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Manual - KVA Diesel-EL

1. 15 11 5500 Hours of operation 02 7 Adjusting Contrast 000005 15 13 6000 Hours of operation 02 7 Selecting Units Of Measurement 15 15 6500 Hours of operation 02 8 setup 1 Up Display 15 18 7000 Hours of operation s ete ae yey pes 02 8 setup 4 Up Display 15 24 7500 Hours of operation 5 02 9 Break in period au oa cast eee de eee eS Soe aS 15 29 8000 Hours of operation o a cexcna ante ae yg ely eles 02 9 Starting the engine 000 0 15 30 8500 Hours of operation 02 10 Cold weather operation 5 15 30 9000 Hours of operation eu we eu wate wo ee 02 10 Using a booster battery or charger 15 33 9500 Hours of operation 02 11 Engine operation ance a anaana anane 15 34 10000 Hours of operation 02 11 Standby power units 05 15 34 Stopping the engine 005 15 35 Serial Numbers Changing Generator Frequency 15 35 POWERTech label 0008 03 1 Engine serial number plate 03 1 Maintenance Record engine serial number 03 2 Observe service intervalS 4 20 1 Engine option COdES nua ecw ec ae eewnw enn 03 3 Use correct fuels lubricants and coolant 20 1 Record fuel injection pump model number 03 5
2. 0 00 cee eee 40 4 2500 hours 3 years U Drain and flush cooling system 45 1 500 hours Chanongendne oland ier eesosa 30 1 Units of measure changing 15 15 Checking OC Cac cece ese es em ew ke oe a od wot oto 30 6 Replace fuel filter 0 30 4 Maintenance records 0 000 eae 02 1 V Mixing lubricants 0000005 10 5 Valve clearance Adjust 3029 and 4039 engines 35 4 O Adjust 4045 and 6068 engines 40 1 Operating the engine Break in period 000 0 eae 15 29 W Changing Generator Frequency 15 35 Standby power units 15 34 Wiring harness Starting the engine 15 30 With Denso High Pressure Common Rail 55 3 Stopping the engine 15 35 With Stanadyne DE10 pump 05 2 Using a booster battery or charger 15 33 Index 2 061208 PN 2
3. Continued on next page DPSG CD03523 33 19 22JANO07 1 2 35 1 061208 PN 89 Maintenance 1000 hours 1 year If engine has a rubber dust unloader valve C inspect the valve on bottom of air filter for cracks or plugging Replace as necessary 5 Service air filter as necessary RG4687 UN 20DEC88 DPSG CD03523 33 19 22JAN07 2 2 Checking automatic belt tensioner 4045 and 6068 Engines Belt drive systems equipped with automatic spring belt tensioners cannot be adjusted or repaired The automatic belt tensioner is designed to maintain proper belt tension over the life of the belt If tensioner spring tension is not within specification replace tensioner assembly e Checking belt wear The belt tensioner is designed to operate within the limit of arm movement provided by the cast stops A and B when correct belt length and geometry is used If the tensioner stop on swing arm A is hitting the fixed stop B check mounting brackets alternator belt tensioner idler pulley etc and the belt length Replace belt as needed see REPLACING FAN AND ALTERNATOR BELTS N O gt O Z l Z l O O m O v O o A Swing arm stop B Fixed cast stop RG13744 UN 11NOV04 Continued on next page DPSG CD03523 34 19 30JANO07 1 2 35 2 061208 PN 90 Maintenance 1000 hours 1 year e Checking tensioner spring tension A belt tension gauge will not give an accurate measure of the
4. J Crankcase vent tube clean Number of hours Observation Dealer or distributor stamp Job done by DPSG CD03523 61 19 22JAN07 1 1 02 4 061208 PN 13 Maintenance Records 3500 Hours of operation J Engine oil drain J Engine oil filter replace g Fuel filter replace J Belt check tension and wear 800 Series and POWERTech with manual tensioner g Valve clearance adjust 300 Series Number of hours Observation Dealer or distributor stamp Job done by DPSG CD03523 62 19 22JAN07 1 1 4000 Hours of operation J Engine oil drain J Cooling system drain and flush if COOL GARD is not used J Engine oil filter replace g Valve clearance adjust POWERTech g