Kohler 200REOZJF Operating instructions

PowerTechPlus

4045and6068

OEMDieselEngines

*OMRG36852*

OPERATOR'SMANUAL

PowerTech™Plus4045and6068

OEMDieselEngines

OMRG36852ISSUE03AUG17(ENGLISH)

CALIFORNIA

Proposition65Warning

Dieselengineexhaustandsomeofitsconstituents

areknowntotheStateofCaliforniatocausecancer,

birthdefects,andotherreproductiveharm.

Ifthisproductcontainsagasolineengine:

WARNING

Theengineexhaustfromthisproductcontains

chemicalsknowntotheStateofCaliforniatocause

cancer,birthdefectsorotherreproductiveharm.

TheStateofCaliforniarequirestheabovetwowarnings.

AdditionalProposition65Warningscanbefoundinthismanual.

JohnDeerePowerSystems

WorldwideEdition

PRINTEDINU.S.A.

TP-6455 8/17

Introduction

ZE59858,000025E-19-31MAY17-1/1

OEMEngineandDrivetrainWarrantyRegistration

RG24614—UN—21OCT13

ScanthiscodetoregisteryourOEMengineonline.Youcanalso

visitusdirectlyatJohnDeere.com/warranty.

WhyregisteringyourOEMengineordrivetrain

productisareallysmartidea:

•

Getfasterservice.Registeringyourengineor

drivetrainproductgivesustheinformationweneedto

meetyourserviceneedspromptlyandcompletely.

•

Protectyourinvestment.You’llbekeptup-to-dateon

engineordrivetrainproductupdates.

•

Extendyourwarranty.You’llbegiventheoptionto

extendyourcoveragebeforeyourstandardwarranty

termexpires.

•

Stayinformed.Bethefirsttoknowaboutnewproducts

andmoney-savingoffersfromJohnDeere.

You’reCovered

WhenyoubuyaJohnDeereengineordrivetrainproduct

youaren’tjustbuyingpistonsandcrankshaftsandgear

drives.You’rebuyingtheabilitytogetworkdone.Without

downtime,withoutworries,andwithouthassles.And

you’rebuyingtheassurancethatifyoudoneedhelp,a

strongsupportnetworkwillbethere—readytostepin.

Confidence.That'swhatJohnDeereengines,John

Deeredrivetrains,andJohnDeereWarrantiesareall

about.

Longdurations.Warrantiesdesignedtogiveyou

confidenceinyourengineordrivetrainproduct.

Worldwidesupport.Getservicewhenandwhere

youneedit.JohnDeerehas4,000+servicelocations

worldwide.

GenuineJohnDeerepartsandservice.Authorized

serviceoutletswilluseonlyneworremanufacturedparts

orcomponentsfurnishedbyJohnDeere.

WarrantyDuration

Equipmentoperatorscan’tafforddowntimeorunexpected

repairs.That’swhyweoffera2-year/2,000-hourwarranty,

withunlimitedhoursinthefirstyear,onourOEMindustrial

andmarineengines.Thiswarrantytakeseffectthedate

thattheengineisdeliveredtothefirstretailpurchaser.In

addition,extendedwarrantiesareavailableundercertain

conditions.JohnDeereoffersavarietyofpurchased

warrantiestoextendthewarrantyperiodforyourengine.

You'llbegiventheoptiontoextendyourcoveragebefore

yourstandardwarrantytermexpires.Besuretoregister

yourengineordrivetrainproductandtakefulladvantage

oftheJohnDeereserviceandsupportnetwork.

ObtainingWarrantyService

Warrantyservicemustberequestedthroughan

authorizedJohnDeereserviceoutletbeforetheexpiration

ofthewarranty.Evidenceoftheengine’sordrivetrain

product’sdeliverydatetothefirstretailpurchasermustbe

presentedwhenrequestingwarrantyservice.Authorized

serviceoutletsinclude:

•

JohnDeeredistributor

•

JohnDeereOEMservicedealer

•

JohnDeereequipmentdealer

•

JohnDeeremarinedealer

WorldwideSupportNetwork

VisitJohnDeere.com/dealertofindtheauthorizedengine

ordrivetrainservicelocationnearestyou.Forcomplete

warrantydetailsvisitJohnDeere.com/warrantystatements

toview,download,orprintthewarrantystatementforyour

engineordrivetrainproduct.

080417

PN=3

Introduction

RK80614,000050A-19-18AUG15-1/1

Foreword

THISMANUALCONTAINSINFORMATIONtooperate

andservicePowerTechPlus4.5Land6.8LTier3/Stage

IIIAemission-certified

1

OEMengines:

IMPORTANT :Someinformationcontainedwithin

thismanualreferstoenginesthatarecapable

ofrunningonaviation(jet)fuels.These

enginesarespecificallyorderedandoutfitted

withspecialhardenedcomponentsandfuel

dosingelement(s)thatmaketheengine

capableofusingthesefuels.

CAUTION:EnginesNOTorderedandoutfitted

withthesespecialcomponentsareNOT

capableofusingaviation(jet)fuels.Ifyou

haveanyquestions,pleasecontactyour

localservicingdealer.

