John-deere POWERTECH 4045 User Manual Page 1

POWERTECH4.5 and 6.8 L4045 and 6068Tier 2 / Stage IIOEM Diesel EnginesOPERATOR’S MANUALPOWERTECH4.5 and 6.8 L Tier 2 /Stage II OEM Diesel EnginesOMRG

ContentsPage PageAuxiliary Gear Drive Limitations ...19-17 Checking Crankshaft Vibration DamperGenerator Set (Standby) Applications...19

Instrument Panel - Mech. Cont. “270” EnginesOURGP11,0000160 –19–27JUL06–2/2H—Key Switch - The key switch controls the electricalsystem. Positions of k

Engine Operation - Except 4.5L “270” EnginesOURGP11,0000075 –19–27JUL06–1/4Engine Break-In ServiceRG8009 –UN–06JAN99Check Engine OilThe engine is read

Engine Operation - Except 4.5L “270” EnginesOURGP11,0000075 –19–27JUL06–2/4RG8028A –UN–15JAN99Crosshatch Pattern On DipstickA—Crosshatch Pattern On Di

Engine Operation - Except 4.5L “270” EnginesOURGP11,0000075 –19–27JUL06–3/4RG11616 –UN–24OCT01Engine Oil FilterA—Engine Oil Filter4. During the first

Engine Operation - Except 4.5L “270” EnginesOURGP11,0000076 –19–27JUL06–1/3Starting the EngineTS220 –UN–23AUG88Use Proper VentilationThe following ins

Engine Operation - Except 4.5L “270” EnginesOURGP11,0000076 –19–27JUL06–2/3RG13279 –UN–30OCT03Analog Throttle Control and Speed Select Switch On Earli

Engine Operation - Except 4.5L “270” EnginesOURGP11,0000076 –19–27JUL06–3/3RG13280 –UN–30OCT03Start And Idle Engine On Earlier Panel (Left) or Later P

Engine Operation - Except 4.5L “270” EnginesOURGP11,0000077 –19–27JUL06–1/1Normal Engine OperationObserve engine coolant temperature and engine oilpre

Engine Operation - Except 4.5L “270” EnginesOURGP11,0000137 –19–27JUL06–1/1Warming EngineRG13281 –UN–30OCT03Oil Pressure and Coolant Temperature Gauge

Engine Operation - Except 4.5L “270” EnginesOURGP11,0000078 –19–27JUL06–1/2Cold Weather OperationTS1356 –UN–18MAR92Handle Starting Fluid with CareRG11

ContentsPage PageEngine Wiring Layout (Electronic Fuel Lubrication and Maintenance RecordsUsing Lubrication and Maintenance Records . . . 60-1System W

Engine Operation - Except 4.5L “270” EnginesOURGP11,0000078 –19–27JUL06–2/2NOTE: Air intake heaters (275 engines) and glow plugs(475 engines) operate

Engine Operation - Except 4.5L “270” EnginesRG,RG34710,5564 –19–27JUL06–1/2Using a Booster Battery or ChargerTS204 –UN–23AUG88Exploding BatteryRG4678

Engine Operation - Except 4.5L “270” EnginesRG,RG34710,5564 –19–27JUL06–2/26. Start the engine. Disconnect jumper cablesimmediately after engine start

Engine Operation - Except 4.5L “270” EnginesOURGP11,0000079 –19–27JUL06–1/3Changing Engine SpeedRG13282 –UN–30OCT03Changing Engine Speed On Earlier Pa

Engine Operation - Except 4.5L “270” EnginesOURGP11,0000079 –19–27JUL06–2/3• For fast speed, press upper half of rocker switch(indicated by rabbit sym

Engine Operation - Except 4.5L “270” EnginesOURGP11,0000079 –19–27JUL06–3/3RG13289 –UN–30OCT03Changing Engine Speed With Basic PanelE—High-Low Speed S

Engine Operation - Except 4.5L “270” EnginesOURGP11,0000139 –19–27JUL06–1/1Stopping The EngineRG13280 –UN–30OCT03Stopping the Engine On Earlier Panel

Engine Operation - Except 4.5L “270” EnginesRG,RG34710,5555 –19–27JUL06–1/1Auxiliary Gear Drive LimitationsRG7634A –UN–22JAN99Auxiliary Gear DriveA—Au

Engine Operation- 4.5 L “270” EnginesOURGP11,000007A –19–27JUL06–1/1Normal Engine OperationRG13343 –UN–24NOV03Instrument Panel (Earlier 4.5 L “270” En

Engine Operation- 4.5 L “270” EnginesOURGP11,0000169 –19–27JUL06–1/3Break-In ServiceRG12692 –UN–07FEB03Check Engine Oil Level DailyBefore starting, fi

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Engine Operation- 4.5 L “270” EnginesOURGP11,0000169 –19–27JUL06–3/3RG11616 –UN–24OCT01Engine Oil Filter5. Change engine oil and oil filter after the

Engine Operation- 4.5 L “270” EnginesRG41183,000002F –19–27JUL06–1/1Generator Set (Standby) Power UnitsTo assure that your engine will deliver efficie

Engine Operation- 4.5 L “270” EnginesOURGP11,000016A –19–27JUL06–2/2RG6580 –UN–20JAN93Starting Engine Using Key Switch (Earlier Engines)RG13366 –UN–12

Engine Operation- 4.5 L “270” EnginesOURGP11,000007B –19–27JUL06–1/2Cold Weather StartingWhen outside temperatures fall below 0°C (32° F) it maybe nec

Engine Operation- 4.5 L “270” EnginesOURGP11,000007B –19–27JUL06–2/2RG6580 –UN–20JAN93Starting EngineIMPORTANT: Do not operate the starter for more th

Engine Operation- 4.5 L “270” EnginesOURGP11,000007C –19–27JUL06–1/1Warming EngineRG6574 –UN–17FEB03Oil Pressure and Coolant Temperature Gauges (Earli

Engine Operation- 4.5 L “270” EnginesOURGP11,000007D –19–27JUL06–1/1Avoid Excessive Engine IdlingAvoid excessive engine idling. Prolonged idling may c