Fuel filter replace g Air intake system check J Check belt and tensioning system g Vibration damper check J Crankcase vent tube clean Number of hours Observation Dealer or distributor stamp Job done by DPSG CD03523 63 19 22JAN07 1 1 02 5 061208 PN 14 Maintenance Records 4500 Hours of operation J Engine oil drain O Vibration damper replace 6 cyl g Fuel filter replace J Belt check tension and wear 3800 Series and POWERTech with manual tensioner g Valve clearance adjust 300 Series Number of hours Observation Dealer or distributor stamp Job done by DPSG CD03523 64 19 22JAN07 1 1 5000 Hours of operation J Engine oil drain g Injection nozzles replace J Engine
5. A pent 3 at Mey nO O me r Ps A p aM a os nent O a O gt lt gee S ie Le al g o A Coolant Temperature H Oil Pressure Sensor N CAN Network Diagnostic R Engine Wiring Harness Sensor Connector Connector Connector S Fuel Heater Connector B Fuel Temperature Sensor I Main System Fuse 10 amp O Instrument Panel T Manifold Air Temperature Connector J Power and Ground Battery Connector Harness MAT Sensor Connector C Injection Pump Solenoid Connections P 23 pin Optional Feature U Alternator Ignition Connector K Fuse Holder Connector Connector D SAE 1939 CAN Connector L Transient Voltage Extended feature ECU V Optional Instrument Panel E Crankshaft Position Sensor Protection TVP Module only or Generator Instrument Connector Connector Q 21 pin Instrument Panel Panel F ECU Connector M Remote ON OFF Connector G Starter Relay Connector Connector CD03523 000018E 19 02FEB07 1 1 55 2 061208 PN 111 Troubleshooting Engine Wiring Layout Electronic Fuel System With Denso High Pressure Common Rail ra O G RG12224 UN 19JUN02 6068HFU74 Engine shown A Engine Coolant D ECU Connector G Engine Oil Pressure J Crankshaft Position Sensor Temperature ECT Sensor E Optional Instrument Panel Sensor Connector K Pump Position Sensor B Electronic Injector or Generator Instrument H Power and Ground Battery L Pump Control Valv
6. John Deere engines can be stored inside warehoused for up to six 6 months with no long term preparation DPSG CD03523 51 19 22JAN07 1 1 Preparing engine for long term storage The following storage preparations are good for long appropriate coolant See DIESEL ENGINE term engine storage up to one year After that the COOLANT engine should be started warmed up and retreated for an extended storage period Fill the fuel tank IMPORTANT Any time your engine will not be Remove fan alternator belt if desired used for over six 6 months the following recommendations for Remove and clean batteries Store them in a cool storing it and removing it from dry place and keep them fully charged storage will help to minimize corrosion and deterioration Clean the exterior of the engine with salt free water and touchup any scratched or chipped painted Change engine oil and replace filter Used oil will surfaces with a good quality paint not give adequate protection See CHANGING ENGINE OIL AND FILTER Coat all exposed machined metal surfaces with grease or corrosion inhibitor if not feasible to paint Service air cleaner See CLEAN OR REPLACE AIR FILTER Seal all openings on engine with plastic bags and tape Draining and flushing of cooling system is not necessary if engine is to be stored only for several 10 Store the engine in a dry protected place If months However for extended storage periods of a e
