John Deere PowerTech 13.5 L OEM 6135HF485 / HF475 Emissions Diesel Engines Operator’s Manual

John Deere PowerTech 13.5 L OEM 6135HF485 / HF475 Emissions Diesel Engines Operator’s Manual

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OMRG36873 ISSUE 16DEC10

Record Keeping
Record Engine Serial Number……………………….011
Engine Option Codes …………………………………..012
Record Engine Control Unit (ECU)
Serial Number …………………………………………013
Record Rear Power TakeOff
(PTO)
Serial Number (If Equipped)………………………014
Safety…………………………………………………. 051
Fuels, Lubricants, and Coolant
Diesel Fuel………………………………………………….101
Lubricity of Diesel Fuel …………………………………101
Handling and Storing Diesel Fuel …………………..102
Testing Diesel Fuel ………………………………………102
Biodiesel Fuel ……………………………………………..103
Minimizing the Effect of Cold Weather
on Diesel Engines ……………………………………104
Diesel Engine BreakIn
Oil ……………………………105
Diesel Engine Oil …………………………………………106
Diesel Engine Oil and Filter Service Intervals ….107
Mixing of Lubricants……………………………………..108
OILSCAN ™ and COOLSCAN ™ ………………….109
Alternative and Synthetic Lubricants ………………109
Lubricant Storage ………………………………………..109
Oil Filters ………………………………………………….1010
Heavy Duty Diesel Engine Coolant ………………1010
Supplemental Coolant Additives………………….. 1011
Drain Intervals for Diesel Engine Coolant……… 1011
Additional Information About Diesel
Engine Coolants and John Deere
LIQUID COOLANT CONDITIONER………….1012
Testing Diesel Engine Coolant……………………..1013
Operating in Warm Temperature Climates …….1013
Disposing of Coolant ………………………………….1014
Instrument Panel and Diagnostic Gauge
Instrument Panels………………………………………..151
Using Diagnostic Gauge to Access
Engine Information …………………………………..153
Main Menu Navigation………………………………….153
Engine Configuration Data ……………………………155
Accessing Stored Trouble Codes …………………..157
Accessing Active Trouble Codes……………………159
Engine Shutdown Codes ……………………………. 1511
Adjusting Backlighting ………………………………..1512
Page
Adjusting Contrast ……………………………………..1514
Selecting Units Of Measurement………………….1515
Setup 1Up
Display…………………………………….1517
Setup 4Up
Display…………………………………….1523
Engine Operation
Engine BreakIn
Service……………………………….201
Auxiliary Gear Drive Limitations …………………….203
Generator Set (Standby) Applications …………….203
Starting the Engine ………………………………………204
Restarting Engine Which Has Run Out
Of Fuel …………………………………………………..205
Warming Engine ………………………………………….206
Normal Engine Operation ……………………………..206
Cold Weather Operation……………………………….207
Changing Engine Speed……………………………….208
Avoid Excessive Engine Idling……………………….209
Stopping the Engine …………………………………..2010
Using a Booster Battery or Charger …………….. 2011
Lubrication and Maintenance
Observe Service Intervals …………………………….251
Use Correct Fuels, Lubricants, and Coolant…….251
Lubrication and Maintenance Service
Interval Chart—Industrial Unit and
Generator (Prime Power) ………………………….252
Lubrication and Maintenance Service
Interval Chart—Generator (Standby)
Applications…………………………………………….253
Lubrication and Maintenance/Daily
Daily Prestarting Checks ………………………………301
Lubrication & Maintenance/500 Hour/12 Month
Servicing Fire Extinguisher……………………………351
Servicing Battery …………………………………………351
Changing Engine Oil and Replacing Oil Filter ….353
Visually Inspecting Coolant Pump ………………….355
Replacing Fuel Filters/Cleaning Water
Separator (Earlier Engines)……………………….355
Replacing Fuel Filters/Cleaning Water
Separator (Later Engines)…………………………359
Checking and Adjusting Engine Speeds ………. 3511
Checking Engine Mounts……………………………. 3511