Engine Operation- 4.5 L “270” EnginesOURGP11,0000134 –19–27JUL06–1/2Stopping the EngineRG6574B –UN–07JAN03Key Switch on Instrument Panel (Earlier Engi

Engine Operation- 4.5 L “270” EnginesRG,RG34710,5564 –19–27JUL06–1/2Using a Booster Battery or ChargerTS204 –UN–23AUG88Exploding BatteryRG4678 –UN–14D

Engine Operation- 4.5 L “270” EnginesRG,RG34710,5564 –19–27JUL06–2/26. Start the engine. Disconnect jumper cablesimmediately after engine starts. Disc

Record KeepingOURGP11,0000274 –19–04AUG06–1/1POWERTECH MedallionRG11608 –UN–17OCT01RG11609 –UN–17OCT01A medallion is located on the rocker arm cover

Lubrication and MaintenanceOURGP11,0000241 –19–27JUL06–1/1Observe Service IntervalsRG13283 –UN–30OCT03Hour Meter On Earlier Panel (Left) or Later Pane

Lubrication and MaintenanceOURGP11,000007E –19–27JUL06–1/2Lubrication and Maintenance Service IntervalChart—Standard Industrial EnginesNOTE: The servi

Lubrication and MaintenanceOURGP11,000007E –19–27JUL06–2/2Lubrication and Maintenance Service Intervals500 Hour/ 2000 Hour/Item Daily 12 Month 24 Mont

Lubrication and MaintenanceOURGP11,000007F –19–27JUL06–1/2Lubrication and Maintenance Service IntervalChart—Generator (Standby) ApplicationsNOTE: Use

Lubrication and MaintenanceOURGP11,000007F –19–27JUL06–2/2Lubrication and Maintenance Service Intervals500 Hours or 2000 Hours orItem Every 2 Weeks 12

Lubrication & Maintenance/DailyOURGP11,000018F –19–27JUL06–1/5Daily Prestarting ChecksRG8009A –UN–16JUN00Left Side Oil Filler CapRG8054A –UN–16JUN

Lubrication & Maintenance/DailyOURGP11,000018F –19–27JUL06–2/5TS281 –UN–23AUG88High-Pressure FluidsRG4675 –UN–14DEC88Fill RadiatorA—Fill RadiatorC

Lubrication & Maintenance/DailyOURGP11,000018F –19–27JUL06–3/5RG12222 –UN–24MAY02Drain Final Fuel FilterRG11955 –UN–05DEC01Drain Primary Fuel Filt

Lubrication & Maintenance/DailyOURGP11,000018F –19–27JUL06–4/5RG7332A –UN–22JAN99Dust Unloader Valve and Indicator GaugeA—Dust Unloader ValveB—Air

Lubrication & Maintenance/DailyOURGP11,000018F –19–27JUL06–5/5RG6578 –UN–29JAN93Key Switch in "ON" Position (4.5 L “270” Engines)6. 4.5

Record KeepingOURGP11,0000070 –19–27JUL06–1/1Record Engine Serial NumberRG11949 –UN–07NOV01Saran Engine Serial Number PlateRG11948 –UN–06NOV01Torreon

Lubrication & Maintenance/500 Hour/12 MonthOURGP11,000015F –19–27JUL06–1/1Servicing Fire ExtinguisherRW4918 –UN–15DEC88Fire ExtinguisherA—Fire Ext

Lubrication & Maintenance/500 Hour/12 MonthRG,RG34710,5568 –19–27JUL06–1/2Servicing BatteryTS204 –UN–23AUG88Exploding BatteryCAUTION: Battery gas

Lubrication & Maintenance/500 Hour/12 MonthRG,RG34710,5568 –19–27JUL06–2/2TS203 –UN–23AUG88Sulfuric AcidCAUTION: Sulfuric acid in battery electrol

Lubrication & Maintenance/500 Hour/12 MonthDPSG,RG41165,128 –19–27JUL06–1/1Manual Belt Tensioner AdjustmentRG10556 –UN–21DEC99Check Belt TensionRG

Lubrication & Maintenance/500 Hour/12 MonthOUOD002,000016D –19–27JUL06–1/2Manual Belt Tensioner Adjustment UsingBelt Tension Tool (Alternate Metho

Lubrication & Maintenance/500 Hour/12 MonthOUOD002,000016D –19–27JUL06–2/2RG11814 –UN–31OCT01Belt Tension Tool and Torque WrenchRG11815 –UN–31OCT0

Lubrication & Maintenance/500 Hour/12 MonthOURGP11,000008C –19–27JUL06–1/4Changing Engine Oil and Replacing FilterRG11616 –UN–24OCT01Special Oil F

Lubrication & Maintenance/500 Hour/12 MonthOURGP11,000008C –19–27JUL06–2/43. Drain crankcase oil from engine while warm.NOTE: Drain plug location

Lubrication & Maintenance/500 Hour/12 MonthOURGP11,000008C –19–27JUL06–4/4RG11619 –UN–24OCT01Rocker Arm Cover Oil Filler OpeningRG11942 –UN–24OCT0

Lubrication & Maintenance/500 Hour/12 MonthOURGP11,000014F –19–27JUL06–2/2RG12426 –UN–20NOV03Closed Crankcase VentRG12427 –UN–03FEB04Closed Crankc

Record KeepingRG,RG34710,5508 –19–27JUL06–1/2Engine Option CodesRG11946 –UN–06NOV01A—Engine Base CodeIn addition to the serial number plate, OEM engin

Lubrication & Maintenance/500 Hour/12 MonthRG,RG34710,5575 –19–27JUL06–1/1Checking Air Intake SystemRG4689 –UN–20DEC88Check ClampsRG7332B –UN–22JA

Lubrication & Maintenance/500 Hour/12 MonthOURGP11,000021F –19–27JUL06–1/2Replacing Fuel Filter ElementsX9811 –UN–23AUG88High-Pressure FluidsRG772

Lubrication & Maintenance/500 Hour/12 MonthOURGP11,000021F –19–27JUL06–2/2NOTE: Raised locators on fuel filter canisters must beindexed properly w

Lubrication & Maintenance/500 Hour/12 MonthOURGP11,0000080 –19–27JUL06–1/3Checking Belt Tensioner Spring Tension andBelt Wear (Automatic Tensioner

Lubrication & Maintenance/500 Hour/12 MonthOURGP11,0000080 –19–27JUL06–3/3RG7977 –UN–14NOV97Marks on TensionerRG8037C –UN–11SEP00Align MarksRG1206

Lubrication & Maintenance/500 Hour/12 MonthOUOD002,0000169 –19–27JUL06–1/1Checking Engine Electrical GroundConnectionsKeep all engine ground conne

Lubrication & Maintenance/500 Hour/12 MonthDPSG,OUOD002,1921 –19–27JUL06–1/2Replenishing Supplemental CoolantAdditives (SCAs) Between Coolant Chan

Lubrication & Maintenance/500 Hour/12 MonthDPSG,OUOD002,1921 –19–27JUL06–2/2IMPORTANT: ALWAYS maintain coolant at correctlevel and concentration.

