Instruction/ maintenance manual of the product OMRG25204 PowerTec
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PowerTech 4.5 L and 6.8 L Non-Certified and Tier 1 Certified OEM Diesel Engines OPERATOR’S MANUAL PowerTech 4.5 L and 6.8 L Non-Certified and Tier 1 Certified OEM Diesel Engines OMRG25204 Is.
Introduction OURGP11,0000004 –19–27OCT06–1/2 Foreword This manual contains information to operate and service the following 4.5 L & 6.8 L non-certified and Tier 1 1 emission certified OEM engines built at Dubuque Iowa (T0), Saran France (CD) and Torreon Mexico (PE) from 1996 on.
Introduction OURGP11,0000004 –19–27OCT06–2/2 • PE4045TF151 • PE4045HF150 • PE4045HF252 • PE6068DF150 • PE6068TF150 • PE6068TF151 • PE6068TF250 • PE6068HF150 • PE6068HF250 DUBUQ.
Introduction OURGP11,0000251 –19–11OCT06–1/1 Engine Owner John Deere Engine Owner: Don’t wait until you need warranty or other service to meet your local John Deere Engine Distributor or Service Dealer. To register your engine for warranty via the Internet, use the following URL: http://www.
Introduction RG,RG34710,5501 –19–04JAN02–1/1 P OWER T ECH 4.5 L Engines With Mechanical Controls (Tier 1 Emission Certified) RG7999 –UN–19JUN00 4045D Engine RG7998 –UN–19JUN00 4045D .
Introduction RG,RG34710,5503 –19–04JAN02–1/1 P OWER T ECH 6.8 L Engines With Mechanical Controls (Tier 1 Emission Certified) RG8003 –UN–19JUN00 6068D Engine RG8002 –UN–19JUN00 6068D .
Contents Page Page Record Keeping Instrument (Gauge) Panel (North America) ..... 15-2 PowerTech Medallion ..................... 01-1 VDO Instrument (Gauge) Panel (Except Engine Serial Number Plate ................ 01-1 North America) .................
Contents Page Page Replacing Fuel Filter Elements (Dual Filters) . . . 35-5 Specifications General OEM Engine Specifications—4.5 L Checking Belt Tensioner Spring Tension and Belt Wear (Automatic Tensioner) ....... 35-6 Engines ......................
Record Keeping RG,RG34710,5505 –19–04JAN02–1/1 P OWER T ECH Medallion RG11608 –UN–17OCT01 RG11609 –UN–17OCT01 A medallion is located on the rocker arm cover which identifies each engine as a John Deere P OWER T ECH engine. P OWER T ECH is a trademark of Deere & Company.
Record Keeping RG,RG34710,5507 –19–04JAN02–1/1 Record Engine Serial Number RG7936 –UN–13NOV97 Dubuque Engine Serial Number Plate RG7935 –UN–13NOV97 Saran Engine Serial Number Plate RG906.
Record Keeping OURGP11,0000005 –19–24JUN04–1/2 Engine Option Codes RG10603A –UN–15JUN00 Engine Option Codes A—Engine Base Code In addition to the serial number plate, OEM engines have an engine option code label affixed to the rocker arm cover.
Record Keeping OURGP11,0000005 –19–24JUN04–2/2 NOTE: Your engine option code label may not contain all option codes if an option has been added after the engine left the producing factory. If option code label is lost or destroyed, consult your servicing dealer or engine distributor selling the engine for a replacement.
Record Keeping RG,RG34710,5511 –19–20MAY96–1/1 Record Fuel Injection Pump Model Number RG8008A –UN–13JUN00 Record Injection Pump Serial Number A—Serial Number Plate Record the fuel injection pump model and serial information found on the serial number plate (A).
Safety DX,ALERT –19–29SEP98–1/1 Recognize Safety Information T81389 –UN–07DEC88 This is a safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. Follow recommended precautions and safe operating practices.
Safety DX,SIGNS1 –19–04JUN90–1/1 Replace Safety Signs TS201 –UN–23AUG88 Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement. DX,BYPAS1 –19–29SEP98–1/1 Prevent Machine Runaway TS177 –UN–11JAN89 Avoid possible injury or death from machinery runaway.
Safety DX,FIRE2 –19–03MAR93–1/1 Prepare for Emergencies TS291 –UN–23AUG88 Be prepared if a fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.
Safety DX,LOOSE –19–04JUN90–1/1 Service Machines Safely TS228 –UN–23AUG88 Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result.
Safety DX,MSDS,NA –19–03MAR93–1/1 Handle Chemical Products Safely TS1132 –UN–26NOV90 Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere equipment include such items as lubricants, coolants, paints, and adhesives.
Safety DX,SERV –19–17FEB99–1/1 Practice Safe Maintenance TS218 –UN–23AUG88 Understand service procedure before doing work. Keep area clean and dry. Never lubricate, service, or adjust machine while it is moving. Keep hands, feet , and clothing from power-driven parts.
Safety DX,FLUID –19–03MAR93–1/1 Avoid High-Pressure Fluids X9811 –UN–23AUG88 Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.
Safety DX,PAINT –19–24JUL02–1/1 Remove Paint Before Welding or Heating TS220 –UN–23AUG88 Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. Remove paint before heating: • Remove paint a minimum of 100 mm (4 in.
Safety OUOD006,000009D –19–11OCT06–1/1 Install Fan Guards TS677 –UN–21SEP89 Rotating Fan Rotating cooling system fans can cause serious injury.
Safety DX,DUST –19–15MAR91–1/1 Avoid Harmful Asbestos Dust TS220 –UN–23AUG88 Avoid breathing dust that may be generated when handling components containing asbestos fibers.
