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OPERATION AND SERVICE MANUAL OEM Diesel Engines fi 2.9 L

1. 50 8 Inspect element 50 7 Air filter replace n n nannaa ee eee 50 5 Air filter Service 0 ee 50 7 Air intake system Troubleshooting 55 18 Air intake system check 40 2 Alternator belt 0 0 000000 eens 30 7 AMME as ra tae de a aa ee Ge ear ay a E 15 1 Auxiliary gear drive limitations 15 12 B Batteries Service 2 6 ee eee 30 2 Belts fan and alternator Checking tension 30 7 HEDIAGING cam ee eae eae wee as 30 7 50 8 Bleeding fuel system 50 3 Break in engine oil 10 4 Break in engine 15 8 C Chart service interval prime power 20 3 Chart service interval standby power 20 5 Checking fUS S 00 000 eee eee 50 9 Clutch adjustment 0 0005 30 9 Cold weather aids 10 3 15 15 Coolant POGUE AE age es oe oe we oo 2 50 2 Additional information 10 10 Additives 0 0 0a 10 12 Diesel engine 0 ce eee ees 10 9 Disposing oe eo ot apn ee AS 10 13 Replenishing supplemental additives 40 7 Supplemental additives SCAs 10 12 VGSHWNG 322 ce eeenese ac coeee eng ce ee 10 11 40 6 Warm temperature climates 10 13 Coolant temperature gauge 15 1 Cooling system Adding coolant 000 000 ae 50 2 D
2. C0 specific hazards General precautions are listed on m O o CAUTION safety signs CAUTION also calls attention to ji A CAUTION 3 safety messages in this manual DX SIGNAL 19 03MAR93 1 1 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 TS201 UN 23AUG88 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 DX READ 19 03MAR93 1 1 05 1 021201 PN 11 REPLACE SAFETY SIGNS Replace missing or damaged safety signs See the machine operator s manual for correct safety sign placement Co Co O lt ep N Z 7 N U EF DX SIGNS1 19 04JUN90 1 1 PREVENT BYPASS STARTING Avoid possible injury or death from engine runaway Do not start engine by shorting across starter terminal Engine will start with PTO engaged if normal circuitry is bypassed Start engine only from operator s stati
3. RG11593 UN 08DECOO RG10613 UN 210CT99 RG RG34710 5051 19 30JAN98 1 1 15 16 021201 PN 50 Engine Operating Guidelines CHANGING ENGINE SPEED STANDARD MECHANICAL GOVERNOR NOTE Throttle levers are usually supplied by OEM manufacturer Consult supplier literature to familiarize yourself with throttle lever used on your engine To increase engine speed turn throttle 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 A Throttle Handle o o O LU Q 5 Z st op LO O oc Throttle Handle on North American Instrument Panel RG RG34710 5052 19 30JAN98 1 1 IDLING ENGINE Avoid excessive engine idling Prolonged idling may speed Slow idle speed for this engine is 850 rpm at cause the engine coolant temperature to fall below its factory If an engine will be idling for more than 5 normal range This in turn causes crankcase oil minutes stop and restart later dilution due to incomplete fuel combustion and permits formation of gummy deposits on valves NOTE Generator set applications where the governor pistons and piston rings It also promotes rapid is locked at a specified soeed may not have a accumulation of engine sludge and unburned fuel in slow idle function These engines will idle at no the exhaust system load governed speed high
4. Engine Mounted Oil Filter Engine Mounted Oil Filter L RG11529 UN 01DEC00 RG11530 UN 01DEC00 5 After the first 100 hours maximum of operation drain engine oil and change engine oil filter A See CHANGING ENGINE OIL AND REPLACING OIL FILTER in Lubrication and Maintenance 250 Hour Section Fill crankcase with seasonal viscosity grade oil See DIESEL ENGINE OIL in Fuels Lubricants and Coolant Section A Oil Filter RG11549 UN O6DECO00 3029 Engines with Remote Oil Filter Continued on next page OQUOD002 000001C 19 01DEC00 1 2 15 10 021201 PN 44 Engine Operating Guidelines z O LU Q 5 ra T a O QC 5 z 5 5 Z l T bs LO do RG11587 g fc VDO Instrument Panel Except North America North American Instrument Panel A Coolant Temperature Gauge NOTE 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 new John Deere oil filter 6 Watch coolant temperature gauge 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 approxima
5. 1 Keep a record of the number of hours you operate your engine by regular observation of hour meter Check your record regularly to learn when your engine needs service 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 covered 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 RG RG34710 5103 19 30JAN98 1 1 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 Visual walkaround inspection Check fuel filter RG RG34710 5104 19 30JAN98 1 1 70 1 021201 PN 137 Lubrication and Maintenance Records 250 HOUR 6 MONTH SERVICE Check engine mounts Lubricate PTO clutch shaft bearings service fire extinguisher Service battery Change engine oil and filter Check fan and alternator belt tension Check PTO clutch adjustment RG RG34710 5105 19 30JAN98 1 1 70 2 021201 PN 138 Lubrication and Maintenance Records 400 HOUR SERVIC
6. 181389 19 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 RG11546 UN O01DECOO d n y EE F TE i F m e E r I LN AF Fuel Injection Pump RG RG34710 5081 19 30JAN98 1 1 50 1 021201 PN 95 Service As Required ADDING COOLANT CAUTION 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 UN 23AUG88 IMPORTANT Never pour cold liquid into a hot engine as it may crack cylinder head or block NEVER operate engine without coolant John Deere TY15161 Cooling System eee 1 ww SG l j Sealer may be added to the radiator to i stop leaks on a temporary or ih o emergency basis only DO NOT use any ly Hi other stop leak additives in the cooling ABR A system Leaks should be permanently repaired as quickly as possible RG11607 UN 25JAN01 Air must be expelled from cooling ei a system when coolant is added Sending Unit Fitting 1 Loosen temperature sending unit fitting A at rear of A Sending Unit Fitting cylinder head to allow air to escape when filling system IMPORTANT When adding coolant to the system use the appropr
7. Controls engine speed RG11527 UN 01DECOO North American Instrument Panel A Oil Pressure Gauge B Coolant Temperature Gauge C Key Switch D Tachometer E Reset Safety Switch F Fuse Holder G Ammeter H Hour Meter I Hand Throttle Continued on next page 15 2 OUOD002 0000028 19 18JAN01 2 6 021201 PN 36 Engine Operating Guidelines AEZ Instrument Gauge Panel Except North America A Oil Pressure Gauge The oil pressure gauge indicates engine oil pressure B Coolant Temperature Gauge The coolant temperature gauge indicates the engine coolant temperature C Engine Control Light The engine control light indicates that the engine protection is activated D Oil Pressure Light The oil pressure light illuminates when the key switch is turned to the CONTROL position The light will remain on until the engine is started and the specified oil pressure is reached If oil pressure is lost during engine operation the light will illuminate and protection circuitry will stop the engine The oil pressure light will remain on indicating that the engine was stopped due to a low oil pressure condition E Alternator Light The alternator light illuminates when the key is turned to the CONTROL position The light will remain on until the engine is started After the engine is running if the alternator stops charging the light will illuminate and protection circuitry will stop the engi
8. SAE 15W 40 The following oil is also recommended SAE 5W 30 SAE 0W 40 e John Deere TORQ GARD SUPREME paaa SAE 10W 40 Other oils may be used if they meet one or more of the following API Service Classification CH 4 API Service Classification CG 4 API Service Classification CF 4 ACEA Specification E3 ACEA Specification E2 TS1661 UN 100CT97 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 Extended service intervals may apply when John Deere preferred engine oils are used Consult your John Deere dealer for more information PLUS 50 is a registered trademark of Deere amp Company TORQ GARD SUPREME is a registered trademark of Deere amp Company DX ENOIL 19 24JAN00 1 1 1 0 5 021201 PN 26 Fuels Lubricants and Coolant EXTENDED DIESEL ENGINE OIL SERVICE INTERVALS When John Deere PLUS 50 oil and the specified John Deere filter are used the service interval for engine oil and filter changes may be increased by 50 If other than PLUS 50 oil and the specified John Deere filter are used change the engine oil and filter at the normal service interval PLUS 50 is a registered trademark of Deere amp Company DX ENOIL6 19 100CT97 1 1 MIXING OF LUBRICANTS In general avoid mixing different brands or types of oil Consult your John Deere dealer to obtain specific Oil manuf
9. into the detent DO NOT overtighten 10 If equipped with water separator remove water separator bowl from removed filter element Drain and clean separator bowl Dry with compressed air Install water separator bowl onto new element Tighten securely O O O LU Q si Z I l N co D oc Leave fuel shut off valve open and bleed the fuel system See BLEED FUEL SYSTEM in Service As Fuel Filter Dust Seal Installation Required Section Tighten bleed plug A Correct Installation B Incorrect Installation C Seal RG RG34710 5071 19 30JAN98 2 2 40 4 021201 PN 81 Lubrication amp Maintenance 600 Hour 12 Month CHECKING COOLING SYSTEM CAUTION 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 UN 23AUG88 IMPORTANT Air must be expelled from cooling system when system is refilled Loosen temperature sending unit fitting at rear of cylinder head to allow air to escape when filling system Retighten fitting when all the air has been expelled Beware of Pressurized Fluids Check entire cooling system for leaks Tighten all clamps securely Thoroughly inspect all cooling system hoses Replace hoses when hardened softened or cracked If coolant must be added use mixture as recommended in
10. Check Fuses Lubrication and Maintenance Lubrication and Maintenance Service Intervals 20 4 RG RG34710 5058 19 30JAN98 2 2 021201 PN 59 Lubrication and Maintenance LUBRICANT AND MAINTENANCE SERVICE INTERVAL CHART GENERATOR STANDBY APPLICATIONS NOTE The service intervals in the Lubrication and Maintenance Sections that follow reflect standard engines Use service intervals listed below for generator standby applications Match service items below to titles in Lubrication and Maintenance Sections for procedures Lubrication and Maintenance Service Intervals Every 2 250 Hours or 600 Hour or 12 1200 Hour or Operate Engine at Rated Speed and 50 70 Load a Minimum of 30 Minutes Check Engine Oil and Coolant Level e o Jo fo Check Fuel Fiter loo Lo Jo fl lubricate PTO Release Bearings e Jo fo Ea a ff Valve amp Restriction Indicator Gauge Visual Walkaround Visual Walkaround Inspection Service Fire Extinguisher gt Lubricate PTO Clutch Shaft Bearings pete To Gen Se Bonus ff Service Service Battery i Change Engine Oil and Replace Oil Filter Check Fan and Alternator Bett Tension J oe Check PTO Clutch Adjustment oe loo loo loo Check Engine Mounts loo loo loo Initial Valve Clearance Adjustment cl eo S S Grek ane rd Cesta a Clean Crankcase Vent Tube Crankcase Vent Tube Check Air Intake Hoses Connections amp aaa eves Fe Fue Eent Fuel Filter
11. If 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 15 minutes before welding or heating TS220 UN 23AUG88 Do all work in an area that is ventilated to carry toxic fumes and dust away Dispose of paint and solvent properly DX PAINT 19 220CT99 1 1 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 UN 23AUG88 DX RCAP 19 04JUN90 1 1 05 8 021201 PN 18 Safety 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 UN 23AUG88 Avoid creating dust Never use compressed air for cleaning Avoid brushing or grinding material containing asbestos When servicing wear an approved respirator
12. RG11548 UN 01DEC00 North American Instrument Panel Continued on next page OUOD013 0000003 19 28NOV00 1 3 50 9 021201 PN 103 Service As Required On AEZ Instrument Panels Except North America 1 Remove the four cap screws B holding the instrument panel board 2 Open fuse holder C 3 Replace as necessary with an equivalent 16 amp fuse D IMPORTANT Always replace a blown fuse with a fuse of the same amperage 4 Reinstall the instrument panel board B Cap Screws C Fuse Holder D 16 Amp Fuse AEZ Instrument Panel Except North America RG8149 UN 01DECO00 OUOD013 0000003 19 28NOV00 2 3 On VDO Instrument Panels Except North America 5 The fuse is located on the electronic control card inside the panel s rear access cover Remove cover and check fuse If defective replace with a 10 amp fuse There is a spare fuse available on the card in the SPARE terminal N Poe o A iy NG Tyan UN 19JUN00 ae fe So amp RG10606A VDO Instrument Panel Except North America OUOD013 0000003 19 28NOV00 3 3 50 1 0 021201 PN 104 Troubleshooting GENERAL TROUBLESHOOTING INFORMATION Troubleshooting engine problems can be difficult An engine wiring diagram is provided in this section to help isolate electrical problems on power units using John Deere wiring harness and instrument gauge panel Later in this section Is a list o
13. real world problems and offers practical solutions in the areas of marketing financing equipment selection and compliance Fundamentals of Services manuals show you how to repair and maintain off road equipment Fundamentals of Machine Operation manuals explain machine capacities and adjustments how to improve machine performance and how to eliminate unnecessary field operations 80 1 THE PRECISION FARMING GUIDE FOR AN a Th TS224 UN 17JAN89 TS191 UN 02DEC88 TS189 UN 17JAN89 TS1663 UN 100CT97 DX SERVLIT 19 11NOV97 1 1 021201 PN 144 John Deere Service Literature Available PUBLICATIONS FOR THIS ENGINE Technical information is available from John Deere in support of our products Some of this information is available in electronic as well as printed form Order from your John Deere dealer or call 1 800 522 7448 Please have available the model number and serial number and name of your John Deere engine Powentecn 29L OEM Engines Parts Catalog Emission Non Certified PC3202 Engines Component Technical Manual All 2 9 L Engines Ui Repair Operation and Diagnostics CTM125 OEM Engine Accessories CTM67 Alternators and Starter Motors CTM77 OUOD013 0000005 19 28NOVO00 1 1 80 2 021201 PN 145 John Deere Service Literature Available 80 3 021201 PN 146 Index Page A Air cleaner Cleaning element 50 7 Element storage
14. 19 30AUG96 1 1 REPLACE FAN AND ALTERNATOR BELTS Inspect belts for cracks fraying or stretched out areas Replace if necessary See CHECKING FAN AND ALTERNATOR V BELT TENSION in Lubrication and Maintenance 250 Hour Section RG RG34710 5086 19 30JAN98 1 1 50 8 021201 PN 102 Service As Required POWER TAKE OFF PTO CLUTCH CAUTION Entanglement in rotating driveline can cause serious injury or death Keep shield on PTO drive shaft A between the clutch housing and the engine driven equipment at all times during engine operation Wear close fitting clothing Stop the engine and be sure ms Jam PTO driveline is stopped before making adjustments TS198 UN 23AUG88 Proper performance of the power take off unit will be related to the care it is given Lubricate it periodically and keep the clutch properly adjusted See LUBRICATION AND MAINTENANCE 250 HOUR Section Beware of Rotating Drivelines If the power take off does not work properly after adjustment and lubrication contact your authorized servicing dealer or engine distributor A PTO Driveshaft RG4693 UN 14DEC88 ee pan 1 4 x 8 4 TESS f E sA Yi ek PTO Drive Shaft RG RG34710 5087 _ 19 30JAN98 1 1 CHECKING FUSES The following instructions apply to engines equipped with a John Deere instrument panel On North American Instrument Panels 1 Check the fuse A and replace as necessary with an equivalent 14 amp fuse
15. 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 DX DUST 19 15MAR91 1 1 PREVENT BATTERY EXPLOSIONS Keep sparks lighted matches and open flame away from the top of battery Battery gas can explode Never check battery charge by placing a metal object across the posts Use a volt meter or hydrometer Do not charge a frozen battery it may explode Warm battery to 16 C 60 F TS204 UN 23AUG88 DX SPARKS 19 03MAR93 1 1 05 9 021201 PN 19 PREVENT ACID BURNS Sulfuric acid in battery 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 Filling batteries in a well ventilated area Wearing eye protection and rubber gloves Avoiding breathing fumes when electrolyte is added Avoiding spilling or dripping electrolyte 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 15 30 minutes Get medical attention immediately If acid is swallowed Do not induce vomiting Drink large amounts of water or milk but do not exceed 2 L 2 quarts Get medical attention immediately PROTECT AGAINST HIGH PRESSURE SPRAY Spray from hi
16. DO NOT incinerate or puncture a starting fluid container Engines may be equipped with intake air heaters coolant heaters or ether injectors as a cold weather starting aid Starting aids are required below 32 F 0 C They will enhance starting performance above these temperatures and may be needed to start applications that have high parasitic loads during cranking and or start acceleration to idle Using correct grade of oil per engine and machine operator s manual is critical to achieving adequate cold weather cranking speed Other cold weather starting aids are required at temperatures below 22 F 30 C or at altitudes above 1500 m 5000 ft 1 Follow steps 1 4 as listed under STARTING THE ENGINE then proceed as follows according to the instrument control panel on your engine 2 Switch on the air intake heater for 30 seconds or activate ether injector by following suppliers instructions 3 Follow remaining steps 5 8 as listed under STARTING THE ENGINE earlier in this section Additional information on cold weather operation is available from your authorized servicing dealer 15 15 140 to o on i sk Do tn co Minimum Cranking RPM S Le 100 100 100 RG11521 we NA Handle Starting Fluid with Care Cold Weather Starting Guidelines t oa I 2 LI TS1356 UN 18MAR92 RG11521 19 10JANO01 RG RG34710 5050 19 30JAN98 1 1 021201 PN 49
17. Do not pour waste onto the ground down a drain or into any water source 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 DX DRAIN 19 03MAR93 1 1 05 11 021201 PN 21 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 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 Cold Filter Plugging Point CFPP below the expected low temperature OR Cloud Point at least 5 C 9 F below the expected low temperature LUBRICITY OF DIESEL FUEL Diesel fuel must have adequate lubricity to ensure proper operation and durability of fuel injection system componenis Diesel fuels for highway use in the United States and Canada require sulfur content less than 0 05 Di
