POWERTECH 13.5 L 6135HF485/HF475 Operators Manual

POWERTECH™ 13.5 L OEM 6135HF485/HF475 Emis sions Diesel Engines OPERATOR’S MANUAL 13.5 L OEM 6135HF485/HF475 Emissions Diesel Engines OMRG36873 ISSUE 16DEC10 (ENGLISH) CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. If this product contains a gasoline engine: WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. The State of California requires the above two warnings. Additional Proposition 65 Warnings can be found in this manual. John Deere Power Systems LITHO IN U.S.A.

Introduction JR74534,00002EA 1916DEC101/1 Foreword READ THIS MANUAL carefully to learn how to operate and service your engine correctly. Failure to do so could result in personal injury or equipment damage. THIS MANUAL SHOULD BE CONSIDERED a permanent part of your engine and should remain with the engine when you sell it. MEASUREMENTS IN THIS MANUAL are given in both metric and customary U.S. unit equivalents. Use only correct replacement parts and fasteners. Metric and inch fasteners may require a specific metric or inch wrench. RIGHTHAND AND LEFTHAND sides are determined by standing at the drive or flywheel end (rear) of the engine and facing toward the front of the engine. WRITE ENGINE SERIAL NUMBERS and option codes in the spaces indicated in the Record Keeping section. Accurately record all the numbers. Your dealer also needs these numbers when you order parts. File the identification numbers in a secure place off the engine. SETTING FUEL DELIVERY beyond published factory specifications or otherwise overpowering will result in loss of warranty protection for this engine. CERTAIN ENGINE ACCESSORIES such as radiator, air cleaner, and instruments are optional equipment on John Deere OEM Engines. These accessories may be provided by the equipment manufacturer instead of John Deere. This operator’s manual applies only to the engine and those options available through the John Deere distribution network. NOTE: This operator’s manual covers only engines provided to OEM (Original Equipment Manufacturers). For engines in Deere machines, refer to the machine operator’s manual. This manual covers primarily the PowerTech Plus 13.5 L (6135HF485) OEM engines. These engines meet emission standards for EPA Tier 3 and EU Stage III A. 010311 PN=2

Introduction OURGP11,0000251 1918SEP07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.johndeere.com/enginewarranty Learn who your dealer is and where he is. At your first convenience, go meet him. He’ll want to get to know you and to learn what your needs might be. Aux Utilisateurs De Moteurs John Deere: N’attendez pas d’être obligé d’avoir recours à votre concessionnaire John Deere ou au point de service le plus proche pour vous adresser à lui. Pour enregistrer votre moteur pour la garantie via Internet, utilisez l’adresse suivante: http://www.johndeere.com/enginewarranty Renseignezvous dès que possible pour l’identifier et le localiser. A la première occasion, prenez contact avec lui et faitesvous connaître. Il sera lui aussi heureux de faire votre connaissance et de vous proposer ses services le moment venu. An Den Besitzer Des John Deere Motors: Warten Sie nicht auf einen evt. Reparaturfall, um den nächstgelegenen John Deere Händler kennen zu lernen. Zur Registrierung Ihres Motors für die Garantie dient folgende InternetAdresse: http://www.johndeere.com/enginewarranty Machen Sie sich bei ihm bekannt und nutzen Sie sein “Service Angebot”. Proprietario del motore John Deere: Non aspetti fino al momento di far valere la garanzia o di chiedere assistenza per fare la conoscenza del distributore dei motori John Deere o del concessionario che fornisce l’assistenza tecnica. Per registrare via Internet la garanzia del suo motore, si collegi al seguente sito URL: http://www.johndeere.com/enginewarranty Lo identifichi e si informi sulla sua ubicazione. Alla prima occasione utile lo contatti. Egli desidera fare la sua conoscenza e capire quali potrebbero essere le sue necessità. Propietario De Equipo John Deere: No espere hasta necesitar servicio de garantía o de otro tipo para conocer a su Distribuidor de Motores John Deere o al Concesionario de Servicio. Registre su motor para la garantía en la siguiente dirección de internet: http://www.johndeere.com/enginewarranty Aprenda quién es su distribuidor y donde él está situado. Cuando tenga un momento, vaya a visitarlo. A él le gustará conocerlo, y saber cuáles podrían ser sus necesidades. Till ägare av John Deere motorer: Ta reda på vem din återförsäljare är och besök honom så snart tillfälle ges. Vänta inte tills det är dags för service eller eventuellt garantiarbete. Din motor garantiregistrerar Du via Internet på http://www.johndeere.com/enginewarranty Din återförsäljare vill mycket gärna träffa dig för att lära känna dina behov och hur bäst han kan hjälpa dig. 010311 PN=3