Safety DPSG,OUO1004,2758 –19–11OCT06–1/1 Handling Batteries Safely TS204 –UN–23AUG88 Explosion TS203 –UN–23AUG88 Acid CAUTION: Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check battery electrolyte level.
Safety DX,SPRAY –19–16APR92–1/1 Protect Against High Pressure Spray TS1343 –UN–18MAR92 Spray from high pressure nozzles can penetrate the skin and cause serious injury. Keep spray from contacting hands or body. If an accident occurs, see a doctor immediately.
Safety DX,DRAIN –19–03MAR93–1/1 Dispose of Waste Properly TS1133 –UN–26NOV90 Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with John Deere equipment include such items as oil, fuel, coolant, brake fluid, filters, and batteries.
Fuels, Lubricants, and Coolant DX,FUEL1 –19–17NOV05–1/1 Diesel Fuel Consult your local fuel distributor for properties of the diesel fuel available in your area. In general, diesel fuels are blended to satisfy the low temperature requirements of the geographical area in which they are marketed.
Fuels, Lubricants, and Coolant DX,FUEL4 –19–19DEC03–1/1 Handling and Storing Diesel Fuel CAUTION: Handle fuel carefully. Do not fill the fuel tank when engine is running.
Fuels, Lubricants, and Coolant DX,FUEL7 –19–14NOV05–1/1 Bio-Diesel Fuel Consult your local fuel distributor for properties of the bio-diesel fuel available in your area. Bio-diesel fuels may be used ONLY if the bio-diesel fuel properties meet the latest edition of ASTM D6751, EN 14214, or equivalent specification.
Fuels, Lubricants, and Coolant OURGP12,000003F –19–07JUL04–1/1 Aviation (Jet) Fuels Aviation (jet) fuels may be used with the following restrictions. Type Comments Jet A Lower viscosity and density than base No. 2-D diesel fuel. Power loss up to 10% can be expected.
Fuels, Lubricants, and Coolant DX,FUEL10 –19–16DEC05–1/2 Minimizing the Effect of Cold Weather on Diesel Engines John Deere diesel engines are designed to operate effectively in cold weather. However, for effective starting and cold weather operation, a little extra care is necessary.
Fuels, Lubricants, and Coolant DX,FUEL10 –19–16DEC05–2/2 If winterfronts are used, they should never totally close off the grill frontal area. Approximately 25% area in the center of the grill should remain open at all times. At no time should the air blockage device be applied directly to the radiator core.
Fuels, Lubricants, and Coolant DX,ENOIL –19–13SEP06–1/2 Diesel Engine Oil TS1681 –UN–09OCT06 Oil Viscosities for Air Temperature Ranges Use oil viscosity based on the expected air temperature range during the period between oil changes. John Deere PLUS-50 oil is preferred.
Fuels, Lubricants, and Coolant DX,ENOIL –19–13SEP06–2/2 DO NOT use diesel fuel with sulfur content greater than 1.00% (10 000 ppm). DX,ENOIL6 –19–13SEP06–1/1 Extended Diesel Engine Oil Ser.
Fuels, Lubricants, and Coolant DX,OILSCAN –19–02DEC02–1/1 OILSCAN and COOLSCAN T6828AB –UN–15JUN89 T6829AB –UN–18OCT88 OILSCAN and COOLSCAN are John Deere sampling programs to help you monitor machine performance and identify potential problems before they cause serious damage.
Fuels, Lubricants, and Coolant DX,LUBST –19–18MAR96–1/1 Lubricant Storage Your equipment can operate at top efficiency only when clean lubricants are used. Use clean containers to handle all lubricants. Whenever possible, store lubricants and containers in an area protected from dust, moisture, and other contamination.
Fuels, Lubricants, and Coolant DX,GREA1 –19–07NOV03–1/1 Grease TS1673 –UN–31OCT03 Use grease based on NLGI consistency numbers and the expected air temperature range during the service interval.
Fuels, Lubricants, and Coolant DX,COOL3 –19–27OCT05–1/2 Diesel Engine Coolant The engine cooling system is filled to provide year-round protection against corrosion and cylinder liner pitting, and winter freeze protection to -37 ° C (-34 ° F).
Fuels, Lubricants, and Coolant DX,COOL3 –19–27OCT05–2/2 Water quality is important to the performance of the cooling system. Distilled, deionized, or demineralized water is recommended for mixing with ethylene glycol and propylene glycol base engine coolant concentrate.
Fuels, Lubricants, and Coolant DX,COOL7 –19–19DEC03–1/2 Additional Information About Diesel Engine Coolants and Supplemental Coolant Additives Engine coolants are a combination of three chemical components: ethylene glycol or propylene glycol antifreeze, inhibiting coolant additives, and quality water.
Fuels, Lubricants, and Coolant DX,COOL7 –19–19DEC03–2/2 Ethylene Glycol Freeze Protection Limit 40% -24 ° C (-12 ° F) 50% -37 ° C (-34 ° F) 60% -52 ° C (-62 ° F) Propylene Glycol Freeze Pr.
Fuels, Lubricants, and Coolant DX,COOL7 –19–19DEC03–1/2 Additional Information About Diesel Engine Coolants and Supplemental Coolant Additives Engine coolants are a combination of three chemical components: ethylene glycol or propylene glycol antifreeze, inhibiting coolant additives, and quality water.
Fuels, Lubricants, and Coolant DX,COOL7 –19–19DEC03–2/2 Ethylene Glycol Freeze Protection Limit 40% -24 ° C (-12 ° F) 50% -37 ° C (-34 ° F) 60% -52 ° C (-62 ° F) Propylene Glycol Freeze Pr.
Fuels, Lubricants, and Coolant DX,COOL6 –19–18MAR96–1/1 Operating in Warm Temperature Climates John Deere engines are designed to operate using glycol base engine coolants. Always use a recommended glycol base engine coolant, even when operating in geographical areas where freeze protection is not required.
