,0000135 1911OCT061/1

    Avoid Hot Parts

    TS27

    1U

    N23

    AUG8

    8

    Hot Surface

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

    External dry exhaust parts become very hot duringoperation. Turbochargers and exhaust manifolds mayreach temperatures as high as 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).

    05-9 110306PN=20

  • Safety

    DX,DUST 1915MAR911/1

    Avoid Harmful Asbestos Dust

    TS22

    0U

    N23

    AUG8

    8

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

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

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

    Keep bystanders away from the area.

    DX,SPARKS 1903MAR931/1

    Prevent Battery Explosions

    TS20

    4U

    N23

    AUG8

    8

    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).

    DX,CLEAN 1904JUN901/1

    Work in Clean Area

    T664

    2EJ

    UN

    18OC

    T88

    Before starting a job:

    Clean work area and machine. Make sure you have all necessary tools to do your job. Have the right parts on hand. Read all instructions thoroughly; do not attemptshortcuts.

    05-10 110306PN=21

  • Safety

    DX,LIGHT 1904JUN901/1

    Illuminate Work Area Safely

    TS22

    3U

    N23

    AUG8

    8

    Illuminate your work area adequately but safely. Use aportable safety light for working inside or under themachine. Make sure the bulb is enclosed by a wire cage.The hot filament of an accidentally broken bulb can ignitespilled fuel or oil.

    05-11 110306PN=22

  • Safety

    DPSG,OUO1004,2758 1911OCT061/1

    Handling Batteries Safely

    TS20

    4U

    N23

    AUG8

    8

    Explosion

    TS20

    3U

    N23

    AUG8

    8Acid

    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 1530

    minutes. Get medical attention immediately.

    If acid is swallowed:

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

    not exceed2L(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.

    05-12 110306PN=23

  • Safety

    DX,SPRAY 1916APR921/1

    Protect Against High Pressure Spray

    TS13

    43U

    N18

    MAR9

    2

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

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

    DX,LIFT 1904JUN901/1

    Use Proper Lifting Equipment

    TS22

    6U

    N23

    AUG8

    8

    Lifting heavy components incorrectly can cause severeinjury or machine damage.

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

    DX,REPAIR 1917FEB991/1

    Use Proper Tools

    TS77

    9U

    N08

    NOV8

    9

    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.

    05-13 110306PN=24

  • Safety

    DX,DRAIN 1903MAR931/1

    Dispose of Waste Properly

    TS11

    33U

    N26

    NOV9

    0

    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.

    05-14 110306PN=25

  • Fuels, Lubricants, and Coolant

    DX,FUEL1 1917NOV051/1

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

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

    Diesel fuels specified to EN 590 or ASTM D975 arerecommended.

    Required fuel properties

    In all cases, the fuel shall meet the followingproperties:

    Cetane number of 45 minimum. Cetane numbergreater than 50 is preferred, especially fortemperatures below -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 level of 3100grams as measured by ASTM D6078 or maximum

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

    Sulfur content:

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

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

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

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

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

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

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

    DX,FUEL5 1927OCT051/1

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

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

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

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

    10-1 110306PN=26

  • Fuels, Lubricants, and Coolant

    DX,FUEL4 1919DEC031/1

    Handling and Storing Diesel Fuel

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

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

    Fill the fuel tank at the end of each 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.

    Monitor water content of the fuel regularly.

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

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

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

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

    DX,FUEL6 1914NOV051/1

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

    Check with your John Deere dealer for availability ofDIESELSCAN kits.

    DIESELSCAN is a trademark of Deere & Company

    10-2 110306PN=27

  • Fuels, Lubricants, and Coolant

    DX,FUEL7 1914NOV051/1

    Bio-Diesel FuelConsult your local fuel distributor for properties of thebio-diesel fuel available in your area.

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

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

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

    When using a blend of bio-diesel fuel, the engine oillevel must be checked daily when the air temperatureis 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 by

    leaving deposits on injectors and inthe combustion chamber.

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

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

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

    Power loss and deterioration of performance Fuel leakage Corrosion of fuel injection equipment Coked and/or blocked injector nozzles, resulting inengine 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 110306PN=28

  • Fuels, Lubricants, and Coolant

    DX,FUEL10 1916DEC051/2

    Minimizing the Effect of Cold Weather on Diesel EnginesJohn Deere diesel engines are designed to operateeffectively in cold weather.