18. Increase engine rpm when heavy electrical load is used Inspect clean and tighten 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 RG RG34710 5093 19 30JAN98 1 2 021201 PN 116 Symptom Starter cranks slowly Entire electrical system does not function Troubleshooting Problem Low battery output Crankcase oil too heavy Loose or corroded connections Faulty battery connection Sulfated or worn out batteries Blown fuse 55 13 Solution See your authorized servicing dealer or engine distributor Use proper viscosity oil Clean and tighten loose connections Clean and tighten connections See your authorized servicing dealer or engine distributor Replace fuse RG RG34710 5093 19 30JAN98 2 2 021201 PN 117 Troubleshooting LUBRICATION SYSTEM TROUBLESHOOTING Symptom Low Oil Pressure High Oil Pressure Problem Low crankcase oil level Clogged oil cooler or filter Excessive oil temperature Defective oil pump Incorrect oil Oil pressure regulating
19. 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 RG RG34710 5045 19 30JAN98 1 1 1 5 7 021201 PN 41 Engine Operating Guidelines BREAK IN SERVICE 5 a 3 a F Ndi i 5 A aA C e 5 Diostick Marki AR TA pstick Markings Li 5 Check Engine Oil Level A Full Mark B Crosshatch The engine is ready for normal operation However arrow on dipstick If make up oil is extra care during the first 100 hours of operation will required during the break in period result in more satisfactory long term engine an additional 100 hour break in performance and life DO NOT exceed 100 hours of period is required John Deere operation with break in oil Engine Break In Oil TY22041 should be used to make up any oil 1 This engine is factory filled with a special break in consumed during the break in oil Operate the engine at heavy loads with minimal period idling during the break in period DO NOT fill above the top of the 2 If the engine has significant operating time at idle mark A or crosshatch pattern B constant speeds and or light load usage or whichever is present Oil levels make up oil is required in the first 100 hour period anywhere within arrows or a longer break in period may be required In these crosshatch a
20. Tag f rsta tillf lle att bes ka honom Han vill ocks tr ffa Dig f r att f veta vad Du beh ver och hur han kan hj lpa Dig DPSG OUOE003 2736 19 11JAN99 1 1 021201 PN 3 Introduction IDENTIFICATION VIEWS RG9172 UN 29NOV00 3029D Left Front View RG9173 UN 29NOV00 3029D Right Front View RG RG34710 4501 19 30JAN98 1 2 O O gt O Z O T Z D l N D CC 3029T Left Front View RG9175 UN 29NOV00 3029T Right Front View RG RG34710 4501 19 30JAN98 2 2 021201 PN 4 Contents Page Page Record Keeping iding ENGNG res oon eet te geesee 15 17 Engine Serial Number Plate 01 1 Stopping the Engine 15 18 Record Engine Serial Number 01 1 Using a Booster Battery or Charger 15 20 Engine Option Codes 01 2 Record Fuel Injection Pump Model Number 01 4 Lubrication and Maintenance Observe Service Intervals 20 1 Say APA 05 1 Use Correct Fuels Lubricants and Coolant 20 2 Lubrication and Maintenance Service Fuels Lubricants and Coolant Interval Prime Power Engines 20 3 Diesel FUG AA 10 1 Lubrication and Maintenance Service Lubricity of Diesel Fuel 10 1 Interval Standby Power 20 5 Diesel Fuel Storage 10 2 DIESELSCAN Fuel Analysis 10 2 Lubrication amp Maintenance Daily Minimizing the Eff
21. They often contain a high concentration of silicates and may damage the engine or cooling system 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 Chlorides lt 40 mg L Total Dissolved Solids lt 340 mg L Total Hardness lt 170 mg L 55 to 9 0 Freeze Protection The relative concentrations of ethylene glycol and water in the engine coolant determine its freeze protection limit Ethylene Glycol Freeze Protection Limit 20c 12 F ITC 34 F 50 627 DO NOT use a coolant water mixture greater than 60 ethylene glycol DX COOL7 19 24JAN00 1 1 1 0 1 0 021201 PN 31 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 intervals of 12 months or less and whenever excessive coolant is lost through leaks or overheating DX COOL9 19 17FEB99 1 3 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 add
22. 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 CHANGING ENGINE OIL AND FILTER in Lubrication and Maintenance 250 Hour Section 2 Service air cleaner See REPLACING AIR CLEANER FILTER ELEMENT 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 ENGINE 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 10 11 12 13 14 capacity Completely drain fuel filter and close fuel valve if equipped 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 belt if desired Remove and clean batteries Store t
23. torque of generator manufacturer A Engine Mounting Brackets Engine Mounting 2 Inspect overall condition of vibration isolators if equipped Replace isolators if rubber has deteriorated or mounts have collapsed as necessary DPSG OUOD002 1578 19 21JUN00 1 1 30 1 0 021201 PN 76 Lubrication amp Maintenance 400 Hour ADJUSTING ENGINE VALVE CLEARANCE NEW OR REBUILT ENGINES Adjust engine valve clearance after the first 400 hours on new or rebuilt engines See CHECKING AND ADJUSTING ENGINE VALVE CLEARANCE in Lubrication and Maintenance 1200 Hour Section or have your authorized servicing dealer or engine distributor adjust the valve clearance IMPORTANT Have valves adjusted after the first 400 hours of operation on new or rebuilt engines Then adjust valves at 1200 hour 24 month intervals thereafter T81224 UN 07NOV88 RG RG34710 5077 19 30JAN98 1 1 35 1 021201 PN 77 Lubrication amp Maintenance 600 Hour 12 Month LUBRICATING PTO CLUTCH INTERNAL LEVERS AND LINKAGE CAUTION Never attempt to service the 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 Jam Remove the PTO housing cover and apply one shot of John Deere Multipurpose Lubricant or equivalent See FUELS LUBRICANTS and COOLANT Section to the Use Extreme Care When Working Around the PTO pivot points A of each clutc
24. Center TDC Compression stroke Insert timing pin in flywheel lf Number 1 cylinder rocker arms are loose the engine is at Number 1 TDC Compression If Number 1 cylinder rocker arms are not loose rotate engine one full revolution 360 to Number 1 TDC Compression NOTE Firing order is 1 2 3 4 With engine lock pinned at TDC of Number 1 piston s compression stroke B check valve clearance using a feeler gauge on Number 1 and 2 exhaust valves and Number 1 and 3 intake valves Specification Intake Valve Clearance Checking Rocker Arm to Valve Tip i eNi Engine Cold Specification Hg Clearance aa 0 31 0 38 mm 0 012 0 015 in 5 Exhaust Valve Clearance 4 4 Checking Rocker Arm to Valve Ha Tip Engine Cold Valve Adjusting Order Specification Clearance a 0 41 0 48 mm 0 016 0 019 in A Front of Engine B Number 1Piston at TDC Compression Stroke 5 Rotate flywheel 360 degrees and lock Number 1 piston C Number 1 Piston at TDC a Stroke at TDC exhaust stroke C E Exhaust Valve I Intake Valve 6 Check valve clearance on Number 3 exhaust valve and Number 2 intake valve 7 If valves need adjusting use following valve clearance adjustment procedure and specifications 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
25. Connect one end of the other jumper cable to the B 12 Volt Booster Battery ies NEGATIVE post of the booster battery C Booster Cable D Cable to Starting Motor 5 ALWAYS complete the hook up by making the last connection of the NEGATIVE cable to a good ground on the engine frame and away from the battery ies Continued on next page RG RG34710 4060 19 01JAN96 1 2 15 20 021201 PN 54 Engine Operating Guidelines 6 Start the engine Disconnect jumper cables immediately after engine starts Always disconnect NEGATIVE cable first RG RG34710 4060 19 01JAN96 2 2 15 21 021201 PN 55 Lubrication and Maintenance OBSERVE SERVICE INTERVALS S O LU Q 5 3 T Tr B O CC AEZ Instrument Panel Hour Meter Ng APMx309 2g O LU Q 00 l 3 F O O 9 N E3 3 3 O l as ee North American Instrument Panel Hour Meter Using hour meter A as a guide perform all services at VDO Instrument Panel Hour Meter the hourly intervals indicated on following pages At each scheduled maintenance interval perform all previous A Hour Meter 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
26. Element Check Check Cooling System System Coolant Solution Analysis Add SCAs as required Replace primary air cleaner element when restriction indicator shows a vacuum of 625 mm 25 in H20 Change the oil for the first time before 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 percent to 375 hours Have your authorized servicing dealer or engine distributor adjust valve clearance after the first 400 hours of operation Then have the valve clearance adjusted at 1200 Hour 24 Month intervals thereafter Continued on next page QUOD002 0000022 19 06DEC00 1 2 20 5 021201 PN 60 Lubrication and Maintenance Lubrication and Maintenance Service Intervals a aa CC Mo as eto eoe ats mine Pressure Test Pressure Test Cooling System System paaa T T Tr l adjust Variable Speed OT Ye Joo Flush and Refill Cooling System Test Thermostats Add Coolan Bleed Fuel System Replace Air Cleaner Elements P Replace Bets Ff Check Fuses lf John Deere COOL GARD is used the flushing and refilling interval may be extended to 3000 hours or 36 months If John Deere COOL GARD is used and the coolant is tested annually AND additives are replenished by adding supplemental coolant additives the flushing and refilling interval may be extended to 5000 hours or 60
27. Fuels Lubricants and Coolant section RG RG34710 5073 19 30JAN98 1 1 40 5 021201 PN 82 Lubrication amp Maintenance 600 Hour 12 Month TESTING DIESEL ENGINE COOLANT Maintaining adequate concentrations of glycol and Compare the results to the supplemental coolant inhibiting additives in the coolant Is critical to protect additive SCA chart to determine the amount of the engine and cooling system against freezing inhibiting additives in your coolant and whether more corrosion and cylinder liner erosion and pitting John Deere COOLANT CONDITIONER should be added Test the coolant solution at intervals of 12 months or less and whenever excessive coolant is lost through COOLSCAN leaks or overheating For a more thorough evaluation of your coolant Coolant Test Strips perform a COOLSCAN analysis See your John Deere dealer for information about COOLSCAN 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 DX COOL9 19 17FEB99 1 1 40 6 021201 PN 83 Lubrication amp Maintenance 600 Hour 12 Month REPLENISHING SUPPLEMENTAL COOLANT ADDITIVES SCAs BETWEEN COOLANT CHANGES IMPORTANT Do not add supplemental coolant additives when the cooling system is drained and refilled with John Deere COOL GARD NOTE If system is to be filled with coolant that does not contain SCAs the coolan
28. PREMIUM DIESEL FUEL CONDITIONER or equivalent at the specified concentration DX FUEL5 19 24JAN00 1 1 021201 PN 22 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 DIESELSCAN FUEL ANALYSIS DIESELSCAN is a John Deere fuel sampling program to help you monitor the quality of your fuel source It verifies fuel type cleanliness water content suitability for cold weather operation and if fuel is within ASTM specifications Check with your John Deere dealer for availability of DIESELSCAN kits DIESELSCAN is a trademark of Deere amp Company 10 2 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
29. PTO Clutch Levers and Linkage Clean Crankcase Vent Tube Check Air Intake Hoses Connections and System Replace Fuel Filter Element Check Cooling System Coolant Solution Analysis Add SCAs as needed Pressure Test Cooling System Check and Adjust Valve Clearance l o e d y o Flush and Refill Cooling System Test Thermostats Add Coolant l S o e Replace primary air cleaner element when restriction indicator shows a vacuum of 625 mm 25 in H20 Change the oil and filter for the first time after 100 hours maximum of 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 percent to 375 hours Have your authorized servicing dealer or engine distributor adjust valve clearance after the first 400 hours of operation Then have the valve clearance adjusted at 1200 Hour 24 Month intervals thereafter lf John Deere COOL GARD is used the flushing and refilling interval may be extended to 3000 hours or 36 months If John Deere COOL GARD is used and the coolant is tested annually AND additives are replenished by adding supplemental coolant additives SCAs the flushing and refilling interval may be extended to 5000 hours or 60 months whichever occurs first Continued on next page RG RG34710 5058 19 30JAN98 1 2 20 3 021201 PN 58 Bleed Fuel System Replace Air Cleaner Elements Replace Belts Inspect PTO Clutch
30. UN 13SEP00 RG RG34710 5091 19 30JAN98 1 2 021201 PN 106 Troubleshooting A1 Speed Control Unit H2 Oil Pressure Indicator P6 Ammeter Y2 Fuel Shut Off Solenoid Bi Magnetic Speed Sensor Lamp R1 Resistor 48 ohm BLK Black B2 Coolant Temperature K1i Starter Relay S1 Key Switch BLU Blue Sensor M1 Starter Motor S2 Magnetic Safety Switch BRN Brown B3 Oil Pressure Sensor P1 Coolant Temperature North American Auto DK BLU Dark Blue F1 Starting Circuit Fuse 14 Gauge Override Module GRN Green Amp P2 Oil Pressure Gauge European Saran ORG Orange F3 Fuse Early Models P3 Crankcase Oil Level W1 Ground on K1 Starter PUR Purple G1 Battery Switch Gauge Relay Mounting Stud RED Red G2 Alternator P4 Tachometer Y1 Starter Solenoid YEL Yellow H1 Coolant Temperature P5 Hourmeter Indicator Light P4 tachometer has a built in hourmeter On some earlier engines a separate hourmeter P5 and fuse F3 are used 2P4 tachometer has a built in hourmeter On some engines a separate hourmeter P5 and fuse F3 are used RG RG34710 5091 19 30JAN98 2 2 55 3 021201 PN 107 ENGINE TROUBLESHOOTING Symptom Engine Will Not Crank Engine cranks but will not start Troubleshooting Problem Weak battery Corroded or loose battery connections Defective main switch or start safety switch Starter solenoid defective Starter defective Incorrect starting procedure No f
31. always follow manufacturer s instructions Continued on next page RG RG34710 5049 19 30JAN98 1 4 1 5 1 2 021201 PN 46 Engine Operating Guidelines A CAUTION Before starting engine in a confined building install proper outlet exhaust ventilation equipment Always use safety approved fuel storage and piping eo bud No hi kA LED ry o f ka o NOTE If temperature is below O C 32 F it may be necessary to use cold weather starting aids See COLD WEATHER OPERATION later in this section Perform all prestarting checks outlined in Lubrication amp Maintenance Daily Section later in this manual TS220 UN 23AUG88 Avoid Toxic Fumes Open the fuel supply shut off valve if equipped RG RG34710 5049 19 30JAN98 2 4 If equipped with PTO clutch pull lever arrow rearward away from engine to disengage PTO clutch RG5602 UN 16JUN00 PTO Clutch Lever Continued on next page RG RG34710 5049 19 30JAN98 3 4 15 13 021201 PN 47 Engine Operating Guidelines 4 Pull hand throttle A 1 3 of the way out Turn the handle in either direction to lock it in place 5 If 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 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 Troubleshooti
32. 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 TS1132 UN 26NOV90 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 DX MSDS NA 19 03MAR93 1 1 STAY CLEAR OF ROTATING DRIVELINES Entanglement in rotating driveline can cause serious injury or death Keep tractor master shield and driveline shields in place at all times Make sure rotating shields turn freely aa Wear close fitting clothing Stop the engine and be sure Ba PTO driveline is stopped before making adjustments connections or cleaning out PTO driven equipment N TS1644 UN 22AUG95 DX PTO 19 12SEP95 1 1 05 5 021201 PN 15 Safety 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
33. circuitry will stop the engine The coolant temperature light will remain on indicating the engine was stopped due to the engine overheating Other components on the instrument panel J Key Start Switch The four position key start switch controls the electrical system K Hour Meter The hour meter is an integral part of the tachometer It shows the accumulated hours of engine service The hour meter operates when the engine is running and accumulated hours are displayed in hours and tenths of hours 15 6 OUOD002 0000028 19 18JAN01 6 6 021201 PN 40 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 112 C 234 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 IMPORTANT Should the engine die while operating under load immediately remove load and restart the engine Overheating of the turbocharger parts may occur when oil flow is stopped Stop engine immediately if there are any signs of part failure
34. for water or debris and drain as necessary 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 RG11539 UN 01DECO0 2 Loosen air bleed plug A two full turns on fuel filter base and drain water from bottom until fuel starts to drain out 3 When fuel starts to drain out hand tighten drain plug After draining water from the fuel filter the filter must be primed by bleeding all air from the fuel system 4 Operate primer lever C of the fuel supply pump until fuel flow is free from air bubbles 5 Tighten bleed plug A securely by hand Continue operating hand primer until pumping action is not felt When finished pull hand primer outward away from engine as far as it will go RG11540 UN 01DECOO Fuel Sippy Pump Primer Lever A Bleed Plug If the fuel system needs further bleeding of air see B Drain Plug BLEED FUEL SYSTEM in Service As Required C Primer Lever Section later in this manual RG RG34710 5059 19 30JAN98 5 5 25 5 021201 PN 66 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
35. hs engine E certilied bo ren on Diesel Fuel This engine conforms to 2001 Calitomia and U S EPA regulations for off road compression iqnition engines Family NG WIDXLO2 S018 EU No E1197 680A NON ko 111700 wer SS EW 2500 mm BAR CODE AREA ee E a a8 A504341 1509001 Registered For Engine Service and Parts Call 1 800 JD ENGINE Emissions Label RG11606 UN 24JANO1 RG RG34710 7628 19 30JUN97 1 1 021201 PN 142 Emission System Warranty U S Emissions Control Warranty Statement United States Only 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 emissions related parts and components of your of operation whichever occurs first John Deere further engine The complete engine warranty less warrants that the engine covered by this warranty was emissions related parts and components is provided designed built and equipped so as to conform at the separately as the John Deere New Off Highway time of sale with all U S emissions standards at the Engine 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 RG RG34710 5112 19 30JAN98 1 1 75 2 021201 PN 143 John Deere Service Literature Available TECHNICAL INFORMATION Techni