Engine Operating Guidelines DPSG,RG34710,107 –19–10JAN02–1/1 Instrument (Gauge) Panels RG11299 –UN–12SEP00 North American Instrument Panel RG10606A –UN–19JUN00 VDO Instrument Panel (Except North America) All controls and gauges are optional equipment for John Deere OEM Engines.
Engine Operating Guidelines DPSG,RG34710,108 –19–08JAN02–1/2 Instrument (Gauge) Panel (North America) RG11299B –UN–17AUG00 North American Instrument Panel RG10607 –UN–19OCT99 Hour Meter .
Engine Operating Guidelines DPSG,RG34710,108 –19–08JAN02–2/2 The reset button has to be held in when starting the engine. The button allows the safety switch to override the shut-down circuits until safe engine oil pressure is maintained.
Engine Operating Guidelines DPSG,RG34710,109 –19–08JAN02–1/2 VDO Instrument (Gauge) Panel (Except North America) RG10606B –UN–20OCT99 VDO Instrument Panel A—Oil Pressure Gauge B—Coolant .
Engine Operating Guidelines DPSG,RG34710,109 –19–08JAN02–2/2 G—Battery Light - The battery light illuminates when the key is turned to the bulb test position (position I).
Engine Operating Guidelines OURGP12,0000076 –19–09SEP04–1/4 Engine Break-In Service RG8009 –UN–06JAN99 Check Engine Oil The engine is ready for normal operation. However, extra care during the first 250 hours of operation will result in more satisfactory long-term engine performance and life.
Engine Operating Guidelines OURGP12,0000076 –19–09SEP04–2/4 RG8028A –UN–15JAN99 Crosshatch Pattern On Oil Dipstick A—Crosshatch Pattern On Oil Dipstick IMPORTANT: DO NOT add makeup oil until the oil level is BELOW the ADD mark on dipstick.
Engine Operating Guidelines OURGP12,0000076 –19–09SEP04–3/4 RG7961B –UN–22JAN99 Changing Oil And Oil Filter Before First 250 Hours 4. During the first 20 hours, avoid prolonged periods of engine idling or sustained maximum load operation. If engine will idle longer than 5 minutes, stop engine.
Engine Operating Guidelines RG,RG34710,5555 –19–27JUL06–1/1 Auxiliary Gear Drive Limitations RG7634A –UN–22JAN99 Auxiliary Gear Drive A—Auxiliary Gear Drive IMPORTANT: When attaching an ai.
Engine Operating Guidelines RG,RG34710,5557 –19–07JAN02–1/2 Starting the Engine TS220 –UN–23AUG88 Use Proper Ventilation The following instructions apply to the optional controls and instruments available through the John Deere Parts Distribution Network.
Engine Operating Guidelines RG,RG34710,5557 –19–07JAN02–2/2 RG11299X –UN–18OCT01 North American Standard Instrument Panel (1999— ) Shown RG11610 –UN–17OCT01 VDO Standard Instrument Pan.
Engine Operating Guidelines RG,RG34710,5560 –19–08JAN02–1/1 Warming Engine RG11612 –UN–17OCT01 Standard North American Instrument Panel RG10613 –UN–21OCT99 Standard VDO Instrument Panel .
Engine Operating Guidelines RG,RG34710,5552 –19–20MAY96–1/1 Normal Engine Operation Observe engine coolant temperature and engine oil pressure. Temperatures and pressures will vary between engines and with changing operating conditions, temperatures, and loads.
Engine Operating Guidelines RG,RG34710,5050 –19–08JAN02–1/1 Cold Weather Operation TS1356 –UN–18MAR92 Handle Starting Fluid with Care RG11521 –19–10JAN01 Cold Weather Starting Guidelines CAUTION: Ether injector starting fluid is highly flammable.
Engine Operating Guidelines RG,RG34710,5561 –19–07JAN02–1/1 Changing Engine Speed RG11299I –UN–11SEP00 North American Standard Instrument Panel Shown A—Throttle Handle To increase engine speed, turn throttle handle (A), if equipped, to the horizontal position and pull out until desired engine speed is obtained.
Engine Operating Guidelines RG,RG34710,5563 –19–07JAN02–1/1 Stopping the Engine RG11299J –UN–11SEP00 North American Standard Instrument Panel Shown RG10616 –UN–16JUN00 Exhaust Stack Rain Cap A—Throttle B—Key Switch 1. Disengage clutch (if equipped) controlling engine drivelines.
Engine Operating Guidelines RG,RG34710,5564 –19–27JUL06–1/2 Using a Booster Battery or Charger TS204 –UN–23AUG88 Exploding Battery RG4678 –UN–14DEC88 12-Volt System RG4698 –UN–14DEC8.
Engine Operating Guidelines RG,RG34710,5564 –19–27JUL06–2/2 6. Start the engine. Disconnect jumper cables immediately after engine starts. Disconnect NEGATIVE (–) cable first.
Lubrication and Maintenance DPSG,OUOE003,20 –19–07JAN02–1/1 Observe Service Intervals RG11299A –UN–17AUG00 North American Instrument Panel Hour Meter Shown A—Hour Meter Using hour meter (A) as guide, perform all services at the hourly intervals indicated on following pages.
Lubrication and Maintenance OURGP11,0000006 –19–13OCT06–1/2 Lubrication and Maintenance Service Interval Chart—Standard Industrial Engines NOTE: The service intervals below are for standard industrial engines. See details in Sections which follow these charts.
Lubrication and Maintenance OURGP11,0000006 –19–13OCT06–2/2 Lubrication and Maintenance Service Intervals 250 Hour/ 500 Hour/ 2000 Hour/ Item Daily 6 Month 12 Month 24 Month As Required Check Ai.