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

    Use Winter Grade Fuel

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

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

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

    Air Intake Heater

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

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

    Starting Fluid

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

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

    Coolant Heater

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

    Seasonal Viscosity Oil and Proper CoolantConcentration

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

    Diesel Fuel Flow Additive

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

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

    Winterfronts

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

    10-4 110306PN=29

    Continued on next page

  • Fuels, Lubricants, and Coolant

    DX,FUEL10 1916DEC052/2

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

    Radiator Shutters

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

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

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

    For more information, see your John Deere dealer.

    DX,ENOIL4 1913SEP061/1

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

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

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

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

    API Service Classification CE API Service Classification CD API Service Classification CC ACEA Oil Sequence E2 ACEA Oil Sequence E1

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

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

    API CJ-4 ACEA E7API CI-4 PLUS ACEA E6API CI-4 ACEA E5API CH-4 ACEA E4API CG-4 ACEA E3API CF-4API CF-2API CF

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

    PLUS-50 is a trademark of Deere & Company.10-5 110306

    PN=30

  • Fuels, Lubricants, and Coolant

    DX,ENOIL11 1913SEP061/1

    Diesel Engine Oil

    SAE 15

    W-40

    SAE 10

    W-40

    SAE 10

    W-30

    SAE 0W

    -40SA

    E 5W

    -30

    50 Co

    40 Co

    30 Co

    20 Co

    10 Co

    0 C o

    -10 Co

    -20 Co

    -30 Co

    -40 Co

    122 Fo

    50 Fo

    32 Fo

    14 Fo

    -4 Fo

    -22 Fo

    -40 Fo

    104 Fo

    68 Fo

    86 Fo

    TS16

    84U

    N09

    OCT0

    6

    Oil Viscosities for Air Temperature Ranges

    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 E7 ACEA Oil Sequence E6

    Extended service intervals may apply when John DeerePLUS-50 , ACEA E7, or ACEA E6 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 CJ-4 API Service Category CI-4 PLUS API Service Category CI-4 ACEA Oil Sequence E5 ACEA Oil Sequence E4

    Multi-viscosity diesel engine oils are preferred.

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

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

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

    10-6 110306PN=31

  • Fuels, Lubricants, and Coolant

    OURGP11,0000016 1913OCT061/2

    Diesel Engine Oil and Filter Service IntervalsThe oil and filter service intervals in the following chartshould be used as guidelines. Actual service intervalsdepend on operation and maintenance practices. Useoil analysis to determine the actual useful life of the oiland to aid in selection of the proper oil and filterservice interval.

    Oil and filter service intervals are based on acombination of oil pan capacity, type of engine oil andfilter used, and sulfur content of the diesel fuel.

    Diesel fuel sulfur level will affect engine oil and filterservice intervals. Higher fuel sulfur levels reduce oiland filter service intervals as shown in the table:

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

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

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

    DO NOT use diesel fuel with sulfur content greaterthan 1.00% (10 000 ppm).

    Oil types (premium or standard) in the tables include:

    Premium Oils include John Deere PLUS-50 ,ACEA E7, or ACEA E6 oils.

    Standard Oils include John Deere TORQ-GARDSUPREME , API CJ-4, API CI-4 PLUS, API CI-4,ACEA E5, or ACEA E4 oils.Use of lower specification oils in U.S. Tier 3 and EUStage IIIA engines may result in premature enginefailure.

    NOTE: The 500 hour extended oil and filter changeinterval is allowed only if ALL the followingconditions are met:

    Engine equipped with an oil pan that allows capacityfor this extended drain interval.

    Use of premium oil John Deere PLUS-50, ACEA E7or ACEA E6

    Perform engine oil analysis to determine the actualextended service life of ACEA E7 and ACEA E6 oils.

    Use of the approved John Deere oil filter Use of diesel fuel with sulfur content less than0.50% (5000 ppm)

    Refer to the charts on the following pages to find theproper oil and filter service interval for your engine.

    Using Charts to Find Oil and Filter Service Interval

    1. Determine your engine model and power rating andfind it in the left column of 6090HF485 chart.

    2. Locate your engine oil pan option code (19__) onengine label.

    3. In the chart column under your oil pan code, selectwhether you use premium oil (PLUS-50 orequivalent) or standard grade oil.

    4. Determine the sulfur content of your diesel fuel.

    5. Now you can find the proper oil and filter changeinterval by lining up your power level and fuel sulfurcontent with oil pan/oil type column. The numberindicates how frequently your oil and filter should bechanged.