Introduction OMRGP15,000011D 1912SEP061/1 Engine Identification Views RG13885 —UN—19MAY05 13.5L Engine  Left Front View RG13886 —UN—19MAY05 13.5L Engine  Right Front View 010311 PN=4

Contents Page Record Keeping Record Engine Serial Number ............................ 011 Engine Option Codes ......................................... 012 Record Engine Control Unit (ECU) Serial Number ................................................ 013 Record Rear Power TakeOff (PTO) Serial Number (If Equipped)........................... 014 Safety .......................................................... 051 Fuels, Lubricants, and Coolant Diesel Fuel.......................................................... 101 Lubricity of Diesel Fuel ....................................... 101 Handling and Storing Diesel Fuel ....................... 102 Testing Diesel Fuel ............................................. 102 Biodiesel Fuel ..................................................... 103 Minimizing the Effect of Cold Weather on Diesel Engines .......................................... 104 Diesel Engine BreakIn Oil ................................. 105 Diesel Engine Oil ................................................ 106 Diesel Engine Oil and Filter Service Intervals .... 107 Mixing of Lubricants............................................ 108 OILSCAN ™ and COOLSCAN ™ ...................... 109 Alternative and Synthetic Lubricants .................. 109 Lubricant Storage ............................................... 109 Oil Filters .......................................................... 1010 Heavy Duty Diesel Engine Coolant .................. 1010 Supplemental Coolant Additives....................... 1011 Drain Intervals for Diesel Engine Coolant......... 1011 Additional Information About Diesel Engine Coolants and John Deere LIQUID COOLANT CONDITIONER............. 1012 Testing Diesel Engine Coolant.......................... 1013 Operating in Warm Temperature Climates ....... 1013 Disposing of Coolant ........................................ 1014 Instrument Panel and Diagnostic Gauge Instrument Panels............................................... 151 Using Diagnostic Gauge to Access Engine Information ......................................... 153 Main Menu Navigation ........................................ 153 Engine Configuration Data ................................. 155 Accessing Stored Trouble Codes ....................... 157 Accessing Active Trouble Codes ........................ 159 Engine Shutdown Codes .................................. 1511 Adjusting Backlighting ...................................... 1512 Page Adjusting Contrast ............................................ 1514 Selecting Units Of Measurement ...................... 1515 Setup 1Up Display........................................... 1517 Setup 4Up Display........................................... 1523 Engine Operation Engine BreakIn Service ..................................... 201 Auxiliary Gear Drive Limitations ......................... 203 Generator Set (Standby) Applications ................ 203 Starting the Engine ............................................. 204 Restarting Engine Which Has Run Out Of Fuel ........................................................... 205 Warming Engine ................................................. 206 Normal Engine Operation ................................... 206 Cold Weather Operation ..................................... 207 Changing Engine Speed..................................... 208 Avoid Excessive Engine Idling............................ 209 Stopping the Engine ......................................... 2010 Using a Booster Battery or Charger ................. 2011 Lubrication and Maintenance Observe Service Intervals .................................. 251 Use Correct Fuels, Lubricants, and Coolant....... 251 Lubrication and Maintenance Service Interval Chart—Industrial Unit and Generator (Prime Power) ............................... 252 Lubrication and Maintenance Service Interval Chart—Generator (Standby) Applications .................................................... 253 Lubrication and Maintenance/Daily Daily Prestarting Checks .................................... 301 Lubrication & Maintenance/500 Hour/12 Month Servicing Fire Extinguisher ................................. 351 Servicing Battery ................................................ 351 Changing Engine Oil and Replacing Oil Filter .... 353 Visually Inspecting Coolant Pump ...................... 355 Replacing Fuel Filters/Cleaning Water Separator (Earlier Engines)............................ 355 Replacing Fuel Filters/Cleaning Water Separator (Later Engines) .............................. 359 Checking and Adjusting Engine Speeds .......... 3511 Checking Engine Mounts.................................. 3511 Checking Crankcase Vent Tube and Valve ...... 3511 Checking Air Intake System ............................. 3512 Continued on next page Original Instructions. All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice. COPYRIGHT © 2010 DEERE & COMPANY Moline, Illinois All rights reserved. A John Deere ILLUSTRUCTION ® Manual Previous Editions Copyright © 2005, 2006, 2008, 2009 i 010311 PN=1