Lubrication and Maintenance OURGP11,0000007 –19–31OCT06–1/2 Lubrication and Maintenance Service Interval Chart—Generator (Standby) Applications NOTE: Use service intervals listed below for generator (standby) applications. Match service items below to titles in Lubrication and Maintenance Sections for procedures.
Lubrication and Maintenance OURGP11,0000007 –19–31OCT06–2/2 Lubrication and Maintenance Service Intervals Every 2 250 Hours or 500 Hours or 2000 Hours Item Weeks 12 Months 12 Months or 24 Months.
Lubrication & Maintenance/Daily OURGP12,0000048 –19–13OCT06–1/4 Daily Prestarting Checks RG8009A –UN–16JUN00 Left Side Oil Filler Cap RG8054A –UN–16JUN00 Right Side Oil Filler Cap RG.
Lubrication & Maintenance/Daily OURGP12,0000048 –19–13OCT06–2/4 TS281 –UN–23AUG88 High-Pressure Fluids RG4675 –UN–14DEC88 Fill Radiator A—Fill Radiator CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns.
Lubrication & Maintenance/Daily OURGP12,0000048 –19–13OCT06–3/4 RG13542 –UN–20JUL04 Drain Fuel Filters (Dual Filters Shown) RG7317A –UN–16JUN00 Priming At Fuel Supply Pump A—Air Bleed Plugs B—Drain Plugs C—Fuel Supply Pump Primer Lever 3.
Lubrication & Maintenance/Daily OURGP12,0000048 –19–13OCT06–4/4 RG7332A –UN–22JAN99 Dust Unloader Valve and Indicator Gauge A—Dust Unloader Valve B—Air Restriction Indicator 4. If the air cleaner has an automatic dust unloader valve (A), squeeze the unloader valve on air cleaner assembly to clear away any dust buildup.
Lubrication & Maintenance/250 Hour/6 Month RG,RG34710,5567 –19–20MAY96–1/1 Servicing Fire Extinguisher RW4918 –UN–15DEC88 Fire Extinguisher A—Fire Extinguisher A fire extinguisher (A) is available from your authorized servicing dealer or engine distributor.
Lubrication & Maintenance/250 Hour/6 Month OURGP12,0000078 –19–31OCT06–1/3 Changing Engine Oil and Replacing Filter RG11616 –UN–24OCT01 Oil Filter RG4881 –UN–29NOV88 Oil Pan Drain Pl.
Lubrication & Maintenance/250 Hour/6 Month OURGP12,0000078 –19–31OCT06–2/3 RG7961A –UN–22JAN99 Removing Oil Filter Element A—Oil Filter Element 4. Turn filter element (A) counterclockwise using a suitable filter wrench to remove. Discard oil filter element.
Lubrication & Maintenance/250 Hour/6 Month OURGP12,0000078 –19–31OCT06–3/3 RG8025A –UN–19JUN00 Rocker Arm Cover Oil Filler RG8054B –UN–19JUN00 Side Oil Filler B—Rocker Arm Cover Oil Filler C—Side Oil Filler 9.
Lubrication & Maintenance/250 Hour/6 Month RG,RG34710,5568 –19–27JUL06–1/2 Servicing Battery TS204 –UN–23AUG88 Exploding Battery CAUTION: Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check battery electrolyte level.
Lubrication & Maintenance/250 Hour/6 Month RG,RG34710,5568 –19–27JUL06–2/2 TS203 –UN–23AUG88 Sulfuric Acid CAUTION: Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.
Lubrication & Maintenance/250 Hour/6 Month OURGP11,0000008 –19–24JUN04–1/1 Manual Belt Tensioner Adjustment RG10556 –UN–21DEC99 Check Belt Tension RG10557 –UN–21DEC99 Adjust Belt Tension A—Belt Tension Gauge B—Cap Screw C—Cap Screw D—Tensioner Bracket NOTE: Two types of manual tensioners shown.
Lubrication & Maintenance/250 Hour/6 Month OURGP11,0000009 –19–24JUN04–1/2 Manual Belt Tensioner Adjustment Using Belt Tension Tool (Alternate Method For Engines Without Auxiliary Drive) RG1.
Lubrication & Maintenance/250 Hour/6 Month OURGP11,0000009 –19–24JUN04–2/2 RG11814 –UN–31OCT01 Belt Tension Tool and Torque Wrench RG11815 –UN–31OCT01 Scribe Reference Mark A—Alternator B—Belt Tensioning Tool C—Torque Wrench D—Reference Mark E—Alternator Upper Bracket Notch 3.
Lubrication & Maintenance/500 Hour/12 Month RG,RG34710,5574 –19–08JAN02–1/1 Cleaning Crankcase Vent Tube RG8017A –UN–19JUN00 Crankcase Vent Tube A—Crankcase Vent Tube If you operate the engine in dusty conditions, clean the tube at shorter intervals.
Lubrication & Maintenance/500 Hour/12 Month RG,RG34710,5575 –19–07JAN02–1/1 Checking Air Intake System RG4689 –UN–20DEC88 Check Clamps RG7332B –UN–22JAN99 Unloader Valve and Air Restriction Indicator A—Clamps B—Dust Unloader Valve C—Air Restriction Indicator IMPORTANT: The air intake system must not leak.
Lubrication & Maintenance/500 Hour/12 Month OURGP11,000000A –19–24JUN04–1/2 Replacing Fuel Filter Element (Single Filter) X9811 –UN–23AUG88 High-Pressure Fluids RG7721 –UN–15JAN99 Fu.
Lubrication & Maintenance/500 Hour/12 Month OURGP11,000000A –19–24JUN04–2/2 7. Align keys on filter element with slots in filter base. 8. Install retaining ring onto mounting base making certain dust seal is in place on filter base. Hand tighten ring (about 1/3 turn) until it “snaps” into the detent.
