John Deere PowerTech 4.5L 6.8L Non-Certified, Tier 1 Certified OEM Diesel Engine Operator Manual OMRG25204

Contents:
Record Keeping
PowerTech is a trademark of Deere & Company. Medallion
Engine Serial Number Plate
Record Engine Serial Number
Engine Option Codes
Record Fuel Injection Pump Model Number
Safety
Recognize Safety Information
Understand Signal Words
Follow Safety Instructions
Replace Safety Signs
California Proposition 65 Warning
Illuminate Work Area Safely
Work in Clean Area
Use Proper Tools
Live With Safety
Prevent Machine Runaway
Handle Fuel Safely-Avoid Fires
Prepare for Emergencies
Handle Starting Fluid Safely
In Case of Fire
Handle Fluids Safely-Avoid Fires
Avoid Static Electricity Risk When Refueling
Service Machines Safely
Wear Protective Clothing
Protect Against Noise
Handling Batteries Safely
Prevent Acid Burns
Stay Clear of Rotating Drivelines
Install All Guards
Practice Safe Maintenance
Remove Paint Before Welding or Heating
Avoid Heating Near Pressurized Fluid Lines
Avoid High-Pressure Fluids
Do Not Open High-Pressure Fuel System
Protect Against High Pressure Spray
Prevent Battery Explosions
Avoid Hot Exhaust
Work In Ventilated Area
Service Cooling System Safely
Decommissioning – Proper Recycling and Disposal of Fluids and Components
Fuels, Lubricants, and Coolant
Diesel Fuel
Supplemental Diesel Fuel Additives
Lubricity of Diesel Fuel
Handling and Storing Diesel Fuel
Biodiesel Fuel
Testing Diesel Fuel
Aviation (Jet) Fuels
Burner Fuels
Fuel Filters
Minimizing the Effect of Cold Weather on Diesel Engines
Diesel Engine Break-In Oil – Non-Emissions Certified and Certified Tier 1, Tier 2, Tier 3, Stage I, Stage II, and Stage III
Diesel Engine Oil – Non-Emissions Certified and Certified Tier 1 and Stage I
Extended Diesel Engine Oil Service Intervals – Non-Emissions Certified and Certified Tier 1 and Stage I
Mixing of Lubricants
Alternative and Synthetic Lubricants
Lubricant Storage
Oil Filters
Diesel Engine Coolant (engine with wet sleeve cylinder liners)
Water Quality for Mixing with Coolant Concentrate
Operating in Warm Temperature Climates
Testing Coolant Freeze Point
Disposing of Coolant
Engine Operating Guidelines
Instrument (Gauge) Panels
Instrument (Gauge) Panel (North America)
VDO Instrument (Gauge) Panel (Except North America)
Engine Break-In Service
Auxiliary Gear Drive Limitations
Generator Set (Standby) Applications
Starting the Engine
Warming Engine
Normal Engine Operation
Cold Weather Operation
Changing Engine Speed
Avoid Excessive Engine Idling
Stopping the Engine
Using a Booster Battery or Charger
Lubrication and Maintenance
Required Emission-Related Information
Observe Service Intervals
Use Correct Fuels, Lubricants, and Coolant
Lubrication and Maintenance Service Interval Chart
Lubrication & Maintenance – Daily
Daily Prestarting Checks
Lubrication & Maintenance – 250 Hours/6 Months
Servicing Fire Extinguisher
Changing Engine Oil and Replacing Filter
Checking Engine Mounts
Servicing Battery
Manual Belt Tensioner Adjustment
Manual Belt Tensioner Adjustment Using Belt Tension Tool (Alternate Method For Engine Without Auxiliary Drive)
Lubrication & Maintenance – 500 Hours/12 Months
Cleaning Crankcase Vent Tube
Checking Air Intake System
Replacing Fuel Filter Element (Single Filter)
Replacing Fuel Filter Elements (Dual Filters)
Checking Belt Tensioner Spring Tension and Belt Wear (Automatic Tensioner)
Checking Engine Speeds
Checking Engine Electrical Ground Connections
Checking Cooling System
Replenishing Supplemental Coolant Additives (SCAs) Between Coolant Changes
Testing Diesel Engine Coolant
Pressure Testing Cooling System
Lubrication & Maintenance – 2000 Hours/24 Months
Adjusting Variable Speed (Droop) on Generator Set Engines
Checking Crankshaft Vibration Damper (6-Cylinder Engine Only)
Flushing and Refilling Cooling System
Testing Thermostats Opening Temperature
Check and Adjust Valve Clearance
Service as Required
Additional Service Information
Do Not Modify Fuel System
Adding Coolant
Pre-Start Cleaning Guide
Replacing Single Stage Air Cleaner
Replacing Axial Seal Air Cleaner Filter Element
Replacing Radial Seal Air Cleaner Filter Element
Replacing Fan and Alternator Belts
Checking Fuses In Instrument Panels
Checking Air Compressor (If Equipped)
Bleeding the Fuel System
Troubleshooting
General Troubleshooting Information
Engine Wiring Diagram Legend (Standard Instrument Panel For North America)
Wiring Diagram (Standard Instrument Panel For North America)
Engine Wiring Diagram-VDO Instrument Panel (Except North America)
Engine Wiring Diagram Legend-VDO Instrument Panel (Except North America)
Engine Troubleshooting
Storage
Engine Storage Guidelines
Preparing Engine for Long-Term Storage
Removing Engine from Long Term Storage
Specifications
General OEM Engine Specifications – 4.5 L Engines
General OEM Engine Specifications – 6.8 L Engines
Engine Power Ratings And Fuel Injection Pump Specifications – 4.5 L Engines
Engine Power Ratings And Fuel Injection Pump Specifications – 6.8 L Engines
Engine Power Ratings And Fuel Injection Pump Specifications
Engine Crankcase Oil Fill Quantities
Unified Inch Bolt and Screw Torque Values
Metric Bolt and Screw Torque Values
Lubrication and Maintenance Records
Using Lubrication and Maintenance Records
Daily (Prestarting) Service
250 Hour/6 Month Service
500 Hour/12 Month Service
2000 Hour/24 Month Service
Service as Required
Warranty
John Deere Warranty in OEM Applications
Emissions Control System Certification Label
EPA Non-road Emissions Control Warranty Statement-Compression Ignition
CARB Non-road Emissions Control Warranty Statement-Compression Ignition
John Deere Service Literature Available
Technical Information