Lubrication & Maintenance/500 Hour/12 MonthOUOD002,0000175 –19–27JUL06–1/1Testing Diesel Engine CoolantMaintaining adequate concentrations of glyc

Lubrication & Maintenance/500 Hour/12 MonthOURGP11,0000220 –19–27JUL06–1/1Pressure Testing Cooling SystemRG6557 –UN–20JAN93Test Radiator CapRG6558

Record KeepingRG,RG34710,5508 –19–27JUL06–2/2NOTE: Your engine option code label may not containall option codes if an option has been addedafter the

Lubrication & Maintenance/500 Hour/12 MonthOURGP12,00001DB –19–27JUL06–1/1Checking and Adjusting Engine SpeedsRG12607 –UN–24OCT02Using Tachometer

Lubrication & Maint./2000 Hour/24 MonthOURGP12,00001ED –19–27JUL06–1/1Adjusting Variable Speed (Droop) — 4.5 L“270” Generator Set Engines OnlyRG12

Lubrication & Maint./2000 Hour/24 MonthRG,RG34710,5585 –19–27JUL06–1/1Checking Crankshaft Vibration Damper(6-Cylinder Engine Only)RG8018 –UN–15JAN

Lubrication & Maint./2000 Hour/24 MonthOURGP11,0000081 –19–27JUL06–1/4Flushing and Refilling Cooling SystemTS281 –UN–23AUG88High-Pressure FluidsRG

Lubrication & Maint./2000 Hour/24 MonthOURGP11,0000081 –19–27JUL06–2/4RG8019A –UN–19JUN00Engine Block Drain Valve- Except 475 EnginesRG12223 –UN–1

Lubrication & Maint./2000 Hour/24 MonthOURGP11,0000081 –19–27JUL06–3/410. After draining water, close drain valves. Reinstallradiator cap and radi

Lubrication & Maint./2000 Hour/24 MonthOURGP11,0000081 –19–27JUL06–4/416. Inspect the fan belt for wear and check belt tension.(See Checking Belt

Lubrication & Maint./2000 Hour/24 MonthDPSG,RG34710,112 –19–27JUL06–3/5RG5971 –UN–23NOV97Testing Thermostat Opening TemperatureTesting Thermostats

Lubrication & Maint./2000 Hour/24 MonthDPSG,RG34710,112 –19–27JUL06–4/5RG7614A –UN–06NOV97Installing Thermostat CoverRG7921B –UN–13NOV97Thermostat

Lubrication & Maint./2000 Hour/24 MonthDPSG,RG41165,137 –19–27JUL06–1/5Check and Adjust Valve Clearance (AllEngines Except 4045HF475 And 6068HF475

Record KeepingOURGP12,00000AD –19–27JUL06–1/1Record Engine Control Unit (ECU) SerialNumberRG13799 –UN–18NOV04Record Engine Control Unit (ECU) Serial N

Lubrication & Maint./2000 Hour/24 MonthDPSG,RG41165,137 –19–27JUL06–2/54. With engine lock-pinned at TDC of No. 1 piston’scompression stroke, chec

Lubrication & Maint./2000 Hour/24 MonthDPSG,RG41165,137 –19–27JUL06–4/5RG4776 –UN–31OCT974-Cylinder Engine Valve AdjustmentA—Front of EngineB—No.

Lubrication & Maint./2000 Hour/24 MonthOUO1089,0000208 –19–27JUL06–1/5Check and Adjust Valve Clearance(4045HF475 And 6068HF475 Engines)RG12168 –UN

Lubrication & Maint./2000 Hour/24 MonthOUO1089,0000208 –19–27JUL06–2/54. With engine lock-pinned at TDC of No. 1 piston’scompression stroke, check

Lubrication & Maint./2000 Hour/24 MonthOUO1089,0000208 –19–27JUL06–4/5ABEI4E3IE2IE1IE4IE3IE2IE1ICRG12357 –UN–29MAY024-Cylinder Valve AdjustmentA—F

Lubrication & Maint./2000 Hour/24 MonthOURGP11,0000082 –19–27JUL06–1/1Test Glow Plugs for Continuity (4045HF475And 6068HF475 Engines)RG13802 –UN–1

Service as RequiredRG,RG34710,5591 –19–27JUL06–1/1Additional Service InformationRG4624 –UN–15DEC88Component Technical ManualThis is not a detailed ser

Service as RequiredOURGP11,0000083 –19–27JUL06–1/1Do Not Modify Fuel SystemTS1343 –UN–18MAR92High-Pressure Fuel LinesRG11953 –UN–26NOV01Fuel Injection

Service as RequiredOURGP11,0000222 –19–27JUL06–1/2Adding CoolantTS281 –UN–23AUG88High-Pressure FluidsRG13295 –UN–20NOV03Radiator and CoolantA—Radiator

Service as RequiredOURGP11,0000222 –19–27JUL06–2/23. Tighten plugs and fittings when air has been expelledfrom system.4. Run engine until it reaches o

SafetyDX,ALERT –19–29SEP98–1/1Recognize Safety InformationT81389 –UN–07DEC88This is a safety-alert symbol. When you see this symbolon your machine or

Service as RequiredRG,RG34710,5594 –19–27JUL06–1/1Replacing Single Stage Air CleanerRG11319A –UN–06SEP00Single Stage Air FilterRG11320 –UN–07SEP00Inst