Lubrication & Maintenance/500 Hour/12 Month OURGP12,000004B –19–13OCT06–1/2 Replacing Fuel Filter Elements (Dual Filters) X9811 –UN–23AUG88 High-Pressure Fluids RG13543 –UN–21JUL04 D.
Lubrication & Maintenance/500 Hour/12 Month OURGP12,000004B –19–13OCT06–2/2 NOTE: Raised locators on fuel filter canister must be indexed properly with slots in mounting base for correct installation. 7. Install new filter element onto mounting base.
Lubrication & Maintenance/500 Hour/12 Month OURGP12,000004A –19–28JUL04–2/3 RG8098 –UN–18NOV97 Cast Stops A—Cast Stops B—Cast Stop Checking Belt Wear The belt tensioner is designed to operate within the limit of arm movement provided by the cast stops (A and B) when correct belt length and geometry is used.
Lubrication & Maintenance/500 Hour/12 Month OURGP12,000004A –19–28JUL04–3/3 RG7977 –UN–14NOV97 Marks on Tensioner RG12054 –UN–08JAN02 Align Marks RG12065 –UN–28JAN02 Align Torque.
Lubrication & Maintenance/500 Hour/12 Month OURGP11,000000B –19–24JUN04–1/1 Checking Engine Speeds RG11299A –UN–17AUG00 Check Engine Speed On Tachometer A—Tachometer Observe tachometer (A) reading on the instrument panel to verify engine speeds while running engine.
Lubrication & Maintenance/500 Hour/12 Month RG,RG34710,5580 –19–20MAY96–1/1 Checking Cooling System TS281 –UN–23AUG88 High-Pressure Fluids CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off engine.
Lubrication & Maintenance/500 Hour/12 Month DPSG,OUOD002,1921 –19–07JAN02–1/2 Replenishing Supplemental Coolant Additives (SCAs) Between Coolant Changes RG6261 –UN–08DEC97 Radiator Coola.
Lubrication & Maintenance/500 Hour/12 Month DPSG,OUOD002,1921 –19–07JAN02–2/2 IMPORTANT: ALWAYS maintain coolant at correct level and concentration.
Lubrication & Maintenance/500 Hour/12 Month RG,RG34710,5586 –19–07JAN02–1/1 Pressure Testing Cooling System RG6557 –UN–20JAN93 Test Radiator Cap RG6558 –UN–20JAN93 Test Cooling System CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns.
Lubrication & Maint./2000 Hour/24 Month RG,RG34710,5583 –19–28JAN02–1/3 Adjusting Variable Speed (Droop) on Generator Set Engines RG12066 –UN–29JAN02 Droop Adjustment Screw A—Adjustment Screw B—Fast Idle Adjustment C—Slow Idle Adjustment Stanadyne Mechanical Injection Pumps Only 1.
Lubrication & Maint./2000 Hour/24 Month RG,RG34710,5583 –19–28JAN02–2/3 RG5752 –UN–03NOV97 DENSO In-Line Injection Pump A—Fast Idle (Stop) Screw B—Droop Adjusting Screw Access Plug L.
Lubrication & Maint./2000 Hour/24 Month RG,RG34710,5583 –19–28JAN02–3/3 Delphi (Lucas) Injection Pumps Only See your authorized Delphi (Lucas) Repair Station for speed droop adjustment. This service requires that an internal pump adjustment be made.
Lubrication & Maint./2000 Hour/24 Month OURGP11,000000C –19–24JUN04–1/3 Flushing and Refilling Cooling System TS281 –UN–23AUG88 High-Pressure Fluids RG12833 –UN–13FEB03 Radiator Cap CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns.
Lubrication & Maint./2000 Hour/24 Month OURGP11,000000C –19–24JUN04–2/3 RG8019A –UN–19JUN00 Engine Block Drain Valve A—Engine Block Drain Valve B—Engine Block Drain Plug C—Engine Block Drain Plug 3. Open engine block drain valve (A) on left side of engine.
Lubrication & Maint./2000 Hour/24 Month OURGP11,000000C –19–24JUN04–3/3 11. After cleaning the cooling system, drain cleaner and fill with water to flush the system. Run the engine about 10 minutes, remove radiator cap and pull off lower radiator hose to drain out flushing water.
Lubrication & Maint./2000 Hour/24 Month DPSG,RG34710,112 –19–07JAN02–1/5 Testing Thermostats Opening Temperature TS281 –UN–23AUG88 High Pressure Fluids RG8115A –UN–15JAN98 Thermostat.
Lubrication & Maint./2000 Hour/24 Month DPSG,RG34710,112 –19–07JAN02–3/5 RG5971 –UN–23NOV97 Testing Thermostat Opening Temperature Testing Thermostats Opening Temperature 1. Remove thermostat(s). 2. Visually inspect thermostat(s) for corrosion or damage.
Lubrication & Maint./2000 Hour/24 Month DPSG,RG34710,112 –19–07JAN02–4/5 RG7614A –UN–06NOV97 Installing Thermostat Cover RG7921B –UN–13NOV97 Thermostat Cover Seal A—Guide Studs B.
Lubrication & Maint./2000 Hour/24 Month DPSG,RG41165,137 –19–16JAN02–1/5 Check and Adjust Valve Clearance RG7408 –UN–06AUG96 Flywheel Housing Timing Holes A—Timing/Rotation Hole B—Timing Pin Hole CAUTION: To prevent accidental starting of engine while performing valve adjustments, always disconnect NEGATIVE (—) battery terminal.