36. idle Once an engine is warmed to normal operating temperatures engine should be idled at slow idle RG RG34710 5053 19 30JAN98 1 1 15 17 021201 PN 51 Engine Operating Guidelines STOPPING THE ENGINE 1 Pull PTO clutch lever arrow rearward away from engine to disengage clutch if equipped 2 Z pe co Z N O LO CJ oc PTO Clutch Lever Continued on next page RG RG34710 5054 19 30JAN98 1 2 15 18 021201 PN 52 Engine Operating Guidelines 2 Move the throttle handle 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 idle and no load 3 Turn key switch to OFF position Remove ignition key IMPORTANT Make sure that exhaust stack cap rain cap is installed when engine is not 5 running This will prevent water and dirt from entering engine 5 5 LO A Throttle Handle 5 QC Throttle Handle on North American Instrument Panel S D g q CO z O QC Rain Cap RG RG34710 5054 19 30JAN98 2 2 1 5 1 9 021201 PN 53 Engine Operating Guidelines USING A BOOSTER BATTERY OR CHARGER CAUTION Gas given off by ba
37. it last Exploding Battery A CAUTION Sulfuric acid in battery 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 tease a 3 Coeeecs KC If you spill acid on yourself Flush your skin with water 2 Apply baking soda or lime to help neutralize the acid 3 Flush your eyes with water for 15 30 minutes Get medical attention immediately If acid is swallowed 1 Do not induce vomiting 2 Drink large amounts of water or milk but do not exceed 2 L 2 quarts Sulfuric Acid 3 Get medical attention immediately TS203 UN 23AUG88 WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling DPSG OUOD002 1577 19 21JUN00 1 1 30 3 021201 PN 69 Lubrication and Maintenance 250 Hour CHANGING ENGINE OIL AND REPLACING OIL FILTER NOTE Change engine oil and filter for the first time after 100 hours maximum of operation then every 250 hours thereafter If John Deere PLUS 50 engine oil and a John Deere oil filter are used the o
38. mixing with ethylene glycol base engine coolant concentrate IMPORTANT Do not use cooling system sealing additives or antifreeze that contains sealing additives Coolant Drain Intervals Drain the factory fill engine coolant flush the cooling system and refill with new coolant after the first 3 years or 3000 hours of operation Subsequent drain intervals are determined by the coolant used for service At each interval drain the coolant flush the cooling system and refill with new coolant When John Deere COOL GARD is used the drain interval may be extended to 5 years or 5000 hours of operation provided that the coolant is tested annually AND additives are replenished as needed by adding a supplemental coolant additive If COOL GARD is not used the drain interval is reduced to 2 years or 2000 hours of operation DX COOL3 19 05FEB99 1 1 1 0 9 021201 PN 30 Fuels Lubricants and Coolant DIESEL ENGINE COOLANTS SUPPLEMENTAL ADDITIVE INFORMATION Engine coolants are a combination of three chemical components ethylene glycol antifreeze inhibiting coolant additives and quality water Coolant Specifications Some products including John Deere John Deere COOL GARD Prediluted Coolant 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 in
39. not confuse the whine heard during run down with noise which indicates a bearing failure Air leak in engine intake or exhaust manifold Improper clearance between turbine wheel and turbine housing Broken blades or other wheel failures Continued on next page 55 18 Solution See ENGINE TROUBLESHOOTING earlier in this section See ENGINE TROUBLESHOOTING earlier in this section See ENGINE TROUBLESHOOTING earlier in this section See ENGINE TROUBLESHOOTING earlier in this section Check intake manifold gasket and manifold repair as required See your John Deere engine distributor or servicing dealer Determine cause of lack of lubrication repair as required See your John Deere engine distributor or servicing dealer Check intake and exhaust manifold gaskets and manifolds repair as required See your John Deere engine distributor or servicing dealer Inspect turbocharger repair replace as required See your John Deere engine distributor or servicing dealer Inspect turbocharger repair replace as required See your John Deere engine distributor or servicing dealer RG RG34710 7602 19 30JUN97 1 3 021201 PN 122 Symptom Oil on Turbocharger Compressor Wheel or in Compressor Housing Oil Being Pushed or Pulled Through Center Housing Oil in Intake Manifold or Dripping from Turbocharger Housing Troubleshooting Problem Excessive crankcase pressure Air intake restriction D
40. oil cooler Defective oil cooler O rings Faulty coolant pump seal weep hole plugged coolant leaking through bearing Defective thermostat s 55 17 Solution Replace cylinder head gasket See your John Deere engine distributor or servicing dealer Locate crack repair replace components as required Remove and inspect cylinder liners See your John Deere engine distributor or servicing dealer Pressure test oil cooler repair replace as required See your John Deere engine distributor or servicing dealer Remove and inspect oil cooler O rings replace as required See your John Deere engine distributor or servicing dealer Replace coolant pump seals See your John Deere engine distributor or servicing dealer Test thermostats replace thermostats as required RG RG34710 7601 19 30JUN97 2 2 021201 PN 121 Troubleshooting AIR INTAKE SYSTEM TROUBLESHOOTING If turbocharger requires replacement determine what caused the failure of the defective unit and correct the condition This will prevent an immediate repeat failure of the replacement unit NOTE Turbochargers are equipped on 3029T engines only Symptom Problem Hard to Start or Will Not Start Engine Misfiring or Runs Irregularly Black or Grey Exhaust Smoke Lack of Engine Power Turbocharger Screams Air leak in intake manifold Turbocharger Noise or Vibration Bearings not lubricated insufficient oil pressure NOTE Do
41. 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 RG4687 UN 20DEC88 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 4 To replace 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 i i ar Er u a 5 Install new primary element and tighten wing nut k i E ASA NA securely Install cover assembly and tighten retaining wing Air Cleaner Secondary Element nut securely RG11068 UN 26JUN00 A Wing Nut B Primary Element C Unloader Valve D Retaining Nut E Secondary Element Continued on next page DPSG OUOD002 1580 19 21JUN00 1 2 50 5 021201 PN 99 Service As Required 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 release to reset indicator On European Sourced Air Cleaner Kits Clean filter element wh
42. valve failure Clogged oil pump screen or cracked pick up tube Excessive main or connecting rod bearing clearance Improper oil classification Oil pressure regulating valve failure Stuck or damaged filter bypass valve Stuck or damaged oil cooler bypass valve Continued on next page 99 14 Solution Fill crankcase to proper oil level Remove and inspect oil cooler See your John Deere engine distributor or servicing dealer Remove and inspect oil cooler See your John Deere engine distributor or servicing dealer Remove and inspect oil pump See your John Deere engine distributor or servicing dealer Drain crankcase and refill with correct oil Remove and inspect oil pressure regulating valve See your John Deere engine distributor or servicing dealer Remove oil pan and clean screen replace pick up tube Determine bearing clearance See your John Deere engine distributor or servicing dealer Drain crankcase and refill with correct oil Remove and inspect oil pressure regulating valve See your John Deere engine distributor or servicing dealer Remove and inspect filter bypass valve See your John Deere engine distributor or servicing dealer Remove and inspect oil cooler bypass valve See your John Deere engine distributor or servicing dealer RG RG34710 7600 19 30JUN97 1 3 021201 PN 118 Symptom Excessive Oil Consumption Troubleshooting Problem Too low viscosity crankc
43. 0 1300 1400 1500 1600 1700 1900 2000 2100 2200 2390 2600 2800 2900 3000 3100 3500 3600 3700 3900 400074100 4400 4600 4700 4800 4900 5000 5100 5200 5500 5600 5700 5900 6000 6200 6400 6500 6800 6900 7400 7500 7600 8800 9100 9700 9800 SW Option Code Label 3029TF150 Shown A Dipstick Tube Option used to determine crankcase oil fill quantity 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 shown above The first two digits of the code 40 see A identify the dipstick tube group The last two digits of the code identify the specific dipstick and tube assembly on your engine Listed on next page are engine crankcase oil fill quantities Continued on next page 65 5 RG11604 UN 24JAN01 RG RG34710 5100 19 30JAN98 1 3 021201 PN 132 Engine Model CD3029DF 120 CD3029DF 121 CD3029DF 122 CD3029DF 123 CD3029DF 124 CD3029DF 150 CD3029DF 151 CD3029DF 152 CD3029DF 160 CD3029DF 161 CD3029DF 162 CD3029DF 163 CD3029DF 164 CD3029DF 165 CD3029DF 180 CD3029TF120 CD3029TF121 CD3029TF123 CD3029TF150 CD3029TF152 CD3029TF160 CD3029TF161 CD3029TF162 Specifications Dipstick Tube Option Code s 4002 4003 4004 4005 4006 4004 4005 4004 4004 4004 4004 4005 4024 4022 4004 4004 4024 4022 4033 4024 4006 4024 4033 4024 4022 4033 4006 4025 4023 4024 4006 4024 4
44. 0 850 2700 16PN RE502217 43 58 2500 850 2700 CD3029DF 151 16DZ RE501258 43 58 2500 850 2700 CD3029DF 152 16KZ RE502217 43 58 2500 850 2700 CD3029DF 180 16DR RE502217 43 58 2500 850 2700 16EH RE501983 43 58 2500 850 2700 16NP RE502217 43 58 2500 850 2700 CD3029TF150 16DE RE502218 59 79 2500 850 2700 16DF RE502238 52 70 2500 850 2700 CD3029TF152 16EA RE501218 59 79 2500 850 2700 CD3029TF180 16DG RE502218 59 79 2500 850 2700 16DH RE502238 52 70 2500 850 2700 16EL RE501985 59 79 2500 850 2700 16EM RE501986 52 70 2500 850 2700 PE3029DF 150 16DP RE502217 43 58 2500 850 2700 16EG RE501983 43 58 2500 850 2700 16EQ RE502182 43 58 2500 850 2700 16HW RE501259 36 49 2500 850 2700 16PH RE501259 36 49 2500 850 2700 PE3029TF150 16DE RE502218 59 79 2500 850 2700 16DF RE502238 52 69 2500 850 2700 16EJ RE501985 59 79 2500 850 2700 16EK RE502986 52 69 2500 850 2700 16TR RE506877 48 64 1800 1890 16TS RE506878 48 64 1800 1890 aPower ratings are for a bare engine without the drag effect of accessories like fans transmission and auxiliary drives 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 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 Engine speeds listed are preset to factory specificatio
45. 00 800 2700 1890 1560 1890 1560 800 2700 1560 850 2700 850 2400 850 2700 850 2700 800 2400 800 2600 850 2700 850 2700 800 2700 800 2700 800 2700 800 2700 800 2700 aPower ratings are for a bare engine without the drag effect of accessories like fans transmission and auxiliary drives 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 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 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 Continued on next page 65 3 OUOD002 000002A 19 18JAN01 1 2 021201 PN 130 Specifications RE53958 CD3029TF123 RE53783 CD3029TF160 RE53783 RE58903 RE51979 RE53783 RE53958 CD3029TF 161 RE53958 CD3029TF162 RE51979 CD3029TF163 RE53783 PE3029DF120 RE53785 RE53786 RE64241 RE67271 RE41939 RE64242 RE41938 RE53785 PE3029TF120 RE506879 RE506880 RE53783 RE58903 RE53958 OUOD002 000002A 19 18JAN01 2 2 65 4 021201 PN 131 Specifications ENGINE CRANKCASE OIL FILL QUANTITIES TO KAUA NAAA PowerTech 3029TF150 2 9L 1553F 1100 120
46. 006 4006 4025 4023 4024 4006 4024 4026 4033 4024 4006 4026 Continued on next page 65 6 Crankcase Oil Capacity 6 0 L 6 5 qt 8 0 L 8 5 qt 6 0 L 6 5 qt 6 0 L 6 5 qt 6 0 L 6 5 qt 6 0 L 6 5 qt 6 0 L 6 5 at 7 0 L 7 5 at 6 0 L 6 5 qt 6 0 L 6 5 qt 6 0 L 6 5 qt 7 0 L 7 5 qt 8 0 L 8 5 qt 6 0 L 6 5 qt 8 0 L 8 5 qt 6 0 L 6 5 qt 8 0 L 8 5 qt 6 0 L 6 5 qt 7 0 L 7 5 at 8 0 L 8 5 qt 8 0 L 8 5 qt 9 0 L 9 5 at 6 0 L 6 5 qt 8 0 L 8 5 qt 8 0 L 8 5 qt 8 0 L 8 5 qt 9 0 L 9 5 at 6 0 L 6 5 qt 8 0 L 8 5 qt 6 0 L 6 5 qt 8 5 L 9 0 at 8 0 L 8 5 qt 6 0 L 6 5 qt 8 0 L 8 5 qt 8 5 L 9 0 qt RG RG34710 5100 19 30JAN98 2 3 021201 PN 133 Specifications Engine Model Dipstick Tube Option Code s Crankcase Oil Capacity CD3029TF163 4024 6 0 L 6 5 at CD3029TF180 4023 9 0 L 9 5 at 4024 6 0 L 6 5 at 4026 8 5 L 9 0 at 4033 8 0 L 8 5 qt PE3029DF120 4004 4005 6 0 L 6 5 qt 4006 8 0 L 8 5 qt 4022 7 0 L 7 5 at PE3029DF150 4004 6 0 L 6 5 qt PE3029TF120 4025 8 0 L 8 5 qt PE3029TF150 4006 4025 8 0 L 8 5 at 4023 9 0 L 9 5 at Crankcase oil capacity may vary slightly from amount crosshatch or between arrows on dipstick whichever shown ALWAYS fill crankcase to full mark or within is present DO NOT overfill RG RG34710 5100 19 30JAN98 3 3 65 7 021201 PN 134 Specifications UNIFIED INCH BOLT AND CAP SCREW
47. 12 Month IMPORTANT ALWAYS maintain coolant at correct level and concentration DO NOT operate engine without coolant even for a few minutes If frequent coolant makeup is required the glycol concentration should be checked with JTO7298 Coolant Battery Tester to ensure that the desired freeze point is maintained Follow manufacturer s instructions provided with Coolant Battery Tester Add the manufacturers 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 DIESEL ENGINE COOLANTS AND SUPPLEMENTAL ADDITIVE INFORMATION for proper mixing of coolant ingredients before adding to the cooling system DPSG OQUOD002 1921 19 12DEC00 2 2 40 8 021201 PN 85 Lubrication amp Maintenance 600 Hour 12 Month PRESSURE TESTING COOLING SYSTEM RG6557 UN 20JAN93 Pressure Testing Radiator Cap CAUTION 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 Test Radiator Cap 1 Remove radiator cap and attac
48. 15 16 Warranty Emission system 20000 eee eee 75 1 EPA emissions statement 75 2 Winterfronts cee eee 10 3 Wiring diagram North American a 55 2 Index 3 021201 PN 3 Index Index 4 021201 PN 4 TP 6144 3 03a
49. 716 mm 28 2 in 317 kg 698 Ib NOTE Engine models listed above with numbers ending in 120 and 160 are emission non certified Engines with model numbers ending in 150 and 180 are emission certified as explained later in this manual 65 1 3029TF120 3 Diesel 106 5 mm 4 19 in 110 mm 4 33 in 2 9 L 179 CU IN 17 8 1 519 mm 20 4 in 928 mm 36 5 in 716 mm 28 2 in 328 kg 722 Ib 3029TF150 3 Diesel 106 5 mm 4 19 in 110 mm 4 33 in 2 9 L 179 cu in 17 8 1 519 mm 20 4 in 928 mm 36 5 in 716 mm 28 2 in 328 kg 722 Ib 3029TF160 3 Diesel 106 5 mm 4 19 in 110 mm 4 33 in 2 9 L 179 CU IN 17 8 1 528 mm 20 8 in 928 mm 36 5 in 716 mm 28 2 in 329 kg 724 Ib 3029TF180 3 Diesel 106 5 mm 4 19 in 110 mm 4 33 in 2 9L 179 CU IN 1 81 528 mm 20 8 in 928 mm 36 5 in 716 mm 28 2 in 329 kg 724 Ib RG RG34710 5098 19 30JAN98 1 1 021201 PN 128 Specifications FUEL INJECTION PUMP SPECIFICATIONS EMISSION CERTIFIED ENGINES ENGINE OPTION FUEL INJECTION POWER RATING RATED SPEED SLOW IDLE FAST IDLE MODEL CODES PUMP RATED SPEED rpm rpm rpm PART NUMBER kW hp CD3029DF 150 16DP RE502217 43 58 2500 850 2700 16EG RE501983 43 58 2500 850 2700 16EQ RE502509 43 58 2500 1700 2700 16HW RE501259 36 48 250
50. 800 1350 1000 160 2000 1475 1580 2700 200 2150 3700 2730 2770 4750 3500 19 5 14 5 7 TW oe a ed SIllIlljLClL amp NO 0 0 mah ae IN o_o O IN NA x w O _ Jar x r2 rs Re xo toa a Gia b Dry means plain or zinc plated without any lubrication DO NOT use these values if a different torque value or tightening Make sure fastener threads are clean and that you properly start procedure is given for a specific application Torque values listed are thread engagement This will prevent them from failing when for general use only Check tightness of fasteners periodically tightening Shear bolts are designed to fail under predetermined loads Always Tighten plastic insert or crimped steel type lock nuts to approximately replace shear bolts with identical property class 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 Fasteners should be replaced with the same or higher property class If higher property class fasteners are used these should only be tightened to the strength of the original 65 9 DX TORQ2 19 010CT99 1 1 021201 PN 136 Lubrication and Maintenance Records USING LUBRICATION AND MAINTENANCE RECORDS Refer to specific Lubrication and Maintenance Section for detailed service procedures
51. E Initial valve clearance adjustment Hours PP aes Sooo lolo loo Have your authorized servicing dealer or engine distributor adjust valve clearance after the first 400 hours of operation Thereafter have the valve clearance adjusted at 1200 Hour 24 Month intervals RG RG34710 5107 19 30JAN98 1 1 600 HOUR 12 MONTH SERVICE Lubricate PTO clutch internal levers and linkage Coolant solution analysis add SCAs as needed Clean crankcase vent tube Check air intake hoses connections and system Pressure test cooling system Replace air cleaner element Check cooling system RG RG34710 5108 19 30JAN98 1 1 70 3 021201 PN 139 Lubrication and Maintenance Records 1200 HOUR 24 MONTH SERVICE Check and adjust engine valve clearance Test thermostat opening temperature Adjust variable speed on generator set engines Flush and refill cooling system lf John Deere COOL GARD is used the flushing interval may be extended to 3000 hours or 36 months If John Deere COOL GARD is used and the coolant is tested annually AND additives are replenished by adding supplemental coolant additives SCA s the flushing interval may be extended to 5000 hours or 60 months whichever occurs first RG RG34710 5109 19 30JAN98 1 1 70 4 021201 PN 140 Lubrication and Maintenance Records SERVICE AS REQUIRED Replace air cleaner elements Replace belts Bleed fuel system Add coolant Check fuses Inspect PTO clutc
