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Anchor Applicator Model E Engine 3

1. DO NOT use these values if a different torque value or tightening procedure is given for a specific application Torque values listed are for general use only Check tightness of fasteners periodically Shear bolts are designed to fail under predetermined loads Always replace shear bolts with identical grade Lubricated means coated with a lubricant such as engine oil or fasteners with phosphate and oil coatings Dry means plain or zinc plated without any lubrication P Grade 2 applies for hex cap screws not hex bolts up to 152 mm 6 in long Grade 1 applies for hex cap screws over 152 mm 6 in long and for all other types of bolts and screws of any length Fasteners should be replaced with the same or higher grade If higher grade fasteners are used these should only be tightened to the strength of the original Make sure fasteners threads are clean and that you properly start thread engagement This will prevent them from failing when tightening Tighten plastic insert or crimped steel type lock nuts to approximately 50 percent of the dry torque shown in the chart applied to the nut not to the bolt head Tighten toothed or serrated type lock nuts to the full torque value 105 Specifications METRIC BOLT AND CAP SCREW TORQUE VALUES Property Class and Head Markings Property Class and Nut Markings Class 4 8
2. 67 Lubrication amp Maintenance 1200 Hour 24 Month PRESSURE TESTING COOLING SYSTEM RG6557 pressurized cooling system can cause CAUTION Explosive release of fluids from serious burns Shut off engine Only remove filler cap when cool enough to touch with bare hands Slowly loosen cap to first stop to relieve pressure before removing completely Test Radiator Cap 1 Remove radiator cap and attach to D05104ST Tester as shown 2 Pressurize cap to 70 kPa 0 7 bar 10 psi Gauge should hold pressure for 10 seconds within the normal range if cap is acceptable If gauge does not hold pressure replace radiator cap 3 Remove the cap from gauge turn it 180 and retest cap This will verify that the first measurement was accurate Test pressures recommended are for all Deere OEM cooling systems On specific vehicle applications test cooling system and pressure cap according to the recommended pressure for that vehicle RG6558 Test Cooling System NOTE Engine should be warmed up to test overall cooling system 1 Allow engine to cool then carefully remove radiator cap 2 Fill radiator with coolant to the normal operating level IMPORTANT DO NOT apply excessive pressure to cooling system doing so may damage radiator and hoses 3 Connect gauge and adapter to radiator filler neck Pressurize cooling system to 70 kPa 0 7 bar 10 psi 4 With pressure applied check all coo
3. PLB Operating equipment safely requires the full attention of the operator Do not wear radio or music headphones while operating machine TS206 PROTECT AGAINST NOISE Prolonged exposure to loud noise can cause impairment or loss of hearing Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises TS207 10 Ad HANDLE CHEMICAL PRODUCTS SAFELY 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 A Material Safety Data Sheet MSDS provides specific details on chemical products physical and health hazards safety procedures and emergency response techniques Check the MSDS before you start any job using a hazardous chemical That way you will know exactly what the risks are and how to do the job safely Then follow procedures and recommended equipment See your John Deere dealer for MSDS s on chemical products used with John Deere equipment TS1132 STAY CLEAR OF ROTATING DRIVELINES Entanglement in rotating driveline can cause serious injury or death Keep master shield and driveline shields in place at all times Make sure rotating shields turn freely Wear close fitting clothing Stop the engine and be sure the PTO driveline is stopped before making adj
4. If ANY fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result Doctors unfamiliar with this type of injury may call the Deere amp Company Medical Department in Moline Illinois or other knowledgeable medical source Whenever the fuel system has been opened up for service lines disconnected or filters removed it will be necessary to bleed air from the system 1 Loosen the air bleed vent screw A two full turns by hand on fuel filter base 2 Operate supply pump primer lever B until fuel flow is free from air bubbles 3 Tighten bleed plug securely continue operating hand primer until pumping action is not felt Push hand primer inward toward engine as far as it will go 4 Start engine and check for leaks If engine will not start it may be necessary to bleed air from fuel system at fuel injection pump or injection nozzles as explained next e 3 X A RG7947 84 Service As Required BLEEDING THE FUEL SYSTEM CONTINUED e At Fuel Injection Pump On Stanadyne rotary pumps 1 Slightly loosen fuel return line connector A at fuel injection pump 2 Operate fuel supply pump primer lever until fuel without air bubbles flows from fuel return line connection 3 Tighten return line connector to 16 N m 12 lb ft 4 Leave hand primer in the inward position towa
5. 101 Fuel Injection Pump Specifications 103 Engine Crankcase Oil Fill Quantities 104 Unified Inch Bolt and Cap Screw Torque Values 105 Metric Bolt and Cap Screw Torque Values 106 Lubrication and Maintenance Records 107 Emission System Warranty 113 Service Literature Order Form Index Record Keeping POWERTECH MEDALLION A medallion is located on the rocker arm cover which identifies each engine as a John Deere POWERTECH engine Xe ECH 4 5 liter RG8041 ENGINE SERIAL NUMBER PLATE Each engine has a 13 digit John Deere engine serial number The first two digits identify the factory that produced the engine TO indicates the engine was built in Dubuque lowa CD indicates the engine was built in Saran France Your engine s serial number plate A is located on the right hand side of cylinder block behind the fuel filter RG8007 Record Keeping RECORD ENGINE SERIAL NUMBER 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 B Engine Model Number C Coefficient of Absorption Value D JOHN DEERE Engine Serial Number T04045T123456 3 T04045TF150 9 DEERE amp COMPANY MOLINE ILLINOIS MADE IN USA Dubuque Serial Number Plate
6. Fundamentals of Service FOS Fundamentals of Compact Equipment Service FCP 117 John Deere Service Literature Available John Deere Distribution Service Center Name Service Publications Department P O Box 186 Moline IL 61266 0186 Address To order fill out this form and mail it to the address above Check for prices Ci with your John Deere dealer or call 1 800 522 7448 You may also place ity credit card orders by calling this number Make checks payable to Deere amp Co Service Publications Allow three weeks for delivery No COD orders State Zip Do not send cash or stamps If you want manuals or catalogs for equipment not shown on this list provide the model number serial number and name of product Phone Title Order Number Price Each x Quantity z Total PowERTECH 4 5 L and 6 8 L OEM Engines Operators Manual English OMRG25204 x Parts Catalog PowerTEcH 4 5 L PC2521 x PowerTecH 6 8 L PC2522 Component Technical Manual S E PowerTecH 4 5 L and 6 8 L Engines CTM104 B OEM Engine Accessories CTM67 x Alternators and Starting Motors CTM77 x FOS Manual Hydraulics FOS1005B x FOS Manual Electrical Systems FOS2006B x FOS Manual Engines FOS3007B x u FOS Manual Power Trains FOS4006B x FOS Manual Shop Tools FOS5105B x FOS Manual Welding FOS5207B x FOS Manaul Belts and Chains F
7. JOHN DEERE RG7936 DEERE A COMPANY MOLINE ILLINOIS MADE IN FRANCE RG7935 Saran Serial Number Plate Record Keeping ENGINE OPTION CODES JOHN DEERE PowERTECH Number T06068T000000 6068TF150 6 8L 2135F 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500 2600 2700 2800 2900 3000 3100 3200 3500 3600 3700 3900 4000 4100 4300 4400 4500 4600 4700 4800 4900 5000 5100 5200 5500 5600 5700 5900 6000 6200 6400 6500 6600 6700 6800 6900 7400 7500 7600 8600 8700 8800 9100 9700 9800 0000000000000 OPTION CODES Customer No Option Code Label In addition to the serial number plate OEM engines have an engine option code label affixed to the rocker arm 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 engine base code A This base code must also be recorded along with the option codes At times it will be necessary to furnish this base code to differentiate two identical option codes for the same engine model 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 12 volt 55 amp alternator NOTE These option codes are based on the latest informati
8. su 100 5 9 Total Dissolved Solids maximum 340 20 Total Hardness maximum 170 10 pHibevel 2 2 rt ana e REPE 5 5 9 0 Ethylene Glycol Concentrate Antifreeze IMPORTANT Do not use cooling system sealing additives or antifreeze that contains sealing additives The use of John Deere coolant products as outlined on the previous page is strongly recommended If John Deere coolant products are not used other low silicate ethylene glycol base coolants for heavy duty diesel engines may be used when mixed with quality water and supplemental coolant additives SCAs if they meet one of the following specifications e ASTM D5345 prediluted coolant e ASTM D4985 coolant concentrate in a 4096 to 60 mixture of concentrate with quality water Coolants meeting these specifications require addition of supplemental coolant additives SCAs formulated for heavy duty diesel engines for protection against corrosion and cylinder liner erosion and pitting IMPORTANT Never use automotive type coolants such as those meeting ASTM D3306 or ASTM D4656 These coolants do not contain the correct additives to protect heavy duty diesel engines They often contain a high concentration of silicates and may damage the engine or cooling system 25 Fuels Lubricants and Coolant ENGINE COOLANT SPECIFICATIONS CONTINUED Supplemental Coolant Additives SCAs IMPORTANT DO NOT over inhibit antifr
9. 1680 127 170 1681 1688 112 150 1696 1697 116 155 1615 1668 1686 138 185 1619 1685 124 166 RATED SPEED rpm 2500 2500 1800 2500 1800 2500 2400 1800 2500 2500 1800 2500 2400 1800 SLOW IDLE rpm 850 850 850 850 850 850 850 850 850 FAST IDLE rpm 2700 2700 1890 2700 1890 2700 2600 1890 2700 2700 1890 2700 2600 1890 d Engine speeds listed are preset to factory specification Slow idle speed may be reset depending upon specific vehicle application requirements Refer to your machine operator s manual for engine speeds that are different from those preset at the factory Generator set engines 3 5 governor usually run at 1500 rpm 50 Hz or 1800 60 Hz when operating under load depending on cycles of AC current 3 For engines with standard governor fast idle is 7 10 above rated speed For engines with generator set governors fast idle is 3 5 above rated speed 103 Specifications ENGINE CRANKCASE OIL FILL QUANTITIES JOHN DEERE PoWwERTECH 6068TF150 1100 1200 1300 1400 1500 1600 1700 Number T06068T000000 1800 1900 2000 2100 2200 2300 6 8L 2135F 2400 2500 2600 2700 2800 2900 3000 3100 3200 3500 3600 3700 3900 4000 4100 4300 4400 4500 4600 4700 4800 4900 5000 5100 5200 5500 5600 5700 5900 6000 6200 6400 6500 7600 8600 8700 8800 9100 9700 9800 Customer No Each engine has a 13 digit John
10. 3 Drain crankcase oil from engine while warm NOTE Drain plug location may vary depending on the application 4 Remove and discard oil filter element A using a suitable filter wrench NOTE Depending on engine application oil filter may be located on either side of the engine 5 Remove oil filter packing and clean filter mounting pad IMPORTANT Filtration of oils is critical to proper lubrication Always change filter regularly Use filter meeting John Deere performance specifications RG7961 54 Lubrication and Maintenance 250 Hour CHANGING ENGINE OIL AND REPLACING OIL FILTER CONTINUED 6 Oil new packing and install new filter element Hand tighten element according to values printed on filter element If values are not provided tighten element approximately 3 4 1 1 4 turn after packing contacts filter housing DO NOT overtighten filter element 7 Install oil pan drain plug with a new seal when equipped 8 Fill engine crankcase with correct John Deere engine oil through rocker arm cover opening B or either side oil filler C depending on engine application See DIESEL ENGINE OIL in Fuels Lubricants and Coolant Section for determining correct engine oil To determine the correct oil fill quantity for your engine see ENGINE CRANKCASE OIL FILL QUANTITIES in the Specifications Section NOTE Crankcase oil capacity may vary slightly ALWAYS fill crankcase to full mark or withi
11. ELEMENT STORAGE Seal element in a plastic bag and store in shipping IMPORTANT Air cleaner element MUST BE DRY container to protect against dust and damage before storing in plastic bag 80 Service As Required REPLACING FAN AND ALTERNATOR BELTS Refer to CHECKING BELT TENSIONER SPRING TENSION AND BELT WEAR in Lubrication and Maintenance 600 Hour 12 Month Section for additional information on the belt tensioner 1 Inspect belts for cracks fraying or stretched out areas Replace if necessary To replace release tension on belt using a breaker bar and socket on tension arm Remove poly vee belt from pulleys and discard belt Install new belt making sure belt is correctly seated in all pulley grooves Refer to belt routing at right for your application Apply tension to belt with tensioner Remove Socket Start engine and check belt alignment A Alternator CP Crank Pulley FC Freon Compressor FD Fan Drive idler Pulley T Tensioner WP Water Pump Measured from crank centerline to fan drive center CP 290 mm 11 4 in Fan Height and Lower 838 mm 13 3 in Fan Height and Higher Without Freon Compressor 402 mm 15 8 in Fan Height With Freon Compressor 81 Service As Required POWER TAKE OFF PTO CLUTCH CAUTION Entanglement in rotating A driveline can cause serious injury or death Keep shield on PTO drive shaft A betwee
12. Maintenance 1200 Hour 24 Month Adjusting Variable Speed Droop on Generator Set Engines usur nete d e ne 65 Checking Crankshaft Vibration Damper 6 Cylinder Engine Only 67 Pressure Testing Cooling System 68 Flushing Cooling System lusus 69 Lubrication and Maintenance 2000 Hour Checking and Adjusting Engine Valve Clearance 71 Service As Required Additional Service Information 75 Do Not Modify Fuel System 75 Adding Coolant 0000e eee 76 Replacing Air Cleaner Filter Elements 77 Inspecting Primary Filter Element 78 Cleaning Primary Filter Element 79 Washing Primary Filter Element 80 Element Storage 00 0c nennen 80 Replacing Fan and Alternator Belts 81 Power Take off PTO Clutch 82 Checking Fuses 000 cea eeu 83 Bleeding the Fuel System 84 Troubleshooting General Troubleshooting Information 87 Engine Wiring Diagram Legend 88 Wiring Diagram llle 89 Engine Troubleshooting 90 Electrical Troubleshooting 95 Storage Engine Storage Guidelines 97 Use AR41785 Engine Storage Kit 97 Preparing Engine for Long Term Storage 98 Removing Engine from Long Term Storage 99 Specifications General OEM Engine Specifications
13. load and readjust high idle adjusting screw until 1500 rpm is obtained at the specified power 8 Screw in idle bumper spring until engine speed increases 5 10 rpm 9 Repeat steps 4 through 7 until governor regulation is within the 5 7 range 10 Replace all cap nuts onto adjusting screws and tighten lock nuts securely RG5752 A Fast Idle Stop Screw B Droop Adjusting Screw Access Plug Location C Droop Adjusting Screw D Slow Idle Adjusting Screw E Idle Bumper Spring F Throttle Lever G Mechanical Shutoff Lever 66 Lubrication amp Maintenance 1200 Hour 24 Month CHECKING CRANKSHAFT VIBRATION DAMPER 6 CYLINDER ENGINE ONLY 1 Remove belts shown removed 2 Grasp vibration damper with both hands and attempt to turn it in both directions If rotation is felt damper is defective and should be replaced IMPORTANT The vibration damper assembly is not repairable and should be replaced every 4500 hours or 60 months e whichever occurs first Ka RG8018 3 Check vibration damper radial runout by positioning a dial indicator A so probe contacts damper outer diameter 4 With engine at operating temperature rotate crankshaft using either JD281A JDG820 or JDE83 Flywheel Turning Tool 5 Note dial indicator reading If runout exceeds specifications given below replace vibration damper Damper Radial Runout Specification Maxim m ut een 1 50 mm 0 060 in
14. Class 8 8 or 9 8 Class 10 9 Class 12 9 Size Lubricated Dry Lubricated Dry Lubricated Dry Lubricated Dry Nem lb ft Nem Ib ft Nem Ib ft Nem Ib ft Nem Ib ft Nem Ib ft Nem Ib ft Nem Ib ft M6 4 8 3 5 6 4 5 9 6 5 11 8 5 13 9 5 17 12 15 11 5 19 14 5 M8 12 8 5 15 11 22 16 28 20 32 24 40 30 37 28 47 35 M10 23 17 29 21 43 32 55 40 63 47 80 60 75 55 95 70 M12 40 29 50 37 75 55 95 70 110 80 140 105 130 95 165 120 M14 63 47 80 60 120 88 150 110 175 130 225 165 205 150 260 190 M16 100 738 125 92 190 140 240 175 275 200 350 255 320 240 400 300 M18 135 100 175 125 260 195 330 250 375 275 475 350 440 325 560 410 M20 190 140 240 180 375 275 475 350 530 400 675 500 625 460 800 580 M22 260 190 330 250 510 375 650 475 725 540 925 675 850 625 1075 800 M24 330 250 425 310 650 475 825 600 925 675 1150 850 1075 800 1350 1000 M27 490 360 625 450 950 700 1200 875 1350 1000 1700 1250 1600 1150 2000 1500 M30 675 490 850 625 1300 950 1650 1200 1850 1350 2300 1700 2150 1600 2700 2000 M33 900 675 1150 850 1750 1300 2200 1650 2500 1850 3150 2350 2900 2150 3700 2750 M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2750 4750 3500 DO NOT use these values if a different torque value or tightening procedure is given for a specific application Torque values listed are for general use only Check tightness of fasteners periodically Shear bolts are designed to fail under predetermined loads Always replace shear bolts with