Lubrication & Maint./2000 Hour/24 Month DPSG,RG41165,137 –19–16JAN02–2/5 4. With engine lock-pinned at TDC of No. 1 piston’s compression stroke, check valve clearance to following specifications. (Use sequence for 4-cylinder or 6-cylinder engines as outlined on next page.
Lubrication & Maint./2000 Hour/24 Month DPSG,RG41165,137 –19–16JAN02–4/5 RG4776 –UN–31OCT97 4-Cylinder Engine Valve Adjustment A—Front of Engine B—No. 1 Piston TDC Compression C—No. 4 Piston TDC Compression E—Exhaust Valve I—Intake Valve 4-Cylinder Engine: NOTE: Firing order is 1-3-4-2.
Service as Required RG,RG34710,5591 –19–20MAY96–1/1 Additional Service Information RG4624 –UN–15DEC88 Component Technical Manual This is not a detailed service manual. If you want more detailed service information, use the form in the back of this manual to order a component technical manual.
Service as Required OURGP12,0000049 –19–22JUL04–1/1 Adding Coolant TS281 –UN–23AUG88 High-Pressure Fluids RG12833 –UN–13FEB03 Radiator Filler Cap A—Radiator Filler Cap CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns.
Service as Required RG,RG34710,5594 –19–07JAN02–1/1 Replacing Single Stage Air Cleaner RG11319A –UN–06SEP00 Single Stage Air Filter RG11320 –UN–07SEP00 Installation of Single Stage Air C.
Service as Required RG41165,000008A –19–12NOV01–1/2 Replacing Axial Seal Air Cleaner Filter Element RG4686 –UN–20DEC88 Wing Nut and Primary Element RG4687 –UN–20DEC88 Dust Unloader Valve.
Service as Required RG41165,000008A –19–12NOV01–2/2 IMPORTANT: Whenever the air cleaner has been serviced or had cover removed, ALWAYS fully depress the air restriction indicator reset button (if equipped) to assure accurate readings. 6. If equipped, fully depress air restriction indicator reset button and release to reset indicator.
Service as Required RG41165,000008B –19–27JUL06–1/2 Replacing Radial Seal Air Cleaner Filter Element RG11321A –UN–08SEP00 Dust Cup/Cover RG11322A –UN–08SEP00 Primary Filter Element RG113.
Service as Required RG41165,000008B –19–27JUL06–2/2 IMPORTANT: Whenever the air cleaner has been serviced or cover has been removed, ALWAYS fully depress the air restriction indicator reset button (if equipped) to assure accurate readings. 8. If equipped, fully depress air restriction indicator reset button and release to reset indicator.
Service as Required OURGP12,000004C –19–29JUL04–1/1 Replacing Fan and Alternator Belts RG11950 –UN–07NOV01 290 mm (11.4 in.) Fan Height and Lower* RG11951 –UN–07NOV01 338 mm (13.3 in.) Fan Height and Higher Without Freon Compressor* RG11952 –UN–07NOV01 402 mm (15.
Service as Required RG,RG34710,5601 –19–07JAN02–1/1 Checking Fuses In Instrument Panels RG4493 –UN–14DEC88 North American ( —1998) Standard Instrument Panel Shown RG4496A –UN–01JUN01 N.
Service as Required OURGP12,00001E0 –19–26FEB03–1/1 Checking Air Compressor (If Equipped) RG12836 –UN–27FEB03 Air Compressor (Optional) Air compressors are offered as options with John Deere OEM engines to provide compressed air to operate air-powered devices like vehicle air brakes.
Service as Required OURGP11,000000D –19–18OCT06–1/7 Bleeding the Fuel System X9811 –UN–23AUG88 High-Pressure Fluids CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting fuel or other lines.
Service as Required OURGP11,000000D –19–18OCT06–2/7 RG13544 –UN–29JUL04 Air Bleed Vent Screws (Final Filter at Left, Primary Filter with Separator Bowl at Right) A—Air Bleed Vent Screws IMPORTANT: Do not operate the engine at high speeds or full loads just before bleeding the fuel system as this may cause fuel injection pump failure.
Service as Required OURGP11,000000D –19–18OCT06–4/7 RG6264 –UN–03NOV97 Stanadyne Rotary Fuel Injection Pump A—Fuel Return Line Connector At Fuel Injection Pump On Stanadyne rotary pumps: 1. Slightly loosen fuel return line connector (A) at fuel injection pump.
Service as Required OURGP11,000000D –19–18OCT06–6/7 RG8069 –UN–23NOV97 DENSO Fuel Injection Pump Shown On DENSO and Motorpal in-line pumps: 1. On DENSO pump shown, unscrew hand primer on fuel supply pump until it can be pulled by hand. 2. Open fuel filter port plug.
Troubleshooting RG,RG34710,5605 –19–07JAN02–1/1 General Troubleshooting Information Troubleshooting engine problems can be difficult. An engine wiring diagram is provided in this section to help isolate electrical problems on power units using John Deere wiring harness and instrument (gauge) panel.
Troubleshooting 50-2 110306 PN=121.
Troubleshooting DPSG,RG41165,126 –19–19JUN00–1/1 Engine Wiring Diagram Legend (Standard Instrument Panel For North America) A1 — Speed Control Unit B1 — Magnetic Speed Sensor B2 — Coolant .
Troubleshooting DPSG,RG41165,127 –19–19JUN00–1/1 Wiring Diagram (Standard Instrument Panel For North America) RG11329 –UN–13SEP00 50-4 110306 PN=123.
Troubleshooting DPSG,RG41165,131 –19–19JUN00–1/1 Engine Wiring Diagram—VDO Instrument Panel (Except North America) CD623P5 –UN–13NOV98 50-5 110306 PN=124.