Service as RequiredOURGP11,000013A –19–27JUL06–1/2Replacing Axial Seal Air Cleaner FilterElementRG8719B –UN–03SEP99Air restriction IndicatorIMPORTANT:

Service as RequiredOURGP11,000013A –19–27JUL06–2/2RG4686 –UN–20DEC88Wing Nut and Primary ElementRG4687 –UN–20DEC88Dust Unloader Valve and Restriction

Service as RequiredRG41165,000008B –19–27JUL06–1/2Replacing Radial Seal Air Cleaner FilterElementRG11321A –UN–08SEP00Dust Cup/CoverRG11322A –UN–08SEP0

Service as RequiredRG41165,000008B –19–27JUL06–2/2IMPORTANT: Whenever the air cleaner has beenserviced or cover has been removed,ALWAYS fully depress

Service as RequiredOURGP11,000013B –19–27JUL06–1/1Replacing Fan and Alternator BeltsRG11950 –UN–07NOV01290 mm (11.4 in.) Fan Height and Lower*RG11951

Service as RequiredOURGP11,000013C –19–27JUL06–1/1Checking FusesRG11938 –UN–06NOV01Early Engines with Electronic Instrument PanelA—5 Amp FuseNOTE: The

Service as RequiredOURGP11,000000E –19–27JUL06–1/3Bleeding the Fuel System (Engines WithElectronic Fuel Systems And Bosch VP44Pump)X9811 –UN–23AUG88Hi

Service as RequiredOURGP11,000000E –19–27JUL06–2/3RG11719A –UN–20JUN01Bleed Fuel SystemA—Bleed Orifice in Final Fuel Filter BaseB—Fuel Return LineIMPO

Service as RequiredOUOD002,000016F –19–27JUL06–1/5Bleed the Fuel System (Engines withElectronic Fuel Systems and StanadyneDE10 Pump)X9811 –UN–23AUG88H

SafetyDX,SIGNS1 –19–04JUN90–1/1Replace Safety SignsTS201 –UN–23AUG88Replace missing or damaged safety signs. See themachine operator’s manual for corr

Service as RequiredOUOD002,000016F –19–27JUL06–2/5RG11805 –UN–25OCT01Final Fuel Filter Bleed Vent ScrewA—Bleed Vent Screw1. Loosen the air bleed vent

Service as RequiredOUOD002,000016F –19–27JUL06–4/5RG11807 –UN–25OCT01Fuel Injection Pump Return LineA—Fuel Return LineAt Fuel Injection Pump1. Loosen

Service as RequiredOURGP11,000000F –19–27JUL06–1/3Bleed the Fuel System (Engines withElectronic Fuel Systems and Denso HighPressure Common Rail) (4045

Service as RequiredOURGP11,000000F –19–27JUL06–2/3RG12220 –UN–24MAY02Final Fuel Filter Bleed Vent ScrewA—Bleed Vent ScrewIMPORTANT: NEVER pressurize t

Service as RequiredOURGP11,0000010 –19–27JUL06–1/5Bleed the Fuel System (4045DF270,4045TF270)X9811 –UN–23AUG88High-Pressure FluidsCAUTION: Escaping fl

Service as RequiredOURGP11,0000010 –19–27JUL06–2/5RG7947 –UN–13NOV97Air Bleed Vent ScrewA—Vent ScrewIMPORTANT: NEVER pressurize the fuel tank to prime

Service as RequiredOURGP11,0000010 –19–27JUL06–4/5RG6264 –UN–03NOV97Stanadyne Rotary Fuel Injection PumpA—Fuel Return Line ConnectorAt Fuel Injection

TroubleshootingRG,RG34710,5605 –19–27JUL06–1/1General Troubleshooting InformationTroubleshooting engine problems can be difficult. Anengine wiring dia

TroubleshootingOUOD002,000016B –19–27JUL06–1/1Precautions For Welding On EnginesEquipped With Electronic Engine ControlUnit (ECU)IMPORTANT: ALWAYS dis

TroubleshootingOURGP11,0000276 –19–27JUL06–1/1Engine Wiring Layout (Electronic Fuel System With Stanadyne DE10 Injection Pump)RG12201 –UN–24MAY02A—Coo

IntroductionOURGP11,000006E –19–04AUG06–1/2ForewordTHIS MANUAL CONTAINS INFORMATION to operateand service the following Tier 2 / Stage IIemission-cert

SafetyDX,FIRE2 –19–03MAR93–1/1Prepare for EmergenciesTS291 –UN–23AUG88Be prepared if a fire starts.Keep a first aid kit and fire extinguisher handy.Ke

TroubleshootingOURGP11,0000277 –19–27JUL06–1/1Engine Wiring Layout (Electronic Fuel System With Bosch VP44 Injection Pump)RG11939A –UN–05JUN02A—Oil Pr

TroubleshootingOURGP11,0000278 –19–27JUL06–1/1Engine Wiring Layout (Electronic Fuel System With Denso High Pressure CommonRail)(4045HF475,6068HF475)RG

TroubleshootingOURGP11,000026F –19–27JUL06–1/1Engine Wiring Diagram (With Earlier Electronic Instrument Panel)414 BATB BABAX6REMOTE ON/OFFPLUG022 0320

TroubleshootingOURGP11,0000270 –19–27JUL06–1/1Engine Wiring Diagram (With Earlier Electronic Instrument Panel)—ContinuedRG10040 –19–18MAY99B1—Analog T

TroubleshootingOURGP11,0000271 –19–27JUL06–1/1Engine Wiring Diagram (With Later Full-Featured Electronic Instrument Panel)RG13354 –UN–22JAN04B1—Analog

TroubleshootingOURGP11,0000272 –19–27JUL06–1/1Engine Wiring Diagram (With Later Full-Featured Electronic Instrument Panel)—ContinuedRG13272 –UN–26JAN0

TroubleshootingRG,RG34710,5608 –19–27JUL06–1/8Engine TroubleshootingSymptom ProblemSolutionEngine cranks but will not start Incorrect starting procedu

TroubleshootingRG,RG34710,5608 –19–27JUL06–2/8Symptom ProblemSolutionEngine hard to start or will not Engine starting under load. Disengage PTO.startI

TroubleshootingRG,RG34710,5608 –19–27JUL06–3/8Symptom ProblemSolutionEngine runs irregularly or stalls Low coolant temperature. Remove and check therm

TroubleshootingRG,RG34710,5608 –19–27JUL06–4/8Symptom ProblemSolutionLack of power Engine overloaded. Reduce load.Intake air restriction. Service air

SafetyOURGP12,00001DA –19–27JUL06–1/1Service Engines SafelyTS228 –UN–23AUG88Moving PartsTie long hair behind your head. Do not wear a necktie,scarf, l

TroubleshootingRG,RG34710,5608 –19–27JUL06–5/8Symptom ProblemSolutionHigh oil consumption Crankcase oil too light. Use proper viscosity oil.Oil leaks.