Checking Crankcase Vent Tube and Valve …… 3511
Checking Air Intake System ………………………..3512
Check Engine Electrical Ground Connection …3512
Checking Belt Tensioner Spring
Tension and Belt Wear ……………………………3513
Checking Cooling System …………………………..3514
Testing Diesel Engine Coolant……………………..3515
Replenishing Supplemental Coolant
Additives (SCAs) Between Coolant
Changes……………………………………………….3516
Pressure Testing Cooling System…………………3517
Lubrication & Maintenance/2000 Hr/24 Month
Checking Crankshaft Vibration Damper ………….401
Flushing and Refilling Cooling System ……………402
Testing Thermostats Opening Temperature …….405
Lubrication and Maintenance/2500 Hour
Checking and Adjusting Engine Valve
Clearance and Electronic Unit
Injector Preload ……………………………………….451
Do Not Modify Fuel System…………………………..451
Service as Required
Additional Service Information……………………….501
Adding Coolant ……………………………………………501
Replacing Air Cleaner Filter Elements…………….502
Draining Fuel Filter Water Separator Bowl ………503
Bleeding Fuel System (Earlier Engines)………….504
Bleeding Fuel System (Later Engines) ……………504
Replacing Fan/Alternator VBelts
…………………..505
VBelt
Routing …………………………………………….506
Checking Fuses…………………………………………..506
Air Compressors………………………………………….506
Rear Power TakeOff
(PTO) ………………………….507
Troubleshooting
General Troubleshooting Information ……………..551
Instrument Panel Method for Retrieving
Diagnostic Trouble Codes …………………………552
Displaying Of Diagnostic Trouble
Codes (DTCs) …………………………………………552
Listing of Diagnostic Trouble Codes (DTCs) ……553
Intermittent Fault Diagnostics ………………………..558
Displaying Diagnostic Gauge Software …………..558
Engine Troubleshooting………………………………5510
Engine Troubleshooting (Continued)…………….5512
Electrical Troubleshooting …………………………..5514
Lubrication System Troubleshooting …………….5516
Cooling System Troubleshooting………………….5519
Air Intake and Exhaust System
Troubleshooting……………………………………..5521
Low Pressure Fuel System Troubleshooting….5523
Electrical System Layout …………………………….5524
Electrical System LayoutContinued…………….
5525
Precautions for Welding on Vehicles
Equipped with Electronic Engine
Control Unit (ECU) …………………………………5526
Precautions for Electrical System
When Steam Cleaning Engine …………………5526
Page
Engine Wiring Diagram (Engines With
FullFeatured
Instrument Panel) ………………5527
Engine Wiring Diagram (Engines With
FullFeatured
Instrument Panel)
(Continued) …………………………………………..5528
Engine Wiring Diagram (Engines With
FullFeatured
Instrument Panel)
(Continued) …………………………………………..5529
Storage
Engine Storage Guidelines……………………………601
Preparing Engine for Long Term Storage ………..601
Removing Engine from Long Term Storage …….602
Specifications
General OEM Engine Specifications ………………651
Engine Power Ratings And Fuel System
Specifications ……………………………………………..653
Engine Crankcase Oil Fill Quantities ………………654
Unified Inch Bolt and Screw Torque Values……..655
Metric Bolt and Screw Torque Values……………..656
Lubrication and Maintenance Records
Using Lubrication and Maintenance Records…..701
Daily (Prestarting) Service…………………………….701
500 Hours of Operation/or 12 Months Service …701
2000 Hours of Operation/or 24 Months
Service …………………………………………………..702
2500 Hours of Operation Service …………………..702
Service as Required …………………………………….702
Emission System Warranty
U.S. EPA Emissions Control Warranty
Statement……………………………………………….751
Emissions Control System Certification Label….751
Technical Information……………………………………752

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