Troubleshooting DPSG,RG41165,129 –19–19JUN00–1/1 Engine Wiring Diagram Legend—VDO Instrument Panel (Except North America) A —6 m m 2 , Red B — 1.5 mm 2 , Black C —6 m m 2 , Blue D —4 m m 2 , Black E — 0.75 mm 2 , Orange F — 0.75 mm 2 , White G — 0.
Troubleshooting OUOD006,000004C –19–13OCT06–1/7 Engine Troubleshooting Symptom Problem Solution Engine cranks but will not start Incorrect starting procedure. Verify correct starting procedure. No fuel. Check fuel in tank and manual shut-off valve.
Troubleshooting OUOD006,000004C –19–13OCT06–2/7 Symptom Problem Solution Engine knocks Low engine oil level. Add oil to engine crankcase. Injection pump out of time. See your authorized servicing dealer or engine distributor. Low coolant temperature.
Troubleshooting OUOD006,000004C –19–13OCT06–3/7 Symptom Problem Solution Lack of power Engine overloaded. Reduce load. Intake air restriction. Service air cleaner. Clogged fuel filter. Replace filter elements. Improper type of fuel. Use proper fuel.
Troubleshooting OUOD006,000004C –19–13OCT06–4/7 Symptom Problem Solution High oil consumption Crankcase oil too light. Use proper viscosity oil. Oil leaks. Check for leaks in lines, gaskets, and drain plug. Restricted crankcase vent tube. Clean vent tube.
Troubleshooting OUOD006,000004C –19–13OCT06–5/7 Symptom Problem Solution Engine overheats Engine overloaded. Reduce load. Low coolant level. Fill radiator to proper level, check radiator and hoses for loose connections or leaks. Faulty radiator cap.
Troubleshooting OUOD006,000004C –19–13OCT06–6/7 Symptom Problem Solution Undercharged electrical system Excessive electrical load from added Remove accessories or install higher accessories. output alternator. Excessive engine idling. Increase engine rpm when heavy electrical load is used.
Troubleshooting OUOD006,000004C –19–13OCT06–7/7 Symptom Problem Solution Starter and hour meter functions; Blown fuse on magnetic switch. Replace fuse. rest of electrical system does not function Entire electrical system does not Faulty battery connection.
Storage OURGP12,00000DF –19–11OCT06–1/1 Engine Storage Guidelines 1. John Deere engines can be stored outside for up to three (3) months with no long term preparation IF COVERED BY WATERPROOF COVERING. No outside storage is recommended without a waterproof covering.
Storage OURGP11,000006C –19–27JUL06–1/2 Preparing Engine for Long Term Storage The following storage preparations are used for long term engine storage up to one year. After that, the engine should be started, warmed up, and retreated for an extended storage period.
Storage OURGP11,000006C –19–27JUL06–2/2 15. Store the engine in a dry protected place. If engine must be stored outside, cover it with a waterproof canvas or other suitable protective material and use a strong waterproof tape.
Specifications OURGP12,0000041 –19–18OCT06–1/1 General OEM Engine Specifications—4.5 L Engines ITEM ENGINE 4045DF120 4045DF150 4045TF120 4045TF150 4045TF220 4045TF250 4045HF120 4045HF150 Number of Cylinders 4 4 4 4 4 4 4 4 Bore 106 mm 106 mm 106 mm 106 mm 106 mm 106 mm 106 mm 106 mm (4.
Specifications OURGP12,0000042 –19–07JUL04–1/1 General OEM Engine Specifications—6.8 L Engines ITEM ENGINE 6068DF150 6068TF120 6068TF150 6068TF220 6068TF250 6068HF120 6068HF150 6068HF250 Number of Cylinders 6 6 6 66666 Bore 106 mm 106 mm 106 mm 106 mm 106 mm 106 mm 106 mm 106 mm (4.
Specifications OURGP11,000001D –19–13OCT06–1/9 Engine Power Ratings And Fuel Injection Pump Specifications NOTE: The power specifications shown below apply to Dubuque, Torreon and Saran-built OEM engines. Specifications are subject to change. Refer to factory DTAC for assistance.
Specifications OURGP11,000001D –19–13OCT06–2/9 POWER RATINGS ON DYNAMOMETER FOR OEM ENGINES Injection Original Replaced Pump Injection By Injection Rated No Load Power Option Pump (Part Pump (Part Governor Speed (rpm) Slow Idle Fast Idle Rating Engine Model Code No.
Specifications OURGP11,000001D –19–13OCT06–3/9 POWER RATINGS ON DYNAMOMETER FOR OEM ENGINES Injection Original Replaced Pump Injection By Injection Rated No Load Power Option Pump (Part Pump (Part Governor Speed (rpm) Slow Idle Fast Idle Rating Engine Model Code No.
Specifications OURGP11,000001D –19–13OCT06–4/9 POWER RATINGS ON DYNAMOMETER FOR OEM ENGINES Injection Original Replaced Pump Injection By Injection Rated No Load Power Option Pump (Part Pump (Part Governor Speed (rpm) Slow Idle Fast Idle Rating Engine Model Code No.
Specifications OURGP11,000001D –19–13OCT06–5/9 POWER RATINGS ON DYNAMOMETER FOR OEM ENGINES Injection Original Replaced Pump Injection By Injection Rated No Load Power Option Pump (Part Pump (Part Governor Speed (rpm) Slow Idle Fast Idle Rating Engine Model Code No.
Specifications OURGP11,000001D –19–13OCT06–6/9 POWER RATINGS ON DYNAMOMETER FOR OEM ENGINES Injection Original Replaced Pump Injection By Injection Rated No Load Power Option Pump (Part Pump (Part Governor Speed (rpm) Slow Idle Fast Idle Rating Engine Model Code No.