READTHISMANUALcarefullytolearnhowtooperate

andserviceyourenginecorrectly.Failuretodosocould

resultinpersonalinjuryorequipmentdamage.

THISMANUALSHOULDBECONSIDEREDapermanent

partofyourengineandshouldremainwiththeengine

whenyousellit.

MEASUREMENTSINTHISMANUALaregiveninboth

metricandcustomaryU.S.unitequivalents.Useonly

correctreplacementpartsandfasteners.Metricandinch

fastenersmayrequireaspecificmetricorinchwrench.

WRITEENGINESERIALNUMBERSandoptioncodes

inthespacesindicatedintheRecordKeepingSection.

Accuratelyrecordallthenumbers.Yourdealeralso

needsthesenumberswhenyouorderparts.Filethe

identificationnumbersinasecureplaceofftheengine.

SETTINGFUELDELIVERYbeyondpublishedfactory

specificationsorotherwiseoverpoweringwillresultinloss

ofwarrantyprotectionforthisengine.

CERTAINENGINEACCESSORIESsuchasradiator,

aircleaner,andinstrumentsareoptionalequipmenton

JohnDeereOEMEngines.Theseaccessoriesmaybe

providedbytheequipmentmanufacturerinsteadofJohn

Deere.Thisoperator'smanualappliesonlytotheengine

andthoseoptionsavailablethroughtheJohnDeere

distributionnetwork.

IMPORTANT :Thismanualcoversonlythe

PowerTech™PlusTier3/StageIIIA

emission-certified4.5Land6.8LOEMengines.

TheseenginesmeetTier3/StageIIIAemission

certificationstandards.(Thisisforboththe

U.S.EPAandEuropeanUnionCouncil(EU)

standards.)Engineswithmechanicalcontrols

whicharenon-emissioncertifiedorTier1/Stage

Iemissioncertified(U.S.andEU)arecovered

inaseparateoperatorsmanual.Engines

whichareTier2/StageIIemission-certified

arecoveredinaseparateoperatorsmanual..

EngineswhicharePowerTech™ETier3/

StageIIIAemission-certifiedarecoveredin

aseparateoperatorsmanual.

NOTE:Thismanualcoversenginesprovidedto

OEM(OriginalEquipmentManufacturers).

ForenginesinDeeremachines,refertothe

machineoperator'smanual.

1

EmissioncertifiedforUnitedStatesasEPATier3andfor

EuropeanUnionasStageIIIA.

080417

PN=4

Introduction

JR74534,00002F9-19-10JAN11-1/1

EngineOwner

JohnDeereEngineOwner:

Itisimportantforyoutoregisteryournewenginefor

factorywarranty.Registeringyourenginewillallowyour

ServiceDealertoverifyyourwarrantystatusshould

arepairbeneeded.Theeasiestwaytoregisteryour

engineisviatheinternet.T oregisteryourenginefor

warrantyviatheinternet,pleaseusethefollowingURL:

http://www.johndeere.com/enginewarrantyYourJohn

DeereEngineDistributororlocalJohnDeereService

Dealerwillalsobehappytoprovidethisservice.Ifyou

wouldliketoviewtheJohnDeereServiceDealernetwork

orlocateyournearestDealer,usethefollowingURL:

http://www.johndeere.com/dealer

080417

PN=5

Introduction

JR74534,00002F6-19-18AUG15-1/1

IdentificationViews

RG13547—UN—11NOV04

6068Engine-LefSideView

RG13546—UN—11NOV04

6068Engine-RightSideView

RG14361—UN—14DEC05

4045Engine-RightSideView

080417

PN=6

Introduction

ContinuedonnextpageZE59858,0000006-19-09MAR16-1/2

Trademarks

AdBlue®

AdBlueisatrademarkofVDA,theGermanAssociationofthe

AutomotiveIndustry.

AMP®AMPisatrademarkofTycoElectronics

BIO-GREASE-GARD™BIO-GREASE-GARDisatrademarkofDeere&Company

BioHy-Gard™BioHy-GardisatrademarkofDeere&Company

Bluetooth®BluetoothisatrademarkofBluetoothSIG

Break-In™Plus

Break-InisatrademarkofDeere&Company

CINCH™CINCHisatrademarkofCinchInc.

COOL-GARD™PLUSCOOL-GARDisatrademarkofDeere&Company

CoolScan™CoolScanisatrademarkofDeere&Company

COOLSCAN™PLUSCOOLSCANisatrademarkofDeere&Company

CustomPerformance™CustomPerformanceisatrademarkofDeere&Company

Deere™

DeereisatrademarkofDeere&Company

DENSO®DENSOisatrademarkofDENSOCorporation

DEUTSCH®DEUTSCHisatrademarkofDeutschCo.