7. PLUS 50 is a trademark of Deere amp Company TORQ GARD SUPREME is a trademark of Deere amp Company 10 4 50 C 40 C 30 C F F 20 C D 3 E F of ft z ww 0C lt lt Oo w 10 C 200C 5 30 C Q i 400C 7 z H Oil Viscosities for Air Temperature Ranges CD ENOIL 19 25JAN07 1 1 061208 PN 39 Fuels Lubricants and Coolant Lubricant Storage Your equipment can operate at top efficiency only when clean lubricants are used Use clean containers to handle all lubricants Whenever possible store lubricants and containers in an area protected from dust moisture and other contamination Store containers on their side to avoid water and dirt accumulation Mixing of Lubricants In general avoid mixing different brands or types of oil Oil manufacturers blend additives in their oils to meet certain specifications and performance requirements Mixing different oils can interfere with the proper functioning of these additives and degrade lubricant performance Make certain that all containers are properly marked to identify their contents Properly dispose of all old containers and any residual lubricant they may contain DX LUBST 19 18MAR96 1 1 Consult your John Deere dealer to obtain specific information and recommendations DX LUBMIX 19 18MAR96 1 1 1 0 5 061208 PN 40 Fuels Lubricants and Coolant Diesel Engine Coolant The engine cooling system is fi
8. lt o o_o h aAlolnl N N10 cn co on anlololo la On on ie gt N NO O1 ide NO o O1 GO N 0l NO DA NO O i O O01 W N NO O1 NIOJN 00 oO N o_o CO O h N O N N N O pO oO oO D Ol KIO o N X oO h no o h O Ol N NIO OI O1 N N O1 aa O N k NO O1 N O1 O1 O Ce O1 k 00 O co O1 O O1 O O o1 O O O O N O 1750 2200 1075 2250 1650 2850 Torque values listed are for general use only based on the strength of the bolt or screw DO NOT use these values if a different torque value or tightening procedure is given for a specific application For stainless steel fasteners or for nuts on U bolts see the tightening instructions for the specific application Tighten plastic insert or crimped steel type lock nuts by turning the nut to the dry torque shown in the chart unless different instructions are given for the specific application IN N O1 N N gt A O IAIA O O Se O1 W oO JN O ge oO oO O ow NO ee O1 ge N l o k O1 O1 amp D O1 D oO o oa o o oO O1 O O O O O1 15 5 k D O hk N N NO N hk co O1 ioe O1 O1 O1 N O D O1 O1 N Q O k O1 O NO O O O1 wlrplrm D olNnilo iN olalo O on N Q O1 AJO N O o NIOJ A O Io oO Olojo QgJIJAJIOJ J gt O J ojoo
9. Fill the fuel tank at the end of each day s operation to prevent water condensation and freezing during cold weather IMPORTANT The fuel tank is vented through the filler cap If a new filler cap is required always replace it with an Keep all storage tanks as full as practicable to original vented cap minimize condensation When fuel is stored for an extended period or if there is a slow turnover of fuel add a fuel conditioner to stabilize the fuel and prevent water condensation Contact your fuel supplier for recommendations Ensure that all fuel tank caps and covers are installed properly to prevent moisture from entering Monitor water content of the fuel regularly DX FUEL4 19 19DEC03 1 1 10 2 061208 PN 37 Fuels Lubricants and Coolant Diesel Engine Break In Oil New engines are filled at the factory with John Deere ENGINE BREAK IN OIL During the break in period add John Deere ENGINE BREAK IN OIL as needed to maintain the specified oil level Change the oil and filter after the first 100 hours of operation of a new or rebuilt engine After engine overhaul fill the engine with John Deere ENGINE BREAK IN OIL If John Deere ENGINE BREAK IN OIL is not available use a diesel engine oil meeting one of the following during the first 100 hours of operation e API Service Classification CE API Service Classification CD API Service Classification CC ACEA Oil Sequence E2 ACEA Oil Sequence E1 PLUS 5