52. E Thermostat Housing Pe A Plug 9 Stop engine pull off lower radiator hose and remove B Cover radiator cap to immediately drain the water from the system before rust and sediment settle 10 After draining water close drain valves Install radiator cap radiator hose and clamp Fill the cooling system with clean water and a heavy duty cooling system cleaner such as FLEETGUARD RESTORE or RESTORE PLUS Follow manufacturer s directions on label FLEETGUARD is a trademark of Cummins Engine Company Inc RESTORE is a trademark of Fleetguard Inc RESTORE PLUS is a trademark of Fleetguard Inc Continued on next page RG RG34710 5079 19 30JAN98 2 3 45 6 021201 PN 92 Lubrication amp Maintenance 1200 Hour 24 Month 11 After cleaning the cooling system drain cleaner and po ZN fill with water to flush the system Run the engine wo about 5 minutes remove radiator cap and pull off lower radiator hose immediately draining out flushing water Pa IMPORTANT Air must be expelled from cooling system when system is refilled Loosen temperature sending unit fitting at rear of cylinder head to allow air to escape when filling system Retighten fitting when all the air has been expelled gm O AP a re es ee eS ee ae oe a ee am a te bo SN Ng ae AG am e 4 F RG11605 UN 24JAN01 Jiggle Wire 12 Close all drain valves on engine and radiator Install A Jiggle Wire lower r
53. E PANELS IMPORTANT Any time an electric gauge or meter does not register correctly replace it with a new one Do not attempt to repair it 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 Continued on next page QUOD002 0000028 19 18JAN01 1 6 15 1 021201 PN 35 Engine Operating Guidelines Instrument Gauge Panel North American Following is a brief description of the components on the John Deere instrument gauge panel A Oil Pressure Gauge Indicates engine oil pressure B Coolant Temperature Gauge Indicates the engine coolant temperature C Key Switch The four position key switch controls the electrical system D Tachometer optional Indicates engine speed in revolutions per minute rpm 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 F Fuse Holder Contains 14 amp fuse G Ammeter Indicates charging current within electrical system H Hour Meter optional 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 I Hand Throttle optional
54. 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 1 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 4103 kPa 3 45 bar 1 03 bar 50 15 psi at rated full load North American Instrument Panel speed 1800 2500 rpm with oil at normal operating temperature of 105 C 221 F 2 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 A Oil Pressure Gauge B Coolant Temperature Gauge VDO Instrument Panel Except North America RG11533 UN 01DEC00
55. POWERTECH 2 9 L OEM Diesel Engines OPERATION AND SERVICE MANUAL Deere Power Systems Group DEERE OMRG27897 Issue 13FEB01 TP 6144 3 03a ENGLISH Kna EL 7 Introduction FOREWORD THIS MANUAL CONTAINS INFORMATION to operate and service the following engines Saran built France Emission Non Certified Engines CD3029DF 120 CD3029DF 121 CD3029DF 122 CD3029DF 123 CD3029DF 124 CD3029DF 160 CD3029DF 161 CD3029DF 162 CD3029DF 163 CD3029DF 164 CD3029DF 165 CD3029TF120 CD3029TF121 CD3029TF123 CD3029TF160 CD3029TF161 CD3029TF162 CD3029TF163 Saran built France Emission Certified Engines CD3029DF 150 CD3029DF 151 CD3029DF 152 CD3029DF 180 CD3029TF150 CD3029TF152 CD3029TF180 Torreon built Mexico Emission Non Certified Engines e PE3029DF120 e PE3029TF120 Torreon built Mexico Emission Certified Engines e PE3029DF150 e PE3029TF150 IMPORTANT This manual replaces two Operation and Maintenance Manuals OMRG27897 30JAN98 and OMRG24311 30AUG96 Cancelled READ THIS MANUAL carefully to learn how to operate and service your machine correctly Failure to do so could result in personal injury or equipment damage THIS MANUAL SHOULD BE CONSIDERED a permanent part of your machine and should remain with the machine 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 an
56. See your John Deere engine distributor or servicing dealer RG RG34710 7602 19 30JUN97 2 3 021201 PN 123 Symptom Turbocharger Turbine Wheel Drag Troubleshooting Problem Bearing wear Oil starvation or insufficient lubrication Shaft seals worn Carbon build up behind turbine wheel caused by coked oil or combustion deposits Dirt build up behind compressor wheel caused by air intake leaks Bearing seizure or dirty worn bearings 55 20 Solution Inspect turbocharger repair replace as required See your John Deere engine distributor or servicing dealer Determine cause of lack of lubrication repair as required See your John Deere engine distributor or servicing dealer Inspect turbocharger repair replace as required See your John Deere engine distributor or servicing dealer Inspect turbocharger repair replace as required See your John Deere engine distributor or servicing dealer Inspect turbocharger repair replace as required See your John Deere engine distributor or servicing dealer Inspect turbocharger repair replace as required See your John Deere engine distributor or servicing dealer RG RG34710 7602 19 30JUN97 3 3 021201 PN 124 Storage ENGINE STORAGE GUIDELINES John Deere engines can be stored outside for up to 4 John Deere engines expected to be stored more three 3 months with no long term preparation IF than six 6 months long term storage prepa
57. TORQUE VALUES UN 27SEP99 TORQ1A Top SAE Grade and Head Markings Bottom SAE Grade and Nut Markings Grade 1 No Mark Grade 2 No Mark Grade 5 5 1 or 5 2 Grade 8 or 8 2 tt Nem Ib ft Nem Ib ft Nem Ib ft Nem Ib ft Nem Ib ft N m ib ft Nem Ib ft _Nem Ib ft aa seo 22 16 63 46 56 41 42 31 67 49 85 63 110 80 120 88 155 005 705 25 pa 7 00 5 00 ota 15 110 100 a A oo ao 90 ao T 1850 1350 aao 05 950 700 950 700 2700 2000 3400 2500 1 1 2 990 730 1250 930 990 730 1250 930 2250 1650 4 Grade 2 applies for hex cap screws not hex bolts up to 6 in 152 mm long Grade 1 applies for hex cap screws over 6 in 152 mm long and for all other types of bolts and screws of any length b Lubricated means coated with a lubricant such as engine oil or fasteners with phosphate and oil coatings e Dry means plain or zinc plated without any lubrication DO NOT use these values if a different torque value or tightening Make sure fastener threads are clean and that you properly start procedure is given for a specific application Torque values listed are thread engagement This will prevent them from failing when for general use only Check tightness of fasteners periodically tightening Shear bolts are designed to fail under predetermined loads Always Tighten plastic insert or crimped steel type lock nuts to approximately replace shear bolts with identical g
58. acturers blend additives in their oils to meet information and recommendations certain specifications and performance requirements Mixing different oils can interfere with the proper functioning of these additives and degrade lubricant performance DX LUBMIX 19 18MAR96 1 1 1 0 6 021201 PN 27 Fuels Lubricants and Coolant OILSCAN AND COOLSCAN OILSCAN andCOOLSCAN 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 andCOOLSCAN kits T6828AB UN 15JUN89 T6829AB UN 180CT88 OILSCAN is a registered trademark of Deere amp Company COOLSCAN is a registered trademark of Deere amp Company DX OILSCAN 19 16APR92 1 1 ALTERNATIVE AND SYNTHETIC LUBRICANTS Conditions in certain geographical areas may require lubricant recommendations different from those printed in this manual Some John Deere brand coolants and lubricants may not be available in your location Consult your John Deere dealer to obtain information and recommendations Synthetic lubricants may be used if they meet the performance requirements as shown in this manual The temperature limits and service intervals shown in this manual apply to both conventional and synthetic oils Re refin
59. adiator hose and tighten clamp NOTE Install thermostat with jiggle wire A at top position 13 Install thermostat and cover using a new gasket Tighten cap screws to specification Specification Capscrews Torque ccccecececeeeeeeeeeeeeeeeeeeeeeeeeeseeeeeeseenes 47 Nem 35 Ib ft 14 Add coolant to radiator until coolant touches bottom of filler neck See ADDING COOLANT in Service As Required Section 15 Run engine until 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 16 After running engine check coolant level and entire cooling system for leaks Cooling system capacity for the Saran sourced 3029 L engine factory generator set package is 12 L 11 5 qt Refer to OEM manufacturer for capacities of cooling systems not supplied by John Deere RG RG34710 5079 19 30JAN98 3 3 45 7 021201 PN 93 Lubrication amp Maintenance 1200 Hour 24 Month TESTING THERMOSTAT OPENING TEMPERATURE 1 Remove thermostat 2 Visually inspect thermostat for corrosion or damage A CAUTION DO NOT allow thermostat or thermometer to rest against the side or bottom of container when heating water Either may rupture if overheated 3 Suspend thermostat and a thermometer in a container of water 4 Stir the water as it heats Observe opening action of o thermostat and compare te
60. ae AA Oe OY nee ee ee 40 5 Flush and refill 00000005 45 5 Pressure 1 easa eo ese oy ee ees ae 2 40 9 Pressure test radiator cap 40 9 Page Troubleshooting 24626 aana anaana 55 16 Crankcase vent tube clean 40 1 D Diesel engine oll 10 5 Diesel fuel uaaaaaaanapan kk PRE nA 10 1 Sis AA 10 2 E Electrical system diagram North American 55 2 Electrical system troubleshooting 55 12 Emissions EPA statement a 25 2 Warranty label APA PA AE 75 1 Engine loko AE 50 2 Breakin AA RA 15 8 Idling AA 15 17 01 12 0 AA MAA NAA oe 15 7 AA a e a AG AG ae ee GO 15 12 OPANI APP 15 18 Storage Kit 6 Aa 60 1 Troubleshooting 000000 eee 55 1 Warming 15 16 Engine electrical system Troubleshooting 00005 eae 55 12 Wiring diagram North American 55 2 Engine oil Break In 0 aa 10 4 ee AA AP 30 4 IS SOW BA 10 5 Oil filter change 1 0 0 2 0 0 30 4 Engine speed changing 15 17 DOOD 2 caggecaeqndsees aad ad oa haa 45 4 Extended diesel engine oil service intervals 10 6 F Fan belts 00 00 ee ee 30 7 Filter replace Ait eee 50 5 PUG b 00 044 3 ou ou ee enw eee eee eee 40 3 PARA PE 30 4 Filters air service 43w Eh 00 ae cae aa LA 50 7 Fire extinguisher service 30 1 1 021201 PN 1 Index Page Page Fuel Lubricity of di
61. and Linkage oe tee ee oe Bh Dd wee Pa DHS 40 1 Engine Operating Guidelines Cleaning Crankcase Vent Tube 40 1 Instrument Gauge Panels 15 1 Checking Air Intake System 40 2 Normal Engine Operation 15 7 Replacing Fuel Filter Element 40 3 Break In Service 2 0000 aa 15 8 Checking Cooling System 40 5 Auxiliary Gear Drive Limitations 15 12 Testing Diesel Engine Coolant 40 6 Generator Sets Standby Applications 15 12 Replenishing Supplemental Coolant Starting the Engine 005 15 12 Additives SCAs Between Coolant Cold Weather Operation 15 15 Ghange88 2 a saa DRI NEGA wee eee 40 7 Warming Engine a 15 16 Pressurue Testing Cooling System 40 9 Changing Engine Speed Standard Mechanical Governor 15 17 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 COPYRIGHT 2001 DEERE amp COMPANY Moline Illinois All rights reserved A John Deere ILLUSTRUCTION Manual Previous Editions Copyright 1998 l 021201 PN 1 Contents Page Page Lubrication amp Maintenance 1200 Hour 24 Month Service 600 Hour 12 Month 70 3 Checking and Adjusting Eng
62. and tighten locknut to specifications Recheck clearance again after tightening locknut Readjust clearance as necessary 181224 UN 07NOV88 RG4775 UN 06DEC88 Continued on next page RG RG34710 5067 19 30JAN98 2 3 45 2 021201 PN 88 Lubrication amp Maintenance 1200 Hour 24 Month Specification Intake Valve Clearance Adjustment Rocker Arm to Valve Tip Engine Cold Specification Clearance 0 36 mm 0 014 in Exhaust Valve Clearance Adjustment Rocker Arm to Valve Tip Engine Cold Specification Clearance 0 46 mm 0 018 in Rocker Arm Adjusting Screw Jam Nut Specification Torque 27 Nem 20 lb ft 8 Replace rocker arm cover and crankcase vent tube 45 3 RG RG34710 5067 19 30JAN98 3 3 021201 PN 89 Lubrication amp Maintenance 1200 Hour 24 Month ADJUSTING VARIABLE SPEED DROOP ON GENERATOR SET ENGINES STANADYNE INJECTION PUMPS ONLY CAUTION Statutes providing severe penalties for tampering with emissions controls may apply at the user s location 1 Warm engine to normal operating temperature T86735 UN 23FEB89 2 If necessary disconnect throttle linkage or cable Droop Adjusting Knob 3 Run engine at fast idle Check and adjust fast idle speed when necessary 4 Apply full load N y lg N 5 Check power Adjust with knob or screw A if needed ig 6 Remove load HA AO Pa CHOX xX 7 Check and adjust fast idle if knob or scre
63. ase oil Crankcase oil level too high External oil leak s Oil control rings worn or broken Scored cylinder liners or pistons Worn valve guides or stems Excessive oil pressure Piston ring grooves excessively worn Piston rings sticking in ring grooves Insufficient piston ring tension Piston ring gaps not staggered Front and or rear crankshaft oil seal faulty Continued on next page 99 15 Solution Drain crankcase and refill with correct viscosity oil Drain oil until oil level is correct Determine source of oil leak s and repair as required Replace piston rings See your John Deere engine distributor or servicing dealer Remove and inspect cylinders and liners replace as required See your John Deere engine distributor or servicing dealer Inspect and measure valve stems and valve guides repair as required See your John Deere engine distributor or servicing dealer See High Oil Pressure Remove and inspect pistons See your John Deere engine distributor or servicing dealer Remove and inspect pistons See your John Deere engine distributor or servicing dealer Remove and inspect pistons See your John Deere engine distributor or servicing dealer Remove and inspect pistons See your John Deere engine distributor or servicing dealer Replace oil seals See your John Deere engine distributor or servicing dealer RG RG34710 7600 19 30JUN97 2 3 021201 PN 119 Troubl
64. cal information is available from John Deere Some of this information is available in electronic as well as printed form Order from your John Deere dealer or call 1 800 522 7448 Please have available the model number serial number and name of the product Available information includes e PARTS CATALOGS list service parts available for your machine with exploded view illustrations to help you identify the correct parts It is also useful in assembling and disassembling OPERATOR S MANUALS providing safety operating maintenance and service information These manuals and safety signs on your machine may also be available in other languages OPERATOR S VIDEO TAPES showing highlights of safety operating maintenance and service information These tapes may be available in multiple languages and formats TECHNICAL MANUALS outlining service information for your machine Included are specifications illustrated assembly and disassembly procedures hydraulic oil flow diagrams and wiring diagrams Some products have separate manuals for repair and diagnostic information Some components such as engines are available in separate component technical manuals FUNDAMENTAL MANUALS detailing basic information regardless of manufacturer Agricultural Primer series covers technology in farming and ranching featuring subjects like computers the Internet and precision farming Farm Business Management series examines
65. cessary IMPORTANT ALWAYS REPLACE primary air cleaner element when air restriction indicator is red or shows a vacuum of at least 3 5 kPa 14 in H O is torn or visibly dirty RG11067 UN O5JUNO0 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 ELEMENTand REPLACING AIR CLEANER ELEMENTS in Service As Required Section A Clamps B Unloader Valve C Restriction Indicator RG11542 UN 01DEC00 European Air Cleaner RG RG34710 5070 19 30JAN98 1 1 40 2 021201 PN 79 Lubrication amp Maintenance 600 Hour 12 Month REPLACING FUEL FILTER ELEMENT 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 X9811 UN 23AUG88 Beware of High Pressure Fluids 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 u
66. ck oil level after 10 minutes Oil Correct Oil Level Within Crosshatch level reading should be between arrows C or within crosshatch D of dipstick A Timing Gear Cover Opening B Rocker Arm Cover Opening C Arrows D Crosshatch OUOD002 0000024 19 07DEC00 1 1 30 6 021201 PN 72 Lubrication and Maintenance 250 Hour CHECKING FAN AND ALTERNATOR V BELT TENSION Low belt tension causes slippage resulting in excessive cover wear burn spots overheating or slip and grab causing belt breakage High belt tension causes belt heating and excessive stretch as well as damage to drive components such as pulleys and shafts V belts should ride on the sides of standard pulleys not on the bottom of the groove Standard V belt tension can be checked with JDG529 Tension Gauge bold arrow or equivalent gauge Gauge is available from a John Deere Dealer or Distributor NOTE On engines with dual belts check tension of front belt only 1 Inspect belts for cracks fraying or stretched out areas Replace if necessary Using JDG529 Belt Tension Gauge or belt tension tester A and straightedge B check tension of warm belts a When using JDG529 Belt Tension Gauge measure belt tension and compare with specifications on next page Belt deflection when using belt tension tester A with straightedge B with force applied halfway between pulleys Specification Standard V Belt with 89 N 20 Ib force Defl
67. cluding John Deere COOL GARD 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 coolant additives Coolants meeting ASTM D5345 prediluted coolant or ASTM D4985 coolant concentrate require an initial charge of supplemental coolant additives Replenish Coolant Additives The concentration of coolant additives is gradually depleted during engine operation Periodic replenishment of inhibitors is required even when John Deere COOL GARD is used Follow the recommendations in this manual for the use of supplemental coolant additives Why Use Supplemental Coolant Additives Operating without proper coolant additives 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 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 Avoid Automotive Type Coolants 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
68. come 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 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 fuel conditioner and anti gel additive Coolant Heaters Engine block heaters coolant are an available option to aid cold weather starting Intake Air Heaters An electric air heater option consisting of a 12 volt 700 watt 24 volt 480 watt heating element installed in the cylinder head is available Ether Injectors John Deere solenoid powered ether aid kit
69. conditioner such as John Deere PREMIUM DIESEL FUEL CONDITIONER or equivalent to stabilize the fuel and prevent water condensation John Deere 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 RG RG34710 5027 19 30JAN98 1 1 DX FUEL6 19 06DEC00 1 1 021201 PN 23 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 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 be