    Example:

    Engine Model - 6090HF485 Engine Power - 168 kW (225 hp) Oil Pan Code - 1914 Oil Type - Premium Oil Filter - John Deere approved Fuel Sulfur Level - 0.10-0.20 (1000-2000 ppm)

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

    10-7 110306PN=32

    Continued on next page

  • Fuels, Lubricants, and Coolant

    OURGP11,0000016 1913OCT062/2

    In the 6090HF485 chart under 168 kW Power Rating,select the line for 0.10-0.20 Fuel Sulfur Content andmove across to column for 1914 oil pan option code,

    select Prem Oil and read 500 hour oil changeinterval.

    6090HF485 (9.0 L) Engine Oil and Filter Service Intervals in Hours of OperationPower Oil Pan Option CodesRatingkW (hp) Fuel Sulfur Content a 1909 1915 1914 1916 1911

    Interval Interval Interval Interval IntervalStd Prem Std Prem Std Prem Std Prem Std PremOil Oil Oil Oil Oil Oil Oil Oil Oil Oil

    168 (225) Less Than 0.10% (1000 ppm) 250 500 250 500 250 500 250 500 250 5000.10% - 0.20% (1000 - 2000 ppm) 250 500 250 500 250 500 250 500 250 5000.20% - 0.50% (2000 - 5000 ppm) 200 300 200 300 200 300 200 300 250 500

    187-229 Less Than 0.10% (1000 ppm) 250 500 250 500 250 500 250 500 250 500(251-307)

    0.10% - 0.20% (1000 - 2000 ppm) 250 500 250 500 250 500 250 500 250 5000.20% - 0.50% (2000 - 5000 ppm) 200 300 200 300 200 300 200 300 200 300

    242 (325) Less Than 0.10% (1000 ppm) 250 500 250 500 250 500 250 500 250 5000.10% - 0.20% (1000 - 2000 ppm) 200 300 200 300 200 300 200 300 250 5000.20% - 0.50% (2000 - 5000 ppm) 150 250 150 250 150 250 200 300 200 300

    257-261 Less Than 0.10% (1000 ppm) 250 500 250 500 250 500 250 500 250 500(345-350)

    0.10% - 0.20% (1000 - 2000 ppm) 200 300 200 300 200 300 200 300 250 5000.20% - 0.50% (2000 - 5000 ppm) 150 250 150 250 150 250 150 250 200 300

    280 (375) Less Than 0.10% (1000 ppm) 250 375 250 375 250 375 250 500 250 5000.10% - 0.20% (1000 - 2000 ppm) 200 300 200 300 200 300 200 300 250 5000.20% - 0.50% (2000 - 5000 ppm) 150 250 150 250 150 250 150 250 200 300

    287 (385) Less Than 0.10% (1000 ppm) 250 375 250 375 250 375 250 500 250 5000.10% - 0.20% (1000 - 2000 ppm) 200 300 200 300 200 300 200 300 200 3000.20% - 0.50% (2000 - 5000 ppm) 150 250 150 250 150 250 150 250 150 250

    298-315 Less Than 0.10% (1000 ppm) 250 375 250 375 250 375 250 375 250 500(400-422)

    0.10% - 0.20% (1000 - 2000 ppm) 200 300 200 300 200 300 200 300 200 3000.20% - 0.50% (2000 - 5000 ppm) 150 250 150 250 150 250 150 250 150 250

    Perform engine oil analysis to determine the actual extended service life of ACEA E7 and ACEA E6 oils.aBEFORE using diesel fuel with sulfur content greater than 0.50% (5000 ppm), contact your John Deere dealer. (Dealer to reference DTACSolution 73203)

    10-8 110306PN=33

  • Fuels, Lubricants, and Coolant

    DX,LUBMIX 1918MAR961/1

    Mixing of LubricantsIn 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.

    DX,OILSCAN 1902DEC021/1

    OILSCAN and COOLSCAN

    T682

    8AB

    UN

    15JU

    N89

    T682

    9AB

    UN

    18OC

    T88

    OILSCAN and 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.

    10-9 110306PN=34

  • Fuels, Lubricants, and Coolant

    DX,ALTER 1915JUN001/1

    Alternative and Synthetic LubricantsConditions 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.

    DX,LUBST 1918MAR961/1

    Lubricant StorageYour 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.

    10-10 110306PN=35

  • Fuels, Lubricants, and Coolant

    DX,FILT 1918MAR961/1

    Oil FiltersFiltration of oils is critical to proper operation andlubrication.

    Always change filters regularly as specified in this manual.

    Use filters meeting John Deere performancespecifications.

    10-11 110306PN=36

  • Fuels, Lubricants, and Coolant

    DX,COOL3 1927OCT051/2

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

    John Deere COOL-GARD Prediluted Coolant ispreferred for service.