DieselScan™DieselScanisatrademarkofDeere&Company

DuPont®DuPontisatrademarkofE.I.DuPontdeNemoursandCompany

EXTREME-GARD™EXTREME-GARDisatrademarkofDeere&Company

FleetGard™FleetGardisatrademarkofDeere&Company

Fuelscan™

FuelscanisatrademarkofDeere&Company

Funk™

FunkisatrademarkofDeere&Company

GREASE-GARD™GREASE-GARDisatrademarkofDeere&Company

Hy-Gard™Hy-GardisatrademarkofDeere&Company

JDLink™

JDLinkisatrademarkofDeere&Company

JDParts™

JDPartsisatrademarkofDeere&Company

JohnDeere™

JohnDeereisatrademarkofDeere&Company

Loctite®LoctiteisatrademarkofHenkelCorporation

Metri-Pack®Metri-PackisatrademarkofDelphiConnectionSystems

OILSCANPLUS™OILSCANPLUSisatrademarkofDeere&Company

Oilscan™OilscanisatrademarkofDeere&Company

Permatex®PermatexisatrademarkofIllinoisT oolWorksInc.

Phoenix™

PhoenixisatrademarkofDeere&Company

Plastigage®PlastigageisatrademarkofPerfectCircleCorporation

Plus-50™II

Plus-50isatrademarkofDeere&Company

PowerSight™PowerSightisatrademarkofDeere&Company

PowerTech™

PowerTechisatrademarkofDeere&Company

PowerTech™E

PowerTechisatrademarkofDeere&Company

PowerTech™M

PowerTechisatrademarkofDeere&Company

PowerTech™Plus

PowerTechisatrademarkofDeere&Company

Restore®Restoreisatrademarkof"Restore,Inc."

Scotch-Brite®Scotch-Briteisatrademarkof3MCo.

Scotch-Grip®Scotch-Gripisatrademarkof3MCo.

ServiceADVISOR™ServiceADVISORisatrademarkofDeere&Company

SERVICEGARD™SERVICEGARDisatrademarkofDeere&Company

SPEEDI-SLEEVE®SPEEDI-SLEEVEisaregisteredtrademarkoftheSKFGroup.

SWEDA™SWEDAisatrademarkofDeere&Company

Swagelok®SwagelokisaregisteredtrademarkofSwagelokCompany.

TACH-N-TIME™TACH-N-TIMEisatrademarkofBoschAutomotiveServiceSolutionsInc.

TeamMate™

TeamMateisatrademarkofDeere&Company

TEFLON®TEFLONisatrademarkofDuPontCo.

Torq-Gard™Torq-GardisatrademarkofDeere&Company

080417

PN=7

Introduction

ZE59858,0000006-19-09MAR16-2/2

TORX®TORXisaregisteredtrademarkofAcumentIntellectualProperties,LLC

Vari-Cool™Vari-CoolisatrademarkofDeere&Company

WEATHERPACK®WEATHERPACKisatrademarkofPackardElectric

WINDOWS®WINDOWSisatrademarkofMicrosoftCorporation

080417

PN=8

Contents

Page

RecordKeeping

EngineSerialNumberPlate...............................01-1

RecordEngineSerialNumber............................01-1

EngineOptionCodes.........................................01-2

RecordHigh-PressureFuelPump

ModelNumber................................................01-3

RecordEngineControlUnit(ECU)