70. d inch fasteners may require a specific metric or inch wrench WRITE ENGINE SERIAL NUMBERS and option codes in the spaces indicated in the Record Keeping Section Accurately record all the numbers Your dealer also needs these numbers when you order parts File the identification numbers in a secure place off the engine SETTING FUEL DELIVERY beyond published factory specifications or otherwise overpowering will result in loss of warranty protection for this engine CERTAIN ENGINE ACCESSORIES such as radiator air cleaner and instruments are optional equipment on John Deere OEM Engines These accessories may be provided by the equipment manufacturer instead of John Deere This operator s manual applies only to the engine and those options available through the John Deere distribution network CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm NX 450H 3 19 18JAN01 1 1 021201 PN 2 Introduction 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 Aux Utilisateurs De Moteurs John Deere N attendez pas d tre oblig d avoir recours a vot
71. e manufacturer may have placed the label in a specific accessible area inside the enclosure or close to a maintenance area 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 your engine Base Code A in the spaces provided on next page for easy reference Continued on next page RG RG34710 5004 19 30JAN98 1 2 01 2 021201 PN 8 Engine Serial Number Option Codes 20 21 22 23 24 25 26 27 28 29 30 31 32 35 36 Record Keeping Description Rocker Arm Cover Oil Filter Inlet Crankshaft Pulley Flywheel Housing Flywheel Fuel Injection Pump Air Inlet Air Cleaner Oil Pan Coolant Pump Thermostat Cover Thermostat Fan Drive Fan Belt Fan Engine Coolant Heater Radiator Exhaust Manifold Ventilator System Starter Motor Alternator Instrument Panel Fuel Filter Front Plate NOTE These option codes are based on the latest information available at the time of publication Engine Base Code Option Codes 37 40 41 43 44 46 47 48 49 50 51 52 55 56 59 62 64 65 66 69 75 76 95 97 98 Description Fuel Transfer Pump Oil Dipstick Front Auxiliary Drive Starting Aid Timing Gear Cover With Gears Cylinder Block and Liners Crankshaft and Bearings Co
72. e procedures as follows 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 COOL GARD is a registered trademark of Deere amp Company Continued on next page RG RG34710 5079 19 30JAN98 1 3 45 5 021201 PN 91 Lubrication amp Maintenance 1200 Hour 24 Month 3 Open engine block drain valve or plug A on left side of engine Drain all coolant from engine block 4 Open radiator drain valve Drain all coolant from radiator 5 Remove thermostat at this time if not previously done Install cover B without thermostat and tighten cap screws to specification Specification Capscrews Torque cccececeeecesseeeeeeeeeeeeeseeeeseseeeeeesenes 47 Nem 35 Ib ft RG7315 UN O01DECOO fane Bo k oer Vave 6 Test thermostat opening temperature See TEST THERMOSTAT OPENING TEMPERATURE following 7 an in this Section 7 Close all drain valves after coolant has drained A CAUTION Do not run engine longer than 5 minutes at low idle with water as coolant Doing so may cause engine to overheat which may cause burns when water is draining RG11597 UN 08DECOO0O 8 Fill the cooling system with clean water Run the engine about 5 minutes at low idle to stir up possible rust or sediment 7 Ng
73. ealer 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 RG RG34710 5029 19 30JAN98 2 2 DIESEL ENGINE BREAK IN OIL New engines are filled at the factory with John Deere e ACEA Specification E1 ENGINE BREAK IN OIL During the break in period add John Deere ENGINE BREAK IN OIL as needed to After the break in period use John Deere PLUS 50 or maintain the specified oil level other diesel engine oil as recommended in this manual Change the oil and filter after the first 100 hours of operation of a new or rebuilt engine IMPORTANT Do not use PLUS 50 oil or engine oils meeting API CH 4 API CG4 API After engine overhaul fill the engine with John Deere CF4 ACEA E3 or ACEA E2 ENGINE BREAK IN OIL performance levels during the first 100 hours of operation of a new or If John Deere ENGINE BREAK IN OIL is not available rebuilt engine These oils will not use a diesel engine oil meeting one of the following allow the engine to break in during the first 100 hours of operation properly e API Service Classification CE PLUS 50 is a registered trademark of Deere amp Company DX ENOIL4 19 24JANO0 1 1 10 4 021201 PN 25 Fuels Lubricants and Coolant DIESEL ENGINE OIL Use oil viscosity based on the expected air temperature range during the period between oil changes The following oil is preferred e John Deere PLUS 50
74. easure clutch engagement force at handle grip using E a7 a spring scale The engagement force should be 267 311 N 60 70 Ib force TS198 UN 23AUG88 Rotating Driveline IMPORTANT Improper adjustments of the PTO 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 6 Install lock screw and adjusting lock in clutch body R e7S5be splines when specified engagement pressure is achieved R27550 UN 14DEC88 PTO Clutch Adjustment l A Adjusting Lock 7 Tighten screw securely B Adjusting Ring 8 Recheck clutch engagement force with spring scale Install cover plate Disengage clutch RG RG34710 4068 19 01JAN96 1 1 30 9 021201 PN 75 Lubrication and Maintenance 250 Hour CHECKING ENGINE MOUNTS GENERATOR SETS Engine mounting is the responsibility of the generator manufacturer Follow manufacturer s guidelines for mounting specifications IMPORTANT Use only Grade SAE 8 or higher grade of hardware for engine mounting RG10795 UN 22MAR00 1 Check the engine mounting brackets A vibration isolators and mounting bolts on support frame and engine block for tightness Tighten as necessary to recommended
75. ect of Cold Weather on Daily Prestarting Checks 25 1 Diesel Engines cic samen eens onan ad aa ae 10 3 Diesel Engine Break In Oil 10 4 Lubrication and Maintenance 250 Hour Diesel Engine Oil 0 0008 10 5 Servicing Fire Extinguisher 30 1 Extended Diesel Engine Oil Service Interval 10 6 Lubricating PTO Clutch Shaft Bearings 30 1 Mixing of Lubricants 10 6 Servicing Battery 0 0 00 00 c eee ee 30 2 OILSCAN and COOLSCAN 10 7 Handling Batteries Safely 30 3 Alternative and Synthetic Lubricants 10 7 Changing Engine Oil and Replacing Oil Filter 30 4 Lubricant Storage eee ANA 10 8 Checking Fan and Alternator V Belt Tension 30 7 Grease aa 10 8 Checking PTO Clutch Adjustment 30 9 Diesel Engine Coolant 10 9 Checking Engine Mounts Generator Sets 30 10 Diesel Engine Coolants Supplemental Additive Information 00 10 10 Lubrication amp Maintenance 400 Hour Testing Diesel Engine Coolant 10 11 Adjusting Engine Valve Clearance New or Replenishing Supplemental Coolant Rebuilt Engines 000 eevee 35 1 Additives Between Coolant Changes 10 12 Operating in Warm Temperature Climates 10 13 Lubrication amp Maintenance 600 Hour 12 Month Disposing of Coolant nanana NAA 10 13 Lubricating PTO Clutch Internal Levers
76. ection 19 mm 3 4 in A Tension Tester B Straightedge Continued on next page 30 7 a a P w Checking Belt Tension with RG RG34710 5065 19 30JAN98 1 3 RG7333 UN 01DEC00 RG7334 UN 01DECO0 E See _ be D LE i A VA Straightedge RG RG34710 5065 19 30JAN98 2 3 021201 PN 73 Lubrication and Maintenance 250 Hour If adjustment is necessary loosen alternator bracket cap screw C and nut D on mounting bolt Pull alternator frame outward until belts are correctly tensioned IMPORTANT Do not pry against the alternator rear frame Do not tighten or loosen belts while they are hot 4 Tighten alternator bracket cap screw and nut firmly RG7329 UN 01DECO00 5 After a new or used belt has run for 10 minutes recheck belt tension Alternator Mounting Brackets C Cap Screw TANDARD V BELT 2 o D Nut New Belt Tension Used Belt Tension Single Belt 578 623 N 130 140 lb 378 423 N 85 95 Ib force force Dual Belts 423 463 N 95 104 Ib 378 423 N 85 95 Ib force force aBelts are considered used after 10 minutes of operation RG RG34710 5065 19 30JAN98 3 3 30 8 021201 PN 74 Lubrication and Maintenance 250 Hour CHECKING PTO CLUTCH ADJUSTMENT CAUTION Never attempt to service the 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 M
77. ed base stock products may be used if the finished lubricant meets the performance requirements DX ALTER 19 15JUN00 1 1 10 7 021201 PN 28 Fuels Lubricants and Coolant LUBRICANT STORAGE Your equipment can operate at top efficiency only Make certain that all containers are properly marked to when clean lubricants are used identify their contents Use clean containers to handle all lubricants Properly dispose of all old containers and any residual lubricant they may contain 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 DX LUBST 19 18MAR96 1 1 GREASE Use grease based on NLGI consistency numbers and the expected air temperature range during the service interval The following greases are preferred e John Deere SD POLYUREA GREASE NLGI Number 2 The following greases are also recommended je ohn Deere GREASE GAR e John Deere HD MOLY GREASE e John Deere HD LITHIUM COMPLEX GREASE e John Deere HD WATER RESISTANT GREASE e John Deere GREASE GARD Mm o gt gt O IS O n o 5 o o gO O 53 O Ko ohn Deere HD LITHIUM COMPLEX ohn Deere HD WATER RESISTANT NLGI Number 0 TS1667 UN 30JUN99 j Other greases may be used if they meet the following aQ REorR Atty rt LGI Number 1 e NLGI Performance Classification GC LB IMPORTANT Some ty
78. eevee vedo 30 1 Sitel AP 10 8 Intervals prime power 20 3 Lubrication and maintenance Intervals standby power 20 5 Service interval chart prime power 20 3 Specifications Service interval chart standby power 20 5 Engine crankcase oil fill 65 5 Lubrication system Fuel injection pump emission certified Troubleshooting 55 14 Sel AA eee a eee amp 65 2 Index 2 021201 PN 2 Page Fuel injection pump emission non certified ENGINES aaa 65 3 General OEM 6061 06 wow owe ee oe we es 65 1 Torque values metric 70 1 Standby power units 15 12 Starting ICING AA 15 12 Stopping ENGINE s oc cceceacedeceu ee KG KG 15 18 Storage Air cleaner element 50 8 AP eee 10 2 Storing lubricants 10 8 Supplemental coolant additives Replenishing 0 eee eee 40 7 Supplemental coolant additives SCAs 10 12 T Tachometer 0 00 0 eee eee eee 15 1 Temperature gauge coolant 15 1 Thermostat test opening temperature 45 8 Torque values INCH ee es 65 8 NGA 65 9 70 1 Troubleshooting Air intake 00 00 es 55 18 go 55 16 Electrical AA 95 12 Ce nsx eure eh ak ak ah ea careers 55 1 Lubrication 6 4 4 206008088 Geeeeneee en aaa 55 14 TUNDOGChAIOE sce osee sn aeacncs cee ee ens 55 18 W Warming engine 00 0 eee
79. en air restriction indicator A is red Replace filter element every 6 cleanings or once every 12 months 1 Remove cover B 2 Remove filter element C 3 Thoroughly clean all dirt from inside filter housing 4 Squeeze dust unloader valve D to remove dust deposits If clogged remove and clean the dust unloader valve Replace if damaged 5 Clean filter element using compressed air 6 Reinstall the filter element and cover 7 Depress air restriction indicator A button and release to reset indicator 50 6 RG11547 UN 01DEC00 Air Cleaner Components European Sourced A Restriction Indicator B Cover C Filter Element D Dust Unloader Valve DPSG OUOD002 1580 19 21JUN00 2 2 021201 PN 100 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 A inside element and check carefully for holes Discard any element which shows the smallest hole or rupture Be sure outer screen B is not dented Vibration would quickly wear a hole in filter RW4768 UN 15DEC88 Inspecting Primary Air Filter Element Be sure filter gasket C is in good condition If gasket is damaged or missing replace element A Light B Outer Screen IMPORTANT Air cleaner MUST BE DRY before C Gasket storing in plastic bag If the filter is to be stored for later use place it in a plastic bag
80. engine is cold or when cool enough to touch with bare hands Slowly loosen cap to first stop to relieve pressure before removing completely UN 23AUG88 TS281 1 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 Refer to your vehicle s operator s manual for recommendations for non John Deere supplied accessories FEST mao aot Be A Radiator ea ates A BE C0 oO O Ww Q lt 2 D LO N CO O or Coolant Level in Radiator Continued on next page RG RG34710 5059 19 30JAN98 2 5 25 2 021201 PN 63 Lubrication amp Maintenance Daily Lubricate PTO Bearing 1 Apply one shot of John Deere Multi Purpose Lubricant or equivalent at PTO release bearing grease fitting A DO NOT over lubricate A Grease Fitting O O Z D 5 O T Z D l v m N oc PTO Release Bearing Continued on next page RG RG34710 5059 19 30JAN98 3 5 25 3 021201 PN 64 Lubrication amp Maintenance Daily Check Air Cleaner IMPORTANT Maximum air intake restriction is 3 5 kPa 0 03 bar 0 5 psi 14 in H20 A clogged air cleaner element will cause excessive intake restriction and a reduced air supply to the engine 1 Squeeze dust unloader valve A on air cleaner assembly to remove dust deposits If c
81. er block RG RG34710 5084 19 30JAN98 2 3 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 Using two open end wrenches loosen fuel line connection at injection nozzle Crank engine over with starting motor but do not start engine until fuel free from air bubbles flows out of loosened connection Tighten connection to specification Bleeding Fuel System at Injection Nozzle T92924 UN O01NOV88 Specification Connection Torque 27 Nem 20 lb ft 4 Repeat procedure 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 RG RG34710 5084 19 30JAN98 3 3 50 4 021201 PN 98 Service As Required REPLACING AIR CLEANER FILTER ELEMENTS IMPORTANT ALWAYS REPLACE primary air cleaner element when air restriction indicator shows a vacuum of at least 3 5 kPa 14 in of 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 RG4686 UN 20DEC88 p o North American Air Cleaners Air Cleaner Primary Element North American 1 Remove wing nut and remove canister cover shown in small illustration inset 2 Remove wing nut A and
82. esel fuel 10 1 DICSClinndadaae ater edad Pewoeeengeeee sas 10 1 LUBHCIY PA NA BA 10 1 Fuel filter Check 0 a 25 5 M Replace aaa a anata te eae eal he eae ae 40 3 Fuel storage 2 0 eee eee 10 2 Metric torque values 65 9 70 1 Fuel system Mixing Ole dle 2 AA 10 6 Bleeding a ese nannan KAG ea war we ae den Jeena se 50 3 O G Oil Gauge panel Checking and adding 25 1 North American 0 0000 15 1 Fill quantity 2 2 0 eee 65 5 Grease Filter CHANGE one ohne aahhh tee seed 30 4 Extreme pressure and multipurpose 10 8 Refilling crankcase 30 4 Specifications for dipstick options 65 5 Oil pressure gauge 15 1 H Operating engine Break in aa 15 8 Cold weather nann NG KAG eee 10 3 15 15 Hour meter anaana 15 1 Normal operation c0eeee eee 15 7 P Idling engine 0 15 17 Inch torque values 65 8 POWE TAKE Ol ETO Instrument panel Clutch lubricate AT a la a 50 9 AA O 15 4 Levers and linkages lubricate 40 1 Intake and exhaust system Shaft bearings lubricate 30 1 Troubleshooting eee 55 18 PTO clutch adjustment 30 9 K R Kit engine storage e cece eee 60 1 Radiator shutters 0 10 3 L S Lubricant Service MAL P E RAANG 10 6 Fire extinguisher oun sea eee ede
83. esel fuel in the European Union requires sulfur content less than 0 05 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 10 1 Fuel lubricity should pass a minimum of 3100 gram load level as measured by the BOCLE scuffing test Sulfur content Sulfur content should not exceed 0 5 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 50 DO NOT use diesel fuel with sulfur content greater than 1 0 Bio diesel fuels may be used ONLY if the fuel properties meet DIN 51606 or equivalent specification DO NOT mix used engine oil or any other type of lubricant with diesel fuel DX FUEL1 19 24JAN00 1 1 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 specifications do not require fuels to pass a fuel lubricity test If fuel of low or unknown lubricity is used add John Deere
84. eshooting Symptom Fuel in Oil Coolant in Oil Problem COOLING SYSTEM TROUBLESHOOTING Symptom Engine Overheats Problem Lack of coolant in cooling system Radiator core dirty Engine overloaded Too low crankcase oil level Loose or defective fan belt Defective thermostat Damaged cylinder head gasket Defective coolant pump Defective radiator cap Continued on next page 55 16 Solution See LOW PRESSURE SYSTEM FUEL PRESSURE LOW TROUBLESHOOTING earlier in this section See FUEL IN OIL TROUBLESHOOTING earlier in this section See COOLING SYSTEM TROUBLESHOOTING later in this section RG RG34710 7600 19 30JUN97 3 3 Solution Fill cooling system to proper level Clean radiator as required Reduce engine load Fill crankcase to proper oil level Replace fan belt as required Check belt tensioner See Lubrication and Maintenance 600 Hour 12 Month Section Test thermostat opening temperature replace thermostat as required Replace cylinder head gasket See your John Deere engine distributor or servicing dealer Replace coolant pump See your John Deere engine distributor or servicing dealer Replace radiator cap as required RG RG34710 7601 19 30JUN97 1 2 021201 PN 120 Symptom Coolant in Oil Coolant Temperature Below Normal Troubleshooting Problem Cylinder head gasket defective Cylinder head or block cracked Cylinder liner seals leaking Leaking
85. f possible engine problems that may be encountered accompanied by possible causes and corrections The illustrated diagrams and troubleshooting information are of a general nature final design of the overall system for your engine application may be different See your engine distributor or servicing dealer if you are in doubt A reliable program for troubleshooting engine problems should include the following basic diagnostic thought process 55 1 Know the engine and all related systems Study the problem thoroughly Relate the symptoms to your knowledge of engine and systems Diagnose the problem starting with the easiest things first e Double check before beginning the disassembly Determine cause and make a thorough repair After making repairs operate the engine under normal conditions to verify that the problem and cause were corrected RG RG34710 5089 19 30JAN98 1 1 021201 PN 105 Troubleshooting NORTH AMERICAN WIRING DIAGRAM S1 KEY SWITCH ACC OFF P1 P2 P3 ON START P6 RED OR BRN F1 PUR m aa QO O tul CC o m c O O n u G c QN i N x O x T oOo o z z x EF Z tc H cr co 3 EF om x 9 5 o o a TF A w x T r R1 db z L K M1 Wa G2 North American Wiring Diagram Continued on next page 55 2 SIG N B W1 P5 H gt z x 9 Q mM oO g nl o wz a ou a x A go X Y2 Bi RG11329