TroubleshootingRG,RG34710,5608 –19–27JUL06–6/8Symptom ProblemSolutionEngine overheats Engine overloaded. Reduce load.Low coolant level. Fill radiator

TroubleshootingRG,RG34710,5608 –19–27JUL06–7/8Symptom ProblemSolutionUndercharged electrical system Excessive electrical load from added Remove access

TroubleshootingRG,RG34710,5608 –19–27JUL06–8/8Symptom ProblemSolutionStarter and hour meter functions; Blown fuse on magnetic switch. Replace fuse.res

TroubleshootingOURGP12,00001EA –19–27JUL06–1/2Blink Code Method for Retrieving DiagnosticTrouble Codes (Early VP44 Pump EnginesOnly)RG11754A –UN–13JUL

TroubleshootingOURGP12,00001EA –19–27JUL06–2/28. When complete, turn ignition “OFF”, remove jumperwire, and recap the diagnostic reader connector.As a

TroubleshootingOURGP11,0000279 –19–27JUL06–1/1Instrument Panel Method for RetrievingDiagnostic Trouble CodesRG13287 –UN–30OCT03Trouble Code Display On

TroubleshootingDPSG,OUOD002,1591 –19–27JUL06–1/1Displaying Of Diagnostic Trouble Codes (DTCs)There are several different methods for displaying bothst

TroubleshootingOURGP11,0000086 –19–27JUL06–1/2Listing of Diagnostic Trouble Codes (DTCs)(Engines With Electronic Fuel Systems AndStanadyne DE10 Pump)N

TroubleshootingOURGP11,0000086 –19–27JUL06–2/2SPN FMI Blink Codes Description of Fault04 38 Fuel Temperature Input Voltage Low16 81 Fuel Temperature H

SafetyDX,MSDS,NA –19–03MAR93–1/1Handle Chemical Products SafelyTS1132 –UN–26NOV90Direct exposure to hazardous chemicals can causeserious injury. Poten

TroubleshootingOURGP11,0000087 –19–27JUL06–1/2Listing of Diagnostic Trouble Codes (DTCs)(Engines With Electronic Fuel Systems AndBosch VP44 Pump)NOTE:

TroubleshootingOURGP11,0000087 –19–27JUL06–2/2SPN FMI Blink Code Description of Fault04 22 Sensor Supply Voltage Low000627 04 76 ECU Unswitched Power

TroubleshootingOURGP11,0000088 –19–27JUL06–1/3Listing of Diagnostic Trouble Codes (DTCs)(Engines With Electronic Fuel Systems AndDenso High Pressure C

TroubleshootingOURGP11,0000088 –19–27JUL06–2/3SPN FMI Blink Code Description of Fault16 71 Fuel Temperature High Moderately Severe000189 00 — Engine S

TroubleshootingOURGP11,0000088 –19–27JUL06–3/3SPN FMI Blink Code Description of Fault002000 13 — Security ViolationN/A N/A 32 When reading blink codes

TroubleshootingOUOD007,0000036 –19–27JUL06–1/1Intermittent Fault Diagnostics (With Electronic Controls)Intermittent faults are problems that periodica

TroubleshootingOURGP11,000012B –19–27JUL06–2/4RG13234 –UN–22OCT03Select Utilities2. The main menu will be displayed. Use the "Arrow" keyto s

StorageOURGP12,00000DF –19–27JUL06–1/1Engine Storage Guidelines1. John Deere engines can be stored outside for up tothree (3) months with no long term

StorageOURGP11,000006C –19–27JUL06–1/2Preparing Engine for Long Term StorageThe following storage preparations are used for longterm engine storage up

StorageOURGP11,000006C –19–27JUL06–2/215. Store the engine in a dry protected place. Ifengine must be stored outside, cover it with awaterproof canvas

SafetyDX,SERV –19–17FEB99–1/1Practice Safe MaintenanceTS218 –UN–23AUG88Understand service procedure before doing work. Keeparea clean and dry.Never lu

SpecificationsOURGP11,0000089 –19–27JUL06–1/2General OEM Engine SpecificationsITEM 4045DF270 4045TF270 4045TF/HF275 4045HF475 6068TF/HF275 6068HF475Nu

SpecificationsOURGP11,0000089 –19–27JUL06–2/2ITEM 4045DF270 4045TF270 4045TF/HF275 4045HF475 6068TF/HF275 6068HF475Oil Pressure At Rated 345 ± 103 kPa

SpecificationsOURGP11,000008A –19–27JUL06–1/3Engine Power Ratings1And Fuel SystemSpecifications2Engine Fuel System Electronic Software System Power Ra

SpecificationsOURGP11,000008A –19–27JUL06–2/3Engine Fuel System Electronic Software System Power Rated Slow Idle Fast IdleModel Option Codes Option Co

SpecificationsOURGP11,000008A –19–27JUL06–3/3Engine Fuel System Electronic Software System Power Rated Slow Idle Fast IdleModel Option Codes Option Co

SpecificationsOURGP11,000008B –19–27JUL06–1/1Engine Crankcase Oil Fill QuantitiesTo determine the option code for the oil fill quantity ofyour engine,

SpecificationsTORQ1 –19–24APR03–1/1Unified Inch Bolt and Screw Torque ValuesTS1671 –UN–01MAY03Bolt or SAE Grade 1 SAE Grade 2aSAE Grade 5, 5.1 or 5.2