SerialNumber................................................01-4

EmergencyStationaryEngineRule....................01-4

Safety

RecognizeSafetyInformation............................05-1

UnderstandSignalWords...................................05-1

FollowSafetyInstructions...................................05-1

ReplaceSafetySigns.........................................05-2

CaliforniaProposition65Warning......................05-2

IlluminateWorkAreaSafely...............................05-2

WorkinCleanArea............................................05-2

UseProperT ools................................................05-3

LiveWithSafety..................................................05-3

PreventMachineRunaway.................................05-3

HandleFuelSafely—AvoidFires........................05-4

PrepareforEmergencies....................................05-4

HandleStartingFluidSafely...............................05-4

InCaseofFire....................................................05-5

HandleFluidsSafely—AvoidFires.....................05-5

AvoidStaticElectricityRiskWhenRefueling......05-6

ServiceMachinesSafely....................................05-6

WearProtectiveClothing....................................05-6

ProtectAgainstNoise.........................................05-7

HandlingBatteriesSafely...................................05-7

PreventAcidBurns.............................................05-8

StayClearofRotatingDrivelines........................05-8

InstallAllGuards................................................05-9

PracticeSafeMaintenance.................................05-9

RemovePaintBeforeWeldingorHeating........05-10

AvoidHeatingNearPressurizedFluidLines....05-10

AvoidHigh-PressureFluids..............................05-10

DoNotOpenHigh-PressureFuelSystem........05-11

ProtectAgainstHighPressureSpray...............05-11

PreventBatteryExplosions..............................05-11

AvoidHotExhaust............................................05-12

WorkInVentilatedArea....................................05-12

ServiceCoolingSystemSafely........................05-12

Decommissioning—ProperRecycling

andDisposalofFluidsandComponents.....05-13

Page

Fuels,Lubricants,andCoolant

DieselFuel..........................................................10-1

SupplementalDieselFuelAdditives...................10-1

LubricityofDieselFuel.......................................10-2

HandlingandStoringDieselFuel.......................10-2

BioDieselFuel....................................................10-3

TestingDieselFuel.............................................10-4

Aviation(Jet)Fuels.............................................10-5

FuelFilters..........................................................10-5

MinimizingtheEffectofColdWeather

onDieselEngines..........................................10-6

DieselEngineBreak-InOil—

Non-EmissionsCertifiedand

CertifiedTier1,Tier2,Tier3,Stage

I,StageII,andStageIII.................................10-7

DieselEngineOil—Tier3andStageIII............10-8

EngineOilandFilterServiceIntervals

—Tier3andStageIIIA—OEM

Applications....................................................10-9

DieselEngineOilandFilterServiceIntervals..10-10

EngineOilandFilterServiceIntervals

(JetFuelCapableEnginesOnly).................10-12

MixingofLubricants..........................................10-12

AlternativeandSyntheticLubricants................10-12

LubricantStorage.............................................10-13

OilFilters..........................................................10-13

DieselEngineCoolant(enginewith

wetsleevecylinderliners)............................10-14

WaterQualityforMixingwithCoolant

Concentrate..................................................10-15

OperatinginWarmT emperatureClimates.......10-15

TestingCoolantFreezePoint...........................10-16

DisposingofCoolant........................................10-16

InstrumentPanels

PV101InstrumentPanels...................................15-1

PV101DiagnosticGauge—Using....................15-3

PV101DiagnosticGauge—MainMenu............15-4

PV101DiagnosticGauge—EssentialMenus...15-5

DG14DiagnosticGauge—Using......................15-5

DG14DiagnosticGauge—MainMenu.............15-6

DG14DiagnosticGauge—EssentialMenus.....15-7

PV480InstrumentPanel.....................................15-8

PV480DiagnosticGauge—Using....................15-9

PV480DiagnosticGauge—MainMenu..........15-10

Continuedonnextpage

OriginalInstructions.Allinformation,illustrationsandspecificationsinthis

manualarebasedonthelatestinformationavailableatthetimeofpublication.

Therightisreservedtomakechangesatanytimewithoutnotice.

DEERE&COMPANY

Moline,Illinois

Allrightsreserved.

AJohnDeereILLUSTRUCTION™Manual

PreviousEditions

i

080417

PN=1

Contents

Page

PV480DiagnosticGauge—EssentialMenus..15-11

MainMenuNavigation......................................15-12

EngineConfigurationData...............................15-13

AccessingStoredTroubleCodes.....................15-15

AccessingActiveTroubleCodes......................15-17

EngineShutdownCodes..................................15-19

AdjustingBacklighting......................................15-20

AdjustingContrast............................................15-22

SelectingUnitsOfMeasurement......................15-24

Setup1-UpDisplay...........................................15-26

Setup4-UpDisplay...........................................15-31

JohnDeerePowerSight....................................15-35

EngineOperation

EngineBreak-InService.....................................20-1

StartingtheEngine.............................................20-3

RestartingEngineAfterEmergencyShutdown..20-5

NormalEngineOperation...................................20-5

WarmingEngine.................................................20-6

ColdWeatherOperation.....................................20-7

UsingaBoosterBatteryorCharger...................20-9

AvoidExcessiveEngineIdling..........................20-10

ChangingEngineSpeed...................................20-10

StoppingTheEngine........................................20-11

AuxiliaryGearDriveLimitations.......................20-12

GeneratorSet(Standby)Applications..............20-12

LubricationandMaintenance

RequiredEmission-RelatedInformation.............25-1

ObserveServiceIntervals..................................25-1

UseCorrectFuels,Lubricants,andCoolant.......25-1

LubricationandMaintenanceService

IntervalChart—StandardIndustrialEngines..25-2

LubricationandMaintenanceService

IntervalChart—Generator(Standby)