86. f time Turbocharger not functioning Engine burning oil Defective muffler exhaust piping causing back pressure Engine overloaded Low coolant level Faulty radiator cap Loose or defective fan belts Low engine oil level Cooling system needs flushing Defective thermostat Defective temperature gauge or sender Incorrect grade of fuel Continued on next page 55 9 Solution 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 See LUBRICATION SYSTEM TROUBLESHOOTING later in this section Replace muffler or defective piping Reduce load Fill radiator to proper level check radiator and hoses for loose connections or leaks Have technician check Adjust belt tension Replace as required Check oil level Add oil as required Flush cooling system Remove and check thermostat Check coolant temperature with thermometer and replace if necessary Use correct grade of fuel RG RG34710 5092 19 30JAN98 6 8 021201 PN 113 Symptom High fuel consumption Fuel in Oil Troubleshooting 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 tem
87. fixed 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 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 following list 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 An additional option code label may also be delivered in a plastic bag attached to the engine or inserted in the machine documentation It is recommended to place this label either on this page of the operators manual or in the Engine Owner s Warranty booklet under Option Codes The machin
88. gh pressure nozzles can penetrate the skin and cause serious injury Keep spray from contacting hands or body If an accident occurs see a doctor immediately Any high pressure spray 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 05 10 TS203 UN 23AUG88 DX POISON 19 21APR93 1 1 DX SPRAY TS1343 UN 18MAR92 19 16APR92 1 1 021201 PN 20 Safety vetoes a Use tools appropriate to the work Makeshift tools and procedures can create safety hazards Use power tools only to loosen threaded parts and fasteners For loosening and tightening hardware use the correct size tools DO NOT use U S measurement tools on metric fasteners Avoid bodily injury caused by slipping wrenches TS779 UN 08NOV89 Use only service parts meeting John Deere specifications DX REPAIR 19 17FEB99 1 1 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 leakproof containers when draining fluids Do not use food or beverage containers that may mislead someone into drinking from them TS1133 UN 26NOV90
89. h RG RG34710 5110 19 30JAN98 1 1 70 5 021201 PN 141 Emission System Warranty EMISSIONS CONTROL SYSTEM CERTIFICATION LABEL CAUTION Statutes providing severe penalties for tampering with emissions controls may apply at the user s location The emissions warranty described below applies only to those engines marketed by John Deere that have been certified by the United States Environmental Protection Agency EPA and or California Air Resources Board CARB and used in the United States and Canada in non road mobile self propelled or portable transportable equipment The presence of an emissions label like the one shown signifies that the engine has been certified with the EPA and or CARB The EPA and CARB warranties only apply to new engines having the certification label affixed to the engine and sold as stated above in the geographic areas The presence of an EU number in the third line of the label signifies that the engine has been certified with the European Union countries per Directive 97 68 EC The emissions warranty does not apply to the EU countries NOTE The hp kW rating on the engine emissions certification label specifies the gross engine hp kW which is flywheel power without fan In most applications this will not be the same rating as the advertised vehicle hp kW rating Equipment moved at least once every 12 months 75 1 IMPORTANT ENGINE INFORMATION DEERE amp COMPANY A JOHN DEERE
90. h linkage TS198 UN 23AUG88 Apply one shot of John Deere Multipurpose Lubricant or equivalent to the two PTO release lever shaft fittings B A Pivot Points B Fittings mM fo m LU TR 00 Z D st co co oc Lubrication Internal Parts of PTO Clutch RG RG34710 5068 19 30JAN98 1 1 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 tube is not pinched and O ring fits correctly in the rocker arm cover for elbow adapter Tighten hose clamp securely RG6005 UN 27JAN92 A Vent Tube RG RG34710 5069 19 30JAN98 1 1 40 1 021201 PN 78 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 RG4689 UN 20DEC88 2 Check clamps A on piping which connect the air cleaner engine and if present turbocharger 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 ne
91. h to D05104ST Tester as shown 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 Remove the cap from gauge turn it 180 and retest cap This will verify that the first measurement was accurate Test Cooling System NOTE Engine should be warmed up to test overall cooling system 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 40 9 RG6558 UN 20JAN93 Pressure Testing 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 cooling 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 proble
92. hem 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 RG RG34710 5096 19 30JAN98 1 1 021201 PN 126 Storage REMOVING ENGINE FROM LONG TERM STORAGE IMPORTANT DO NOT operate starter more than 30 seconds at a time Wait at least 2 Refer to the appropriate section for detailed services 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 Unseal all openings in engine and remove covering from electrical systems Remove the batteries from storage Install batteries fully charged and connect the terminals Install fan alternator belt if removed Fill fuel tank Perform all appropriate prestarting checks See DAILY PRESTARTING CHECKS in Lubrication and Maintenance Daily Section 60 3 minutes for starter to cool befo
93. hn Deere engine distributor or servicing dealer Inspect pistons See your John Deere engine distributor or servicing dealer Check timing gear back lash See your John Deere engine distributor or servicing dealer Check and adjust valve clearance See your John Deere engine distributor or servicing dealer Inspect camshaft See your John Deere engine distributor or servicing dealer Inspect rocker arm shafts See your John Deere engine distributor or servicing dealer See LUBRICATION SYSTEM TROUBLESHOOTING later in this section See AIR INTAKE SYSTEM TROUBLESHOOTING later in this section RG RG34710 5092 19 30JAN98 8 8 021201 PN 115 Troubleshooting ELECTRICAL TROUBLESHOOTING Symptom Undercharged system Battery used 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 Loose or defective alternator belt PTO engaged Loose or corroded connections Low battery output voltage Faulty start circuit relay Blown fuse Continued on next page 55 12 Solution Remove accessories or install higher output alternator
94. iate 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 fitting when air has been expelled from system RG RG34710 3593 19 30AUG96 1 1 90 2 021201 PN 96 Service As Required BLEEDING THE FUEL SYSTEM 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 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 2 Loosen the air bleed vent screw A two full turns On mechanical supply pumps operate
95. ies 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 decal 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 RG RG34710 4067 19 01JAN96 1 1 30 2 021201 PN 68 Lubrication and Maintenance 250 Hour HANDLING BATTERIES SAFELY CAUTION Battery gas can explode Keep 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 TS204 UN 23AUG88 Always remove grounded battery clamp first and replace
96. il and filter change interval may be increased by 50 RG4881 UN 29NOV88 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 change Refer to instructions provided with kit Oil Pan Drain Plug 1 Run engine approximately 5 minutes to warm up oil Shut engine off 2 Remove oil pan drain plug arrow NOTE Drain plug location may vary depending on the application 3 Drain crankcase oil from engine while warm RG RG34710 5064 19 30JAN98 1 1 30 4 021201 PN 70 Lubrication and Maintenance 250 Hour 4 Remove and discard oil filter A using a suitable filter wrench NOTE Depending on engine application oil filter may be either vertical or horizontal on either engine model 5 Remove oil filter packing and clean filter mounting pad A Oil Filter RG11529 UN 01DEC00 Engine Mounted Oil Filter AN f Bi i 5 RG11530 UN 01DECO0 Engine Mounted Oil Filter RG11549 UN O6DECO00 Engines W Remote Oil Filter OUOD002 0000023 19 07DEC00 1 1 30 5 021201 PN 71 Lubrication and Maintenance 250 Hour 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 approximatel
97. in failures or permanent damage to the engine RG RG34710 5056 19 30JAN98 1 1 20 1 021201 PN 56 Lubrication and Maintenance 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 Servicing Distributor 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 Co Co O lt ep di Z 2 O U KE John Deere Parts RG RG34710 5057 19 30JAN98 1 1 20 2 021201 PN 57 Lubrication and Maintenance LUBRICATION AND MAINTENANCE SERVICE INTERVAL CHART PRIME POWER ENGINES Lubrication and Maintenance Service Intervals Dail 250 Hour or 600 Hour or 12 1200 Hour or AS Required y 6 Month Month 24 Month q 400 Hour Check Engine Oil and Coolant Level Lubricate PTO Release Bearing Check Air Cleaner Dust Unloader Valve amp Restriction Indicator Visual Walk Around Inspection Check Fuel Filter Service Fire Extinguisher Lubricate PTO Clutch Shaft Bearing Service Battery Change Engine Oil and Filter Check Fan and Alternator Belt Tension Check PTO Clutch Adjustment Check Engine Mounts Initial Valve Clearance Adjustment Check Engine Ground Connection Lubricate
98. ine Valve Service 1200 Hour 24 Month 70 4 Clearance nnana nanana 45 1 Service as Required 70 5 Adjusting Variable Speed on Generator Set ENG MET e io ee eee sees eae esas 45 4 Emission System Warranty Flushing and Refilling Cooling System 45 5 Emissions Control System Certification Label 75 1 Testing Thermostat Opening Temperature 45 8 U S Emissions Control Warranty Statement 75 2 Service As Required Additional Service Information 50 1 Do Not Modify Fuel System 50 1 Adding COCs 2oneeccneeeseacacaaseass 50 2 Bleeding the Fuel System 50 3 Replacing Air Cleaner Filter Elements 50 5 Inspecting Primary Filter Element 50 7 Cleaning Primary Filter Element 50 7 Element Storage anana aana 50 8 Replace Fan and Alternator Belts 50 8 Power Take Off PTO Clutch 50 9 Checking Fuses 50 9 Troubleshooting General Troubleshooting Information 55 1 North American Wiring Diagram 55 2 Engine Troubleshooting 55 4 Electrical Troubleshooting 55 12 Lubrication Troubleshooting 55 14 Cooling System Troubleshooting 55 16 Air Intake Troubleshooting 55 18 Storage Engine Storage Guidelines 60 1 Use AR41785 Engine Storage Kit 60 1 Preparing E
99. ine serial number plate in the spaces provided below This information is very important for repair parts or warranty information CD3029DF 150 Abs 7 Ke OelT i Engine Serial Number A DEERE amp COMPANY MOLINE ILLINOIS MADE IN FRANCE o o O Lu Q F Z D l m N LO O oc Engine Application Data B Saran Serial Number Plate Coefficient of Absorption Value For Smoke Emissions C J OH N D E R E alar Nien nee Engine Serial Number O PE3029D001000 237 NOTE Emission certified engines have application data pa B ending in 150s or 180s while emission _ non certified engines have application data B PE3029DF150 lt LA d TE0S OF rel DEERE amp COMPANY MOLINE ILLINOIS MADE IN MEXICO RG11524 UN 01DECOO A Serial Number Torreon Serial Number Plate B Application Data C Coefficient of Absorption Value RG RG34710 5003 19 30JAN98 1 1 01 1 021201 PN 7 Record Keeping ENGINE OPTION CODES JOHN DEERE PowERTECH Number CD3029T000000 3029TF160 ATT o 2 9L 155AH 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500 2700 2800 2900 3000 3100 3200 3500 3600 3700 4000 4100 4300 4400 4600 4700 4800 4900 5000 5100 5200 5500 5600 5900 6200 6400 6500 6600 6900 7500 7600 9100 9700 9800 Customer No 01010 10101010101010101010 OPTION CODES RG11525 UN 01DEC00 Option Code Label A Base Code OEM engines have an engine option code label af
100. ions per minute rpm Continued on next page QUOD002 0000028 19 18JAN01 4 6 15 4 021201 PN 38 Engine Operating Guidelines VDO Instrument Gauge Panel Except North America A Oil Pressure Gauge The oil pressure gauge indicates engine oil pressure B Coolant Temperature Gauge The coolant temperature gauge indicates coolant temperature C Tachometer The tachometer indicates engine speed in hundreds of revolutions per minute rpm The engine control system consists of the following D Engine Control Light The engine control light illuminates after the engine has started and oil pressure is up to specification The light indicates that the engine protection circuitry is activated E Preheater Light The preheater light illuminates when the key is turned to the bulb test position position It should go off after approximately five seconds When the key switch is held in position Il the engine preheater is energized and the preheater light illuminates F Fuel Level Light The fuel level light illuminates when the key is turned to the bulb test position position It should go off after approximately five seconds After the engine is running if the engine runs out of fuel the light will illuminate The fuel level light will remain on indicating the engine was stopped due to the fuel tank being empty G Battery Light The battery light illuminates when the key is turned to the bulb
101. itive 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 John Deere COOLANT CONDITIONER should be added RG7297 UN 22SEP99 Coolant Test Strips DX COOL9 19 17FEB99 2 3 COOLSCAN For a more thorough evaluation of your coolant perform a COOLSCAN analysis See your John Deere dealer for information about COOLSCAN RG7397 UN 05DEC97 COOLSCAN Sampling DX COOL9 19 17FEB99 3 3 10 11 021201 PN 32 Fuels Lubricants and Coolant REPLENISHING SUPPLEMENTAL COOLANT ADDITIVES SCAs BETWEEN COOLANT CHANGES seeenny PUaem mene maga Pa asrama RG6261 UN 08DEC97 RG6241 Sampling of Coolant IMPORTANT Do not add supplemental coolant additives when the cooling system is drained and refilled with 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 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 di
102. logged remove and clean the dust unloader valve Replace if damaged IMPORTANT Do not operate engine without the dust unloader valve If equipped with air intake restriction indicator gauge B check gauge Service air cleaner when indicator is red Inspect Engine Compartment 1 Make a thorough inspection of the engine compartment Look for oil or coolant leaks worn fan and accessory drive belts loose connections and trash build up Remove trash build up and have repairs made as needed if leaks are found fF RG7332 UN 06JAN99 Tani North American Air Cleaner NOTE Wipe all fittings caps and plugs before performing any maintenance to reduce the chance A Dust Unloader Valve of system contamination B Restriction Indicator Gauge Inspect e Radiator for leaks and trash build up e Air intake system hoses and connections for cracks and loose clamps e 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 indicated the need to replace the water pump seal Contact your engine distributor or servicing dealer for repairs RG11535 UN O01DECOO Continued on next page RG RG34710 5059 19 30JAN98 4 5 25 4 021201 PN 65 Lubrication amp Maintenance Daily Checking Fuel Filter Check the fuel filter daily
103. long it must be recharged Keep record of inspections on the tag which comes with the extinguisher instruction booklet RW4918 UN 15DEC88 Service Fire Extinguisher A Fire Extinguisher RG RG34710 5062 19 30JAN98 1 1 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 facings UN 26JUNO00 NOTE Location of pilot bearing fitting will depend on application Only one fitting will be used RG7331C A Release Bearing Grease Fitting B Drive Shaft Bearing Fitting C Lever Cross Shaft Fittings D Pilot Bearing Fitting Lubricate PTO Clutch RG RG34710 5061 19 30JAN98 1 1 30 1 021201 PN 67 Lubrication and Maintenance 250 Hour SERVICING BATTERY CAUTION Battery gas can explode Keep 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 TS204 UN 23AUG88 Always remove grounded NEGATIVE battery clamp first and replace it last Exploding Battery WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling 1 On regular batter
104. lution John Deere COOLANT CONDITIONER 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 COOL GARD is a registered trademark of Deere amp Company COOLSCAN is a registered trademark of Deere amp Company G6262 UN 05DEC97 A Q O N O N R Testing of Coolant for Glycol Concentration a COOLSCAN analysis If a COOLSCAN analysis is not available recharge system per instructions printed on label of John Deere Liquid Coolant Conditioner 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 checked with JT07298 Coolant Battery Tester to assure that the desired freeze point is maintained Follow manufacturer s instructions provided with Coolant Battery Tester If other coolants are used consult the coolant supplier and follow the manufacturer s recommendation for use of supplemental coolant additives The use of non recommended supplemental coolant additives may result in additive drop out and gelation of the coolant Continued on next page RG RG34710 5041 19 30JAN98 1 2 10 12 021201 PN 33 Fuels Lubricants and Coolant Add the manufacturer s recommended concentration of See ENGINE COOLANT SPECIFICATIONS earlier in sup
105. m immediately RG RG34710 5078 19 30JAN98 1 1 021201 PN 86 Lubrication amp Maintenance 1200 Hour 24 Month CHECKING AND ADJUSTING ENGINE VALVE an CLEARANCE NOTE Adjust engine valve clearance after the first 400 hours of engine operation and then at the normal 1200 Hour 24 Month interval thereafter If desired have your authorized servicing dealer or engine distributor adjust the engine valve clearance RG6305 UN 03AUG92 A CAUTION To prevent accidental starting of engine while performing valve adjustments Flywheel Housing Timing Holes always disconnect NEGATIVE battery terminal A Timing Holes 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 wear caps 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 Continued on next page RG RG34710 5067 19 30JAN98 1 3 45 1 021201 PN 87 Lubrication amp Maintenance 1200 Hour 24 Month 3 Using JDE83 Engine Rotation Tool and JDE81 4 Timing Pin rotate engine in running direction clockwise viewed from front until Number 1 front cylinder is at Too Dead