Contents Page Check Engine Electrical Ground Connection ...3512 Checking Belt Tensioner Spring Tension and Belt Wear ................................. 3513 Checking Cooling System ................................ 3514 Testing Diesel Engine Coolant.......................... 3515 Replenishing Supplemental Coolant Additives (SCAs) Between Coolant Changes ....................................................... 3516 Pressure Testing Cooling System..................... 3517 Lubrication & Maintenance/2000 Hr/24 Month Checking Crankshaft Vibration Damper ............. 401 Flushing and Refilling Cooling System ............... 402 Testing Thermostats Opening Temperature ....... 405 Lubrication and Maintenance/2500 Hour Checking and Adjusting Engine Valve Clearance and Electronic Unit Injector Preload .............................................. 451 Do Not Modify Fuel System................................ 451 Service as Required Additional Service Information ............................ 501 Adding Coolant ................................................... 501 Replacing Air Cleaner Filter Elements................ 502 Draining Fuel Filter Water Separator Bowl ......... 503 Bleeding Fuel System (Earlier Engines) ............. 504 Bleeding Fuel System (Later Engines) ............... 504 Replacing Fan/Alternator VBelts ....................... 505 VBelt Routing .................................................... 506 Checking Fuses .................................................. 506 Air Compressors ................................................. 506 Rear Power TakeOff (PTO) ............................... 507 Troubleshooting General Troubleshooting Information ................. 551 Instrument Panel Method for Retrieving Diagnostic Trouble Codes .............................. 552 Displaying Of Diagnostic Trouble Codes (DTCs) ................................................ 552 Listing of Diagnostic Trouble Codes (DTCs) ...... 553 Intermittent Fault Diagnostics ............................. 558 Displaying Diagnostic Gauge Software .............. 558 Engine Troubleshooting.................................... 5510 Engine Troubleshooting (Continued) ................ 5512 Electrical Troubleshooting ................................ 5514 Lubrication System Troubleshooting ................ 5516 Cooling System Troubleshooting...................... 5519 Air Intake and Exhaust System Troubleshooting............................................ 5521 Low Pressure Fuel System Troubleshooting .... 5523 Electrical System Layout .................................. 5524 Electrical System Layout Continued................ 5525 Precautions for Welding on Vehicles Equipped with Electronic Engine Control Unit (ECU) ....................................... 5526 Precautions for Electrical System When Steam Cleaning Engine ..................... 5526 Page Engine Wiring Diagram (Engines With FullFeatured Instrument Panel) .................. 5527 Engine Wiring Diagram (Engines With FullFeatured Instrument Panel) (Continued) .................................................. 5528 Engine Wiring Diagram (Engines With FullFeatured Instrument Panel) (Continued) .................................................. 5529 Storage Engine Storage Guidelines ................................. 601 Preparing Engine for Long Term Storage ........... 601 Removing Engine from Long Term Storage ....... 602 Specifications General OEM Engine Specifications .................. 651 Engine Power Ratings And Fuel System Specifications ..................................................... 653 Engine Crankcase Oil Fill Quantities .................. 654 Unified Inch Bolt and Screw Torque Values........ 655 Metric Bolt and Screw Torque Values ................. 656 Lubrication and Maintenance Records Using Lubrication and Maintenance Records ..... 701 Daily (Prestarting) Service .................................. 701 500 Hours of Operation/or 12 Months Service ...701 2000 Hours of Operation/or 24 Months Service ........................................................... 702 2500 Hours of Operation Service ....................... 702 Service as Required ........................................... 702 Emission System Warranty U.S. EPA Emissions Control Warranty Statement ....................................................... 751 Emissions Control System Certification Label .... 751 Technical Information.......................................... 752 ii 010311 PN=2

Record Keeping OURGP11,000004B 1912SEP061/1 Record Engine Serial Number The engine serial number plate (C) is located on the lefthand side of engine block between intake manifold and starter motor. Record all of the numbers and letters found on your engine serial number plate in the spaces provided below. This information is very important for repair parts or warranty information. Engine Serial Number (A) Engine Model Number (B) NOTE: On engine serial number (A) the 7th digit shows the emission level as follows: • “B” for noncertified engines • “C” for Tier 1 / Stage I engines • “G” for Tier 2 / Stage II engines • “L” for Tier 3 / Stage IIIA engines A—Engine Serial Number B—Engine Model Number C—Engine Serial Number Plate RG14798 —UN—23JUN06 Engine Serial Number/Application Data RG13887 —UN—26JUL05 Location of Engine Serial Number Plate 011 010311 PN=7