SpecificationsDX,TORQ2 –19–24APR03–1/1Metric Bolt and Screw Torque Values4.84.8 8.8 9.8 10.912.912.912.912.910.99.88.84.8TS1670 –UN–01MAY03Bolt or Cla

Lubrication and Maintenance RecordsRG,RG34710,5620 –19–27JUL06–1/1Using Lubrication and Maintenance RecordsRefer to specific Lubrication and Maintenan

Lubrication and Maintenance RecordsOURGP11,000008D –19–27JUL06–1/1500 Hour/12 Month Service• Service fire extinguisher.• Check engine mounts.• Service

SafetyDX,FLUID –19–03MAR93–1/1Avoid High-Pressure FluidsX9811 –UN–23AUG88Escaping fluid under pressure can penetrate the skincausing serious injury.Av

Lubrication and Maintenance RecordsRG,RG34710,5625 –19–27JUL06–1/12000 Hour/24 Month Service• Check crankshaft vibration damper (6-cylinder only).• Fl

Lubrication and Maintenance RecordsRG,RG34710,5627 –19–27JUL06–1/1Service as Required• Add coolant• Service air cleaner.• Replace poly-vee belts.• Che

Emission System WarrantyRG,RG34710,7629 –19–27JUL06–1/1U.S. EPA Emissions Control Warranty StatementEmissions control-related parts and components are

Emission System WarrantyDPSG,RG41165,133 –19–27JUL06–1/1Emissions Control System Certification LabelRG11947 –UN–06NOV01Emissions LabelCAUTION: Statute

John Deere Service Literature AvailableDX,SERVLIT –19–31JUL03–1/2Technical InformationTS189 –UN–17JAN89TS191 –UN–02DEC88TS224 –UN–17JAN89TS1663 –UN–10

John Deere Service Literature AvailableDX,SERVLIT –19–31JUL03–2/2– Fundamentals of Machine Operation manuals explainmachine capacities and adjustments

John Deere Service Literature Available70-3080706PN=244

IndexPage PageACold weather aids...35-15Except 4045DF,TF270 ...19-9Acid burns ...30-24045

IndexPage PageDiagnostic trouble codes (DTCs) With Denso High Pressure Common Rail ...45-5With Stanadyne DE10 pump...45-3Stored service co

IndexPage PageComponent function - earlier engines ...16-1 Filler locations...25-1Oil filter, change...

SafetyDX,PAINT –19–24JUL02–1/1Remove Paint Before Welding or HeatingTS220 –UN–23AUG88Avoid potentially toxic fumes and dust.Hazardous fumes can be gen

IndexPage PageFuel injection pump and power ratings ...55-3WGeneral OEM ...55-1Standby power units...19-17, 20-

SafetyOUOD006,000009D –19–27JUL06–1/1Install Fan GuardsTS677 –UN–21SEP89Rotating FanRotating cooling system fans can cause serious injury.Keep fan gua

SafetyDX,DUST –19–15MAR91–1/1Avoid Harmful Asbestos DustTS220 –UN–23AUG88Avoid breathing dust that may be generated whenhandling components containing

SafetyDX,REPAIR –19–17FEB99–1/1Use Proper ToolsTS779 –UN–08NOV89Use tools appropriate to the work. Makeshift tools andprocedures can create safety haz

SafetyDPSG,OUO1004,2758 –19–27JUL06–1/1Handling Batteries SafelyTS204 –UN–23AUG88ExplosionTS203 –UN–23AUG88AcidCAUTION: Battery gas can explode. Keeps

IntroductionOURGP11,000006E –19–04AUG06–2/2IMPORTANT: This manual covers onlyPOWERTECH Tier 2 / Stage IIemission certified 4.5 and 6.8 L OEMengines l

SafetyDX,SPRAY –19–16APR92–1/1Protect Against High Pressure SprayTS1343 –UN–18MAR92Spray from high pressure nozzles can penetrate the skinand cause se

Fuels, Lubricants, and CoolantDX,FUEL1 –19–17NOV05–1/1Diesel FuelConsult your local fuel distributor for properties of thediesel fuel available in you

Fuels, Lubricants, and CoolantDX,FUEL4 –19–19DEC03–1/1Handling and Storing Diesel FuelCAUTION: Handle fuel carefully. Do not fillthe fuel tank when en

Fuels, Lubricants, and CoolantDX,FUEL7 –19–14NOV05–1/1Bio-Diesel FuelConsult your local fuel distributor for properties of thebio-diesel fuel availabl

Fuels, Lubricants, and CoolantDX,FUEL10 –19–16DEC05–1/2Minimizing the Effect of Cold Weather on Diesel EnginesJohn Deere diesel engines are designed t

Fuels, Lubricants, and CoolantDX,FUEL10 –19–16DEC05–2/2If winterfronts are used, they should never totally closeoff the grill frontal area. Approximat

Fuels, Lubricants, and CoolantDX,ENOIL7 –19–23NOV05–1/1Diesel Engine OilTS1675 –UN–31OCT03Use oil viscosity base on the expected air temperaturerange

Fuels, Lubricants, and CoolantOURGP11,0000012 –19–27JUL06–1/3Diesel Engine Oil and Filter Service IntervalsThe oil and filter service intervals in the

Fuels, Lubricants, and CoolantOURGP11,0000012 –19–27JUL06–2/34.5 L Engine Oil and Filter Service Intervals in Hours of OperationOil Pan Option CodesPo

Fuels, Lubricants, and CoolantOURGP11,0000012 –19–27JUL06–3/36.8 L Engine Oil and Filter Service Intervals in Hours of OperationOil Pan Option CodesPo

Introduction080706PN=4

Fuels, Lubricants, and CoolantDX,FILT –19–18MAR96–1/1Oil FiltersFiltration of oils is critical to proper operation andlubrication.Always change filter

Fuels, Lubricants, and CoolantDX,ALTER –19–15JUN00–1/1Alternative and Synthetic LubricantsConditions in certain geographical areas may requirelubrican

Fuels, Lubricants, and CoolantDX,GREA1 –19–07NOV03–1/1GreaseTS1673 –UN–31OCT03Use grease based on NLGI consistency numbers and theexpected air tempera