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

    Additional recommended coolants

    The following engine coolant is also recommended:

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

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

    Other fully formulated coolants

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

    ASTM D6210 prediluted (50%) coolant ASTM D6210 coolant concentrate in a 40% to 60%mixture of concentrate with quality water

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

    Coolants requiring supplemental coolant additives

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

    ASTM D4985 ethylene glycol base prediluted (50%)coolant

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

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

    Other coolants

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

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

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

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

    Water quality

    COOL-GARD is a trademark of Deere & Company10-12 110306

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  • Fuels, Lubricants, and Coolant

    DX,COOL3 1927OCT052/2

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

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

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

    DX,COOL4 1907NOV031/1

    Supplemental Coolant AdditivesThe 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.

    COOL-GARD is a trademark of Deere & Company

    10-13 110306PN=38

  • Fuels, Lubricants, and Coolant

    DX,COOL11 1919DEC031/1

    Drain Intervals for Diesel Engine CoolantDrain 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.

    COOL-GARD is a trademark of Deere & Company

    10-14 110306PN=39

  • Fuels, Lubricants, and Coolant

    DX,COOL7 1919DEC031/2

    Additional Information About Diesel Engine Coolants and Supplemental CoolantAdditivesEngine coolants are a combination of three chemicalcomponents: ethylene glycol or propylene glycolantifreeze, inhibiting coolant additives, and qualitywater.

    Coolant specifications

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

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

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

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

    Replenish coolant additives

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

    Why use supplemental coolant additives?

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

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

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

    Avoid automotive-type coolants

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

    Water quality

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

  • Fuels, Lubricants, and Coolant

    DX,COOL7 1919DEC032/2

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

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

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

    DX,COOL9 1919DEC031/1

    Testing Diesel Engine CoolantTesting 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

    10-16 110306PN=41

  • Fuels, Lubricants, and Coolant

    DX,COOL6 1918MAR961/1

    Operating in Warm Temperature ClimatesJohn 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 1911OCT061/1

    Disposing of Coolant

    TS11

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    0Recycle 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.

    10-17 110306PN=42

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    OURGP12,0000081 1911OCT061/3

    Instrument Panels

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    Basic Instrument Panel

    ADiagnostic Gauge/Hour FKey Switch KAnalog Throttle Control OArrow KeysMeter GOverride Shutdown Rocker (Optional) PEnter Key

    BTachometer Switch LOil Pressure Gauge QAmber WARNINGCVoltmeter (Optional) HBump Enable Rocker MCoolant Temperature Indicator LightDAudible Alarm (Optional) Switch Gauge RRed STOP ENGINEEAudible Alarm Override ISpeed Select Rocker Switch NMenu Key Indicator Light

    Button JHigh-Low Speed SelectRocker Switch

    Tier 3 John Deere PowerTech Plus OEM Engineshave an electronic control system, which has thefollowing controls and gauges as shown. The followinginformation applies only to those controls and gaugessupplied by John Deere. Refer to your engineapplication manual for specific guidelines if JohnDeere-sourced controls and instrumentation are notused.

    NOTE: Section 20 following covers operation ofengine with these controls.

    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.

    PowerTech Plus is a trademark of Deere & Company.15-1 110306

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    OURGP12,0000081 1911OCT062/3

    Instrument Panels (Continued)

    ADiagnostic Gauge/Hour Meter

    The diagnostic gauge (A) displays diagnostic troublecodes (DTCs) as they are accessed. Other informationon the engine can be accessed using the touch keys(N, O and P). 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.

    BTachometer

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

    CVoltmeter (Optional)

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

    DAudible Alarm (Optional)

    The audible alarm (D) 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).

    EAudible Alarm Override Button

    The optional audible alarm has an override button (E)that silences the audible alarm for approximately twominutes when pressed.

    FKey Start Switch

    The three-position key start switch (F) controls theengine electrical system. When the key switch isturned clockwise to START, the engine will crank.

    When the engine starts, the key is released andreturns to the ON (RUN) position.

    GOverride Shutdown Rocker Switch

    Switch will be present, but may not be active,depending on engine controller (ECU) optionsoriginally selected. If switch is active, pressing theupper half of the override shutdown switch (G) willoverride an engine shutdown signal. The switch mustbe pressed within 30 seconds to prevent undesiredshutdown of engine. Pressing this switch will overridethe engine shutdown for 30 seconds at a time to movevehicle to a safe location.