15. Deere engine serial number The first two digits identify the factory that produced the engine CD indicates the engine was built in Saran France TO indicates the engine was built in Dubuque lowa In addition to the serial number plate OEM engines have an engine option code label affixed to the rocker arm 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 Listed below are engine crankcase oil fill quantities Engine Model 4045DF150 1901 4045DF150 4045TF150 4045TF250 1903 4045DF150 4045TF150 4045TF250 1904 6068DF150 6068TF150 6068TF250 1907 0000000000000 Oil Pan Option Code s 6600 6700 6800 6900 7400 7500 OPTION CODES Option Code Label RG7984 The engine option code label includes an engine base code A At times it will be necessary to furnish this base code to differentiate two identical option codes for the same engine model To determine the option code for the oil fill quantity of your engine refer to the engine option code label affixed to the rocker arm cover The first two digits of the code 40 identify the dipstick tube group The last two digits of each code identify the specific dipstick and tube assembly on your engine Crankcase Oil Capacity 1902 8 5 L 9 0 qt 13 0 L 14 0 qt 18 5 L 14 5 qt 1908 1909 19
16. Engine will start with PTO engaged if normal circuitry is bypassed Start engine only from operator s station with PTO disengaged or in neutral RG5419 Ad HANDLE FUEL SAFELY AVOID FIRES Handle fuel with care it is highly flammable Do not refuel the machine while smoking or when near open flame or sparks Always stop engine before refueling machine Fill fuel tank outdoors Prevent fires by keeping machine clean of accumulated trash grease and debris Always clean up spilled fuel TS202 PREPARE FOR EMERGENCIES 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 HANDLE STARTING FLUID SAFELY Starting fluid is highly flammable Keep all sparks and flame away when using it Keep starting fluid away from batteries and cables To prevent accidental discharge when storing the pressurized can keep the cap on the container and store in a cool protected location Do not incinerate or puncture a starting fluid container TS1356 Ad WEAR PROTECTIVE CLOTHING Wear close fitting clothing and safety equipment appropriate to the job Prolonged exposure to loud noise can cause impairment or loss of hearing Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises
17. Gauge panel s gern ana 31 Gauges oi era p i N E ees 31 39 EINEN 23 H Hand throttle 31 Ho rmet t u VER REPOS 31 l Idling engine 40 Inch torque values 2 105 Instrument panel llle 31 K Key switch ees sr e rude ee ees 31 Kit engine storage 2 2222er 97 Page L Literature ae ala SERE AER 117 Literature order Tomm 118 Lubricants Alternative 222 0 ce ee eee 22 MIXING Of zs uL a she 21 STOrAgEN Aa sun dea RARE 23 SYAthellc iod ein Raves ox eats 2G 22 Lubrication and Maintenance 1200 Hour 24 Month 65 70 2000Hour 2 222222 essen 71 73 Nee re rx ues 51 56 50 Hour 2 Weeks 2 2 2 2 2 2 20 49 50 600 Hour 12 Month 57 64 Dall i iex ue EX 45 47 Service As Required 75 86 Service Interval Chart 0 44 Lubrication and maintenance records 107 111 M Maintenance interval chart 44 Maintenance periodic 1200 Hour 24 Month 65 70 2000 Hour 71 73 250 Hour cs a te ae ee EE I 51 56 50 Hour 2 Weeks 49 50 600 Hour 12 Month 57 64 Daily x ao en AW ROI es 45 47 Service As Required 75 86 Metric torque values 2 2222202200 106 O Oil Diesel engine 02 ee eee 21 Engine break in 2 22 2222 20 Fil quantity leeren 104 Oil filter change 54 Oil pressure gauge 6 ee ee ee 31 OILS CAN Se so ohm cece oes
18. PREMIUM DIESEL FUEL CONDITIONER is available in winter and summer formulas Fuel conditioner also reduces fuel gelling and controls wax separation during cold weather Consult your John Deere engine distributor or servicing dealer for recommendations and local availability Always follow manufacturer s directions on label FILLING FUEL TANK CAUTION Handle fuel carefully Do not fill A the fuel tank when engine is running DO NOT smoke while filling fuel tank or servicing fuel system IMPORTANT The fuel tank is vented through the filler cap If a new filler cap is required always replace it with an original vented cap Fill fuel tank at the end of each day s operation to prevent condensation in tank as moist air cools and freezing during cold weather e 15202 18 Fuels Lubricants and Coolant 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 The information below outlines steps that can minimize the effect that cold weather may have on starting and operation of your engine See your authorized engine distributor or servicing dealer for additional information and local availability of cold weather aids Use Grade No 1 D Fuel When temperatures fall below 5 C 40 F Grade No 1 D fuel is best suited for cold
19. filter from inside to outside and move air gun up and down pleats to remove as much dirt as possible 3 Repeat steps 1 and 2 to remove additional dirt 4 Inspect element for damage after cleaning Replace element if any damage is found RW4765 79 Service As Required WASHING PRIMARY FILTER ELEMENT IMPORTANT Never wash element in gasoline or any solvent Never use compressed air on a wet element Do not oil element Use extreme caution when washing filters as washing can damage filtering media which could result in failure Although filter elements can be washed replacement is RW4766 highly recommended Wash oily or sooty filter only if you have a second clean filter available since it may take up to 3 days to dry after washing 1 Blow dust from the filter with compressed air or flush with clean water 2 Soakfilter for at least 15 minutes in a solution of warm water and John Deere R36757 Filter Element Cleaner Agitate the filter gently to flush out dirt after soaking 3 Rinse element thoroughly from inside B with clean water Keep water pressure under 280 kPa 2 8 RW4767 bar 40 psi to avoid damaging filtering pleats 4 Allow element to dry completely before using This usually takes from one to three days Do not oven dry or use drying agents Protect element from freezing until dry 5 Inspect element before installing See INSPECTING PRIMARY FILTER ELEMENT earlier in this section
20. fuel conditioner and anti gel additive Winterfronts Use of fabric cardboard or solid winterfronts is not recommended with any John Deere engine Their use can result in excessive engine coolant oil and charge air temperatures This can lead to reduced engine life loss of power and poor fuel economy Winterfronts may also put abnormal stress on fan and fan drive components potentially causing premature failures 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 Radiator Shutters If equipped with a thermostatically controlled radiator shutter system this system should be regulated in such a way that the shutters are completely open by the time the coolant reaches 93 C 200 F to prevent excessive intake manifold temperatures Manually controlled systems are not recommended If air to air aftercooling is used the shutters must be completely open by the time the intake manifold air temperature reaches the maximum allowable temperature out of the charge air cooler For more information see your John Deere engine distributor or servicing dealer 19 Fuels Lubricants and Coolant ENGINE BREAK IN OIL New engines are filled at the factory with John Deere ENGINE BREAK IN OIL During the break in period ad
21. identical class Fasteners should be replaced with the same or higher grade If higher grade fasteners are used these should only be tightened to the strength of the original Make sure fasteners threads are clean and that you properly start thread engagement This will prevent them from failing when tightening Tighten plastic insert or crimped steel type lock nuts to approximately 50 percent of the dry torque shown in the chart applied to the nut not to the bolt head Tighten toothed or serrated type lock nuts to the full torque value ubricated means coated with a lubricant such as engine oil or fasteners with phosphate and oil coatings Dry means plain or zinc plated without any lubrication 106 Lubrication and Maintenance Records 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 2 Check your record regularly to learn when your engine needs service 3 DO ALL the services within an interval section Write the number of hours from your service records and the date in the spaces provided For a complete listing of all items to be performed and the service intervals required refer to the quick reference chart near the front of the Lubrication and Maintenance Section IMPORTANT The service recommendations covere
22. leakproof containers when draining fluids Do not use food or beverage containers that may mislead someone into drinking from them Do not pour waste onto the ground down a drain or into any water source TS1133 Air conditioning refrigerants escaping into the air can damage the Earth s atmosphere Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center or from your John Deere dealer 15 Fuels Lubricants and Coolant 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 Diesel fuels specified to EN 590 or ASTM D975 are recommended In all cases the fuel shall meet the following properties e Cetane Number of 40 minimum Cetane number greater than 50 is preferred especially for temperatures below 20 C 4 F or elevations above 1500 m 5000 ft ColdFilter Plugging Point CFPP below the expected low temperature OR Cloud Point at least 5 C 9 F below the expected low temperature Fuel Lubricity should pass a minimum of 3100 gram load level as measured by the BOCLE scuffing test e Sulfur Content Sulfur content
23. obligations of John Deere However the use of add on or modified parts are grounds for disallowing a warranty claim 115 Emission System Warranty 116 John Deere Service Literature Available OPERATOR S MANUAL The operator s manual provides safety operating maintenance and service information about John Deere engine An extra copy of the operator s manual is available The operator s manual and safety signs on your engine may also be available in other languages See your John Deere dealer to order A za RG7258 PARTS CATALOG The parts catalog lists service parts available for your engine with exploded view illustrations to help you identify the correct parts It is also useful in assembling and disassembling RG7252 TECHNICAL AND SERVICE MANUALS Technical and service manuals are service guides for your machine Included in the manual are specifications diagnosis and adjustments also illustrations of assembly and disassembly procedures hydraulic oil flows and wiring diagrams Component technical manuals are require for some products These supplemental manuals cover specific components RG7254 FMO AND FOS MANUALS Covering all types of vehicles regardless of manufacturer each book starts with basic theory and proceeds through complex systems There are four series Farm Business Management FBM Fundamentals of Machine Operation FMO
24. weather operation Grade No 1 D fuel has a lower cloud point and a lower pour point Cloud point is the temperature at which wax will begin to form in the fuel and this wax causes fuel filters to plug Pour point is the temperature at which fuel begins to thicken and become more resistant to flow through fuel pumps and lines NOTE On an average Grade No 1 D fuel has a lower BTU heat content rating than Grade No 2 D fuel When using Grade No 1 D fuel you may notice a drop in power and fuel efficiency but should not experience any other engine performance effects Check the grade of fuel being used before troubleshooting for low power complaints in cold weather operation Coolant Heaters Engine block heaters coolant are an available option to aid cold weather starting Seasonal Viscosity Oil and Proper Coolant Concentration Use seasonal grade viscosity engine oil based on expected air temperature range between oil changes and a proper concentration of low silicate antifreeze as recommended See DIESEL ENGINE OIL and ENGINE COOLANT REQUIREMENTS later in this section Diesel Fuel Flow Additive IMPORTANT Treat fuel when outside temperature drops below 0 C 32 F For best results use with untreated fuel Follow all recommended instructions on label Use John Deere Premium Diesel Fuel Conditioner Winter or equivalent to treat fuel during the cold weather season This winter formulation is a combination diesel
25. 00 5 00 Displacement L 4 5 4 5 4 5 cu in 276 276 276 Compression Ratio 17 6 1 17 0 1 17 0 1 Physical Dimensions Width mm in 598 23 5 598 23 5 598 23 5 Height mm in 854 33 6 980 38 6 980 38 6 Length mm in 861 33 9 861 33 9 861 33 9 Basic Dry Weight kg Ib 387 851 396 872 396 872 101 Specifications GENERAL OEM ENGINE SPECIFICATIONS CONTINUED ITEM Number of Cylinders Fuel Bore Stroke Displacement Compression Ratio Physical Dimensions Width Height Length Basic Dry Weight UNIT OF MEASURE mm in mm in mm in kg Ib 6068DF150 6 Diesel 106 4 19 127 5 00 6 8 414 17 6 1 598 23 5 956 37 6 1117 44 0 522 1149 6068TF150 6 Diesel 106 4 19 127 5 00 6 8 414 17 0 1 598 23 5 984 38 7 1117 44 0 533 1172 6068TF250 6 Diesel 106 4 19 127 5 00 6 8 414 17 0 1 598 23 5 984 38 7 1117 44 0 533 1172 102 Specifications FUEL INJECTION PUMP SPECIFICATIONS ENGINE MODEL 4045DF150 4045TF150 4045TF250 6068DF150 6068TF150 6068TF250 INJECTION PUMP POWER RATING OPTION CODES RATED SPEED WITHOUT FAN kW hp 1601 1671 60 80 1602 63 84 1603 1673 1674 53 71 1605 1675 86 115 1656 1677 75 100 1694 1695 75 100 1606 1667 1683 93 125 1608 1682 84 112 1613 1678 93 125 1614
26. 115 C 240 F NOTE On certain engines the oil pressure and coolant temperature gauges are replaced by indicator warning lights The lights must be OFF when engine is running Watch coolant temperature gauge B Do not place engine under full load until it is properly warmed up The normal engine coolant temperature range is 82 94 C 180 202 F NOTE It is a good practice to operate the engine under a lighter load and at lower speeds than normal for the first few minutes after start up RG8033 39 Engine Operating Guidelines CHANGING ENGINE SPEED STANDARD MECHANICAL GOVERNOR To increase engine speed turn handle A to the horizontal position and pull out until desired engine speed is obtained Turn the handle in either direction to lock throttle position The handle is pushed inward to decrease engine speed RG8039 IDLING ENGINE Avoid excessive engine idling Prolonged idling may cause the engine coolant temperature to fall below its normal range This in turn causes crankcase oil dilution due to incomplete fuel combustion and permits formation of gummy deposits on valves pistons and piston rings It also promotes rapid accumulation of engine sludge and unburned fuel in the exhaust System Once an engine is warmed to normal operating temperatures engine should be idled at slow idle speed Slow idle speed for this engine is 850 rpm at factory If an engine will be idlin
27. 15 minutes before welding or heating SERVICE COOLING SYSTEM SAFELY Explosive release of fluids from pressurized cooling System can cause serious burns Shut off engine Only remove filler cap when cool enough to touch with bare hands Slowly loosen cap to first stop to relieve pressure before removing completely TS281 14 Ad AVOID HARMFUL ASBESTOS DUST Avoid breathing dust that may be generated when handling components containing asbestos fibers Inhaled asbestos fibers may cause lung cancer Components in products that may contain asbestos fibers are brake pads brake band and lining assemblies clutch plates and some gaskets The asbestos used in these components is usually found in a resin or sealed in some way Normal handling is not hazardous as long as airborne dust containing asbestos is not generated TS220 Avoid creating dust Never use compressed air for cleaning Avoid brushing or grinding material containing asbestos When servicing wear an approved respirator A special vacuum cleaner is recommended to clean asbestos If not available apply a mist of oil or water on the material containing asbestos Keep bystanders away from the area DISPOSE OF WASTE PROPERLY 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 Use
28. 200 HOUR 24 MONTH SERVICE Flush cooling system Have your authorized servicing dealer or engine distributor pressure test overall cooling system and Check crankshaft vibration damper 6 cylinder only cap Hours Date Hours Date If John Deere Antifreeze Summer Coolant Concentrate or John Deere COOL GARD is used the flushing interval may be extended to 2000 hours If John Deere Prediluted Antifreeze Summer Coolant is used the flushing interval may be extended to 3000 hours or 36 months whichever occurs first 110 Lubrication and Maintenance Records 2000 HOUR SERVICE Have your authorized servicing dealer or engine distributor adjust valve clearance Hours Date Hours Date SERVICE AS REQUIRED Service air cleaner Replace poly vee belts Hours Date Hours Date 111 Lubrication and Maintenance Records 112 Emission System Warranty EMISSIONS CONTROL SYSTEM WARRANTY LABEL NOTE Emission system warranty applies only to POWERTECH 6 8 L engines with a power rating of 131 kW 175 hp or above at this time As of 01 January 1997 the emission system warranty will apply to all POWERTECH 4 5 L and 6 8 L engines The emissions warranty described below applies only to those engines that have been certified by the Je Doere Engine Manutnch 9001 Regisimmd Environmental Protection Age