Fuels, Lubricants, and CoolantDX,COOL3 –19–27OCT05–1/2Diesel Engine CoolantThe engine cooling system is filled to provideyear-round protection against

Fuels, Lubricants, and CoolantDX,COOL3 –19–27OCT05–2/2Water quality is important to the performance of thecooling system. Distilled, deionized, or dem

Fuels, Lubricants, and CoolantDX,COOL4 –19–07NOV03–1/1Supplemental Coolant AdditivesThe concentration of coolant additives is graduallydepleted during

Fuels, Lubricants, and CoolantDX,COOL6 –19–18MAR96–1/1Operating in Warm Temperature ClimatesJohn Deere engines are designed to operate using glycolbas

Instrument Panel IdentificationOURGP11,0000071 –19–27JUL06–1/2Instrument Panels - IdentificationRG13343 –UN–24NOV03Instrument Panel For Earlier Mechan

Instrument Panel IdentificationOURGP11,0000071 –19–27JUL06–2/2RG13273 –UN–20NOV03Instrument Panel For Earlier Electronically Controlled Engines (SeeSe

Instrument Panel - Elect. Cont. Earlier EnginesOURGP11,000027A –19–07AUG06–1/7Instrument PanelRG11169 –UN–01NOV00Instrument Panel (Earlier Electronica

IntroductionOURGP11,0000251 –19–27JUL06–1/1Engine OwnerJohn Deere Engine Owner:Don’t wait until you need warranty or other service tomeet your local J

Instrument Panel - Elect. Cont. Earlier EnginesOURGP11,000027A –19–07AUG06–2/7RG11169 –UN–01NOV00Instrument PanelIMPORTANT: Any time an electric gauge

Instrument Panel - Elect. Cont. Earlier EnginesOURGP11,000027A –19–07AUG06–3/7RG11169 –UN–01NOV00Instrument Panel For Earlier EnginesTouch SwitchesThe

Instrument Panel - Elect. Cont. Earlier EnginesOURGP11,000027A –19–07AUG06–4/7RG11169 –UN–01NOV00Instrument Panel For Earlier EnginesEngine Preheater

Instrument Panel - Elect. Cont. Earlier EnginesOURGP11,000027A –19–07AUG06–5/7RG11169 –UN–01NOV00Instrument Panel For Earlier EnginesBump Speed Enable

Instrument Panel - Elect. Cont. Earlier EnginesOURGP11,000027A –19–07AUG06–6/7RG11169 –UN–01NOV00Instrument Panel For Earlier EnginesTachometerThe tac

Instrument Panel - Elect. Cont. Earlier EnginesOURGP11,000027A –19–07AUG06–7/7The cancel/resume function is intended for applicationslike agricultural

Instrument Panel - Elect. Cont. Earlier EnginesOURGP11,0000072 –19–27JUL06–1/2Using Diagnostic Gauge to Access EngineInformationRG10031 –UN–28OCT99Dia

Instrument Panel - Elect. Cont. Earlier EnginesOURGP11,0000072 –19–27JUL06–2/2• Electrical potential (voltage)• Battery potential (voltage), switched•

Instrument Panel - Elect. Cont. Earlier EnginesDPSG,OUOD007,2841 –19–27JUL06–1/2Using Touch Switches to Display InformationRG9947 –19–09DEC99Using Tou

Instrument Panel - Elect. Cont. Earlier EnginesDPSG,OUOD007,2841 –19–27JUL06–2/2The touch switches on the diagnostic gauge allowquick and easy navigat

IntroductionOUOD002,0000162 –19–04AUG06–1/1POWERTECH 4.5 L Engines With Electronic Fuel Systems (Tier 2 Emission Certified)(Two-Valve Cylinder Head M

Instrument Panel - Elect. Cont. Earlier EnginesDPSG,OUOD007,2842 –19–27JUL06–1/1Changing Units of Measure (English or Metric)RG10018 –19–28OCT99Changi

Instrument Panel - Elect. Cont. Earlier Engines16-13080706PN=59

Instrument Panel - Elect. Cont. Earlier EnginesDPSG,OUOD007,2842 –19–27JUL06–1/2Viewing Engine Configuration DataRG10019 –19–28OCT99Viewing Engine Con

Instrument Panel - Elect. Cont. Earlier EnginesDPSG,OUOD007,2842 –19–27JUL06–2/2The diagnostic gauge can display the engineconfiguration data stored i

Instrument Panel - Elect. Cont. Earlier EnginesDPSG,OUOD002,1928 –19–27JUL06–1/1Viewing Active Engine Service Codes/Diagnostic Trouble Codes (DTCs)RG1

Instrument Panel - Elect. Cont. Earlier EnginesOUOD006,000006B –19–27JUL06–1/1Viewing Stored Service Codes/Diagnostic Trouble Codes (DTCs) in the Engi

Instrument Panel - Elect. Cont. Later EnginesOURGP11,0000073 –19–04AUG06–1/3Instrument PanelsRG13276 –UN–28OCT03Full-Featured Instrument PanelRG13277

Instrument Panel - Elect. Cont. Later EnginesOURGP11,0000073 –19–04AUG06–2/3Instrument Panel (Continued)A—Diagnostic Gauge/Hour MeterThe diagnostic ga

Instrument Panel - Elect. Cont. Later EnginesOURGP11,0000073 –19–04AUG06–3/3How To Select Preset Operating Speeds (BumpSpeeds)First select Turtle (Slo

Instrument Panel - Elect. Cont. Later EnginesOURGP11,0000074 –19–27JUL06–1/1Using Diagnostic Gauge to Access EngineInformationRG13132 –UN–09SEP03Diagn

IntroductionOUOD002,0000163 –19–04AUG06–1/1POWERTECH 6.8 L Engines With Electronic Fuel Systems (Tier 2 Emission Certified)(Two-Valve Cylinder Head M

Instrument Panel - Elect. Cont. Later EnginesOURGP11,00000A9 –19–27JUL06–1/5Main Menu NavigationRG13159 –UN–26SEP03Menu KeyNOTE: The engine does not n