106. months whichever occurs first OUOD002 0000022 19 06DEC00 2 2 20 6 021201 PN 61 Lubrication amp Maintenance Daily DAILY PRESTARTING CHECKS Do the following BEFORE STARTING THE ENGINE for the first time each day Check Engine Oil Level IMPORTANT There is no need to add makeup oil until the oil level is BELOW the add mark RG11536 UN 01DEC00 DO NOT fill above the top mark on the dipstick Oil levels anywhere within arrows C or crosshatch D whichever is present are considered in the acceptable operating range 1 Check engine oil level on dipstick A Oil level on dipstick should be within arrows C or crosshatch D Add oil at filler cap B as required using seasonal viscosity grade oil See DIESEL ENGINE OIL in Fuels Lubricants and Coolant Section for oil specifications Some engines may have the oil filler cap on rocker arm cover while others will have the filler cap on the timing gear cover RG11595 UN 08DECO00 3029T Engines RG11537 UN 01DEC00 A Dipstick B Oil Filler Cap O C Arrows D Crosshatch vo Correct Oil Level Within Arrows RG11538 UN 01DECO0 Correct Oil Level Within Crosshatch Continued on next page RG RG34710 5059 19 30JAN98 1 5 25 1 021201 PN 62 Lubrication amp Maintenance Daily Check Coolant Level CAUTION Explosive release of fluids from pressurized cooling system can cause serious burns Only remove filler cap when
107. mperatures with specification given in chart below gt NOTE Due to varying tolerances of different suppliers 3 initial opening and full open temperatures may Testing Thermostats vary slightly from specified temperatures THERMOSTAT TEST SPECIFICATIONS Rating Initial Opening Range Full Open Nominal 82 C 180 F 80 84 C 175 182 F 94 C 202 F 5 Remove thermostat and observe its closing action as it cools In ambient air the thermostat should close completely Closing action should be smooth and slow 6 Replace thermostat if opening temperature is not within specification RG RG34710 5083 19 30JAN98 1 1 45 8 021201 PN 94 Service As Required ADDITIONAL SERVICE INFORMATION This is not a detailed service manual If you want more detailed service information see John Deere Service Literature Available later in this manual to order the Component Technical Manuals for Repair and Operation and Diagnosis RG4624 UN 15DEC88 John Deere Service Manuals RG RG34710 5080 19 30JAN98 1 1 DO NOT MODIFY FUEL SYSTEM IMPORTANT Modification or alteration of the injection pump the injection pump timing or the fuel injectors in ways not recommended by the manufacturer will terminate the warranty obligation to the purchaser In addition tampering with fuel system which alters emission related equipment on engines may result in fines or other penalties per EPA regulations or other local emission laws
108. n 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 65 2 OUOD002 0000029 19 18JAN01 1 1 021201 PN 129 Specifications FUEL INJECTION PUMP SPECIFICATIONS EMISSION NON CERTIFIED ENGINES ENGINE MODEL CD3029DF 120 CD3029DF 121 CD3029DF 122 CD3029DF 123 CD3029DF 124 CD3029DF 160 CD3029DF 162 CD3029DF 163 CD3029DF 164 CD3029DF 165 CD3029TF120 CD3029TF121 OPTION CODES 1602 1603 1641 1642 1644 1648 1650 1655 1602 1650 1603 1641 1644 1648 16BS 1641 1602 1632 1643 1650 16YG 1654 16DV 16TH 1602 1632 1640 1602 1632 FUEL INJECTION PUMP PART NUMBER RE53785 RE53786 RE53787 RE67271 RE41939 RE64242 RE41938 RE53785 RE53785 RE41938 RE53786 RE53787 RE41939 RE64272 RE53785 RE53787 RE53785 RE51940 RE67271 RE41938 RE51940 RE63523 RE53785 RE53785 RE53783 RE58903 RE53958 RE53783 RE58903 POWER RATING RATED SPEED RATED SPEED rpm kW hp 59 79 59 79 59 79 59 79 59 79 2500 1800 1500 2500 1800 1500 2500 2500 2500 2500 1800 1500 1800 1500 2500 1500 2500 2200 2500 2500 2200 2400 2500 2500 2500 2500 2500 2500 2500 SLOW IDLE FAST IDLE rpm rpm 850 2700 1890 1560 850 2700 1890 1560 850 2700 850 2700 800 27
109. ne The alternator light will remain on indicating the engine was stopped due to the alternator not charging F Coolant Temperature Light The coolant temperature light illuminates only if the engine has overheated After the engine is running if the engine overheats the light will illuminate and protection circuitry will stop the engine The coolant temperature light will remain on indicating the engine was stopped due to the engine overheating G Fuel Level Light The fuel level light illuminates only if the engine has stopped due to fuel tank being empty After the engine is running if the engine runs out of fuel the light will illuminate The fuel level light will remain on indicating the engine was stopped due to the fuel tank being empty H Key Switch The key switch controls the electrical system RG11590 UN 08DECOO AEZ Instrument Panel A Oil Pressure Gauge B Coolant Temperature Gauge C Engine Control Light D Oil Pressure Light E Alternator Light F Coolant Temperature Light G Fuel Level Light H Key Switch I Hour Meter J Tachometer Continued on next page 15 3 OUOD002 0000028 19 18JAN01 3 6 021201 PN 37 Engine Operating Guidelines I 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 J Tachometer Indicates engine speed in revolut
110. nfamiliar 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 at tank if equipped 2 Thoroughly clean fuel filter assembly and surrounding area KO a RG11543 UN 01DEC00 3 Loosen filter drain plug C and air bleed plug D Drain fuel into a suitable container Dispose of fuel in A Retaining Ring an environmentally safe manner B Filter Element C Filter Drain Plug NOTE Lifting up on retaining ring as it is rotated helps to D Air Bleed Plug get it past raised locators 4 Firmly grasp the retaining ring A lift up and rotate it clockwise 1 4 turn Remove ring with filter element B 5 Save retaining ring and if equipped water separator bowl for reuse 6 Remove red plug from new filter and install into removed filter to protect the environment from leaking fuel 7 Inspect filter mounting base for cleanliness Clean as required Continued on next page RG RG34710 5071 19 30JAN98 1 2 40 3 021201 PN 80 Lubrication amp Maintenance 600 Hour 12 Month 8 Inspect condition of dust seal C Replace if necessary Install dust seal as shown NOTE Proper installation is indicated when a click is heard and a release of pressure on the ring is felt 9 Align keys on filter element with slots in filter base then tighten retaining ring counterclockwise 1 4 turn until it snaps
111. ng 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 RG11532 UN 01DEC00 7 After the engine starts continue to hold the reset North American Instrument Panel button in until the oil pressure gauge D reads at least 105 kPa 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 while operating under load immediately disengage PTO clutch and restart the engine Overheating of turbocharger parts may 7 occur when oil flow is stopped gt 8 Check all gauges for normal engine operation If operation is not normal stop the engine and determine the cause A Hand Throttle B Reset Button C Key Switch D Oil Pressure Gauge 5 LU Ga T 7 RG11588 C 5 VDO Instrument Panel Except North America RG RG34710 5049 19 30JAN98 4 4 1 5 1 4 021201 PN 48 Engine Operating Guidelines COLD WEATHER OPERATION CAUTION Ether injector starting fluid is highly flammable DO NOT use starting fluid on engines equipped with air intake heaters DO NOT use starting fluid near fire sparks or flames
112. ngine for Long Term Storage 60 2 Removing Engine from Long Term Storage 60 3 Specifications General OEM Engine Specifications 65 1 Fuel Injection Pump Specifications Emission Certified Engines 65 2 Fuel Injection Pump Specifications Emission Non Certified Engines naa ARRANGE oe oho ee oes Da wd NA we 65 3 Engine Crankcase Oil Fill Quantities 65 5 Unified Inch Bolt and Cap Screw Torque VUCO 52 s Eee ween ee een ees nee ee ee ee 65 8 Metric Bolt and Cap Screw Torque Values 65 9 Lubrication and Maintenance Records Using Lubrication and Maintenance Records 70 1 Daily Prestarting Service 70 1 Service 50 Hour Every 2 Weeks 70 2 Service 400 HourS nananana KGG AG JAG NA 70 3 II 021201 PN 2 Record Keeping 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 e CD indicates the engine was built in Saran France e PE indicates the engine was built in Torreon Mexico Your engine s serial number plate A is located on the right hand side of cylinder block near the starter motor RG11522 UN 01DEC00 Engine Serial Number Plate Location A Serial Number Plate RG RG34710 5002 19 30JAN98 1 1 RECORD ENGINE SERIAL NUMBER JOHN DEERE Engine Serial Number A CD3029D500000 Record all of the numbers and letters found on your eng
113. nnecting Rods and Pistons Valve Actuating Mechanisms Oil Pump Cylinder Head With Valves Auxiliary Drive Adapters Shipping Stand Paint Option Oil Cooler and Filter Alternator Mounting Exhaust Elbow Turbocharger Temperature Sensor Switch Engine Serial Number Plate Air Restriction Indicator Oil Pressure Sensor Switch Special Equipment Factory Installed Special Equipment Field Installed Kits Shipping The right is reserved to make changes at any time without notice 01 3 RG RG34710 5004 19 30JAN98 2 2 021201 PN 9 Record Keeping RECORD FUEL INJECTION PUMP MODEL NUMBER Record the fuel injection pump model and serial information found on the serial number plate A Model No CU RPM Manufacturer s No Serial No o o O LU Q F Z ao co N LO O aa MW ei maa A Serial Number Plate Injection Pump Serial Number Plate RG RG34710 5005 19 30JAN98 1 1 01 4 021201 PN 10 Safety RECOGNIZE SAFETY INFORMATION This is a 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 UN 07DEC88 DX ALERT 19 29SEP98 1 1 UNDERSTAND SIGNAL WORDS IN DANGER A signal word DANGER WARNING or CAUTION is used with the safety alert symbol DANGER identifies the most serious hazards DANGER or WARNING safety signs are located near A WARNING
114. o 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 DX FLUID 19 03MAR93 1 1 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 Ki flame area O D gt lt LO oD LO D 0p DX TORCH 19 03MAR93 1 1 USE PROPER LIFTING EQUIPMENT Lifting heavy components incorrectly can cause severe injury or machine damage Follow recommended procedure for removal and installation of components in the manual co Co O D lt CI N Z D l CO N N U EF DX LIFT 19 04JUN90 1 1 05 7 021201 PN 17 Safety 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 Remove paint before heating Remove paint a minimum of 76 mm 3 in from area to be affected by heating If you sand or grind paint avoid breathing the dust Wear an approved respirator
115. on with PTO disengaged or in neutral Q Co Mm LU LL Co ii Z D D LO O oc Prevent Bypass Starting OQUOD013 0000001 19 28NOVO00 1 1 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 UN 23AUG88 DX FIRE1 19 03MAR93 1 1 05 2 021201 PN 12 Safety 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 HANDLE FLUIDS SAFELY AVOID FIRES When you work around fuel do not smoke or work near heaters or other fire hazards Store flammable fluids away from fire hazards Do not incinerate or puncture pressurized containers Make sure machine is clean of trash grease and debris Do n
116. ot store oily rags they can ignite and burn spontaneously 05 3 TS1356 UN 18MAR92 DX FIRE3 19 16APR92 1 1 TS227 UN 23AUG88 DX FLAME 19 29SEP98 1 1 021201 PN 13 Safety SERVICE MACHINES SAFELY Tie long hair behind your head Do not wear a necktie scarf loose clothing or necklace when you work near machine tools or moving parts If these items were to get caught severe injury could result Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts TS228 UN 23AUG88 DX LOOSE 19 04JUN90 1 1 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 PLB TS206 UN 23AUG88 Operating equipment safely requires the full attention of the operator Do not wear radio or music headphones while operating machine DX WEAR 19 10SEP90 1 1 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 UN 23AUG88 DX NOISE 19 03MAR93 1 1 05 4 021201 PN 14 Safety HANDLE CHEMICAL PRODUCTS SAFELY Direct exposure to hazardous
117. perature Compression too low Cracked cylinder head Continued on next page 55 10 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 Determine cause of low compression and repair as needed Locate crack repair replace components as required See your John Deere engine distributor or servicing dealer RG RG34710 5092 19 30JAN98 7 8 021201 PN 114 Troubleshooting Symptom Abnormal Engine Noise Problem Worn main or connecting rod bearings Excessive crankshaft end play Loose main bearing caps Worn connecting rod bushings and piston pins Scored pistons Worn timing gears or excess backlash Excessive valve clearance Worn camshaft lobes Worn rocker arm shaft s Insufficient engine lubrication Turbocharger noise 55 11 Solution Determine bearing clearance See your John Deere engine distributor or servicing dealer Check crankshaft end play See your John Deere engine distributor or servicing dealer Check bearing clearance replace bearings and bearing cap screws as required See your John Deere engine distributor or servicing dealer Inspect piston pins and bushings See your Jo
118. pes of grease thickener are not compatible with others Consult your grease supplier before mixing different types of grease DX GREA1 19 24JAN00 1 1 1 0 8 021201 PN 29 Fuels Lubricants and Coolant DIESEL ENGINE COOLANT The engine cooling system is filled to provide year round protection against corrosion and cylinder liner pitting and winter freeze protection to 37 C 34 F The following engine coolant is preferred for service e John Deere COOL GARD Prediluted Coolant The following engine coolant is also recommended e John Deere COOL GARD Coolant Concentrate in a 40 to 60 mixture of concentrate with quality water Other low silicate ethylene glycol base coolants for heavy duty engines may be used if they meet one of the following specifications e ASTM D5345 prediluted coolant e ASTM D4985 coolant concentrate in a 40 to 60 mixture of concentrate with quality water Coolants meeting these specifications require use of supplemental coolant additives formulated for heavy duty diesel engines for protection against corrosion and cylinder liner erosion and pitting A 50 mixture of ethylene glycol engine coolant in water provides freeze protection to 37 C 34 F If protection at lower temperatures is required consult your John Deere dealer for recommendations Water quality is important to the performance of the cooling system Distilled deionized or demineralized water is recommended for
119. plemental coolant additive DO NOT add more than this section for proper mixing of coolant ingredients the recommended amount before adding to the cooling system RG RG34710 5041 19 30JAN98 2 2 OPERATING IN WARM TEMPERATURE CLIMATES John Deere engines are designed to operate using glycol base engine coolants Always use a recommended glycol base engine coolant even when operating in geographical areas where freeze protection is not required IMPORTANT Water may be used as coolant in emergency situations only Foaming hot surface aluminum and iron corrosion scaling and 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 DX COOL6 19 18MAR96 1 1 DISPOSING OF COOLANT Improperly disposing of engine coolant can threaten the environment and ecology Used 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 UN 26NOV90 Inquire on the proper way to recycle or dispose of waste Recycle Waste from your local environmental or recycling center or from your John Deere engine distributor or servicing dealer OUOD002 000002B 19 24JANO01 1 1 1 0 1 3 021201 PN 34 Engine Operating Guidelines INSTRUMENT GAUG
120. rade 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 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 DX TORQ1 19 010CT99 1 1 65 8 021201 PN 135 Specifications METRIC BOLT AND CAP SCREW TORQUE VALUES Top Property Class and Head Markings Bottom Property Class and Nut Markings N m Ib ft N m Ib ft N m Ib ft N m b ft N m b ft N m b ft 0 29 5 95 70 80 63 46 74 xr 140 105 9 48 aise 120 08 A 190 140 240 175 275 200 170 125 265 195 330 245 375 275 190 140 245 180 375 275 675 500 xr 350 255 475 350 w S la la ua rez Cas Kan a w ee lea pq 490 360 950 700 1700 1250 200 0700 900 665 1150 850 2500 1850 3150 2325 1150 850 1450 1075 3200 2350 4050 3000 4 Lubricated means coated with a lubricant such as engine oil or fasteners with phosphate and oil coatings 140 275 195 375 330 245 650 480 360 700 TORQ2 UN 07SEP99 Class 12 9 Lubricated Dry N m Ib ft N m Ib ft 15 5 37 5 130 205 320 440 625 850 1080 1580 2140 2900 3750 i Ang ENG mah Ta 11 5 27 5 47 55 95 95 165 150 260 235 400 325 560 60 790 580 25 1080 800
121. rain tube restriction Excessive crankcase pressure Air intake restriction Drain tube restriction Damaged or worn housing bearings Imbalance of rotating assembly Damage to turbine or compressor wheel or blade Dirt or carbon build up on wheel or blade Continued on next page 55 19 Solution Determine cause of excessive crankcase pressure repair as required See your John Deere engine distributor or servicing dealer Determine cause of intake restriction repair as required See your John Deere engine distributor or servicing dealer Determine cause of drain tube restriction repair as required See your John Deere engine distributor or servicing dealer Determine cause of excessive crankcase pressure repair as required See your John Deere engine distributor or servicing dealer Determine cause of intake restriction repair as required See your John Deere engine distributor or servicing dealer Determine cause of drain tube restriction repair as required See your John Deere engine distributor or servicing dealer Inspect turbocharger repair replace as required See your John Deere engine distributor or servicing dealer Inspect turbocharger repair replace as required See your John Deere engine distributor or servicing dealer Inspect turbocharger repair replace as required See your John Deere engine distributor or servicing dealer Inspect turbocharger repair replace as required
122. ration COVERED BY WATERPROOF COVERING MUST BE taken See PREPARING ENGINE FOR LONG TERM STORAGE later in this section John Deere engines can be stored in a standard overseas shipping container for up to three 3 For John Deere engines not yet installed in months with no long term preparation machines run a line from a container of AR41937 Nucle Oil to the fuel transfer pump intake and John Deere engines can be stored inside another line from the fuel return manifold to the warehoused for up to six 6 months with no long tank so that Nucle Oil is circulated through the term preparation injection system during cranking RG RG34710 5094 19 30JAN98 1 1 USE AR41785 ENGINE STORAGE KIT IMPORTANT Inhibitors can easily change to gas Seal or tape each opening immediately after adding inhibitor See your John Deere servicing dealer or engine distributor for an AR41785 Engine Storage Kit Closely follow instructions provided with this kit T85452 UN 06DEC88 AR41785 Engine Storage Kit RG RG34710 5095 19 30JAN98 1 1 60 1 021201 PN 125 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