29. 30 CHH 86 F 5 a gt 5 S r Me E SG o 20 CHH 68 F 1 3 O s o o tc 10 C HH 50 F 22 gt o A EZ EN e z S 2 O CHH 32 F 5 5 Q a E 2 2 10 CHH 14 F 3 L ael ac 24 20 3 30 C HH 22 F 4 40 C HH 40 F 55 o RG7241 23 Fuels Lubricants and Coolant DIESEL ENGINE COOLANT RECOMMENDATIONS Contact your engine distributor or servicing dealer to determine what the cooling system of this engine is filled with and the winter freeze protection level Solutions of antifreeze and supplemental coolant additives MUST be used year round for freeze protection boil over protection and to provide a stable noncorrosive environment for seals hoses and metal engine parts The following engine coolant is preferred for service John Deere PREDILUTED ANTIFREEZE SUMMER COOLANT John Deere COOL GARD where available The following engine coolant is also recommended John Deere ANTIFREEZE SUMMER COOLANT CONCENTRATE in a 40 to 60 percent mixture of concentrate with quality water JOHN DEERE PREDILUTED ANTIFREEZE SUMMER COOLANT This product contains all the necessary ingredients that make up the proper coolant solution chemically pure water ethylene glycol low silicate antifreeze and supplemental coolant additives SCAs It is ready to use no mixing is required John Deere Prediluted Antifreeze Summer Coolant permits extended service life to 3000 hours or 36 mo
30. Cleaner Dust Valve amp Restriction Indicator Lubricate PTO Release Bearing Visual Walkaround Inspection e Check Fuel Filter Lubricate PTO Clutch Shaft Bearings Service Fire Extinguisher Service Battery Change Engine Oil and Replace Filter Check PTO Clutch Adjustment Lubricate PTO Clutch Levers and Linkage s Clean Crankcase Vent Tube s Check Air Intake Hoses Connections amp System Replace Fuel Filter Element Check Automatic Belt Tensioner and Belt Wear Check Cooling System Coolant Solution Analysis Add SCAs as needed Adjust Droop on Generator Set Engines Check Crankshaft Vibration Damper 6 Cylinder Pressure Test Cooling System Flush Cooling System Check and Adjust Engine Valve Clearance Replace primary air cleaner element when restriction indicator shows a vacuum of 625 mm 25 in H20 Change the oil for the first time after 100 hours maximum of break in operation then every 250 hours thereafter If PLUS 50 oil is used along with a John Deere oil filter the oil change interval may be extended by 50 hours f John Deere Antifreeze Summer Coolant Concentrate or John Deere COOL GARD is used the flushing interval may be extended to 2000 hours If John Deere Prediluted Antifreeze Summer Coolant is used the flushing interval may be extended to 3000 hours or 36 m
31. EL ENGINE OIL in Fuels Lubricants and Coolant Section NOTE Some increase in oil consumption may be RG7981 expected when low viscosity oils are used Check oil levels more frequently If air temperature is below 10 C 14 F use an engine block heater 6 Watch coolant temperatures A closely If coolant temperature rises above 112 C 234 F reduce load on engine Unless temperature drops quickly stop the engine and determine the cause before resuming operation NOTE When the coolant temperature gauge reads approximately 115 C 239 F the engine will shutdown automatically if equipped with safety controls 7 Check poly vee belt for proper alignment and seating in pulley grooves RG8029 34 Engine Operating Guidelines AUXILIARY GEAR DRIVE LIMITATIONS IMPORTANT When attaching an air compressor hydraulic pump or other accessory to be driven by the auxiliary gear drive A engine timing gear train at front of engine power requirements of the accessory must be limited to values listed below 30 kW 40 hp Continuous Operation 37 kW 50 hp Intermittent Operation RG7634 STANDBY POWER UNITS To assure that your engine will deliver efficient standby operation when needed start engine and run at rated speed with 50 70 load for 30 minutes every 2 weeks DO NOT allow engine to run extended period of time with no load 35 Engine Operating Gu
32. G4675 3 Apply one shot of John Deere Multi Purpose Lubricant or equivalent at PTO release bearing grease fitting A DO NOT over lubricate RG7331 46 Lubrication amp Maintenance Daily 4 Ifthe air cleaner has an automatic dust unloader valve A squeeze the unloader valve on air cleaner assembly to clear away any dust buildup If equipped with air intake restriction indicator gauge B check gauge to determine if air cleaner needs to be serviced IMPORTANT Maximum air intake restriction is 6 25 kPa 0 06 bar 1 0 psi 25 in H O A clogged air cleaner element will cause excessive intake restriction and a reduced air supply to the engine 5 Make a thorough inspection of the engine Inspect compartment Look for oil or coolant leaks worn fan and accessory drive belts loose connections Radiator for leaks and trash build up and trash build up Remove trash build up and have repairs made as needed if leaks are found Airintake system hoses and connections for cracks and loose clamps NOTE Wipe all fittings caps and plugs before performing any maintenance to reduce the chance of system contamination Fan alternator and accessory drive belts for cracks breaks or other damage e Water pump for coolant leaks NOTE It is normal for a small amount of leakage to occur as the engine cools down and parts contract Excessive coolant leakage may indicate the need to re
33. GINE COOLANT in Fuels Lubricants and Coolant Section and ADDING COOLANT in Service As Required Section 4 Drain fuel tank and add 30 ml 1 oz of inhibitor to the fuel tank for each 15 L 4 U S gal of tank capacity Completely drain fuel filter and close fuel valve if equipped 5 10 11 12 13 14 Add 30 ml 1 oz of inhibitor to the engine crankcase for each 0 95 L 1 qt of crankcase oil Disconnect air intake piping from the manifold Pour 90 ml 3 oz of inhibitor into intake system and reconnect the piping Crank the engine several revolutions with starter do not allow the engine to start Remove fan alternator poly vee belt if desired Remove and clean batteries Store them in a cool dry place and keep them fully charged Disengage the PTO clutch Clean the exterior of the engine with salt free water and touchup any scratched or chipped painted surfaces with a good quality paint Coat all exposed machined metal surfaces with grease or corrosion inhibitor if not feasible to paint Seal all openings on engine with plastic bags and tape supplied in storage kit Follow instructions supplied in kit 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 98 Storage REMOVING ENGINE FROM LONG TERM STORAGE Refer to the appropriate section f
34. L 20 0 qt Crankcase oil capacity may vary slightly from amount shown ALWAYS fill crankcase to full mark or between arrows on dipstick whichever is present DO NOT overfill 104 Specifications UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUES 1 or 2b 5 5 1 5 2 8 8 2 m a gt 3 GS 85 2 5 SAE Grade and Head Markings SAE Grade and Nut Markings NO MARK Grade 1 Grade 2b Grade 5 5 1 or 5 2 Grade 8 or 8 2 Size Lubricated Dry Lubricated Lubricated Lubricated Dry Nem Per sees fom un uo a wo o uo i wo o uo Ib 1 4 3 7 2 8 4 7 3 5 6 13 5 12 5 5 16 7 7 5 5 10 7 12 rs EE 2 2 M 28 A x 26 3 8 14 10 17 13 22 16 27 20 35 26 44 33 50 36 63 46 7 16 22 16 28 20 35 26 44 32 55 41 70 52 80 58 100 75 1 2 33 25 42 31 53 39 67 50 85 63 110 80 120 90 150 115 9 16 48 36 60 45 75 56 95 70 125 90 155 115 175 130 225 160 5 8 67 50 85 62 105 78 135 100 170 125 215 160 240 175 300 225 3 4 120 87 150 110 190 140 240 175 300 225 375 280 425 310 550 400 7 8 190 140 240 175 190 140 240 175 490 360 625 450 700 500 875 650 1 290 210 360 270 290 210 360 270 725 540 925 675 1050 750 1300 975 1 1 8 400 300 510 375 400 300 510 375 900 675 1150 850 1450 1075 1850 1350 1 1 4 570 425 725 530 570 425 725 530 1300 950 1650 1200 2050 1500 2600 1950 1 3 8 750 550 950 700 750 550 950 700 1700 1250 2150 1550 2700 2000 3400 2550 1 1 2 1000 725 1250 925 990 725 1250 930 2250 1650 2850 2100 3600 2650 4550 3350
35. OS5304B x FOS Manual Bearings and Seals FOS5405B x FOS Manual Tires and Tracks FOS5507B x FOS Manual Air Conditioning FOS5707B x FOS Manual Fuels Lubricants amp Coolant FOS5807B x FOS Manual Fasteners FOS6004B x FOS Manual ldentification of Parts Failures FOS6104B x 1 inch 3 Ring Binder 400 pages max SX2062 D 1 1 2 inch 3 Ring Binder 600 pages max SX2063 x 1 1 1 2 inch 3 Post Binder 600 pages max SX2066 x i 2 3 1 2 inch 3 Post Binder 1400 pages max SX2064 x 2 4 inch 4 Post Expandable 2000 pages max SX2056 x Catalog of Available Service Publications DB1112 No Charge Subtotal Method of Payment Shipping 2 Cimcon Ode een sup aig 0 50to 24 99 3 00 Illinois state residents add 6 2596 and lowa C Master Card CI Discover 25 0010 49 99 4 25 state residents add 5 for Retail I Visa O American Express 4 UU uu als E state residents a o 10 etal 50 00 to 99 99 5 50 Occupation Tax or show tax exemption 100 00 to 199 99 7 50 number Other states excluded 200 00 and over 4 of subtotal Credit Card Account Number 13 or 16 dig its Expiration date Optional shipping available Total Shipping amp Handling Please check and add cost to normal shipping above P O1 day air 15 00 Amount Due in U S Dollars Your Signature 312 day ait 10 00 Prices subject to change without notice Ind
36. PowERTECH4 5 L amp 6 8 L 4045 and 6068 OEM Diesel Engines 1996 EPA Certification Levels U S A OPERATION AND MAINTENANCE MANUAL Deere Power Systems Group OMRG25204 20MAY96 S A ENGLISH DEERE Bes MIT POWER Introduction 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 b
37. REPLENISHING SUPPLEMENTAL COOLANT ADDITIVES SCAs BETWEEN COOLANT CHANGES RG6261 IMPORTANT Do not add supplemental coolant additives when the cooling system is drained and refilled with John Deere ANTIFREEZE SUMMER COOLANT or John Deere COOL GARD Through time and use the concentration of coolant additives is gradually depleted during engine operation Periodic replenishment of inhibitors is required even when John Deere ANTIFREEZE SUMMER COOLANT or John Deere COOL GARD is used The cooling system must be recharged with additional supplemental coolant additives available in the form of liquid coolant conditioner Maintaining the correct coolant conditioner concentration SCAs and freeze point is essential in your cooling system to protect against rust liner pitting and corrosion and freeze ups due to incorrect coolant dilution John Deere LIQUID COOLANT CONDITION is recommended as a supplemental coolant additive in John Deere engines Test the coolant solution at 600 hours or 12 months of operation using either John Deere coolant test strips or a CoolScan analysis If a CoolScan analysis is not available recharge system per instructions printed on label of John Deere Liquid Coolant Conditioner RG6262 IMPORTANT ALWAYS maintain coolant at correct level and concentration DO NOT operate engine without coolant for even a few minutes If frequent coolant makeup is required the glycol concentration should be chec
38. Record Fuel Injection Pump Model Number 5 Safety 2s s seo ANS EE 7 Fuels Lubricants and Coolant Diesel Fuel 17 Lubricity of Diesel Fuels 17 Diesel Fuel Storage 18 Filling Fuel Tank 18 Minimizing the Effect of Cold Weather on Diesel Engines ee 19 Engine Break in Oil 222 2 c nee 20 Diesel Engine OU 21 Mixing of Lubricants 2 222202 21 OILSCAN and CoolScan 2 22 Alternative and Synthetic Lubricants 22 Lubricant Storage 0000 eee ee eee 23 Grease cs ooo eL SM IM hag 23 Diesel Engine Coolant Recommendations 24 Engine Coolant Specifications 25 Testing Diesel Engine Coolant 27 Replenishing Supplemental Coolant Additives SCAs Between Coolant Changes 28 Operating in Warm Temperature Climates 29 Disposing of Coolant aaea anaana aaea 29 Engine Operating Guidelines Instrument Gauge Panel 31 Normal Engine Operation 32 Break in Service 0 0 ces 33 Auxiliary Gear Drive Limitations 35 Standby Power Units 35 Starting the Enge 36 Cold Weather Operation 38 Page Warming Engine 39 Changing Engine Speed Standard Mechanical GOVEMNOR iis ick gal cho El nahen 40 Idling Engine 40 Stopping the Engine 41 Using a Booster Battery or Charger 42 Lubrication and Maintenance Observe Service Interva
39. Rn 22 Operating engine Break in liu PE Uie 33 Cold weather 2 22222200 19 38 Normal operation 32 Warm temperature climates 29 Optio codes iens ey ame nn 3 Index 2 Index P Poly vee belts Replace olere ge RU Power take off PTO Clutch adjustment 2222222200 Levers and linkage lubricate Release bearing nsnnununnnu nnen Shaft bearings lubricate PTO CIUIGhi A 2 es aet ae PTO serialnumber 00000 eee R Radiator shutters Recordkeeping Engine option codes Engine serial number Injection pump model number PTO serial number S Serial number Engines sco E ec m REA s Fuel injection pump PT soa e rua ete Ix utes Dar gas Service Battery a ANAL UL ete Fire extinguisher 22 222 220 IntervalS una enden Specifications Battery capabilities Belttensioner llle Goolant ne Re eth Damper sioe Hr nenn Engine crankcase oil fill Fuel injection pump s es sssasasan General OEM Torque values inch Torque values metric Valve clearance 22220222 Standby power unt Starting engine Stopping engine Page Page Storage Air cleaner element 80 Engine nase ehren 97 99 Fler che eue set NEN 18 Lubricants 23 Supplemental coolant additi
40. a piece of cardboard Protect hands and body from high pressure fluids If an accident occurs see a doctor immediately Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result Doctors unfamiliar with this type of injury should reference a knowledgeable medical source Such information is available from Deere amp Company Medical Department in Moline Illinois U S A X9811 AVOID HEATING NEAR PRESSURIZED FLUID LINES Flammable spray can be generated by heating near pressurized fluid lines resulting in severe burns to yourself and bystanders Do not heat by welding soldering or using a torch near pressurized fluid lines or other flammable materials Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area TS953 13 Ad REMOVE PAINT BEFORE WELDING OR HEATING Avoid potentially toxic fumes and dust Hazardous fumes can be generated when paint is heated by welding soldering or using a torch Do all work outside or in a well ventilated area Dispose of paint and solvent properly Remove paint before welding or heating If you sand or grind paint avoid breathing the dust Kee Wear an approved respirator f you use solvent or paint stripper remove stripper with soap and water before welding Remove solvent or paint stripper containers and other flammable material from area Allow fumes to disperse at least
41. al on dash line and removing cell plugs If necessary add clean soft water to bring level to bottom of filler neck 2 Keep batteries clean by wiping them with a damp cloth Keep all connections clean and tight Remove any corrosion and wash terminals with a solution of 1 part baking soda and 4 parts water Tighten all connections securely NOTE Coat battery terminals and connectors with a mixture of petroleum jelly and baking soda to retard corrosion 3 Keep battery fully charged especially during cold weather If a battery charger is used turn charger off before connecting charger to battery ies Attach POSITIVE battery charger lead to POSITIVE battery post Then attach NEGATIVE battery charger lead to a good ground TS204 52 Lubrication and Maintenance 250 Hour SERVICING BATTERY CONTINUED CAUTION Sulfuric acid in battery A electrolyte is poisonous It is strong enough to burn skin eat holes in clothing and cause blindness if splashed into eyes Avoid the hazard by 1 Filling batteries in a well ventilated area 2 Wearing eye protection and rubber gloves 3 Avoiding breathing fumes when electrolyte is added 4 Avoiding spilling or dripping electrolyte 5 Use proper jump start procedure If you spill acid on yourself 1 Flush your skin with water 2 Apply baking soda or lime to help neutralize the acid 3 Flush your eyes with water for 10 15 minutes Get me
42. an make repairs at your place or at ours depending on the circumstances see us depend on us JOHN DEERE SERVICE SUPERIORITY We ll be around when you need us
43. b ft 6 Close all drain valves after coolant has drained 7 Fillthe cooling system with clean water Run the engine about 10 minutes to stir up possible rust or sediment 8 Stop engine and immediately drain the water from system before rust and sediment settle 69 Lubrication amp Maintenance 1200 Hour 24 Month FLUSHING COOLING SYSTEM CONTINUED 9 After draining water close drain valves and fill the cooling system with clean water and TY15979 John Deere Heavy Duty Cooling System Cleaner or an equivalent cleaner such as Fleetguard RESTORE and RESTORE PLUS Follow manufacturer s directions on label 10 After cleaning the cooling system drain cleaner and fill with water to flush the system Run the engine about 10 minutes then drain out flushing water 11 Close all drain valves on engine and radiator Install thermostats using a new gasket IMPORTANT Air must be expelled from cooling System when system is refilled Loosen temperature sending unit fitting at rear of cylinder head or plug in thermostat housing to allow air to escape when filling system Retighten fitting or plug when all the air has been expelled Fleetguard is a registered trademark of Cummins Engine Company RESTORE and RESTORE PLUS are trademarks of Fleetguard 12 13 14 Add coolant to radiator until coolant touches bottom of filler neck See ADDING COOLANT in Service As Required Section Run engine un