Record Keeping Continued on next page OURGP11,000007F 1911OCT061/2 Engine Option Codes RG13880 —UN—06JUL05 Option Code Label A—Base Engine Code 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 label is lost or destroyed, consult your servicing dealer or engine distributor selling the engine for a replacement. In addition to the serial number plate, OEM engines have an engine option code label affixed to the valve cover. These codes indicate which of the engine options were installed on your engine at the factory. When in need of parts or service, furnish your authorized servicing dealer or engine distributor with these numbers. The engine option code label includes an base engine code (A) (1665F, bold print in label above). Record this code along with option codes on following page. The first two digits of each code identify a specific group, such as alternators. The last two digits of each code identify one specific option provided on your engine, such as a 24volt, 60amp alternator. If an engine is ordered without a particular component, the last two digits of that functional group option code will be 99, 00, or XX. The list on the next page shows only the first two digits of the code numbers. For future reference, such as ordering repair parts, it is important to have these code numbers available. To ensure this availability, enter the third and fourth digits shown on your engine option code label in the spaces provided on the following page. Base Engine Code (See “A” on previous page.) Option Codes Description Option Codes Description 11 Valve Cover 51 Cylinder Head With Valves 12 Oil Fill Inlet 52 Auxiliary Gear Drive 13 Crankshaft Pulley/Damper 53 Fuel Heater 14 Flywheel Housing 54 Air Intake for Turbocharger 15 Flywheel 55 Shipping Stand 16 Fuel Injection Pump 56 Paint Option 17 Air Inlet 57 Coolant Pump Inlet 18 Air Cleaner 59 Oil Cooler 19 Oil Pan 60 Addon Auxiliary Drive Pulley 20 Coolant Pump 62 Alternator Mounting Bracket 21 Thermostat Cover 63 Low Pressure Fuel Line 22 Thermostat 64 Exhaust Elbow 23 Fan Drive 65 Turbocharger 24 Fan Belt 66 Coolant Temperature Switch 25 Fan 67 Electronic Sensors (Base Engine) 26 Engine Coolant Heater 68 Crankshaft Rear Damper 27 Radiator 69 Engine Serial Number Plate 28 Exhaust Manifold 71 Engine Oil Bypass Filter 29 Crankcase Ventilator System 72 ECU Electronic Software Option 30 Starter Motor 74 Air Conditioning (Freon) Compressor 012 010311 PN=8

Record Keeping OURGP11,000007F 1911OCT062/2 OURGP12,0000125 1912SEP061/1 Option Codes Description Option Codes Description 31 Alternator 75 Air Restriction Indicator 32 Instrument Panel 76 Pressure Switches and Sensors 33 Tachometer 77 Timing Gear Cover 35 Fuel Filters 78 Air Compressor 36 Front Plate 79 Engine Certification 37 Fuel Transfer Pump 81 Primary Fuel Filter And Water Separator 39 Thermostat Housing 83 Electronic Software (Vehicle Option) 40 Oil Dipstick 84 Electrical Wiring Harness 41 BeltDriven Front Auxiliary Drive 86 Fan Pulley 43 Starting Aid 87 Belt Tensioner 44 Timing Gear Cover With Gears 88 Oil Filter 45 Balancer Shafts 89 Exhaust Gas Recirculating (EGR) System 46 Cylinder Block With Liners and Camshaft 95 Special Equipment (Factory Installed) 47 Crankshaft and Bearings 96 Engine Installation Kit 48 Connecting Rods and Pistons 97 Special Equipment (Field Installed) 49 Valve Actuating Mechanism 98 Shipping (Engine Hanger Straps) 50 Oil Pump 99 Service Only Items NOTE: These option codes are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice. Record Engine Control Unit (ECU) Serial Number Record the part number and serial number information found on the serial number label (A) on the Engine Control Unit (ECU) mounted on or near the engine. Part No. Serial No. A—Serial Number Label RG13891 —UN—14JUN05 Record Engine Control Unit (ECU) Serial Number 013 010311 PN=9

Record Keeping OUOD006,0000066 1912SEP061/1 Record Rear Power TakeOff (PTO) Serial Number (If Equipped) Record the rear power takeoff (PTO) serial number found on rear PTO serial number plate (A) (if equipped). Rear PTO Serial Number RG12594 —UN—24SEP02 Rear PTO Serial Number Plate 014 010311 PN=10

POWERTECH 13.5 L 6135HF485/HF475 Operators Manual

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