123. re concessionnaire John Deere 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 vous proposer ses services le moment venu An Den Besitzer Des John Deere Motors Warten Sie nicht auf einen evt Reparaturfall um den nachstgelegenen John Deere Handler 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 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 r och vem han r
124. re 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 RG RG34710 5097 19 30JAN98 1 1 021201 PN 127 GENERAL OEM ENGINE SPECIFICATIONS ITEM Number of Cylinders Fuel Bore Stroke Displacement Compression Ratio Physical Dimensions Width Height Length Basic Dry Weight 3029DF120 3 Diesel 106 5 mm 4 19 in 110 mm 4 33 in 2 9 L 179 cu in 17 8 1 519 mm 20 4 in 819 mm 32 2 in 716 mm 28 2 in 316 kg 696 Ib Specifications 3029DF150 3 Diesel 106 5 mm 4 19 in 110 mm 4 33 in 2 9 L 179 cu in 17 8 1 519 mm 20 4 in 819 mm 32 2 in 716 mm 28 2 in 316 kg 696 Ib 3029DF 160 3 Diesel 106 5 mm 4 19 in 110 mm 4 33 in 2 9 L 179 CU in 17 8 1 528 mm 20 8 in 819 mm 32 2 in 716 mm 28 2 in 317 kg 698 Ib 3029DF180 3 Diesel 106 5 mm 4 19 in 110 mm 4 33 in 2 9 L 179 CU IN 17 8 1 528 mm 20 8 in 819 mm 32 2 in
125. re considered in the situations an additional 100 hour break in period is acceptable operating range recommended using a new change of John Deere Engine Break In Oil and new John Deere oil filter 3 Check engine oil level more frequently If oil must be added John Deere Engine Break In Oil is IMPORTANT Do not add makeup oil until the level preferred See ENGINE BREAK IN OIL in Fuels is BELOW the ADD mark or lower Lubricants and Coolant Section Continued on next page RG RG34710 5046 19 30JAN98 1 2 15 8 021201 PN 42 Engine Operating Guidelines IMPORTANT DO NOT use PLUS 50 Engine Oil or 4 During the first 20 hours avoid prolonged periods engine oils meeting API CG4 API of engine idling or sustained maximum load CF4 ACEA E3 ACEA E2 or CCMC operation Vary the engine speed throughout this D5 performance levels during the period If engine will idle longer than 5 minutes first 100 hours of operation of a new stop engine or rebuilt engine These oils will not allow a new or rebuilt engine to break in properly Specification Engine Oil Pressure at Full Load Rated Speed 345 103 kPa 3 45 1 03 bar 50 15 psi Minimum Oil Pressure at Rated 275 2 75 bar 40 psi 105 kPa 1 05 bar 15 psi 82 94 C 180 202 F At normal operating temperature of 115 C 240 F sump RG RG34710 5046 19 30JAN98 2 2 15 9 021201 PN 43 Engine Operating Guidelines BREAK IN SERVICE CONTINUED Li kN
126. rheated engine Below normal engine temperature Improper valve clearance Dirty or faulty injection nozzles Injection pump out of time Turbocharger not functioning Turbocharged engines only Leaking exhaust manifold gasket Defective aneroid control line Restricted fuel hose Low fast idle speed Poor fuel quality Engine out of time Air leak on suction side of air intake system Continued on next page 55 7 Solution Reduce load Service air cleaner Replace filter elements Use proper fuel Drain fuel and replace with quality fuel of the proper grade See Engine Overheats Remove and check thermostat See your authorized servicing dealer or engine distributor Have authorized servicing dealer 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 Drain fuel and replace with quality fuel of the proper grade See your authorized servicing dealer or engine distributor Check hose and pipe connections for tightness repair as required RG RG34710 5092 19 30JAN98 4 8 021201 PN 111 Symptom Low oil pressure High oil consumption Engine emi
127. roper 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 Drain fuel and replace with quality fuel of the proper grade Check for problem in the charging starting system Add oil to engine crankcase See your authorized servicing dealer or engine distributor Remove and check thermostat See Engine Overheats RG RG34710 5092 19 30JAN98 2 8 021201 PN 109 Symptom Engine runs irregularly or stalls frequently Below normal engine temperature Troubleshooting Problem Low coolant temperature Clogged fuel filter Water dirt or air in fuel system Dirty or faulty injection nozzles Defective thermostat Defective temperature gauge or sender Continued on next page 95 6 Solution 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 RG RG34710 5092 19 30JAN98 3 8 021201 PN 110 Symptom Lack of power Engine idles poorly Troubleshooting Problem Engine overloaded Intake air restriction Clogged fuel filter Improper type of fuel Poor fuel quality Ove
128. s deliver ether to intake manifold by depressing a button Ether should be injected in short bursts only from immediately after cranking until when the engine starts and runs Continued on next page RG RG34710 5029 19 30JAN98 1 2 1 0 3 021201 PN 24 Fuels Lubricants and Coolant IMPORTANT If too much ether is injected it can Radiator Shutters prevent proper cranking and cause engine damage If equipped with a thermostatically controlled radiator shutter system this system should be regulated in Winterfronts such a way that the shutters are completely open by the time the coolant reaches 93 C 200 F to prevent Use of fabric cardboard or solid winterfronts is not excessive intake manifold temperatures Manually recommended with any John Deere engine Their use controlled systems are not recommended can result in excessive engine coolant oil and charge air temperatures This can lead to reduced engine life If air to air aftercooling is used the shutters must be loss of power and poor fuel economy Winterfronts completely open by the time the intake manifold air may also put abnormal stress on fan and fan drive temperature reaches the maximum allowable components potentially causing premature failures temperature out of the charge air cooler If winterfronts are used they should never totally close For more information see your John Deere engine off the grill frontal area Approximately 25 area in the distributor or servicing d
129. supply pump primer lever B until fuel flow is free from air bubbles On electric supply pumps turn key switch to ON position until fuel flow is free from air bubbles Tighten bleed plug securely by hand Continue operating hand primer until pumping action is not felt When finished pull hand primer outward away from engine as far as it will go 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 X9811 UN 23AUG88 Keep Skin Away from High Pressure Fluids A Vent Screw B Primer Lever Continued on next page 50 3 Fuel Supply Pump Primer Lever RG11544 UN 01DECOO RG11545 UN 01DECOO RG RG34710 5084 19 30JAN98 1 3 021201 PN 97 Service As Required At Fuel Injection Pump 1 Slightly loosen fuel supply line connector A at injection pump On mechanical supply pumps operate fuel supply pump primer lever until fuel without air bubbles flows from fuel line connection On electric supply pumps turn key switch to ON position until fuel without air bubbles flows from fuel line connection RG7316 UN O01DECOO Fuel Supply Line Connector at Injection Pump Tighten fuel supply line connector to specification A Bonnceion Specification Connector Torque 16 Nem 12 lb ft 5 Leave hand primer in the outward position away from cylind
130. t must be precharged Determine the total system capacity and premix with 3 John Deere Coolant Conditioner Through time and use the concentration of coolant additives is gradually depleted during engine operation Periodic replenishment of inhibitors is required even when Radiator Coolant Check 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 na RG6261 UN 08DEC97 Maintaining the correct coolant conditioner concentration TEX 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 CONDITIONER is recommended as a supplemental coolant additive in John Deere engines 5 LU Q DO NOT mix one brand of SCA with a different brand T l Test the coolant solution at 600 hours or 12 months of S operation using either John Deere coolant test strips or a RG6262 COOLSCAN analysis If a COOLSCAN analysis is not JTO7298 Coolant Battery Tester available recharge the system per instructions printed on label of John Deere Liquid Coolant Conditioner COOL GARD is a registered trademark of Deere amp Company COOLSCAN is a registered trademark of Deere amp Company Continued on next page DPSG OUOD002 1921 19 12DEC00 1 2 40 7 021201 PN 84 Lubrication amp Maintenance 600 Hour
131. tely 115 C 239 F the engine will shutdown automatically if equipped with safety controls 7 The tension on newly installed belts should be checked daily for the first few days of operation because of the initial stretching Also check belts for proper seating in pulley grooves OUOD002 000001C 19 01DEC00 2 2 1 5 1 1 021201 PN 45 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 engine timing gear train at front of engine power requirements of the accessory must be limited to values listed below Power Levels For Right Hand Auxiliary Gear Drive e 16 kW 22 hp Continuous Operation uh i k Cea e 28 kW 37 5 hp Intermittent Operation Auxiliary Gear Drive CD30354 UN 03FEB93 At 2400 engine rom RG RG34710 5047 19 30JAN98 1 1 GENERATOR SET STANDBY APPLICATIONS 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 RG RG34710 5048 19 30JAN98 1 1 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
132. test position position I It should go off after approximately five seconds After the engine is running if the alternator stops charging the light will illuminate and protection circuitry will stop the engine The battery light will remain on indicating the engine was stopped due to the alternator not charging A Oil Pressure Gauge RG10606B UN 200CT99 B Coolant Temperature Gauge C Tachometer D Engine Control Light E Preheater Light F Fuel Level Light G Battery Light H Oil Pressure Light I Coolant Temperature Light J Key Start Switch K Hour Meter Continued on next page 15 5 OUOD002 0000028 19 18JAN01 5 6 021201 PN 39 Engine Operating Guidelines H Oil Pressure Light The oil pressure light illuminates when the key switch is turned to the bulb test position position I The light will remain on until the engine is started and the specified oil pressure is reached If oil pressure is lost during engine operation the light will illuminate and protection circuitry will stop the engine The oil pressure light will remain on indicating that the engine was stopped due to a low oil pressure condition I Coolant Temperature Light The coolant temperature light illuminates when the key is turned to the bulb test position position It should go off after approximately five seconds After the engine is running if the engine overheats the light will illuminate and protection
133. to protect it from dust and damage RG RG34710 3598 19 30AUG96 1 1 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 Continued on next page RG RG34710 3599 19 30AUG96 1 2 50 7 021201 PN 101 Service As Required CAUTION Only a special air cleaning gun 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 Insert the cleaning gun into element hold air nozzle about 25 4 mm 1 0 in from perforated metal retainer Force air through filter from inside to outside and move air gun up and down pleats to remove as much dirt as possible o o Z I pe co i Z D LO co O O oc Cleaning Primary Element Repeat steps 1 and 2 to remove additional dirt A hir Cleaning Gun Inspect element for damage after cleaning Replace element if any damage is found RG RG34710 3599 19 30AUG96 2 2 ELEMENT STORAGE IMPORTANT Air cleaner element MUST BE DRY before storing in plastic bag Seal element in a plastic bag and store in shipping container to protect against dust and damage RG RG34710 3601
134. 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 On self propelled equipment disconnect battery ground cable before making adjustments on electrical systems or welding on machine On towed implements disconnect wiring harnesses from tractor before servicing electrical system components or welding on machine TS218 UN 23AUG88 DX SERV 19 17FEB99 1 1 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 an the exhaust fumes from the area with an exhaust pipe KNANG NS cs ein a L extension If you do not have an exhaust pipe extension open the doors and get outside air into the area TS220 UN 23AUG88 DX AIR 19 17FEB99 1 1 05 6 021201 PN 16 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 a piece of cardboard Protect hands and body from high pressure fluids X9811 UN 23AUG88 If an accident occurs see a doctor immediately Any fluid injected int
135. ts white exhaust smoke Troubleshooting Problem Low oil level Improper type of oil Crankcase oil too light Oil leaks Restricted crankcase vent tube Defective turbocharger Improper type of fuel Low engine temperature Defective thermostat Defective injection nozzles Engine out of time retarded Coolant entering combustion chamber failed cylinder head gasket or cracked cylinder head Engine compression too low Continued on next page 55 8 Solution 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 Use proper fuel Warm up engine to normal operating temperature Remove and check thermostat See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor Repair or replace as required See your John Deere engine distributor or servicing dealer Determine cause of low compression and repair as required See your John Deere engine distributor or servicing dealer RG RG34710 5092 19 30JAN98 5 8 021201 PN 112 Symptom Engine emits black or gray exhaust smoke Engine Overheats Troubleshooting Problem Improper type of fuel Clogged or dirty air cleaner Engine overloaded Injection nozzles dirty Engine out o
136. ttery is explosive Keep sparks and flames away from battery Before connecting or disconnecting a battery charger turn charger off Make last connection and first disconnection at a point away from battery Always connect NEGATIVE cable last and disconnect this cable first TS204 UN 23AUG88 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 WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling RG4678 UN 14DEC88 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 1 Connect booster battery or batteries to produce the required system voltage for your engine application 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 RG4698 UN 14DEC88 3 Connect the other end of the jumper cable to the POSITIVE post of battery connected to starter 24 Volt System A 12 Volt Machine Battery ies 4
137. uel Exhaust restricted Fuel filter plugged or full of water Injection pump not getting fuel or air in fuel system Faulty injection pump or nozzles Continued on next page 55 4 Solution Replace battery Clean battery terminals and connections Repair switch as required Replace solenoid Replace starter 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 RG RG34710 5092 19 30JAN98 1 8 021201 PN 108 Symptom Engine hard to start or will not start Engine knocks Troubleshooting Problem 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 Poor fuel quality Slow cranking speed Low engine oil level Injection pump out of time Low coolant temperature Engine overheating Continued on next page 55 5 Solution Disengage PTO Review starting procedure Check fuel tank Bleed fuel line Use cold weather starting aids See Starter Cranks Slowly Use oil of p
138. w A has been turned 8 Repeat procedure until both the engine power and fast oO idle speed are correct O Q T 9 Connect throttle linkage if previously removed Z l o A Screw 7 oc Droop Adjusting Screw RG RG34710 5076 19 30JAN98 1 1 45 4 021201 PN 90 Lubrication amp Maintenance 1200 Hour 24 Month FLUSHING AND REFILLING COOLING SYSTEM CAUTION Explosive release of fluids from pressurized cooling system can cause serious burns 3 Shut off engine Only remove filler cap when x cool enough to touch with bare hands Slowly 5 loosen cap to first stop to relieve pressure B before removing completely 2 Beware of High Pressure Fluids NOTE Drain the initial factory fill engine coolant after the first 2000 hours or 24 months of operation Subsequent drain intervals are determined by the coolant used for service When John Deere COOL GARD is used the drain interval is 3000 hours or 36 months The drain interval may be extended to 5000 hours or 60 months of operation provided that the coolant is tested annually AND additives are replenished as needed by adding a supplemental cooling additive SCA If COOL GARD is not used the drain interval is reduced to 2000 hours or 24 months of operation Drain old coolant remove thermostat flush the entire cooling system install thermostat and fill with recommended clean coolant For correct coolant mixture refer to Fuels Lubricants and Coolant section Perform thes
139. y 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 5 equipped and tighten using the following specifications Z Conical Plug 55 Nem 41 lb ft i Cylindrical Plug W Copper 70 Nem 52 lb ft pr 2 Washer ry oy Cylindrical Plug W O Ring 50 Nem 37 lb ft Timing Gear Cover Oil Fill 8 Fill engine crankcase with correct John Deere engine oil through timing gear cover opening A or rocker arm cover opening B depending on engine application See DIESEL ENGINE OIL in Fuels Lubricants and Coolant Section for determining correct engine oil NOTE Crankcase oil capacity may vary slightly ALWAYS fill crankcase to top arrow or within crosshatch on dipstick whichever is present This should be checked after engine has run and oil has drained back into crankcase DO NOT overfill RG11596 UN 08DECO00 Rocker Arm Cover Oil Fill To determine the correct oil fill quantity for your engine RG11537 UN 01DEC00 see ENGINE CRANKCASE OIL FILL QUANTITIES in the Specifications Section O IMPORTANT Immediately after completing any oil se change crank engine for 30 seconds without permitting engine to start This Coreea Ol Level Wii dows will help insure adequate lubrication to 5 Re11538 UN 01DECo0 engine components before engine starts 9 Start engine and run to check for possible leaks 10 Stop engine and che

OPERATION AND SERVICE MANUAL OEM Diesel Engines fi 2.9 L

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