44. cation and Maintenance OBSERVE SERVICE INTERVALS Using hour meter A as a guide perform all services at the hourly intervals indicated on following pages At each scheduled maintenance interval perform all previous maintenance operations in addition to the ones specified Keep a record of hourly intervals and services performed using charts provided in Lubrication and Maintenance Records Section IMPORTANT Recommended service intervals are for normal operating conditions Service MORE OFTEN if engine is operated under adverse conditions Neglecting maintenance can result in failures or permanent damage to the engine RG4699 USE CORRECT FUELS LUBRICANTS AND COOLANT IMPORTANT Use only fuels lubricants and coolants meeting specifications outlined in Fuels Lubricants and Coolant Section when servicing your John Deere Engine Consult your John Deere engine distributor servicing dealer or your nearest John Deere Parts Network for recommended fuels lubricants and coolant Also available are necessary additives for use when operating engines in tropical arctic or any other adverse conditions 43 Lubrication and Maintenance LUBRICATION AND MAINTENANCE SERVICE INTERVAL CHART Lubrication and Maintenance Service Intervals d 50 Hour 600 Hour 1200 Hour item Daily Every 2Weeks 250 Hour 12 Mont 24Month 2000 Hour Check Engine Oil and Coolant Level Check Air
45. d John Deere ENGINE BREAK IN OIL as needed to maintain the specified oil level Change the oil and filter after the first 100 hours of operation of a new or rebuilt engine After engine overhaul fill the engine with John Deere ENGINE BREAK IN OIL If John Deere ENGINE BREAK IN OIL is not available use a diesel engine oil meeting one of the following during the first 100 hours of operation APIService Classification CE e ACEA Specification E1 e COMC Specification D4 After the break in period use John Deere PLUS 50 or other diesel engine oil as recommended in this manual IMPORTANT Do not use John Deere PLUS 50 oil or engine oils meeting API CG4 API CF4 ACEA E3 ACEA E2 or CCMC D5 performance levels during the first 100 hours of operation of a new or rebuilt engine These oils will not allow the engine to break in properly 20 Fuels Lubricants and Coolant DIESEL ENGINE OIL Use oil viscosity based on the expected air temperature range during the period between oil changes 122 F The following oil is preferred T 104 F John Deere PLUS 50 9 2 86 F ul If John Deere PLUS 50 engine oil and a John Deere oil Y E 5 filter are used the service interval for oil and filter o 68 F o changes may be extended by 50 hours tu 1 u P 5 e 2 50 F o The following oil is also recommended ul ig 4 O e 32 F John Deere TORQ GARD SUPREME ug An 14 F Other oils may be used if they meet on
46. d in this manual are for the accessories that are provided by John Deere Follow manufacturer s service recommendations for servicing engine driven equipment not supplied by Deere DAILY PRESTARTING SERVICE Check engine oil level Check coolant level Lubricate PTO release bearing Check air cleaner dust unloader valve and air restriction indicator if equipped e Visual walkaround inspection 107 Lubrication and Maintenance Records 50 HOUR EVERY 2 WEEKS SERVICE e Check fuel filter Lubricate PTO clutch shaft bearings Hours Date Hours Date 250 HOUR SERVICE Change engine oil and filter Service fire extinguisher Service battery Check PTO clutch adjustment Hours Date If John Deere PLUS 50 oil is used along with a John Deere oil filter the oil change interval may be extended by 50 hours 108 Lubrication and Maintenance Records 600 HOUR 12 MONTH SERVICE Lubricate PTO clutch internal levers and linkage e Check cooling system Clean crankcase vent tube e Coolant solution analysis add SCAs as needed Replace fuel filter element e Check air intake hoses connections and system Check automatic belt tensioner and belt wear Replace air cleaner elements Hours Date Hours Date 109 Lubrication and Maintenance Records 1
47. ded during this period John Deere Engine Break In Oil is preferred See ENGINE BREAK IN OIL in Fuels Lubricants and Coolant Section IMPORTANT DO NOT use PLUS 50 Engine Oil during the break in period of a new engine or engine that has had a major overhaul PLUS 50 oil will not allow a new or overhauled engine to properly wear during this break in period IMPORTANT DO NOT fill above the crosshatch pattern A or the FULL mark whichever is present Oil levels anywhere within the crosshatch are considered in the acceptable operating range 4g RG8009 RG7330 ENGINE SPECIFICATIONS Oil Pressure at Full Load Rated Speed 345 103 kPa 8 45 1 03 bar 50 15 psi Minimum Oil Pressure at Rated Speed 275 2 75 bar 40 psi Minimum Oil Pressure at 850 rpm 103 kPa 1 03 bar 15 psi Coolant Temperature Range 82 94 C 180 202 F At normal operating temperature of 115 C 240 F sump 33 Engine Operating Guidelines BREAK IN SERVICE CONTINUED 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 5 Afterthe first 100 hours maximum change engine oil and replace engine oil filter A See CHANGE ENGINE OIL AND FILTER in Lubrication and Maintenance 250 Hour Section Fill crankcase with seasonal viscosity grade oil See DIES
48. dical attention immediately If acid is swallowed 1 Drink large amounts of water or milk 2 Then drink milk of magnesia beaten eggs or vegetable oil 3 Get medical attention immediately In freezing weather run engine at least 30 minutes to assure thorough mixing after adding water to battery If necessary to replace battery ies replacements must meet or exceed the following recommended capabilities at 18 C 0 F Battery Capabilities 12V Standard Duty Starter 640 Cold Cranking Amps 12V Heavy Duty Starter 800 Cold Cranking Amps 24V Standard Duty Starter 570 Cold Cranking Amps TS203 53 Lubrication and Maintenance 250 Hour CHANGING ENGINE OIL AND REPLACING OIL FILTER NOTE Change engine oil and filter for the first time BEEN EN after 100 hours maximum of operation then every 250 hours thereafter m HL If John Deere PLUS 50 engine oil and a John Deere oil filter are used the oil and filter change interval may be extended by 50 hours OILSCAN is a John Deere sampling program to help you monitor machine performance and identify potential problems before they cause serious damage OILSCAN kits are available from your John Deere dealer Oil samples should be taken prior to the oil Haren change Refer to instructions provided with kit 1 Run engine approximately 5 minutes to warm up oil Shut engine off 2 Remove oil pan drain plug arrow
49. e 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 CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are know to the State of California to cause cancer birth defects and other reproductive harm 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 Learn who he 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 UTILISATEURS DE MOTEURS JOHN DEERE N attendez pas d tre oblig d avoir recours a votre Concessionnaire ou Point de Service le plus proche pour vous adresser a lui Renseignez vous des que possible pour l identifier et le localiser A la premiere occasion prenez contact avec lui et faites vous connaitre Il sera lui aussi heureux de faire votre connaissance et de savoir que vous pourrez compter sur lui le moment venu AN DEN BESITZER DES JOHN DEERE MOTORS Warten Sie nicht auf einen evt Reparaturfall um den n chstgelegenen John Deere H ndler kennen zu lernen Machen Sie sich bei ihm bekannt und nutzen Sie sein Service Angebot PROPRIETARIO DEL MOTORE JOHN DEERE Non aspetti fino a quando ha bisogno della garanzia o di un altro tipo di assistenza
50. e or more of the ps following mis John Deere UNI GARD 22 F e API Service Classification CG 4 z e API Service Classification CF 4 E E e ACEA Specification E3 e ACEA Specification E2 ias e COMC Specification D5 e CCMC Specification D4 Multi viscosity diesel engine oils are preferred If diesel fuel with sulfur content greater than 0 5 is used reduce the service interval by 50 MIXING OF LUBRICANTS In general avoid mixing different brands or types of oil Consult your John Deere engine distributor or servicing Oil manufacturers blend additives in their oils to meet dealer to obtain specific information and certain specifications and performance requirements recommendations Mixing different oils can interfere with the proper functioning of these additives and degrade lubricant performance 21 Fuels Lubricants and Coolant OILSCAN AND COOLSCAN OILSCAN and COOLSCAN are John Deere sampling programs to help you monitor machine performance and identify potential problems before they cause serious damage Oil and coolant samples should be taken from each system prior to its recommended change interval Check with your John Deere dealer for the availability of OILSCAN and COOLSCAN kits T6829AB ALTERNATIVE AND SYNTHETIC LUBRICANTS Conditions in certain geographical areas may require Synthetic lubricants may be used if they meet the lubricant recommendations different from those printed p
51. e requires that an internal pump adjustment be made RG8101 65 Lubrication amp Maintenance 1200 Hour 24 Month ADJUSTING VARIABLE SPEED DROOP ON GENERATOR SET ENGINES CONTINUED NIPPONDENSO IN LINE INJECTION PUMPS ONLY 1 Check for specified no load frequency If governor regulation is within 5 7 range no adjustment is necessary 2 If governor regulation is above 7 or below 5 stop engine and remove cap nuts from adjusting screws before making adjustments 3 Remove droop adjusting screw access plug B shown removed from top of governor housing 4 Back out slow idle adjusting screw D and bumper screw Pull back on throttle lever F toward rear of governor housing by hand unti Ithe droop adjusting screw C inside housing can be adjusted through the access plug hole 5 Screw the droop screw in clockwise counting the turns until screw bottoms out Then return screw to original setting NOTE A noticable click will occur at each 1 4 turn of droop adjusting screw One click clockwise will increase no load speed approximately 10 rpm counter clockwise will reduce speed by 10 rpm 6 Screw in the droop screw clockwise no more than 1 2 turn two clicks at a time to reducegovernor droop Turn counterclockwise no more than two clicks at a time to increase governor droop to reduce governor sensitivity 7 Replace access plug in top of governor housing Start engine apply full 10096
52. eeze solutions as this can cause silicate dropout When this happens a gel type deposit is created which retards heat transfer and coolant flow causing engine to overheat NOTE John Deere Prediluted Antifreeze Summer Coolant John Deere Antifreeze Summer Coolant Concentrate and John Deere COOL GARD contain supplemental coolant additives SCAs However as the coolant solution loses its effectiveness additives will need to be added Operating without proper coolant additive will result in increased corrosion cylinder liner erosion and pitting and other damage to the engine and cooling system A simple mixture of ethylene glycol and water WILL NOT give adequate protection The use of supplemental coolant additives reduces corrosion erosion and pitting These chemicals reduce the number of vapor bubbles in the coolant and help form a protective film on cylinder liner surfaces This film acts as a barrier against the harmful effects of collapsing vapor bubbles Inhibit the antifreeze coolant mix with a non chromate inhibitor John Deere Liquid Coolant Conditioner is recommended as a supplemental coolant additive in John Deere engines IMPORTANT Check inhibitors between drain intervals every 600 hours or 12 months of operation Replenish inhibitors by the addition of a supplemental coolant additive as necessary DO NOT use soluble oil Additives eventually lose their effectiveness and must be recharged with additional su
53. electrical System does not function Entire electrical system does not function PROBLEM Low battery output Crankcase oil too heavy Loose or corroded connections Blown fuse on magnetic switch Faulty battery connection Sulfated or worn out batteries Blown fuse MDL 25 SOLUTION See your authorized servicing dealer or engine distributor Use proper viscosity oil Clean and tighten loose connections Replace fuse Clean and tighten connections See your authorized servicing dealer or engine distributor Replace fuse 96 Storage 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 2 John Deere engines can be stored in a standard overseas shipping container for up to three 3 months with no long term preparation 3 John Deere engines can be stored inside warehoused for up to six 6 months with no long term preparation 4 John Deere engines expected to be stored more than six 6 months long term storage preparation MUST BE taken See PREPARING ENGINE FOR LONG TERM STORAGE later in this section For John Deere engines not yet installed in machines run a line from a container of AR41937 Nucle Oil to the fuel transfer pump intake and another line from the fuel return manifold to the tank so that Nucle Oil is circulated through the injection system du
54. er Pump Thermostat Housing Cil Dipstick Belt Driven Front Auxiliary Drive Starting Aid Timing Gear Cover With Gears Option Codes 45 46 47 48 49 50 51 52 55 56 57 59 60 62 64 65 66 67 68 69 74 75 76 86 87 88 91 97 98 Description Balancer Shaft Oylinder Block With Liners and Camshaft Crankshaft and Bearings Connecting Rods and Pistons Valve Actuating Mechanisms Oil Pump Cylinder Head With Valves Auxiliary Gear Drive Shipping Stand Paint Option Water Pump Inlet Oil Cooler Add on Auxiliary Drive Pulley Alternator Mounting Exhaust Elbow Turbocharger Temperature Switch Electronic Tachometer Sensor Damper Engine Serial Number Plate Air Conditioner Compressor Mounting Air Restriction Indicator Oil Pressure Switch Fan Pulley Automatic Belt Tensioner Oil Filter Special Equipment Factory Installed Special Equipment Field Installed Shipping Record Keeping RECORD PTO SERIAL NUMBER Serial number and model number are located on cover plate A of PTO housing Record the numbers in the following spaces Serial Number Model Number RG4622 RECORD FUEL INJECTION PUMP MODEL NUMBER Record the fuel injection pump model and serial information found on the serial number plate A Model No RPM Manufacturer s No Serial No RG8008 Record Keeping Safety RECOGNIZE SAFETY INFORMATION This is the
55. er or engine distributor check injectors See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor Clean or replace fuel hose See your authorized servicing dealer or engine distributor Add oil Drain fill crankcase with oil of proper viscosity and quality Use proper viscosity oil Check for leaks in lines gaskets and drain plug Clean vent tube See your authorized servicing dealer or engine distributor Continued on next page 92 Troubleshooting SYMPTOM Engine emits white smoke Engine emits black or gray exhaust smoke Engine overheats PROBLEM Improper type of fuel Low engine temperature Defective thermostat Defective injection nozzles Engine out of time Improper type of fuel Clogged or dirty air cleaner Engine overloaded Injection nozzles dirty Engine out of time Turbocharger not functioning Engine overloaded Low coolant level Faulty radiator cap Stretched poly vee belt or defective belt tensioner Low engine oil level Cooling system needs flushing Defective thermostat Defective temperature gauge or sender Incorrect grade of fuel SOLUTION Use proper fuel Warm up engine to normal operating temperature Remove and check therm
56. erformance requirements as shown in this manual in this manual The temperature limits and service intervals shown in Some John Deere brand coolants and lubricants may this manual apply to both conventional and synthetic not be available in your location oils Consult your John Deere dealer to obtain information Re refined base stock products may be used if the and recommendations finished lubricant meets the performance requirements 22 Fuels Lubricants and Coolant 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 Store containers on their side to avoid water and dirt accumulation Make certain that all containers are properly marked to identify their contents Properly dispose of all old containers and any residual lubricant they may contain GREASE Use grease based on NLGI consistency numbers and the expected air temperature range during the service interval The following greases are preferred John Deere HIGH TEMPERATURE EP GREASE John Deere MOLY HIGH TEMPERATURE EP GREASE John Deere GREASE GARD Other greases may be used if they meet one of the following e NLGI Performance Classification GC LB 50 122 F 2 40 C HH 104 F A a LU eO N Se case C