Specifications OURGP11,000001D –19–13OCT06–7/9 POWER RATINGS ON DYNAMOMETER FOR OEM ENGINES Injection Original Replaced Pump Injection By Injection Rated No Load Power Option Pump (Part Pump (Part Governor Speed (rpm) Slow Idle Fast Idle Rating Engine Model Code No.
Specifications OURGP11,000001D –19–13OCT06–8/9 POWER RATINGS ON DYNAMOMETER FOR OEM ENGINES Injection Original Replaced Pump Injection By Injection Rated No Load Power Option Pump (Part Pump (Part Governor Speed (rpm) Slow Idle Fast Idle Rating Engine Model Code No.
Specifications OURGP11,000001D –19–13OCT06–9/9 POWER RATINGS ON DYNAMOMETER FOR OEM ENGINES Injection Original Replaced Pump Injection By Injection Rated No Load Power Option Pump (Part Pump (Part Governor Speed (rpm) Slow Idle Fast Idle Rating Engine Model Code No.
Specifications OURGP11,000001E –19–31OCT06–2/4 Engine Model Oil Pan Option Crankcase Oil Engine Model Oil Pan Option Crankcase Oil Code(s) Capacity L (qt) Code(s) Capacity L (qt) 4045DF120 1901 7.5 (8.0) 4045TF150 1903 12.0 (12.7) 1902 8.0 (8.5) 1904 13.
Specifications OURGP11,000001E –19–31OCT06–3/4 Engine Model Oil Pan Option Crankcase Oil Engine Model Oil Pan Option Crankcase Oil Code(s) Capacity L (qt) Code(s) Capacity L (qt) 1904 13.5 (14.3) 4045TF258 1949 12.5 (13.2) 1923 15.0 (15.8) 1949 12.
Specifications OURGP11,000001E –19–31OCT06–4/4 Engine Crankcase Oil Fill Quantities (Continued) Engine Model Oil Pan Option Crankcase Oil Engine Model Oil Pan Option Crankcase Oil Code(s) Capacity L (qt) Code(s) Capacity L (qt) 6068TF120 1907 19.
Specifications DX,TORQ1 –19–24APR03–1/1 Unified Inch Bolt and Screw Torque Values TS1671 –UN–01MAY03 Bolt or SAE Grade 1 SAE Grade 2 a SAE Grade 5, 5.
Specifications DX,TORQ2 –19–24APR03–1/1 Metric Bolt and Screw Torque Values 4.8 4.8 8.8 9.8 10.9 12.9 12.9 12.9 12.9 10.9 9.8 8.8 4.8 TS1670 –UN–01MAY03 Bolt or Class 4.
Lubrication and Maintenance Records RG,RG34710,5620 –19–27JUL06–1/1 Using Lubrication and Maintenance Records Refer to specific Lubrication and Maintenance Section for detailed service procedures. 1. Keep a record of the number of hours you operate your engine by regular observation of hour meter.
Lubrication and Maintenance Records OURGP12,0000043 –19–31OCT06–1/1 250 Hour/6 Month Service • Change engine oil and filter. 1 • Service fire extinguisher. • Check engine mounts. • Service battery. • Check automatic belt tensioner and belt wear.
Lubrication and Maintenance Records OURGP12,0000044 –19–07JUL04–1/1 500 Hour/12 Month Service • Clean crankcase vent tube. • Check air intake hoses, connections, and system. • Replace single or dual fuel filter elements. • Check automatic belt tensioner and belt wear.
Lubrication and Maintenance Records RG,RG34710,5625 –19–20MAY96–1/1 2000 Hour/24 Month Service • Check crankshaft vibration damper (6-cylinder only).
Lubrication and Maintenance Records OURGP12,0000045 –19–07JUL04–1/1 Service as Required • Add coolant • Service air cleaner. • Replace poly-vee belts.
Emission System Warranty OUOD006,000004E –19–01NOV06–1/1 U.S. EPA Emissions Control Warranty Statement Emissions control-related parts and components are warranted by John Deere for five years or 3000 hours of operation, whichever occurs first.
John Deere Service Literature Available DX,SERVLIT –19–31JUL03–1/2 Technical Information TS189 –UN–17JAN89 TS191 –UN–02DEC88 TS224 –UN–17JAN89 TS1663 –UN–10OCT97 Technical information can be purchased from John Deere. Some of this information is available in electronic media, such as CD-ROM disks, and in printed form.
John Deere Service Literature Available DX,SERVLIT –19–31JUL03–2/2 – Fundamentals of Machine Operation manuals explain machine capacities and adjustments, how to improve machine performance, and how to eliminate unnecessary field operations.
John Deere Service Literature Available 75-3 110306 PN=160.
Index Page Page A Check .............................. 35-10 Flush ................................ 40-4 Pressure test ......................... 35-13 Acid burns ............................. 30-5 Pressure test radiator cap ............... 35-13 Air cleaner Refill .
Index Page Page Fire extinguisher, service .................. 30-1 L Fuel Aviation .............................. 10-4 Lubricant Burner ............................... 10-4 Mixing ............................... 10-8 Diesel ...........................
Index Page Page Engine serial number ................... 01-1 Vibration damper ........................ 40-3 Injection pump model number ............. 01-5 W S Warming engine ........................ 15-12 Serial number Wiring diagram Engine .........
Index Index-4 110306 PN=4.
An important point after buying a device PowerTec OMRG25204 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought PowerTec OMRG25204 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data PowerTec OMRG25204 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, PowerTec OMRG25204 you will learn all the available features of the product, as well as information on its operation. The information that you get PowerTec OMRG25204 will certainly help you make a decision on the purchase.
If you already are a holder of PowerTec OMRG25204, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime PowerTec OMRG25204.
However, one of the most important roles played by the user manual is to help in solving problems with PowerTec OMRG25204. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device PowerTec OMRG25204 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