    HBump Speed Enable Rocker Switch

    This is a three-position switch (H) with the centerposition as OFF (locked). With this switch in theOFF position, the speed select switch (I) is alsolocked, to prevent accidental changes in operatingspeed. Pressing upper or lower half of switch (H) willunlock or enable the bump speed switch to take effectusing speed select switch (I).

    ISpeed Select Rocker Switch

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

    JHigh-Low Speed Select Rocker Switch

    The high-low speed select switch (J) is used to set theengine operating speeds at slow (turtle) or fast (rabbit).Factory preset idle speeds can also be adjusted usingbump speed enable switch (H) with speed selectswitch (I).

    The basic instrument panel will have the high-lowspeed select switch only. Press and hold up (+) ordown (-) to adjust engine speed as desired. Theengine speed selected will not be held in the memory.To adjust engine speeds, See Changing EngineSpeeds in Section 20.

    15-2 110306PN=44

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    OURGP12,0000081 1911OCT063/3

    How To Select Preset Operating Speeds (BumpSpeeds)

    First select Turtle (Slow) or Adj by pressing speedselect switch (J) to Turtle (slow) or Adj(center).Then you can press either the upper or lower portionof the bump speed enable switch (H) to unlock thesetting. The bump speed enable must be held down asthe speed select switch (J) is used to change thesetting by pressing (+) to increase speed or (-) todecrease speed.

    Once the slow idle speed has been set, the bumpspeed enable switch must be pressed and releasedthree times within two seconds to commit the newoperating speed to memory. If not done, the engine'snew speed will only be effective until the key switch isshut off. Then the speed will revert back to theprevious setting.

    The fast idle speed is not adjustable. It will always goback to the factory preset fast idle speed.

    KAnalog Throttle Control (Optional)

    The throttle control (K) is used to control enginespeed. This control is available only on engines withanalog throttle.

    LEngine Oil Pressure Gauge

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

    MEngine Coolant Temperature Gauge

    The engine coolant temperature gauge (M) indicatesengine coolant temperature. An audible alarm (D)

    warns the operator if coolant temperature rises abovethe preset safe operating temperature.

    NMenu Key

    The menu key is pressed to either enter or exit themenu screens on the diagnostic gauge.

    OArrow Keys

    Use the arrow keys (O) 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.

    PEnter Key

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

    QAmber 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.

    RRed STOP ENGINE Indicator Light

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

    15-3 110306PN=45

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    OURGP11,0000017 1911OCT061/2

    Using Diagnostic Gauge to Access EngineInformation

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    Diagnostic Gauge

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

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

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

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

    Engine hours Engine rpm System voltage Percent engine load at the current rpm Coolant temperature Oil pressure Throttle position Intake manifold temperature Exhaust gas temperature Fuel 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

    Continued on next page

    15-4 110306PN=46

  • Instrument Panels

    OURGP11,0000017 1911OCT062/2

    NOTE: Engine parameters which can be accessed willvary with the engine application. Diagnostic gaugecan be programmed for readouts in one of thefollowing languages; English, French, German,Spanish, Italian and Portuguese. Contact yourengine distributor or dealer.

    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.

    OURGP11,00000A9 1911OCT061/5

    Main Menu Navigation

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    Menu Key

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

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

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    Menu Display

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

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    Main Menu Items

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

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    Last Items On Main Menu

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

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    Use Arrow Buttons To Scroll / Quadrant Display

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

    15-6 110306PN=48

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    OURGP11,00000AB 1911OCT061/6

    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. All ofthe engine values illustrated on the diagnosticgauge indicate the engine is running.

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

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    Select Engine Configuration

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

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    Enter Key

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

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

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    Return To Main Menu

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

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    Exit Main Menu

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

    15-8 110306PN=50

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    OURGP11,00000AC 1911OCT061/6

    Accessing Stored Trouble Codes

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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.

    For description of trouble codes, see chart inTroubleshootingSection.

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

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    Select Stored Codes

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

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    15-9 110306PN=51

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    Enter Key

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

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    Use Arrow Keys To Scroll

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

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    Return To Main Menu

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

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    Exit Main Menu

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

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    Accessing Active Trouble Codes

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    Normal Operation

    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.

    For description of trouble codes, see chart inTroubleshootingSection.

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

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    Active Trouble Codes Displayed

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

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

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    Use Arrow Keys To Scroll

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

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    Hide Trouble Codes

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

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

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    Active Trouble Code Icon

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

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    Enter Key

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

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

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

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    Engine Shutdown Codes

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    Normal Operation

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

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    Shutdown Message

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

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

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