57. escape when filling system Retighten fitting or plug when all the air has been expelled TS281 1 Check entire cooling system for leaks Tighten all clamps securely 2 Thoroughly inspect all cooling system hoses Replace hoses when hard flimsy or cracked 62 Lubrication amp Maintenance 600 Hour 12 Month CHECKING EFFECTIVENESS OF COOLANT SOLUTION When your coolant has accumulated 600 hours or 12 months of operating time the effectiveness of your engine coolant should be evaluated by obtaining a coolant sample Maintaining adequate concentrations of glycol and inhibiting additives SCAs in the coolant is critical to protect the engine and cooling system against freezing corrosion and cylinder liner erosion and pitting A coolant strip test kit provides a simple effective way to check freeze point and additive levels For a more thorough evaluation of your coolant CoolScan where available is a John Deere sampling program to help you monitor the effectiveness of your engine s coolant solution and identify potential problems before they cause serious damage TY16175 or TY16176 3 Way Heavy Duty Coolant Test Kit and DS0251 CoolScan kits are available from your John Deere dealer Refer to instructions provided with kits Usually recharging your engine coolant with the recommended amount of TY16004 or TY16005 Liquid Coolant Conditioner at 600 hours or 12 months of operation is adequate However
58. ex Page Page A Cooling system Adding coolant 222222 een 76 ee e ENEE 53 Check eese n 62 Additives Coolscan Sus s amt SV eure Serius as 22 EE ee ptt ume UE 64 Flush eee nnn nn 69 Air cleaner Pressure test 0 0 2 0 02 eee eee eee 68 Cleaning element 79 Pressure test radiator cap 68 Element storage sese eese 80 Crankcase vent tube clean 57 Inspect element 78 Crankshaft vibration damper 67 Replace element 2 77 Washing element 80 D Air intake system check 58 Alternator bes 81 Daily checks v oo Satoh n cine ore be oa 45 47 Ammeter es Sube een 31 Damper checking a Ra ett eet RA LE are 67 Auxiliary gear drive limitations 35 Diesel engine ol 21 Diesel Tue 17 B Biel oerte RR ER 17 Storage svedese nee Ee na re 18 Batteries Charge Boost n ster eed eina Ao 42 E SERVICE ua me nbus WE Pe RA 52 Battery acid Burns ix s espe E ER E 53 Electrical system diagram 2 2222 88 Battery explosion oss san E eae Sl ds 52 Electrical system troubleshooting 95 Belt tensioner 0 0 0 eee ee eee 61 Emissions Belts fan and alternator GARB Statement coude eee 114 Replacing EN 81 EPA Statement 113 Bleeding fuel system 2 22 2222 20 84 Warranty Jabel 113 Break in engine ol 20 Engine Break in engine 33 Break in en 33 Goolant NN nen a 24 C Daily prestartin
59. facings NOTE Location of pilot bearing fitting will depend on application Only one fitting will be used RG7331 A Release Bearing Grease Fitting B Drive Shaft Bearing Fitting C Lever Cross Shaft Fittings D Pilot Bearing Fitting 50 Lubrication and Maintenance 250 Hour SERVICING FIRE EXTINGUISHER A fire extinguisher A is available from your authorized servicing dealer or engine distributor Read and follow the instructions which are packaged with it The extinguisher should be inspected at least every 250 hours of engine operation or once a month Once extinguisher is operated no matter how long it must be recharged Keep record of inspections on the tag which comes with the extinguisher instruction booklet RW4918 51 Lubrication and Maintenance 250 Hour SERVICING BATTERY CAUTION Battery gas can explode Keep A sparks and flames away from batteries Use a flashlight to check battery electrolyte level Never check battery charge by placing a metal object across the posts Use a voltmeter or hydrometer Always remove grounded NEGATIVE battery clamp first and replace it last 1 On regular batteries check electrolyte level Fill each cell to bottom of filler neck with distilled water NOTE Low maintenance or maintenance free batteries should require little additional service However electrolyte level can be checked by cutting the center section of dec
60. fornia new heavy duty engines must be designed built and equipped to meet the State s stringent anti smog standards John Deere must warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse neglect or improper maintenance of your engine Your emissions control system includes Fuel Metering System Fuel Injection System Air Induction System Intake Manifold Turbocharger System Charge Air Cooling System Miscellaneous Items used in above systems Where a warrantable condition exists i e failure due to defect in John Deere supplied material and or workmanship John Deere will repair your heavy duty engine at no cost to you including diagnosis parts and labor John Deere s Warranty Coverage The emission control system of your heavy duty engine is warranted for five years or 3000 hours of operation whichever occurs first If any emission related part on your engine is defective the part will be repaired or replaced by John Deere Warranties stated in this manual refer only to emissions related parts and components of your engine The complete engine warranty less emissions related parts and components is provided separately as the John Deere New Off Highway Engine Warranty 114 Emission System Warranty CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT CONTINUED Owner s Warranty Responsibilities As the heavy duty engine owner you are re
61. g checks 45 laling REI SNE EE 40 Chart service Internal 44 Operation 6 eee eee nnne 32 Clearance elvis erc oes Lo ok SU at 71 Option codes 1 22 2 sees eee ee 3 Cold weather ele 19 38 SE j ele EEN 31 Starting isse nn 36 Coolant SPPN u ee ea 41 TEE 76 Storage kt 97 Additives o rt rni dates ee 26 28 64 Troubleshooting 222222220 90 EI ele GE 29 Warming 2 2 2 nennen 39 Recommendations 2 2222222222 24 Engine coolant Speciheallonss a hr 25 Disposing ol 29 Jeng A er werden 27 Recommendations ee 24 Coolant solution Specifications 2222222 25 Check effectiveness 0000 63 Engine electrical system Coolant temperature gauge 22 222222 31 Troubleshooting en 95 Coolant supplemental additives SCAs 26 28 Wiring diagram e 88 Index 1 Index Page Engine oil Brealcins i3 nassen sk T ERES 20 Change u ana a 54 Diesel nn an aa re GES 21 Oil filter change 54 Engine speed changing 40 Droop ans draton Deeds 65 66 F Fairbelts thet voL re A 81 Filter replace el ec C px eeu Rr in 59 opc 54 Fire extinguisher service 51 Fuel DIESEL nn a rn 17 Fuel filter Checking n A SA 49 Heplace sceskesd ye ex x eYqex 59 Fuel injection pump model number 5 Fuel storage 2 ee ee ee ee eee 18 Fuel system Bleeding u 84 Fuel tank Filling vy een 18 Fuses checking llle 83 G
62. g for more than 5 minutes stop and restart later NOTE Generator set applications where the governor is locked at a specified speed may not have a slow idle function These engines will idle at no load governed speed high idle 40 Engine Operating Guidelines STOPPING THE ENGINE 1 Pull PTO clutch lever arrow rearward away from engine to disengage clutch if equipped 2 Move the throttle lever A to slow idle on standard mechanical governor engines IMPORTANT Before stopping an engine that has been operating at working load idle engine at least 2 minutes at 1000 1200 rpm to cool hot engine parts Engines in generator set applications where the governor is locked at a specified speed and no slow idle function is available run engine for at least 2 minutes at fast i idle and no load i RG5602 3 Turn key switch to OFF position to stop the engine Remove ignition key IMPORTANT Make sure that exhaust stack cap A rain cap is installed when engine is not running This will prevent water and dirt from entering engine RG8039 41 Engine Operating Guidelines USING A BOOSTER BATTERY OR CHARGER A 12 volt booster battery can be connected in parallel with battery ies on the unit to aid in cold weather starting ALWAYS use heavy duty jumper cables CAUTION Gas given off by battery is A explosive Keep sparks and flames away from battery Before connecting or d
63. idelines STARTING THE ENGINE The following instructions apply to the optional controls and instruments available through the John Deere Parts Distribution Network The controls and instruments for your engine may be different from those shown here always follow manufacturer s instructions CAUTION Before starting engine in a A confined building install proper outlet exhaust ventilation equipment Always use safety approved fuel storage and piping NOTE If temperature is below 0 C 32 F it may be necessary to use cold weather starting aids See COLD WEATHER OPERATION later in this section 1 Berform all prestarting checks outlined in Lubrication amp Maintenance Daily Section later in this manual 2 Openthe fuel supply shut off valve if equipped 3 If equipped with PTO clutch pull lever arrow rearward away from engine to disengage PTO clutch TS220 RG5602 36 Engine Operating Guidelines STARTING THE ENGINE CONTINUED NOTE Some electronically controlled governor applications may be equipped with a rotary speed potentiometer on instrument panel 4 Onstandard mechanical governor 7 10 regulation engines pull hand throttle A 1 3 of the way out Turn the handle in either direction to lock it in place 5 f equipped depress and hold reset button B while starting IMPORTANT Do not operate the starter for more than 30 seconds at a time To do so may
64. 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 DO NOT overtighten retaining ring NOTE The proper installation is indicated when a click is heard and a release of the retaining ring is felt A plug is provided with the new element for plugging the used element 9 Open fuel shut off valve and bleed the fuel system See BLEED FUEL SYSTEM in Service As Required Section Tighten bleed plug D 60 Lubrication amp Maintenance 600 Hour 12 Month CHECKING BELT TENSIONER SPRING TENSION AND BELT WEAR Belt drive systems equipped with automatic spring belt tensioners cannot be adjusted or repaired The automatic belt tensioner is designed to maintain proper belt tension over the life of the belt If tensioner spring tension is not within specification replace tensioner assembly 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 1 Visually inspect cast stops A and B on belt tensioner assembly If the tensioner stop on swing arm A is hitting the fixed stop B check mounting brackets alternator belt tensioner idler pulley etc and the belt length Replace belt as needed see REPLACING FAN AND ALTERNATOR BELTS in Service As Required Sect
65. ion Checking Tensioner Spring Tension A belt tension gauge will not give an accurate measure of the belt tension when automatic spring tensioner is used Measure tensioner spring tension using a torque wrench and procedure outlined below 1 Release tension on belt using a breaker bar and Socket on tension arm Remove belt from pulleys 2 Release tension on tension arm and remove breaker bar RG7977 3 Puta mark A on swing arm of tensioner as shown 4 Measure 21 mm 0 83 in from A and put a mark B on tensioner mounting base 61 Lubrication amp Maintenance 600 Hour 12 Month CHECKING BELT TENSIONER SPRING TENSION CONTINUED 5 Rotate the swing arm using a torque wrench until marks A and B are aligned 6 Record torque wrench measurement and compare with specification below Replace tensioner assembly as required SPRING TENSION SPECIFICATION Spring Tension nennen nenn 18 22 N m 13 16 Ib ft CHECKING COOLING SYSTEM pressurized cooling system can cause CAUTION Explosive release of fluids from serious burns Shut off engine Only remove filler cap when cool enough to touch with bare hands Slowly loosen cap to first stop to relieve pressure before removing completely IMPORTANT Air must be expelled from cooling system when system is refilled Loosen temperature sending unit fitting at rear of cylinder head or plug in thermostat housing to allow air to
66. ions do not require fuels to pass a fuel lubricity test If fuel of low or unknown lubricity is used add John Deere PREMIUM DIESEL FUEL CONDITIONER or equivalent at the specified concentration John Deere PREMIUM DIESEL FUEL CONDITIONER is available in winter and summer formulas Consult your John Deere engine distributor or servicing dealer for more information 17 Fuels Lubricants and Coolant DIESEL FUEL STORAGE Proper fuel storage is critically important Use clean storage and transfer tanks Periodically drain water and sediment from bottom of tank Store fuel in a convenient place away from buildings IMPORTANT DO NOT store diesel fuel in galvanized containers Diesel fuel stored in galvanized containers reacts with zinc coating on container to form zinc flakes If fuel contains water a zinc gel will also form The gel and flakes will quickly plug fuel filters damage injection nozzles and injection pump DO NOT use brass coated containers for fuel storage Brass is an alloy of copper and zinc Store diesel fuel in plastic aluminum and steel containers specially coated for diesel fuel storage Avoid storing fuel over long periods of time If fuel is stored for more than a month prior to use or there is a slow turnover in fuel tank or supply tank add a fuel conditioner such as John Deere PREMIUM DIESEL FUEL CONDITIONER or equivalent to stabilize the fuel and prevent water condensation John Deere
67. ions of quality water ethylene glycol concentrate antifreeze and supplemental coolant additives SCAs MUST be used year round to protect against freezing boil over liner erosion or pitting and to provide a stable noncorrosive environment for seals hoses and metal engine parts Some products including John Deere PREDILUTED ANTIFREEZE SUMMER COOLANT and John Deere COOL GARD are fully formulated coolants that contain all three components in their correct concentrations Do not add an initial charge of supplemental coolant additives to these fully formulated products Some coolant concentrates including John Deere ANTIFREEZE SUMMER COOLANT CONCENTRATE contain both ethylene glycol antifreeze and inhibiting coolant additives Mix these products and quality water but do not add an initial charge of supplemental coolants additives Coolants meeting ASTM D5345 prediluted coolant or ASTM D4985 coolant concentrate require an initial charge of supplemental coolant additives Water Quality Water quality is important to the performance of the cooling system Distilled deionized or demineralized water is recommended for mixing with ethylene glycol base engine coolant concentrate All water used in the cooling system should meet the following minimum specifications for quality Water Quality Specifications Parts Grains Per Per Item Million U S Gallon Chlorides maximum 40 2 5 Sulfates maximum
68. isconnecting a battery charger turn charger off Make last connection and first disconnection at a point away from battery TS204 Always connect NEGATIVE cable last and disconnect this cable first IMPORTANT Be sure polarity is correct before making connections Reversed polarity will damage electrical system Always connect positive to positive and negative to ground Always use 12 volt booster battery for 12 volt electrical systems and 24 volt booster battery ies for 24 volt electrical systems 1 Connect booster battery or batteries to produce the RG4678 required system voltage for your engine application 12 Volt System NOTE To avoid sparks DO NOT allow the free ends of jumper cables to touch the engine 2 Connect one end of jumper cable to the POSITIVE post of the booster battery 3 Connect the other end of the jumper cable to the POSITIVE post of battery connected to starter 4 Connect one end of the other jumper cable to the NEGATIVE post of the booster battery 5 ALWAYS complete the hookup by making the last connection of the NEGATIVE cable to a good ground on the engine frame and away from the battery ies 24 Volt System 6 Start the engine Disconnect jumper cables A 12 Volt Machine Battery ies g l p B 12 Volt Booster Battery ies immediately after engine starts Disconnect C Booster Cable NEGATIVE cable first D Cable to Starting Motor 42 Lubri
69. ked with JT05460 Refractometer to assure that the desired freeze point is maintained Follow manufacturer s instructions provided with refractometer Add the manufacturer s recommended concentration of supplemental coolant additive DO NOT add more than the recommended amount The use of non recommended supplemental coolant additives may result in additive drop out and gelation of the coolant If other coolants are used consult the coolant supplier and follow the manufacturer s recommendation for use of supplemental coolant additives See ENGINE COOLANT SPECIFICATIONS earlier in this section for proper mixing of coolant ingredients before adding to the cooling system 28 Fuels Lubricants and Coolant OPERATING IN WARM TEMPERATURE CLIMATES John Deere engines are designed to operate using IMPORTANT Water may be used as coolant in glycol base engine coolants emergency situations only Always use a recommended glycol base engine Foaming hot surface aluminum and coolant even when operating in geographical areas iron corrosion scaling and where freeze protection is not required cavitation will occur when water is used as the coolant even when coolant conditioners are added Drain cooling system and refill with recommended glycol base engine coolant as soon as possible DISPOSING OF COOLANT Improperly disposing of engine coolant can threaten the environment and ecology Use leakproof containers
70. ling system hose connections radiator and overall engine for leaks If leakage is detected correct as necessary and pressure test system again If no leakage is detected but the gauge indicated a drop in pressure coolant may be leaking internally within the system or at the block to head gasket Have your servicing dealer or distributor correct this problem immediately 68 Lubrication amp Maintenance 1200 Hour 24 Month FLUSHING COOLING SYSTEM pressurized cooling system can cause CAUTION Explosive release of fluids from serious burns Shut off engine Only remove filler cap when cool enough to touch with bare hands Slowly loosen cap to first stop to relieve pressure before removing completely Drain old coolant flush the entire cooling system replace thermostats and fill with recommended clean coolant TS281 1 Pressure test entire cooling system and pressure cap if not previously done See PRESSURE TESTING COOLING SYSTEM earlier in this section 2 Slowly open the engine cooling system filler cap or radiator cap to relieve pressure and allow coolant to drain faster 3 Open engine block drain valve A on left side of engine Drain all coolant from engine block ua 2 RG8019 4 Open radiator drain valve Drain all coolant from radiator 5 Remove thermostats at this time if not previously done Install cover without thermostats and tighten cap screws to 47 N m 35 I