Instrument Panel - Elect. Cont. Later EnginesOURGP11,00000A9 –19–27JUL06–4/5RG13162 –UN–26SEP03Last Items On Main Menu4. Pressing the right arrow key

Instrument Panel - Elect. Cont. Later EnginesOURGP11,00000AB –19–27JUL06–2/6RG13164 –UN–07OCT03Select Engine Configuration2. The main menu will be dis

Instrument Panel - Elect. Cont. Later EnginesOURGP11,00000AB –19–27JUL06–6/6RG13159 –UN–26SEP03Exit Main Menu6. Press the "Menu" key to exit

Instrument Panel - Elect. Cont. Later EnginesOURGP11,00000AC –19–27JUL06–3/6RG13169 –UN–02OCT03Enter Key3. Once the "Stored Codes" menu item

Instrument Panel - Elect. Cont. Later EnginesOURGP11,00000AC –19–27JUL06–6/6RG13159 –UN–26SEP03Exit Main Menu6. Press the "Menu" key to exit

Instrument Panel - Elect. Cont. Later EnginesOURGP11,00000AD –19–27JUL06–3/7RG13241 –UN–30SEP03Use Arrow Keys To Scroll3. If the word "Next"

Instrument Panel - Elect. Cont. Later EnginesOURGP11,00000AD –19–27JUL06–7/7RG13243 –UN–01OCT03Active Trouble Code Condition7. The single or four para

Instrument Panel - Elect. Cont. Later EnginesOURGP11,00000AE –19–27JUL06–4/6RG13179 –UN–26SEP03Flashing Shutdown Icon4. The display will return to the

Instrument Panel - Elect. Cont. Later EnginesOURGP11,0000237 –19–27JUL06–2/6RG13181 –UN–02OCT03Select Adjust Backlight2. The main menu will be display

IntroductionOURGP11,000018B –19–04AUG06–1/1POWERTECH 4.5/6.8 L Engines With Electronic Fuel Systems (Tier 2 Emission Certified)(Four-Valve Cylinder H

Instrument Panel - Elect. Cont. Later EnginesOURGP11,0000237 –19–27JUL06–5/6RG13184 –UN–26SEP03Return To Main Menu5. Press the "Menu" key to

Instrument Panel - Elect. Cont. Later EnginesOURGP11,00000AF –19–27JUL06–2/6RG13161 –UN–02OCT03Select Adjust Contrast2. The main menu will be displaye

Instrument Panel - Elect. Cont. Later EnginesOURGP11,00000AF –19–27JUL06–5/6RG13187 –UN–26SEP03Return To Main Menu5. Press the "Menu" key to

Instrument Panel - Elect. Cont. Later EnginesOURGP11,00000B0 –19–27JUL06–2/7RG13188 –UN–02OCT03Select Units2. The main menu will be displayed. Use the

Instrument Panel - Elect. Cont. Later EnginesOURGP11,00000B0 –19–27JUL06–5/7RG13191 –UN–30SEP03Press Enter Key to Select5. Press the "Enter"

Instrument Panel - Elect. Cont. Later EnginesOURGP11,00000B1 –19–27JUL06–1/18Setup 1-Up DisplayRG13159 –UN–26SEP03Menu Key1. Turn the key switch to th

Instrument Panel - Elect. Cont. Later EnginesOURGP11,00000B1 –19–27JUL06–4/18RG13196 –UN–26SEP031-Up Display Options4. Three options are available for

Instrument Panel - Elect. Cont. Later EnginesOURGP11,00000B1 –19–27JUL06–6/18RG13197 –UN–29SEP03Defaults Selected6. Press the "Enter" key to

Instrument Panel - Elect. Cont. Later EnginesOURGP11,00000B1 –19–27JUL06–9/18RG13199 –UN–26SEP03Engine Parameters9. Press the "Enter" key to

Instrument Panel - Elect. Cont. Later EnginesOURGP11,00000B1 –19–27JUL06–12/18RG13151 –UN–24SEP03Select Desired Parameters12. Use the "Arrow"

ContentsPagePageRecord KeepingUsing Touch Switches to DisplayInformation ...16-10PowerTech Medallion...01-1Ch

Instrument Panel - Elect. Cont. Later EnginesOURGP11,00000B1 –19–27JUL06–15/18RG13222 –UN–26SEP03Automatic Scan On16. Press the "Enter" key

Instrument Panel - Elect. Cont. Later EnginesOURGP11,00000B1 –19–27JUL06–17/18RG13224 –UN–26SEP03Menu Key18. Once the "Use Defaults", "

Instrument Panel - Elect. Cont. Later EnginesOURGP11,00000B2 –19–27JUL06–2/14RG13225 –UN–02OCT03Select Setup 4-Up Display2. The main menu will be disp

Instrument Panel - Elect. Cont. Later EnginesOURGP11,00000B2 –19–27JUL06–4/14RG13244 –UN–02OCT03Select Factory Defaults4. Two options are available fo

Instrument Panel - Elect. Cont. Later EnginesOURGP11,00000B2 –19–27JUL06–7/14RG13228 –UN–26SEP03Select Parameters7. The quadrant with the highlighted

Instrument Panel - Elect. Cont. Later EnginesOURGP11,00000B2 –19–27JUL06–10/14RG13231 –UN–26SEP03Enter Selected Parameter10. Press the "Enter&quo

Instrument Panel - Elect. Cont. Later EnginesOURGP11,00000B2 –19–27JUL06–13/14RG13154 –UN–24SEP03Return To Main Menu13. Repeat the parameter selection

Instrument Panel - Mech. Cont. “270” EnginesOURGP11,000018E –19–27JUL06–1/2Instrument Panel (Earlier 4.5 L “270”Engines)RG6574A –UN–07JAN03Instrument

Instrument Panel - Mech. Cont. “270” EnginesOURGP11,000018E –19–27JUL06–2/2RG6574A –UN–07JAN03Instrument Panel and Gauges (4.5 L “270” Engines)F—Oil P

Instrument Panel - Mech. Cont. “270” EnginesOURGP11,0000160 –19–27JUL06–1/2Instrument Panel (Later 4.5 L “270” Engines)RG13360 –UN–06FEB04Instrument P