10. or other knowledgeable medical source A plug is provided with the new element for plugging the used NOTE Engines with mechanical fuel system have a element single fuel filter while electronically controlled engines DE10 HPCR have two fuel filters 4 Inspect filter mounting base for cleanliness Clean primary and final Both the primary and the aerequicd final filters have to be replaced together at the same time Continued on next page DPSG CD03523 30 19 07FEBO7 1 2 30 4 061208 PN 85 Maintenance 500 hours NOTE Raised locators on fuel filter canister must be tighten ring about 1 3 turn until it snaps into the indexed properly with slots in mounting base detent DO NOT overtighten retaining ring for correct installation NOTE The proper installation is indicated when a Install new filter element dry onto mounting base Click is heard and a release of the retaining Be sure element is properly indexed and firmly ring is felt seated on base It may be necessary to rotate filter for correct alignment 7 Bleed the fuel system Install retaining ring onto mounting base making certain dust seal is in place on filter base Hand DPSG CD03523 30 19 07FEB07 2 2 30 5 061208 PN 86 Maintenance 500 hours Checking belt 3029 and 4039 Engines 1 Inspect belt for cracks fraying or stretched out areas Replace as necessary 2 Check belt tension using one of following methods ee
11. 5 106 5 106 5 106 5 Stroke mm 127 127 127 127 127 Displacement L 6 8 6 8 6 8 6 8 6 8 Compression 17 0 1 19 0 1 17021 17 021 19 0 1 Ratio POWER 1500 kW hp 112 150 139 186 167 224 189 253 rpm Prime POWER 1500 kW hp 123 165 153 205 184 247 207 277 rom Standby POWER 1800 kW hp 134 180 rpm Prime POWER 1800 kW hp 147 197 rpm Standby Width overall mm 784 784 960 960 784 Length overall mm 1500 1500 1509 1509 1500 Height overall mm 1137 1137 1381 1381 1137 Weight dry kg 764 764 764 764 764 Engine oil quantity L 32 32 32 32 32 Engine coolant L 32 32 35 35 32 quantity aWith Fan bApproximate Continued on next page CD03523 0000194 19 O6JUN08 4 5 65 7 061208 PN 133 Specifications ITEM UNIT OF 6068HFS83 6068HFS89 6068HFU72 6068HFU74 6068HFU79 MEASURE Number of 6 6 6 6 6 Cylinders Fuel Diesel Diesel Diesel Diesel Diesel Bore mm 106 5 106 5 106 5 106 5 106 5 Stroke mm 127 127 127 127 127 Displacement L 6 8 6 8 6 8 6 8 6 8 Compression 19 0 1 17 0 1 17 0 1 17 0 1 19 0 1 Ratio POWER 1500 kW hp 111 149 166 223 188 139 186 rpm Prime 252 POWER 1500 kW hp 123 165 184 247 207 153 205 rpm Standby 277 POWER 1800 kW hp 161 216 214 287 191 256 rpm Prime POWER 1800 kW hp 177 237 235 315 201 269 rpm Standby Width overall mm 784 960 784 960 812 Length overall mm 1500 1509 1500 1509 1532 Height overall mm
12. B to adjust droop until the requested power is reached CD30764 UN 24SEP99 NOTE If surging exits upon removing the load turn screw B clockwise to eliminate B Speed droop governor adjusting screw DPSG CD03523 39 19 31JAN07 1 1 40 3 061208 PN 97 Maintenance 2000 hours 2 years Checking crankshaft vibration damper 6 CYLINDER ENGINE ONLY 1 Remove belts shown removed 2 Grasp vibration damper with both hands and attempt to turn it in both directions If rotation is felt damper is defective and should be replaced IMPORTANT The vibration damper assembly is not repairable and should be replaced every 4500 hours or 5 years whichever occurs first RG8018 UN 15JAN99 Check vibration damper radial runout by positioning a dial indicator so probe contacts damper outer circumference With engine at operating temperature rotate crankshaft using JDG820 or JDE83 Flywheel Turning Tool Note dial indicator reading If runout exceeds specifications given below replace vibration damper RG7508 UN 23NOV97 Specification Damper Maximum radial runout 1 50 mm 0 060 in DPSG CD03523 40 19 22JAN07 1 1 40 4 061208 PN 98 Maintenance 2500 hours 3 years Drain and flush cooling system NOTE Drain and flush cooling system every 2500 hours 3 years when John Deere COOL GARD coolant is used Otherwise every 2000 hours 2 years CAUTION Explosive release of fluids from pressuriz