71. ls 00 43 Use Correct Fuels Lubricants and Coolant 43 Lubrication amp Maintenance Service Interval Chart 44 Lubrication amp Maintenance Daily Daily Prestarting Checks ana anaana 45 Lubrication amp Maintenance 50 Hour 2 Weeks Checking Fuel Filter naana 49 Lubricating PTO Clutch Shaft Bearings 50 Lubrication and Maintenance 250 Hour Servicing Fire Extinguisher 51 Servicing Battery eee 52 Changing Engine Oil and Replacing Oil Filter 54 Checking PTO Clutch Adjustment 56 Lubrication amp Maintenance 600 Hour 12 Month Lubricating PTO Clutch Internal Levers amp Linkage 57 Cleaning Crankcase Vent Tube 57 Checking Air Intake System 58 Replacing Fuel Filter Element 59 Checking Belt Tensioner Spring Tension and Belt Wear 200 0c eee eee 61 Checking Cooling System 62 Checking Effectiveness of Coolant Solution 63 Adding Supplemental Coolant Additives 64 Continued on next page 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 OMRG25204 20May96 COPYRIGHTO 1996 DEERE POWER SYSTEMS GROUP Waterloo lowa All rights reserved A John Deere ILLUSTRUCTION Manual Contents Page Lubrication amp
72. ly 8 Recheck clutch engagement force with spring scale Install cover plate Disengage clutch 56 Lubrication amp Maintenance 600 Hour 12 Month LUBRICATING PTO CLUTCH INTERNAL LEVERS AND LINKAGE CAUTION Never attempt to service the A PTO while it is in operation Loose clothing could get caught in moving parts keep clothing tight against body Use extreme care when working around the PTO 1 Remove the PTO housing cover and apply one shot of John Deere Multipurpose Lubricant or equivalent See FUELS LUBRICANTS and COOLANT Section to the pivot points A of each clutch linkage 2 Apply one shot of John Deere Multipurpose Lubricant or equivalent to the two PTO release lever shaft fittings B TS198 RG6641 CLEANING CRANKCASE VENT TUBE If you operate the engine in dusty conditions clean the tube at shorter intervals 1 Remove and clean crankcase vent tube A 2 Install the vent tube Be sure the O ring fits correctly in the rocker arm cover for elbow adapter Tighten hose clamp securely RG8017 57 Lubrication amp Maintenance 600 Hour 12 Month CHECKING AIR INTAKE SYSTEM IMPORTANT The air intake system must not leak Any leak no matter how small may result in engine failure due to abrasive dirt and dust entering the intake system 1 Inspect all intake hoses piping for cracks Replace as necessary 2 Check clamps A on piping which c
73. n crosshatch on dipstick whichever is present DO NOT overfill IMPORTANT Immediately after completing any oil change crank engine for 30 seconds without permitting engine to start This will help insure adequate lubrication to engine components before engine starts 9 Start engine and run to check for possible leaks 10 Stop engine and check oil level after 10 minutes Oil level reading should be within crosshatch of dipstick RG8025 55 Lubrication and Maintenance 250 Hour CHECKING PTO CLUTCH ADJUSTMENT CAUTION Never attempt to service the A PTO while it is in operation Loose clothing could get caught in moving parts keep clothing tight against body Use extreme care when working around the PTO 1 Measure clutch engagement force at handle grip using a spring scale The engagement force should be 267 311 N 60 70 Ib force IMPORTANT Improper adjustments of the PTO TS198 clutch may shorten clutch life Make sure adjustments are made properly 2 If adjustments are needed disengage clutch and stop engine Remove cover plate from clutch housing shown removed 3 Remove adjusting lock A 4 Turn adjusting ring B to adjust clutch engagement pressure 5 Measure engagement force at clutch handle with spring scale R27550 6 Install lock screw and adjusting lock in clutch body splines when specified engagement pressure is achieved 7 Tighten screw secure
74. n fuel system Dirty or faulty injection nozzles Defective thermostat Defective temperature gauge or sender SOLUTION Add oil to engine crankcase See your authorized servicing dealer or engine distributor Remove and check thermostat See Engine Overheats Remove and check thermostat Replace fuel filter element Drain flush fill and bleed system Have authorized servicing dealer or engine distributor check injectors Remove and check thermostat Check gauge sender and connections Continued on next page 91 Troubleshooting SYMPTOM Lack of power Low oil pressure High oil consumption PROBLEM Engine overloaded Intake air restriction Clogged fuel filter Improper type of fuel Overheated engine Below normal engine temperature Improper valve clearance Dirty or faulty injection nozzles Injection pump out of time Turbocharger not functioning Turbocharger engines only Leaking exhaust manifold gasket Defective aneroid control line Restricted fuel hose Low fast idle speed Low oil level Improper type of oil Crankcase oil too light Oil leaks Restricted crankcase vent tube Defective turbocharger SOLUTION Reduce load Service air cleaner Replace filter elements Use proper fuel See Engine Overheats Remove and check thermostat See your authorized servicing dealer or engine distributor Have authorized servicing deal
75. n the clutch housing and the engine driven equipment at all times during engine operation Wear close fitting clothing Stop the engine and be sure PTO driveline is stopped before making adjustments Proper performance of the power take off unit will be T5198 related to the care it is given Lubricate it periodically and keep the clutch properly adjusted See Lubrication and Maintenance 250 Hour Section If the power take off does not work properly after adjustment and lubrication contact your authorized servicing dealer or engine distributor RG4693 82 Service As Required CHECKING FUSES The following instructions apply to engines equipped with a John Deere instrument panel 1 Check the fuse A between the ammeter B and key switch C located on back side of instrument panel If defective replace with an equivalent 25 amp fuse 2 Check the fuse D mounted on the bottom of the magnetic safety switch If defective install an equivalent 14 amp fuse RG4493 83 Service As Required BLEEDING THE FUEL SYSTEM A CAUTION Escaping fluid under pressure can penetrate the skin causing serious injury Relieve pressure before disconnecting fuel or other lines Tighten all connections before applying pressure Keep hands and body away from pinholes and nozzles which eject fluids under high pressure Use a piece of cardboard or paper to search for leaks Do not use your hand
76. ncy EPA and or Vor ferire Sarvics and Parts Cul 1 300 J0 ENGINE California Air Resources Board CARB The presence of an emissions label like the one shown to the right signifies that the engine has been certified with the EPA and CARB The EPA and CARB emissions warranties ques do not apply to engines that were built before 01 January 1996 U S EMISSIONS CONTROL WARRANTY STATEMENT Emissions control related parts and components are Warranties stated in this manual refer only to warranted by John Deere for five years or 3000 hours of emissions related parts and components of your operation whichever occurs first John Deere further engine The complete engine warranty less emissions warrants that the engine covered by this warranty was related parts and components is provided separately designed built and equipped so as to conform at the as the John Deere New Off Highway Engine time of sale with all U S emissions standards at the Warranty time of manufacture and that it is free of defects in materials and workmanship which would cause it not to meet these standards within the period of five years or 3000 hours of operation whichever occurs first 113 Emission System Warranty CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT Your Warranty Rights and Obligations The California Air Resources Board CARB and John Deere are pleased to explain the emission control system on your new engine In Cali
77. nt temperature rises above a preset safe operating level F Tachometer with Electric Hour Meter Tachometer senses engine speed from a speed sensor in front timing gear cover and indicates engine speed in revolutions per minute rpm Hour meter indicates the operating hours of the engine while key switch is in the ON position The hour meter should be used as a guide for scheduling periodic service G Hand Throttle Controls engine speed H Tachometer Binary Code Located in back of tachometer and must be set at 00010011 to operate at 27 pulses per revolution A Oil Pressure Gauge B Ammeter C Coolant Temperature Gauge D Key Switch E Reset Safety Switch F Tachometer with Hour Meter G Hand Throttle H Tachometer Binary Code RG8027 RG6861 31 Engine Operating Guidelines 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 Normal engine coolant operating temperature range is 82 94 C 180 202 F If coolant temperature rises above 105 C 221 F reduce load on engine Unless temperature drops quickly stop engine and determine cause before resuming operation Operate the engine under a lighter load and at slower than normal speed for first 15 minutes after start up DO NOT run engine at slow idle S
78. nths of operation JOHN DEERE COOL GARD In certain geographical areas John Deere COOL GARD is marketed for use in the engine cooling system This product contains all the necessary ingredients that make up the proper coolant solution chemically pure water ethylene glycol low silicate antifreeze and supplemental coolant additives SCAs It is ready to add to cooling system as is no mixing or supplemental coolant additives required Contact your John Deere Parts Network for local availability John Deere COOL GARD has a service life of 2000 hours or 24 months of operation JOHN DEERE ANTIFREEZE SUMMER COOLANT CONCENTRATE This product contains ethylene glycol low silicate antifreeze and supplemental coolant additives SCAs It must be mixed with quality water as described later in this section before adding to the engine cooling system The proportion of water to be used depends upon the lowest freeze protection temperature desired according to the following table CONCENTRATE FREEZE PROTECTION LIMIT 40 24 C 12 F 50 37 C 84 F 60 52 C 62 F John Deere Antifreeze Summer Coolant Concentrate has a service life of 2000 hours or 24 months of operation 24 Fuels Lubricants and Coolant ENGINE COOLANT SPECIFICATIONS Engine coolants are a combination of three chemical components ethylene glycol antifreeze inhibiting coolant additives and quality water Coolant solut
79. ntil Number 1 cylinder is at Top Dead Center TDC Compression stroke Insert timing pin in flywheel If Number 1 cylinder rocker arms are loose the engine is at Number 1 TDC Compression If No 1 cylinder rocker arms are not loose rotate engine one full revolution 360 to Number 1 TDC Compression 4 With engine lock pinned at TDC of Number 1 piston s compression stroke check and adjust as needed valve clearance to following specifications as directed in the procedures on next page for 4 or 6 cylinder engines VALVE CLEARANCE SPECIFICATIONS COLD Intake Valve anie ike itte es 0 35 mm 0 014 in Exhaust Valve ere e yen 0 45 mm 0 018 in 5 f valves need adjusting loosen the locknut on rocker arm adjusting screw Turn adjusting screw until feeler gauge slips with a slight drag Hold the adjusting screw from turning with screwdriver and tighten locknut to 27 N m 20 Ib ft Recheck clearance again after tightening locknut Readjust clearance as necessary 6 Replace rocker arm cover and crankcase ventilator tube 72 Lubrication and Maintenance 2000 Hour e 4 Cylinder Engine NOTE Firing order is 1 3 4 2 Lock No 1 piston at TDC compression stroke B Adjust valve clearance on No 1 and 3 exhaust valves and No 1 and 2 intake valves Rotate flywheel 360 Lock No 4 piston at TDC compression stroke C Adjust valve clearance on No 2 and 4 exhaust valves and No 3 and 4 intake
80. o not start engine until fuel free from bubbles flows out of loosened connection Retighten connection to 27 N m 20 Ib ft RG7725 4 Repeatprocedure for remaining injection nozzles if necessary until all air has been removed from fuel system If engine still will not start see your authorized servicing dealer or engine distributor 86 Troubleshooting GENERAL TROUBLESHOOTING INFORMATION Troubleshooting engine problems can be difficult An A reliable program for troubleshooting engine problems engine wiring diagram is provided in this section to help should include the following basic diagnostic thought isolate electrical problems on power units using John process Deere wiring harness and instrument gauge panel Know the engine and all related systems Later in this section is a list of possible engine problems that may be encountered accompanied by possible Study the problem thoroughly causes and corrections The illustrated diagrams and troubleshooting information are of a general nature Relate the symptoms to your knowledge of engine final design of the overall system for your engine and systems application may be different See your engine distributor or servicing dealer if you are in doubt Diagnose tie pROBIGH staring witi The sasies things first e Double check before beginning the disassembly Determine cause and make a thorough repair e After making repairs operate the engine
81. on available at the time of publication The right is reserved to make changes at any time without notice RG7984 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 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 ENGINE OPTION CODES CONTINUED Engine Base Code Option Codes 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 35 36 37 39 40 41 43 44 Description Rocker Arm Cover Oil Filler Neck Crankshaft Pulley Flywheel Housing Flywheel Fuel Injection Pump Air Inlet Air Cleaner Oil Pan Water Pump Thermostat Cover Thermostat Fan Drive Fan Belt Fan Engine Coolant Heater Radiator Exhaust Manifold Ventilator System Starting Motor Alternator Instrument Panel Fuel Filter Front Plate Fuel Transf
82. onnect the air cleaner engine and if present turbocharger RG4689 Tighten clamps as necessary This will help prevent dirt from entering the air intake system through loose connections causing internal engine damage 3 If engine has a rubber dust unloader valve B inspect the valve on bottom of air cleaner for cracks or plugging Replace as necessary IMPORTANT ALWAYS REPLACE primary air cleaner element when air restriction indicator shows a vacuum of 625 mm 25 in H O is torn or visibly dirty 4 Test air restriction indicator C for proper operation Replace indicator as necessary IMPORTANT If not equipped with air restriction indicator replace air cleaner elements at 600 Hours or 12 Months whichever occurs first 5 Remove and inspect primary air cleaner element Service as necessary See INSPECTING PRIMARY FILTER ELEMENT and REPLACING AIR CLEANER ELEMENTS in Service As Required Section 58 Lubrication amp Maintenance 600 Hour 12 Month REPLACING FUEL FILTER ELEMENT can penetrate the skin causing serious injury Relieve pressure before disconnecting fuel or other lines Tighten all connections before applying pressure Keep hands and body away from pinholes and nozzles which eject fluids under high pressure Use a piece of cardboard or paper to search for leaks Do not use your hand N CAUTION Escaping fluid under pressure If any fluid is injected into the skin it must be s
83. onths whichever occurs first 44 Lubrication amp Maintenance Daily DAILY PRESTARTING CHECKS Do the following BEFORE STARTING THE ENGINE for the first time each day IMPORTANT DO NOT add makeup oil until the oil level is BELOW the add mark 1 Check engine oil level on dipstick Add as required using seasonal viscosity grade oil See DIESEL ENGINE OIL in Fuels Lubricants and Coolant Section for oil specifications Depending on application oil may be added at left A or right B side oil filler cap and rocker arm cover filler cap C locations IMPORTANT DO NOT fill above the top mark D on the dipstick Oil levels anywhere within crosshatch are considered in the acceptable operating range RG8028 45 Lubrication amp Maintenance Daily CAUTION Explosive release of fluids from A pressurized cooling system can cause serious burns Only remove filler cap when engine is cold or when cool enough to touch with bare hands Slowly loosen cap to first stop to relieve pressure before removing completely 2 Check the coolant level when engine is cold Coolant level should be at bottom of filler neck Fill radiator A with proper coolant solution if level is low See ADDING COOLANT in Service As Required Section Check overall cooling system for leaks TS281 Refer to your vehicle s operator s manual for recommendations for non John Deere supplied accessories R