Applications....................................................25-3

LubricationandMaintenanceService

IntervalChart—JetFuelCapableEngines.....25-4

Lubrication&Maintenance/Daily

DailyPrestartingChecks....................................30-1

Lubrication&Maintenance—500Hour/12Month

—JetFuel250Hour

ServicingFireExtinguisher.................................35-1

CheckingEngineMounts....................................35-1

ServicingBattery................................................35-1

ChangingEngineOilandReplacingFilter..........35-3

CheckingCrankcaseVentSystem.....................35-5

CheckingAirIntakeSystem...............................35-6

ReplacingFuelFilterElements(DieselFuel).....35-7

ReplacingFuelFilterandDosing

Elements(JetFuelCapableEngines)............35-8

CheckingBeltTensionerSpring

TensionandBeltWear(Automatic

Tensioner)....................................................35-10

Page

CheckingEngineElectricalGround

Connections.................................................35-11

CheckingCoolingSystem................................35-12

ReplenishingSupplementalCoolant

Additives(SCAs)BetweenCoolant

Changes.......................................................35-13

TestingDieselEngineCoolant..........................35-14

PressureT estingCoolingSystem.....................35-15

CheckingandAdjustingEngineSpeeds..........35-16

Lubrication&Maint./2000Hour/24Month

CheckingCrankshaftVibrationDamper

(6-CylinderEngineOnly)................................40-1

FlushingandRefillingCoolingSystem...............40-2

TestingThermostatsOpeningTemperature.......40-4

CheckingandAdjustingValveClearance...........40-8

TestingGlowPlugsforContinuity(If

Applicable)...................................................40-10

ServiceAsRequired

AdditionalServiceInformation............................45-1

DoNotModifyFuelSystem................................45-1

AddingCoolant...................................................45-2

Pre-StartCleaningGuide...................................45-3

ReplacingSingleStageAirCleaner...................45-4

ReplacingAxialSealAirCleanerFilter

Element..........................................................45-5

ReplacingRadialSealAirCleaner

FilterElement.................................................45-7

ReplacingFanandAlternatorBelts....................45-8

CheckingFuses..................................................45-8

CheckingAirCompressors.................................45-9

BleedingFuelSystem.......................................45-10

Troubleshooting

GeneralTroubleshootingInformation.................50-1

InstrumentPanelMethodforRetrieving

DiagnosticTroubleCodes..............................50-3

DisplayingOfDiagnosticTrouble

Codes(DTCs)................................................50-3

ListingofDiagnosticTroubleCodes(DTCs)......50-4

IntermittentFaultDiagnostics(With

ElectronicControls)........................................50-8

DisplayingDiagnosticGaugeSoftware..............50-8

EngineTroubleshooting....................................50-10

PrecautionsforElectricalSystem

WhenSteamCleaningEngine.....................50-15

EngineWiringLayout.......................................50-16

PrecautionsForWelding..................................50-17

EngineWiringDiagram(EnginesWith

Full-FeaturedInstrumentPanel)..................50-18

EngineWiringDiagram(EnginesWith

Full-FeaturedInstrumentPanel)

(Continued)..................................................50-19

EngineWiringDiagram(EnginesWith

Full-FeaturedInstrumentPanel)

(Continued)..................................................50-20

Continuedonnextpage

ii

080417

PN=2

Contents

Page

Storage

EngineStorageGuidelines.................................55-1

PreparingEngineforLong-TermStorage...........55-1

RemovingEnginefromLongTermStorage.......55-2

Specifications

GeneralOEMEngineSpecifications..................60-1

EnginePowerRatingsAndFuelSystem

Specifications.....................................................60-2

EngineCrankcaseOilFillQuantities..................60-4

UnifiedInchBoltandScrewT orqueValues........60-5

MetricBoltandScrewTorqueValues.................60-6

LubricationandMaintenanceRecords

UsingLubricationandMaintenanceRecords.....65-1

Daily(Prestarting)Service..................................65-1

250Hour/12MonthService(JetFuel

CapableEngines)...........................................65-1

500Hour/12MonthService................................65-2

2000Hour/24MonthService..............................65-3

ServiceasRequired...........................................65-3

Warranty

JohnDeereWarrantyinOEMApplications........70-1

EmissionsControlSystemCertificationLabel....70-4

EPANon-roadEmissionsControl

WarrantyStatement—CompressionIgnition..70-5

CARBNon-roadEmissionsControl

WarrantyStatement—CompressionIgnition..70-7

JohnDeereServiceLiteratureAvailable

TechnicalInformation..........................................75-1

iii

080417

PN=3

Contents

iv

080417

PN=4

RecordKeeping

OURGP12,000007D-19-15SEP04-1/1

OURGP11,00000AB-19-21FEB06-1/1

EngineSerialNumberPlate

Eachenginehasa13-digitJohnDeereengineserial

number.Thefirsttwodigitsidentifythefactorythat

producedtheengine:

•

“CD”=Saran,France

•

“PE”=T orreon,Mexico

Theengine'sserialnumberplate(A)islocatedonthe

right-handsideofcylinderblockbehindthefuelfilter.

A—SerialNumberPlate

RG13550—UN—11NOV04

13-DigitEngineSerialNumberPlate

RecordEngineSerialNumber

Recordallofthenumbersandlettersfoundonyour

engineserialnumberplateinthespacesprovidedbelow.

Thisinformationisveryimportantforrepairpartsor

warrantyinformation.Useall13digitswhenproviding

engineserialnumber.

EngineSerialNumber(B)

__________________________

EngineModelNumber(C)

______________________

NOTE:Engineserialnumbersonthe7thdigitindicates

theEmissionLevelasfollows:

•

“B”fornon-certifiedengines

•

“C”forTier1/StageIengines

•

“G”forTier2/StageIIengines

•

“L”forTier3/StageIIIAengines

RG14627—UN—13JAN06

SaranFactoryEngineSerialNumberPlate

RG13716—UN—23JAN06

TorreonFactoryEngineSerialNumberPlate

01-1

080417

PN=13

RecordKeeping

ContinuedonnextpageRG,RG34710,5004-19-12JUN17-1/2

EngineOptionCodes

1111

4391

6901

1399

4607

72F3

1425

4702

7306

6068HFC09 2732F6.8 L

1524

4803

7703

1606

4903

7897

1708

5002

8422

1928

5103

8911

2002

5215

9805

2699

5407

2815

5511

2909

5615

3008

5709

3512

5927

3914

6543

4026

6801

JOHN DEERE

Customer No. OPTION CODES

Number

PE6068U000094

A

RG24026—UN—05AUG13

OptionCodeLabelExample

A—EngineBaseCode(example)

OEMengineshaveanengineoptioncodelabelaffixedto

therockerarmcover.Thesecodesindicatewhichofthe

engineoptionswereinstalledonyourengineatthefactory.