13. D Z 2 pe Z D t LO CO Q O DPSG CD03523 35 19 31JAN07 3 4 e 4 Cylinder Engine NOTE Firing order is 1 3 4 2 Lock No 1 piston at TDC compression stroke B Adjust valve clearance on No 1 and 3 exhaust valves and No 1 and 2 intake valves Rotate flywheel 360 Lock No 4 piston at TDC compression stroke C Adjust valve clearance on No 2 and 4 exhaust valves and No 3 and 4 intake valves RG4776 UN 310CT97 A Front of engine B No 1 Piston at TDC compression stroke C No 4 Piston at TDC compression stroke E Exhaust valve I Intake valve DPSG CD03523 35 19 31JAN07 4 4 35 5 061208 PN 93 Maintenance 1000 hours 1 year Pressure testing cooling system Test radiador cap CAUTION Explosive release of fluids from pressurized cooling system can cause serious burns Shut off engines Only remove filler cap when cool enough to touch with bare hands Slowly loosen cap to first stop to relieve pressure before removing completely Test Radiator Cap 1 Remove radiator cap and attach to D05104ST tester as shown 2 Pressurize cap to specification listed Gauge should hold pressure for 10 seconds within the normal range if cap is acceptable If gauge does not hold pressure replace radiator cap Specification Radiator Cap Calibration PresSUfe ene nee nee ene ieni 70 kPa 0 7 bar 10 psi for 10 seconds minimum 3 Remove the cap fr
14. Maintenance interval chart 20 2 Record Engine Control Unit ECU Serial Number cu o ae lt 5 eee heed ec daaee eee si 03 5 Maintenance Daily or every 10 hours Record High Pressure Fuel Pump Model Daily prestarting checks 0 25 1 NUMIDCl s cea Gahcntaeusas EN A 03 5 Maintenance 500 hours Safety 6 eee 05 1 Changing engine oil and filter 30 1 Replacing fuel filter element s 30 4 Fuels Lubricants and Coolant Checking belt 3029 and 4039 Engines 30 6 Diesel FUel s acy uuu eee arerereae ceed sda deeded 10 1 Handling and Storing Diesel Fuel 10 2 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 2008 DEERE amp COMPANY European Office Mannheim All rights reserved A John Deere ILLUSTRUCTION Manual Previous Editions Copyright 2007 l 061208 PN 1 Contents Page Checking belt 4045 and 6068 Engines with manual tensioner 00000 30 7 Maintenance 1000 hours 1 year Cleaning crankcase vent tube 35 1 Checking air intake system 35 1 Checking automatic belt tensioner 4045 and 6068 Engines 4 4 0 4s 444 4 0 8 a4 35 2 Check and adjust engine valve clearance 8029 and 4039 Engines 35 4 Pressure testing
15. PN 103 Maintenance As required Clean or replace air filter one piece Clean air filter when restriction indicator A is red Air filter can be cleaned up to six times Thereafter or at least once a year it must be replaced Proceed as follows 1 Thoroughly clean all dirt around air filter area 2 Loosen clamp B then remove air filter CD30766 UN O6SEP99 IMPORTANT Never reinstall an air filter which shows evidence of bad condition punched dented allowing no filtered air to enter the engine 3 Clean air filter with compressed air working from clean to dirty side NOTE Compressed air pressure must not exceed 600 kPa 6 bar 88 psi 4 Mark air filter to keep track of each cleaning operation RG9912 UN 25FEB99 5 Fully depress air restriction indicator reset button and release to reset indicator 6 Check air system entirely for proper condition see CHECKING AIR INTAKE SYSTEM DPSG CD03523 44 19 22JAN07 1 1 50 3 061208 PN 104 Maintenance As required Clean or replace air filter element A Primary element B Secondary safety element Clean air filter when restriction indicator C is red Replace both primary A and secondary B filter elements after primary element has been cleaned six times or at least once a year Proceed as follows 1 Thoroughly clean all dirt around air filter area 2 Remove wing nut D and remove primary element A from c
16. UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT OGO Select Units GO TO 1 UP DISPLAY STORED CODES ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT OCO Press Enter Key ENGLISH Select Desired Units Continued on next page 15 16 RG13188 UN 02OCT03 OURGP11 00000B0 19 03SEP03 2 7 RG13189 UN 020CT03 OURGP11 00000BO 19 03SEP03 3 7 RG13190 UN 26SEP03 OURGP11 00000BO 19 03SEP03 4 7 061208 PN 57 Operating the Engine 5 Press the Enter key to select the highlighted units ENGLISH METRIC KPA METRIC BAR RG13191 UN 30SEP03 Press Enter Key to Select OURGP11 00000BO 19 03SEP03 5 7 6 Press the Menu key to return to the main menu ENGLISH METRIC KPA METRIC BAR RG13192 UN 26SEP03 o O Return To Main Menu OURGP11 00000BO 19 03SEP03 6 7 7 Press the Menu key to return to the engine 98 T000 RPH parameter display LOAD RPM ENG RPM 1800 RPM EXeGG coo TEMP ae eS Press Menu Key RG13159 UN 26SEP03 OURGP11 00000BO 19 03SEP03 7 7 15 17 061208 PN 58 Operating the Engine setup 1 Up Display 98 1000 RPM LOADG RPM ENG RPM 1 Turn the key switch to the ON position Starting at the 1800 RPM single engine parameter display press the Menu key COOL TEMP 14 2 S Menu Key RG13159 UN 26SEP03 OURGP11 00000B1 19 03SEP03 1 18 2 Use the Arrow keys
17. a a Use of JDG529 Tension Gauge A E Specification Belt tension New belt c0ccce 578 622 N 130 140 lb force Used Dal ceninin 378 423 N 85 94 lb force a NOTE Belt is considered used after 10 minutes of operation b Use of tension tester B and straightedge C A 89 N 20 Ib force applied halfway between pulleys should deflect belt by 19 mm 0 75 in 3 If adjustment is necessary loosen alternator nuts D and E Pull alternator frame outward until belt is correctly tensioned CD30645 UN O4MAY98 IMPORTANT Do not pry against the alternator rear frame Do not tighten or loosen belts while they are hot 4 Tighten alternator bracket nuts firmly 5 Run engine for 10 minutes then recheck belt tension A JDG529 Tension Gauge B Tension tester C Straightedge D Upper nut E Lower nut CD30646 UN O4MAY98 DPSG CD03523 31 19 30JAN07 1 1 30 6 061208 PN 87 Maintenance 500 hours Checking belt 4045 and 6068 Engines with manual tensioner Inspect belts for cracks fraying or stretched out areas Replace if necessary NOTE Belt adjustment is measured using a gauge stamped on the top edge of the alternator bracket Loosen cap screws B and C Slide alternator in slot by hand to remove all excess Slack in belt Scribe a reference mark D on line with notch E on upper alternator bracket IMPORTANT Do not pry against alternator re
18. belt tension when automatic spring tensioner is used Measure tensioner spring tension using a torque wrench and procedure outlined below Release tension on belt using a breaker bar and socket on tension arm Remove belt from pulleys Release tension on tension arm and remove breaker bar Put a mark A on swing arm of tensioner as shown Measure 21 mm 0 83 in from A and put a mark B on tensioner mounting base RG7977 UN 14NOV97 NOTE Earlier engines have a LEFT HAND thread roller cap screw while later engines have a 12 7 mm 1 2 in square hole in tensioner e Install torque wrench on roller cap screw or in square hole so that it is aligned with center of roller and tensioner as shown Rotate the swing arm using a torque wrench until marks A and B are aligned Record torque wrench measurement and compare with specification below Replace tensioner assembly as required RG12054 UN O8JANO2 TE SOON H Specification Align marks Spring Force 18 22 Nem 13 16 lb ft A Mark on swing arm B Mark on tensioner mounting base DPSG CD03523 34 19 30JAN07 2 2 35 3 061208 PN 91 Maintenance 1000 hours 1 year Check and adjust engine valve clearance 3029 and 4039 Engines NOTE Valve clearance must be adjusted after the first 500 hours of operation then every 1000 hours thereafter Adjust engine valve clearance as follows or have your authorized servicing dealer or engine distrib