84. or detailed services IMPORTANT DO NOT operate starter more than 30 listed below or have your authorized servicing dealer or engine distributor perform services that you may not be familiar with 1 Remove all protective coverings from engine 6 Unseal all openings in engine and remove covering from electrical systems 2 Remove the batteries from storage Install batteries fully charged and connect the terminals 7 3 Install fan alternator poly vee belt if removed 4 Fill fuel tank 8 5 Perform all appropriate prestarting checks See DAILY PRESTARTING CHECKS in Engine Operating Guidelines Section seconds at a time Wait at least 2 minutes for starter to cool before trying again Crank engine for 20 seconds with starter do not allow the engine to start Wait 2 minutes and crank engine an additional 20 seconds to assure bearing surfaces are adequately lubricated Start engine and run at low idle and no load for several minutes Warm up carefully and check all gauges before placing engine under load On the first day of operation after storage check overall engine for leaks and check all gauges for correct operation 99 Storage 100 Specifications GENERAL OEM ENGINE SPECIFICATIONS ITEM UNIT OF MEASURE 4045DF150 4045TF150 4045TF250 Number of Cylinders 4 4 4 Fuel Diesel Diesel Diesel Bore mm 106 106 106 in 4 19 4 19 4 19 Stroke mm 127 127 127 in 5 00 5
85. ostat See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor Use proper fuel Service air cleaner Reduce load See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor Reduce load Fill radiator to proper level check radiator and hoses for loose connections or leaks Have serviceman check Check automatic belt tensioner and check belts for stretching Replace as required Check oil level Add oil as required Flush cooling system Remove and check thermostat Check water temperature with thermometer and replace if necessary Use correct grade of fuel Continued on next page 93 Troubleshooting SYMPTOM High fuel consumption PROBLEM Improper type of fuel Clogged or dirty air cleaner Engine overloaded Improper valve clearance Injection nozzles dirty Engine out of time Defective turbocharger Low engine temperature SOLUTION Use proper type of fuel Service air cleaner Reduce load See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor Check thermostat 94 Trouble
86. overheat the starter If the engine does not start the first time wait at least 2 minutes before trying again If engine does not start after four attempts see Troubleshooting Section 6 Turn the key switch C clockwise to crank the engine When the engine starts release the key so that it returns to the ON position IMPORTANT If the key switch is released before the engine starts wait until the starter and the engine stop turning before trying again This will prevent possible damage to the starter and or flywheel A Hand Throttle B Reset Button C Key Switch 7 After the engine starts continue to hold the reset e D Oil Pressure Gauge button in until the oil pressure gauge D reads at least 105kPa 1 05 bar 15 psi The safety controls will not allow the engine to run at a lower oil pressure unless the reset button is held in IMPORTANT Should the engine die when operating under load immediately disengage PTO clutch and restart the engine Overheating of turbocharger parts may occur when oil flow is stopped 8 Check all gauges for normal engine operation If operation is not normal stop the engine and determine the cause RG8033 37 Engine Operating Guidelines COLD WEATHER OPERATION Additional information on cold weather operation is available from your engine distributor or authorized servicing dealer Some engines are equipped with an air intake heater which will make
87. per incontrarsi con il Suo Concessionario che fornisce l assistenza tecnica Impari a conoscere chi e dove si trova Alla Sua prima occasione cerchi d incontrarlo Egli desidera farsi conoscere e conoscere le Sue necessit PROPIETARIO DE EQUIPO JOHN DEERE No espere hasta necesitar servicio de garant a o de otro tipo para conocer a su Distribuidor de Motores John Deere o al Concesionario de Servicio Ent rese de qui n es y d nde est situado Cuando tenga un momento vaya a visitarlo A l le gustar conocerlo y saber cu les podr an ser sus necesidades JOHN DEERE MOTOR GARE V nta inte med att bes ka Din John Deere terf rs ljare till dess att Du beh ver service eller garanti reparation Bekanta Dig med var han ar och vem han ar Tag f rsta tillf lle att bes ka honom Han vill ocks tr ffa Dig f r att fa veta vad Du beh ver och hur han kan hj lpa Dig Engine Owner Identification Views POWERTECH 4 5 L ENGINES RG7999 RG7998 4045D Engine RG7996 RG7997 4045T Engine Identification Views POWERTECH 6 8 L ENGINES RG8003 RG8002 6068D Engine RG8000 6068T Engine Contents Page Record Keeping POWERTECH Medallion 1 Engine Serial Number Plate 1 Record Engine Serial Number 2 Engine Option Codes s s s asasan anaa 3 Record PTO Serial Number 5
88. place the water pump seal Contact your engine distributor or servicing dealer for repairs 47 Lubrication amp Maintenance Daily 48 Lubrication amp Maintenance 50 Hour 2 Weeks CHECKING FUEL FILTER Periodically the fuel filter should be checked for water or debris IMPORTANT Drain water into a suitable container and dispose of properly 1 Loosen drain plug B at bottom of fuel filter two or three turns 2 Loosen air bleed plug two full turns A on fuel filter Pas drain water from bottom until fuel starts to rain out 3 When fuel starts to drain out tighten drain plug securely After draining water from the fuel filter the filter must be primed by bleeding all air from the fuel system 4 Operate primer lever of the fuel supply pump C until fuel flow is free from air bubbles 5 Tighten bleed plug securely continue operating hand primer until pumping action is not felt Push hand primer inward toward engine as far as it will go ean If the fuel system needs further bleeding of air see P BLEED FUEL SYSTEM in Service As Required Section later in this manual 49 Lubrication amp Maintenance 50 Hour 2 Weeks LUBRICATING PTO CLUTCH SHAFT BEARINGS Apply one or two shots of John Deere Multipurpose Lubricant or equivalent at clutch drive shaft bearing fitting B and pilot bearing fittings D DO NOT over lubricate to avoid getting oil on clutch
89. pplemental coolant additives available in the form of liquid coolant conditioner See TESTING ENGINE COOLANT and REPLENISHING SUPPLEMENTAL COOLANT ADDITIVES SCAs BETWEEN COOLANT CHANGES as described later in this section John Deere Liquid Coolant Conditioner RG7276 26 Fuels Lubricants and Coolant TESTING DIESEL ENGINE COOLANT Maintaining adequate concentrations of glycol and inhibiting additives in the coolant is critical to protect the engine and cooling system against freezing corrosion and cylinder liner erosion and pitting Test the coolant solution at 600 hours or 12 month intervals and whenever excessive coolant is lost through leaks or overheating to ensure the necessary protection Coolant Test Strips Coolant test strips are available from your John Deere dealer These test strips provide a simple effective method to check the freeze point and additive levels of your engine coolant Compare the results to the supplemental coolant additive SCA chart to determine the amount of inhibiting additives in your coolant and whether more l E Sep mm John Deere Liquid Coolant Conditioner should be W added Pi a L COOLSCAN KL UNE ri For a more thorough evaluation of your coolant E perform a COOLSCAN analysis where available See ERA your John Deere engine distributor or servicing dealer for information about COOLSCAN 27 Fuels Lubricants and Coolant
90. pplicable regulations adopted by the Air Resources Board and that it is free from defects in materials and workmanship which would cause the failure of a warranted part Any warranted part which is scheduled for replacement as required maintenance by this Operation and Maintenance Manual is warranted by John Deere for the period of time prior to the first scheduled replacement point for that part If the part fails prior to the first scheduled replacement point the part shall be repaired or replaced under the warranty Any such part repaired or replaced under warranty is warranted for the remainder of the period prior to the first scheduled replacement point for the part Any warranted part which is not scheduled for replacement as required maintenance or which is scheduled only for regular inspection to the effect of repairing or replacing as necessary is warranted for the warranty period Repair or replacement of a warranted part will be performed at no charge to you by a John Deere engine service dealer You will not be charged for diagnostic labor which leads to the determination that a warranted part is defective if the diagnostic work is performed by a John Deere engine service dealer John Deere is liable for damages to other engine components caused by the failure under warranty of any warranted part Any replacement part may be used in the performance of any maintenance or repairs and such use will not reduce the warranty
91. r cleaner element when air restriction indicator shows a vacuum of 625 mm 25 in H O is torn or visibly dirty NOTE This procedure applies to John Deere air cleaner kits Refer to manufacturers instructions for servicing air cleaners not supplied by John Deere 1 Remove wing nut and remove canister cover shown in small illustration inset 2 Remove wing nut A and remove primary element B from canister 3 Thoroughly clean all dirt from inside canister NOTE Some engines may have a dust unloader valve C on the air cleaner If equipped squeeze valve tip to release any trapped dirt particles IMPORTANT Remove secondary safety element E ONLY for replacement DO NOT attempt to clean wash or reuse secondary element Replacement of secondary element is usually necessary ONLY when primary element has a hole in it RG4687 4 Toreplace secondary element remove retaining nut D and secondary element E Immediately replace secondary element with new element to prevent dust from entering air intake system 5 Install new primary element and tighten wing nut securely Install cover assembly and tighten retaining wing nut securely RG4688 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 relea
92. rd cylinder block On Lucas rotary pumps 1 Loosen bleed screw B on pump cover NOTE On Models DP200 201 Injection Pumps bleed screw is located on top of cover near the fuel return line 2 Operate fuel supply pump primer lever or turn ignition switch to ON 3 Wait until fuel flow is free from air bubbles Tighten bleed screw 4 Leave hand primer in the inward position toward N i cylinder block 1 RG7948 CAUTION NEVER loosen screw C A securing pump head otherwise pump damage may occur 85 Service As Required BLEEDING THE FUEL SYSTEM CONTINUED On Nippondenso in line pumps 1 Unscrew hand primer on fuel supply pump until it can be pulled by hand 2 Operate the hand primer until a smooth flow of fuel free of bubbles comes out of the filter plug hole IMPORTANT Be sure hand primer is all the way down in barrel before tightening to prevent internal thread damage 3 Simultaneously stroke the hand primer down and close the filter port plug This prevents air from TEn _RG8069 entering the system Tighten plug securely DO NOT overtighten 4 Lock hand primer in position At Fuel Injection Nozzles 1 Move the speed control lever to half throttle position On engines equipped with electronic fuel shut off solenoid energize solenoid 2 Using two open end wrenches loosen fuel line connection at injection nozzle 3 Crank engine over with starting motor but d
93. red ADDING COOLANT pressurized cooling system can cause CAUTION Explosive release of fluids from serious burns Shut off engine Only remove filler cap when cool enough to touch with bare hands Slowly loosen cap to first stop to relieve pressure before removing completely IMPORTANT Never pour cold liquid into a hot engine as it may crack cylinder head or block DO NOT operate engine without coolant for even a few minutes John Deere TY15161 Cooling System Sealer may be added to the radiator to stop leaks DO NOT use any other stop leak additives in the cooling system Air must be expelled from cooling system when coolant is added 1 Loosen temperature sending unit fitting at rear of cylinder head or plug in side of thermostat housing to allow air to escape when filling system IMPORTANT When adding coolant to the system use the appropriate coolant solution See ENGINE COOLANT SPECIFICATIONS in Fuels Lubricants and Coolant Section for mixing of coolant ingredients before adding to cooling system Do not overfill cooling system A pressurized system needs space for heat expansion without overflowing at top of radiator 2 Fill until coolant level touches bottom of radiator filler neck 3 Tighten plugs and fittings when air has been expelled from system TS281 76 Service As Required REPLACING AIR CLEANER FILTER ELEMENTS IMPORTANT ALWAYS REPLACE primary ai
94. ring cranking USE AR41785 ENGINE STORAGE KIT See your John Deere servicing dealer or engine distributor for an AR41785 Engine Storage Kit Closely follow instructions provided with this kit IMPORTANT Inhibitors can easily change to gas Seal or tape each opening immediately after adding inhibitor T85452 97 Storage PREPARING ENGINE FOR LONG TERM STORAGE The following storage preparations are good 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 IMPORTANT Any time your engine will not be used for over six 6 months the following recommendations for storing it and removing it from storage will help to minimize corrosion and deterioration Use the AR41785 Engine Storage Kit Follow recommended service procedure included with storage kit 1 Change engine oil and replace filter Used oil will not give adequate protection See CHANGE ENGINE OIL AND FILTER in Lubrication and Maintenance 250 Hour Section 2 Service air cleaner See REPLACING AIR CLEANER FILTER ELEMENTS in Service As Required Section 3 Draining and flushing of cooling system is not necessary if engine is to be stored only for several months However for extended storage periods of a year or longer it is recommended that the cooling system be drained flushed and refilled Refill with appropriate coolant See RECOMMENDED EN
95. 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 T81389 UNDERSTAND SIGNAL WORDS A signal word DANGER WARNING or CAUTION is ADANGER used with the safety alert symbol DANGER identifies the most serious hazards DANGER or WARNING safety signs are located near specific hazards General precautions are listed on A WARNING CAUTION safety signs CAUTION also calls attention to safety messages in this manual TS187 Ad FOLLOW SAFETY INSTRUCTIONS Carefully read all safety messages in this manual and on your machine safety signs Keep safety signs in good condition Replace missing or damaged safety signs Be sure new equipment components and repair parts include the current safety signs Replacement safety signs are available from your John Deere dealer Learn how to operate the machine and how to use controls properly Do not let anyone operate without instruction Keep your machine in proper working condition Unauthorized modifications to the machine may impair the function and or safety and affect machine life If you do not understand any part of this manual and need assistance contact your John Deere dealer TS201 PREVENT BYPASS STARTING Avoid possible injury or death from engine runaway Do not start engine by shorting across starter terminal
96. se to reset indicator 77 Service As Required INSPECTING PRIMARY FILTER ELEMENT Inspect filter to determine if it is practical to clean or for damage after cleaning filter 1 Hold a bright light inside element A and check carefully for holes Discard any element which shows the smallest hole or rupture 2 Be sure outer screen B is not dented Vibration would quickly wear a hole in filter 3 Be sure filter gasket C is in good condition If gasket is damaged or missing replace element IMPORTANT Air cleaner MUST BE DRY before storing in plastic bag If the filter is to be stored for later use place it in a plastic bag to protect it from dust and damage RW4768 78 Service As Required CLEANING PRIMARY FILTER ELEMENT IMPORTANT Always replace secondary safety filter elements DO NOT attempt to clean them Do not blow air from outside portion of filter with air nozzle Wear safety glasses and remove bystanders 1 Gently pat sides of element with palm of hand to loosen dirt DO NOT tap element against a hard surface CAUTION Only a special air cleaning gun A A should be used Concentrated air pressure from an ordinary air nozzle may severely damage filter element Do not exceed 210 kPa 2 1 bar 30 psi when cleaning filter element 2 Insert the cleaning gun into element hold air nozzle about 25 4 mm 1 0 in from perforated metal retainer Force air through
97. shooting ELECTRICAL TROUBLESHOOTING SYMPTOM Undercharged system Battery uses too much water Batteries will not charge Starter will not crank PROBLEM Excessive electrical load from added accessories Excessive engine idling Poor electrical connections on battery ground strap starter or alternator Defective battery Defective alternator Cracked battery case Defective battery Battery charging rate too high Loose or corroded connections Sulfated or worn out batteries Stretched poly vee belt or defective belt tensioner PTO engaged Loose or corroded connections Low battery output voltage Faulty start circuit relay Blown fuse MDL 25 SOLUTION Remove accessories or install higher output alternator Increase engine rpm when heavy electrical load is used Inspect and clean as necessary Test battery Test charging system Check for moisture and replace as necessary Test battery Test charging system Clean and tighten connections See your authorized servicing dealer or engine distributor Adjust belt tension or replace belts Disengage PTO Clean and tighten loose connections See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor Replace fuse Continued on next page 95 Troubleshooting SYMPTOM Starter cranks slowly Starter and hour meter functions rest of