Wheninneedofpartsorservice,furnishyourauthorized

servicingdealerorenginedistributorwiththesenumbers.

Theengineoptioncodelabelincludesanenginebase

code(A).Thisbasecodemustalsoberecordedalong

withtheoptioncodes.Attimesitwillbenecessaryto

furnishthisbasecodetodifferentiatetwoidenticaloption

codesforthesameenginemodel.

Thefirsttwodigitsofeachcodeidentifyaspecificgroup,

suchasalternators.Thelasttwodigitsofeachcode

identifyonespecificoptionprovidedonyourengine,such

asa24volt,120ampalternator.

Ifanengineisorderedwithoutaparticularcomponent,the

lasttwodigitsofthatfunctionalgroupoptioncodewillbe

99,00,orXX.Thefollowinglistshowsonlythefirsttwo

digitsofthecodenumbers.Forfuturereferencesuchas

orderingrepairparts,itisimportanttohavethesecode

numbersavailable.Toensurethisavailability,enterthe

thirdandfourthdigitsshownonyourengineoptioncode

labelinthespacesprovidedonthefollowingpage.

Anadditionaloptioncodelabelmayalsobedelivered(in

aplasticbagattachedtotheengineorinsertedinthe

machinedocumentation).Itisrecommendedtoplacethis

labeleitheronthispageoftheoperatorsmanualorinthe

EngineOwner'sWarrantybookletunderOptionCodes.

Themachinemanufacturermayhaveplacedthelabelina

specificaccessiblearea(insidetheenclosureorcloseto

amaintenancearea).

Yourengineoptioncodelabelmaynotcontainalloption

codesifanoptionhasbeenaddedaftertheengineleft

theproducingfactory.

Ifoptioncodelabelislostordestroyed,consultyour

servicingdealerorenginedistributorsellingtheenginefor

areplacement.

RecordyourengineBaseCode(A)inthespacesprovided

belowforeasyreference.

EngineBaseCode(A):

OptionCodesDescriptionOptionCodesDescription

10PaintProtection56Paint

11

RockerArmCover

57

WaterPumpInlet

12

OilFiller

58

PowerT akeOff

13

CrankshaftPulley

59

OilCooler/OilFilter

14FlywheelHousing60

Add-OnFanDrivePulley

15Flywheel61

AfterTreatmentDevice/Muffler

16

FuelInjectionSystem

62

AlternatorMounting

17AirInlet63Low-PressureFuelLines

18

AirCleaner

64ExhaustElbow

19

OilPan

65Turbocharger

20

WaterPump66

TemperatureSwitch

21

ThermostatCover

67

EngineSensors

22

Thermostat68Damper

23FanDrive69

EngineSerialNumberPlate

24FanBelt70

DecompositionTube(OEM)

01-2

080417

PN=14

RecordKeeping

RG,RG34710,5004-19-12JUN17-2/2

OURGP12,0000080-19-15SEP04-1/1

OptionCodesDescriptionOptionCodesDescription

25

Fan71

SCR(OEM)

26BlockHeater72

PerformanceSoftwareandLabels

27

Radiator/HeatExchanger

7A

PerformanceSoftwareandLabels

28

ExhaustManifold

73

AfterTreatmentDosingSystem

29

VentilatorSystem

74

AirConditioning

30

StartingMotor

75

RestrictionIndicator

31Alternator76

OilPressureSwitch

32

DEFLines,Pressure(OEM)

77

TimingGearCover(S450/S650

33

DEFLines,Supply/ReturntoT ank(OEM)

78

AirCompressor

34

DEFTankandHeader(OEM)

79

Certification

35FinalFuelFilter80

SeaWaterPump(Marine)

36

FrontPlateandIdlerShafts

81

PrimaryFuelFilter/WaterSeparator

37

FuelTransferPump

82

IgnitionSystem(NaturalGas)

38

OperatorManual

83

VehiclePerformanceSoftware

39ThermostatHousing84WiringHarness

40

DipstickandTube85

FuelSystem(NaturalGas)

41

BeltDrivenAuxiliaryDrive(Add-OnCrankPulley)

86FanPulley

42

DEFLine,SupplyModuletoInjector(OEM)

87BeltT ensioner

43

StartingAid

88

OilFilter

44

TimingGearCover(S350)

89

EGRSystem

44

TachometerDriveSensors(S450/S650)

90

TrimSoftware(OEM)

45

SecondaryBalancers

91

EngineInstallationKit(S350)

46

CylinderBlockwithCamshaft

92

EngineT estCertificate/EngineAccessories(S350)

47

Crankshaft/MainBearings

92

EngineInstallationKit(S450)

48

ConnectingRods/Pistons/Liners

93EmissionLabel

49ValveActuatingMechanism94

CustomSoftware

50

OilPump

95PartsInstalledatFactory

51

CylinderHeadwithValves

96

EngineInstallationKit/ShipWith(S450/S650)

52

GearDrivenAuxiliaryDrive

96

ECUWiringHarness(6125/6135)

53FuelHeater97FieldInstalledItems

54

TurboAirIntake98

EngineLiftStrap

55

ShippingStand

99

ServiceOnlyParts

NOTE:Thisisacompleteoptioncodelistbasedon

thelatestinformationavailableatthetimeof

publication.Therightisreservedtomakechanges

atanytimewithoutnotice.Yourenginewillnot

containalloptioncodeslisted.

RecordHigh-PressureFuelPumpModel

Number

Recordthehigh-pressurefuelpumpmodelandserial

numberinformationfoundontheserialnumberplate(A).

ModelNo.RPM

Manufacturer'sNo.

SerialNo.

A—SerialNumberPlate

RG13718—UN—11NOV04

RecordHigh-PressureFuelPumpSerialNumber

01-3

080417

PN=15

RecordKeeping

OURGP12,00000AD-19-27JUL06-1/1

KW40574,0000003-19-12MAY16-1/1

RecordEngineControlUnit(ECU)Serial

Number

Recordthepartnumberandserialnumberinformation

foundontheserialnumberlabel(A)ontheEngineControl

Unit(ECU)mountedonorneartheengine.

PartNo.

SerialNo.

A—SerialNumberLabel

RG13799—UN—18NOV04

RecordEngineControlUnit(ECU)SerialNumber

EmergencyStationaryEngineRule

RG19597—UN—20OCT10

EmissionsLabel

AfterTier4standardstakeeffect,enginemanufacturers

ofemergencystationaryenginesthatdonotmeetthe

standardsfornon-emergencyenginesmustaddtoeach

suchemergencyengineapermanentlabel(suchasthe

emissionlabelasshown)whichstatesthattheengine

islimitedtostationaryemergencyuse.OnJohnDeere

enginesthisisstatedintheEPAemissionlabeloneach

engine.

FuelRequirements

Beginning01Oct10,ownersandoperatorsofstationary

enginesthatusedieselfuelmustonlyusedieselfuel

meetingtherequirementsof40CFR80.510(b),which

requiresthatdieselfuelhaveamaximumsulfurcontent

of15PPMandeitheraminimumcetaneindexof40ora

maximumaromaticcontentof35volumepercent.

Operation,MaintenanceandTesting

Theoperationofemergencyenginesislimitedto

emergencyoperationsandrequiredmaintenanceand

testing.

Thereisnotimelimitontheuseofemergencystationary

enginesinemergencysituations.

Maintenanceandtestingislimitedto100hoursper

year.TheEPAhasalsoincludedaprovisionthatallows

anyonetopetitiontheAdministratorforadditionalhours,

beyondtheallowed100hoursperyear,ifsuchadditional

hoursshouldprovetobenecessaryformaintenanceand

testingreasons.TheEPAwillnotrequireapetitionfor

additionalhoursifthehoursbeyond100hoursperyear

formaintenanceandtestingpurposesaremandatedby

regulationsuchasStateorLocalrequirements.

01-4

080417

PN=16

Safety

DX,ALERT-19-29SEP98-1/1

DX,SIGNAL-19-05OCT16-1/1

DX,READ-19-16JUN09-1/1

RecognizeSafetyInformation

Thisisasafety-alertsymbol.Whenyouseethissymbol

onyourmachineorinthismanual,bealerttothepotential

forpersonalinjury.

Followrecommendedprecautionsandsafeoperating

practices.

T81389—UN—28JUN13

UnderstandSignalWords

DANGER;ThesignalwordDANGERindicatesa

hazardoussituationwhich,ifnotavoided,willresultin

deathorseriousinjury.

WARNING;ThesignalwordWARNINGindicatesa

hazardoussituationwhich,ifnotavoided,couldresultin

deathorseriousinjury.

CAUTION;ThesignalwordCAUTIONindicatesa

hazardoussituationwhich,ifnotavoided,couldresultin

minorormoderateinjury.CAUTIONmayalsobeused

toalertagainstunsafepracticesassociatedwithevents

whichcouldleadtopersonalinjury.

Asignalword—DANGER,WARNING,orCAUTION—is

usedwiththesafety-alertsymbol.DANGERidentifies

themostserioushazards.DANGERorWARNING

safetysignsarelocatednearspecifichazards.General

TS187—19—30SEP88

precautionsarelistedonCAUTIONsafetysigns.

CAUTIONalsocallsattentiontosafetymessagesinthis

manual.

FollowSafetyInstructions

Carefullyreadallsafetymessagesinthismanualandon

yourmachinesafetysigns.Keepsafetysignsingood

condition.Replacemissingordamagedsafetysigns.Be

surenewequipmentcomponentsandrepairpartsinclude

thecurrentsafetysigns.Replacementsafetysignsare

availablefromyourJohnDeeredealer.

Therecanbeadditionalsafetyinformationcontainedon

partsandcomponentssourcedfromsuppliersthatisnot

reproducedinthisoperator'smanual.

Learnhowtooperatethemachineandhowtousecontrols

properly.Donotletanyoneoperatewithoutinstruction.

Keepyourmachineinproperworkingcondition.