98. should not exceed 0 596 Sulfur content less than 0 05 is preferred If diesel fuel with sulfur content greater than 0 5 sulfur content is used reduce the service interval for engine oil and filter by 5096 DO NOT use diesel fuel with sulfur content greater than 1 0 Bio diesel fuels with properties meeting DIN 51606 or equivalent specification may be used DO NOT mix used engine oil or any other type of lubricant with diesel fuel LUBRICITY OF DIESEL FUELS Diesel fuel must have adequate lubricity to ensure proper operation and durability of fuel injection system components Diesel fuels for highway use in the United States and Canada now require sulfur content less than 0 0596 Diesel fuel in the European Union will require sulfur content less than 0 0596 by 1 October 1996 Experience shows that some low sulfur diesel fuels may have inadequate lubricity and their use may reduce performance in fuel injection systems due to inadequate lubrication of injection pump components The lower concentration of aromatic compounds in these fuels also adversely affects injection pump seals and may result in leaks Use of low lubricity diesel fuels may also cause accelerated wear injection nozzle erosion or corrosion engine speed instability hard starting low power and engine smoke Fuel lubricity should pass a minimum of 3100 gram load level as measured by the BOCLE scuffing test ASTM D975 and EN 590 specificat
99. sponsible for the performance of the required maintenance as outlined in this Operation and Maintenance Manual John Deere recommends that you retain all receipts covering maintenance on your heavy duty engine but John Deere cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance However as the heavy duty engine owner you should be aware that John Deere may deny you warranty coverage if your heavy duty engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications Your engine is designed to operate on diesel fuel only Use of any other fuel may result in your engine no longer operating in compliance with California s emissions requirements You are responsible for initiating the warranty process The CARB suggests that you present your heavy duty engine to the nearest John Deere engine service dealer as soon as a problem is suspected The warranty repairs should be completed by the service dealer as expeditiously as possible If you have any questions regarding your warranty rights and responsibilities you should contact John Deere at 1 319 292 5400 The warranty period begins on the date the engine is delivered to an ultimate purchaser or when otherwise put into service John Deere warrants to the ultimate purchaser and each subsequent purchaser that the engine is designed built and equipped so as to conform with all a
100. starting the engine easier in cold weather If equipped follow steps 1 4 as listed under STARTING THE ENGINE earlier in this section Switch on the air intake heater for 30 seconds and then proceed to operate the starter Follow remaining steps 5 8 CAUTION Starting fluid is highly A flammable DO NOT use starting fluid on engines equipped with air intake heaters DO NOT use starting fluid near fire sparks or flames DO NOT incinerate or puncture a starting fluid container CE TS1356 38 Engine Operating Guidelines WARMING ENGINE IMPORTANT To assure proper lubrication operate engine at or below 1200 rpm with no load for 1 2 minutes Extend this period 2 4 minutes when operating at temperatures below freezing Engines used in generator set applications where the governor is locked at a specified speed may not have a slow idle function Operate these engines at high idle for 1 to 2 minutes before applying the load This procedure does not apply to standby generator sets where the engine is loaded immediately upon reaching rated speed Check oil pressure gauge A as soon as engine starts If gauge needle does not rise above minimum oil pressure specification of 105 kPa 1 05 bar 15 0 psi within 5 seconds stop the engine and determine the cause Normal engine oil pressure is 345 kPa 3 45 bar 50 psi at rated full load speed 1800 2500 rpm with oil at normal operating temperature of
101. til it reaches operating temperature This mixes the solution uniformly and circulates it through the entire system The normal engine coolant temperature range is 82 94 C 180 202 F After running engine check coolant level and entire cooling system for leaks 70 Lubrication and Maintenance 2000 Hour CHECKING AND ADJUSTING ENGINE VALVE CLEARANCE NOTE If desired have your authorized servicing dealer or engine distributor adjust the engine valve clearance of engine while performing valve adjustments always disconnect NEGATIVE battery terminal CAUTION To prevent accidental starting IMPORTANT Engine valve clearance MUST BE checked and adjusted with engine COLD 1 Remove rocker arm cover and crankcase ventilator tube IMPORTANT Visually inspect contact surfaces of valve tips and rocker arm wear pads Check all parts for excessive wear breakage or cracks Replace parts that show visible damage Rocker arms that exhibit excessive valve clearance should be inspected more thoroughly to identify damaged parts 2 Remove plastic plugs or cover plate from flywheel housing timing holes A s J RG7408 71 Lubrication and Maintenance 2000 Hour CHECKING AND ADJUSTING ENGINE VALVE CLEARANCE CONTINUED 3 Using either JD281A JDG820 or JDE83 Flywheel Turning Tool and JDE81 4 Timing Pin rotate engine in running direction clockwise viewed from front u
102. top engine immediately if there are any signs of part failure Symptoms that may be early signs of engine problems are Sudden drop in oil pressure Abnormal coolant temperatures Unusual noise or vibration Sudden loss of power Excessive black exhaust Excessive fuel consumption Excessive oil consumption Fluid leaks 32 Engine Operating Guidelines BREAK IN SERVICE The engine is ready for normal operation However extra care during the first 100 hours of operation will result in more satisfactory long term engine performance and life DO NOT exceed 100 hours of operation with break in oil 1 This engine is factory filled with John Deere Engine Break in Oil Operate the engine at heavy loads with minimal idling during the break in period 2 If the engine has significant operating time at idle constant speeds and or light load usage or makeup oil is required in the first 100 hour period a longer break in period may be required In these situations an additional 100 hour break in period is recommended using a new change of John Deere Engine Break In Oil and a new John Deere oil filter IMPORTANT DO NOT add makeup oil until the oil level is BELOW the ADD mark on dipstick John Deere Engine Break In Oil TY22041 should be used to make up any oil consumed during the break in period 3 Check engine oil level more frequently during engine break in period If oil must be ad
103. uel system Faulty injection pump or nozzles Engine starting under load Improper starting procedure No fuel Air in fuel line Cold weather Slow starter speed Crankcase oil too heavy Improper type of fuel Water dirt or air in fuel system Clogged fuel filter Dirty or faulty injection nozzles Injection pump shut off not reset SOLUTION Verify correct starting procedure Check fuel in tank and manual shut off valve Check and correct exhaust restriction Replace fuel filter or drain water from filter Check fuel flow at supply pump or bleed fuel system Consult authorized diesel repair station for repair or replacement Disengage PTO Review starting procedure Check fuel tank Bleed fuel line Use cold weather starting aids See Starter Cranks Slowly Use oil of proper viscosity Consult fuel supplier use proper type fuel for operating conditions Drain flush fill and bleed system Replace filter element Have authorized servicing dealer or engine distributor check injectors Turn key switch to OFF then to ON Continued on next page 90 Troubleshooting SYMPTOM Engine knocks Engine runs irregularly or stalls frequently Below normal engine temperature PROBLEM Low engine oil level Injection pump out of time Low coolant temperature Engine overheating Low coolant temperature Clogged fuel filter Water dirt or air i
104. under normal conditions to verify that the problem and cause was corrected 87 Troubleshooting ENGINE WIRING DIAGRAM LEGEND A1 Speed Control Unit B1 Magnetic Speed Sensor B2 Coolant Temperature Sensor B3 Oil Pressure Sensor F1 Starting Circuit Fuse 25 amp F2 Safety Switch Fuse 10 amp F3 Tachometer Fuse 3 amp G1 Battery G2 Alternator H1 Coolant Temperature Indicator Lamp H2 Oil Pressure Indicator Lamp H3 Alternator Indicator Lamp K1 Starter Relay K2 Fuel Shut off Relay M1 Starter Motor P1 Coolant Temperature Gauge P3 Crankcase Oil Level Switch Gauge P4 Tachometer P5 Hourmeter P6 Ammeter S1 Key Switch S2 Magnetic Safety Switch Y2 Fuel Shut off Solenoid Y3 Electric Fuel Pump BLK Black BLU Blue BRN Brown DK BLU Dark Blue GRN Green ORG Orange PUR Purple RED Red YEL Yellow 88 Troubleshooting WIRING DIAGRAM IHM RED OR BRN REPE NH8 HO d3H NH8 HO Q3H NH8 HO 13H B1 N gt na ya a NH3 HO 34 NH8 HO Gay TI RG7020 89 Troubleshooting ENGINE TROUBLESHOOTING SYMPTOM Engine cranks but will not start Engine hard to start or will not start PROBLEM Incorrect starting procedure No fuel Exhaust restricted Fuel filter plugged or full of water Injection pump not getting fuel or air in f
105. urgically removed within a few hours by a doctor familiar with this type injury or gangrene may result Doctors unfamiliar with this type of injury may call the Deere amp Company Medical Department in Moline Illinois or other knowledgeable medical source 1 Close fuel shut off valve if equipped 2 Thoroughly clean fuel filter assembly and surrounding area 3 Loosen drain plug C and drain fuel into a suitable PORTA container NOTE Lifting up on retaining ring as it is rotated helps A Retaining Ring to get it past raised locators B Filter Element C Drain Plug D Bleed Plug 4 Firmly grasp the retaining ring A and rotate it counterclockwise 1 4 turn Remove ring with filter element B 5 Inspect filter mounting base for cleanliness Clean as required NOTE Raised locators on fuel filter canister must be indexed properly with slots in mounting base for correct installation 6 Install new filter element onto mounting base Be sure element is properly indexed and firmly seated on base It may be necessary to rotate filter for correct alignment 59 Lubrication amp Maintenance 600 Hour 12 Month REPLACING FUEL FILTER ELEMENT CONTINUED If equipped with water separator remove filter element from water separator bowl Drain and clean separator bowl Dry with compressed air Install water separator bowl onto new element Tighten securely 7 Align keys on filter element with slots
106. ustments or performing any type service on the engine or PTO driven equipment Oy TS1644 11 Ad PRACTICE SAFE MAINTENANCE 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 Disengage all power and operate controls to relieve pressure Lower equipment to the ground Stop the engine Remove the key Allow machine to cool Securely support any machine elements that must be raised for service work Keep all parts in good condition and properly installed Fix damage immediately Replace worn or broken parts Remove any buildup of grease oil or debris Disconnect battery ground cable before making adjustments on electrical systems or welding on machine TS218 WORK IN VENTILATED AREA Engine exhaust fumes can cause sickness or death If it is necessary to run an engine in an enclosed area remove the exhaust fumes from the area with an exhaust pipe extension If you do not have an exhaust pipe extension open the doors and get outside air into the area TS220 12 Ad AVOID HIGH PRESSURE FLUIDS 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 Search for leaks with
107. valves RG4776 A Front of Engine B No 1 Piston at TDC Compression Stroke C No 4 Piston at TDC Compression Stroke E Exhaust Valve I Intake Valve e 6 Cylinder Engine NOTE Firing order is 1 5 3 6 2 4 Lock No 1 piston at TDC compression stroke B Adjust valve clearance on No 1 3 and 5 exhaust valves and No 1 2 and 4 intake valves Rotate flywheel 360 Lock No 6 piston at TDC compression stroke C Adjust valve clearance on No 2 4 and 6 exhaust valves and No 3 5 and 6 intake valves RG4777 A Front of Engine B No 1 Piston at TDC Compression Stroke C No 6 Piston at TDC Compression Stroke E Exhaust Valve I Intake Valve 73 Lubrication and Maintenance 2000 Hour 74 Service As Required ADDITIONAL SERVICE INFORMATION 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 RG4624 DO NOT MODIFY FUEL SYSTEM IMPORTANT Modification or alteration of the injection pump arrow the injection pump timing or the fuel injectors in ways not recommended by the manufacturer will terminate the warranty obligation to the purchaser Do not attempt to service injection pump or fuel injectors yourself Special training and special tools are required See your authorized servicing dealer or engine distributor 75 Service As Requi
108. ves SCAs 28 Adding is uui ERES AER 64 Synthetic lubricants 222 220 22 T Tachometer llle eee 31 Temperature gauge coolant 31 Tensioner bet 61 Torque values Inch deum emer ETE ESO 105 Melle usse Rn a 106 Troubleshooting Electrical sa a 95 General engine 90 V Valve clearance check and adjust 71 73 Vibration damper 67 W Warmingengine l l 39 Warranty CARB Statement 25 114 Emission System 5 113 EPA Emissions statement 113 Winterfronts 0 2 e eee eee eee 19 Wiring Diagram 88 Index 3 Index Index 4 John Deere Service Keeps You On the Job JOHN DEERE PARTS We help minimize downtime by putting genuine John Deere parts in your hands in a hurry That s why we maintain a large and varied inventory to stay a jump ahead of your needs THE RIGHT TOOLS Precision tools and testing equipment enable our Service Department to locate and correct troubles quickly to save you time and money WELL TRAINED TECHNICIANS School is never out for John Deere service technicians Training schools are held regularly to be sure our personnel know your equipment and how to maintain it Result Experience you can count on TS102 PROMPT SERVICE Our goal is to provide prompt efficient care when you want it and where you want it We c
109. when draining fluids Do not use food or beverage containers that may mislead someone into drinking from them Do not pour waste onto the ground down a drain or into any water source Inquire on the proper way to recycle or dispose of Telias waste from your local environmental or recycling center or from your John Deere dealer 29 Fuels Lubricants and Coolant 30 Engine Operating Guidelines INSTRUMENT GAUGE PANEL All controls and gauges are optional equipment for John Deere OEM Engines They may be provided by the equipment manufacturer instead of John Deere The following information applies only to those controls and gauges provided by John Deere IMPORTANT Any time an electric gauge or meter does not register correctly replace it with a new one Do not attempt to repair it Following is a brief description of the components on the John Deere instrument gauge panel A Oil Pressure Gauge Indicates engine oil pressure B Ammeter Indicates charging current within electrical system C Coolant Temperature Gauge Indicates the engine coolant temperature D Key Switch The four position key switch controls the electrical system E Reset Safety Switch Overrides safety shutdown switch when depressed and held in during engine start up Hold button in until engine oil pressure is at a safe operating level Switch will shut engine down when oil pressure drops below or coola
110. with a CoolScan analysis report you will be given a more thorough evaluation of your engine coolant condition along with detailed service recommendations See ADDING SUPPLEMENTAL COOLANT ADDITIVES later in this section 3 Wiay Haayy Duty Goclant Tesi Kit 63 Lubrication amp Maintenance 600 Hour 12 Month ADDING SUPPLEMENTAL COOLANT ADDITIVES SCA S After 600 hours or 12 months of engine operating time recharge your engine coolant with the recommended amount see label on container of TY16004 or TY16005 Liquid Coolant Conditioner IMPORTANT TY16004 or TY16005 Liquid Coolant Conditioner is a non chromate inhibitor and should be used only with low silicate ethylene glycol base antifreeze It does not protect the RG7298 cooling system from freezing Liquid Coolant Conditioner 64 Lubrication amp Maintenance 1200 Hour 24 Month ADJUSTING VARIABLE SPEED DROOP ON GENERATOR SET ENGINES STANADYNE INJECTION PUMPS ONLY 1 Warm engine to normal operating temperature Run engine at rated speed Apply full load Boo N Remove load RG8100 e Note the no load speed or frequency 6 Ifthrottle is not spring loaded type disconnect throttle linkage or cable 7 Turn screw A to adjust droop 8 If necessary adjust and connect throttle linkage or cables LUCAS INJECTION PUMPS ONLY See your authorized Lucas Repair Station for speed droop adjustment This servic

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