Unauthorizedmodificationstothemachinemayimpairthe

functionand/orsafetyandaffectmachinelife.

TS201—UN—15APR13

Ifyoudonotunderstandanypartofthismanualandneed

assistance,contactyourJohnDeeredealer.

05-1

080417

PN=17

Safety

DX,SIGNS-19-18AUG09-1/1

RG41061,000001F-19-12JAN10-1/1

DX,LIGHT-19-04JUN90-1/1

DX,CLEAN-19-04JUN90-1/1

ReplaceSafetySigns

Replacemissingordamagedsafetysigns.Usethis

operator’smanualforcorrectsafetysignplacement.

Therecanbeadditionalsafetyinformationcontainedon

partsandcomponentssourcedfromsuppliersthatisnot

reproducedinthisoperator'smanual.

TS201—UN—15APR13

CaliforniaProposition65Warning

Dieselengineexhaust,someofitsconstituents,alongwith

certainmachinecomponentscontainoremitchemicals

knowntotheStateofCaliforniatocausecancerandbirth

defectsorotherreproductiveharm.Inaddition,certain

fluidscontainedinthemachineandcertainproductsof

componentwearcontainoremitchemicalsknowntothe

StateofCaliforniatocausecancerandbirthdefectsor

otherreproductiveharm.

IlluminateWorkAreaSafely

Illuminateyourworkareaadequatelybutsafely.Use

aportablesafetylightforworkinginsideorunderthe

machine.Makesurethebulbisenclosedbyawirecage.

Thehotfilamentofanaccidentallybrokenbulbcanignite

spilledfueloroil.

TS223—UN—23AUG88

WorkinCleanArea

Beforestartingajob:

•

Cleanworkareaandmachine.

•

Makesureyouhaveallnecessarytoolstodoyourjob.

•

Havetherightpartsonhand.

•

Readallinstructionsthoroughly;donotattempt

shortcuts.

T6642EJ—UN—18OCT88

05-2

080417

PN=18

Safety

DX,REPAIR-19-17FEB99-1/1

DX,LIVE-19-25SEP92-1/1

DX,BYPAS1-19-29SEP98-1/1

UseProperTools

Usetoolsappropriatetothework.Makeshifttoolsand

procedurescancreatesafetyhazards.

Usepowertoolsonlytoloosenthreadedpartsand

fasteners.

Forlooseningandtighteninghardware,usethecorrect

sizetools.DONOTuseU.S.measurementtoolson

metricfasteners.Avoidbodilyinjurycausedbyslipping

wrenches.

UseonlyservicepartsmeetingJohnDeerespecifications.

TS779—UN—08NOV89

LiveWithSafety

Beforereturningmachinetocustomer,makesure

machineisfunctioningproperly,especiallythesafety

systems.Installallguardsandshields.

TS231—19—07OCT88

PreventMachineRunaway

Avoidpossibleinjuryordeathfrommachineryrunaway.

Donotstartenginebyshortingacrossstarterterminals.

Machinewillstartingearifnormalcircuitryisbypassed.

NEVERstartenginewhilestandingonground.Start

engineonlyfromoperator’sseat,withtransmissionin

neutralorpark.

TS177—UN—11JAN89

05-3

080417

PN=19

Safety

DX,FIRE1-19-12OCT11-1/1

DX,FIRE2-19-03MAR93-1/1

DX,FIRE3-19-14MAR14-1/1

HandleFuelSafely—AvoidFires

Handlefuelwithcare:itishighlyflammable.Donotrefuel

themachinewhilesmokingorwhennearopenflameor

sparks.

Alwaysstopenginebeforerefuelingmachine.Fillfuel

tankoutdoors.

Preventfiresbykeepingmachinecleanofaccumulated

trash,grease,anddebris.Alwayscleanupspilledfuel.

Useonlyanapprovedfuelcontainerfortransporting

flammableliquids.

Neverfillfuelcontainerinpickuptruckwithplasticbed

liner.Alwaysplacefuelcontainerongroundbefore

refueling.T ouchfuelcontainerwithfueldispensernozzle

beforeremovingcanlid.Keepfueldispensernozzlein

contactwithfuelcontainerinletwhenfilling.

TS202—UN—23AUG88

Donotstorefuelcontainerwherethereisanopenflame,

spark,orpilotlightsuchaswithinawaterheaterorother

appliance.

PrepareforEmergencies

Bepreparedifafirestarts.

Keepafirstaidkitandfireextinguisherhandy.

Keepemergencynumbersfordoctors,ambulanceservice,

hospital,andfiredepartmentnearyourtelephone.

TS291—UN—15APR13

HandleStartingFluidSafely

Startingfluidishighlyflammable.

Keepallsparksandflameawaywhenusingit.Keep

startingfluidawayfrombatteriesandcables.

Topreventaccidentaldischargewhenstoringthe

pressurizedcan,keepthecaponthecontainer,andstore

inacool,protectedlocation.

Donotincinerateorpunctureastartingfluidcontainer.

Donotusestartingfluidonanengineequippedwithglow

plugsoranairintakeheater.

TS1356—UN—18MAR92

05-4

080417

PN=20

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