19. cable first IMPORTANT Be sure polarity is correct before making connections Reversed polarity will damage electrical system Always connect positive to positive and negative to ground Always use 12 volt booster battery for 12 volt electrical systems and 24 volt booster battery ies for 24 volt electrical systems 1 Connect booster battery or batteries to produce the 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 3 Connect the other end of the jumper cable to the POSITIVE post of battery connected to starter 4 Connect one end of the other jumper cable to the NEGATIVE post of the booster battery 5 ALWAYS complete the hookup by making the last connection of the NEGATIVE cable to a good ground on the engine frame and away from the battery ies 6 Start the engine Disconnect jumper cables immediately after engine starts Disconnect NEGATIVE cable first 15 33 TS204 UN 23AUG88 RG4678 UN 14DEC88 RG4698 UN 14DEC88 24 Volts System A 12 Volt Machine battery ies B 12 Volt Booster battery ies C Booster cable D Cable to starter motor DPSG CD03523 20 19 22JAN07 1 1 061208 PN 74 Operating the Engine Engine operation Warming engine Operate engine at high idle for 1 to 2 min
20. cooling system 35 6 Maintenance 2000 hours 2 years Check and adjust engine valve clearance 4045 and 6068 Engines 40 1 Checking engine speed Mechanical fuel SYSE eee ee 40 3 Adjust speed droop governor Mechanical fuel system ae ap an ee ced Ss a 40 3 Checking crankshaft vibration damper 6 CYLINDER ENGINE ONLY 40 4 Maintenance 2500 hours 3 years Drain and flush cooling system 45 1 Maintenance As required Additional service information 50 1 Do not modify fuel system 50 2 Clean or replace air filter one piece 50 3 Clean or replace air filter element 50 4 Replacing fan and alternator belt 4045 and 6068 Engines 0 00 cee eee 50 5 Bleeding the fuel system 0 50 6 Troubleshooting General troubleshooting information 55 1 Engine Wiring Layout Electronic Fuel System With Stanadyne DE10 Injection PUMO oh aeeee65eeeeuseee eee hens eae 55 2 Engine Wiring Layout Electronic Fuel System With Denso High Pressure Common Pall eee Behe hh Gen Ss ge ee eS 55 3 Engine troubleshooting 0000 55 4 Electrical troubleshooting 55 9 Displaying Of Diagnostic Trouble Codes OVGS gc egcetteesesesgeeean sede ee 2 55 10 Using blink code method for retrieving Diagnostic Trouble Codes DTC s 55 11 Using diagnostic gauge for retrieving Diagnostic Trouble Codes D
21. engine values illustrated on the diagnostic gauge indicate the engine is running 1 Turn the key switch to the ON position Starting at the single or four engine parameter display press the Menu key 2 The first seven items of the Main Menu will be displayed CD03523 000018B 19 22JAN07 2 2 98 1000 RPM LOAD RPM 1800 RPM EXeGGI coo TEMP aly a Menu Key GO TO 1 UP DISPLAY SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT Menu Display Continued on next page 15 2 ENG RPM RG13159 UN 26SEP03 OURGP11 00000A9_ 19 03SEP03 1 5 RG13160 UN 020CT03 OURGP11 00000A9_ 19 03SEP03 2 5 061208 PN 43 Operating the Engine 3 Pressing the Arrow keys will scroll through the menu GO TO 1 UP DISPLAY selections STORED CODES ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT Main Menu Items RG13161 UN 020CT03 OURGP11 00000A9_ 19 03SEP03 3 5 4 Pressing the right arrow key me scroll down to reveal ADJUST CONTRAST the last items of Main Menu screen highlighting the UTILITIES next item down Last Items On Main Menu cD oO A Lu top Ke N Z N mN o OURGP11 00000A9_ 19 03SEP03 4 5 5 Use the arrow keys to scroll to the desired menu item GO TO 1 UP DISPLAY 98 1000 RPM or press the Menu Button to exit the main menu and LOAD RPM ENG RPM SETUP 1 UP DISPLAY return
22. for leaks and check all gauges for correct operation DPSG CD03523 54 19 22JAN07 1 1 061208 PN 126 General engine pack specifications Specifications Non Emission Certified Engines ITEM Number of Cylinders Fuel Bore Stroke Displacement Compression Ratio POWER 1500 rpm Prime POWER 1500 rom Standby POWER 1800 rpm Prime POWER 1800 rom Standby Width overall Length overall Height overall Weight dry Engine oil quantity Engine coolant quantity aWith Fan Approximate UNIT OF MEASURE mm mm kW hp kW hp kW hp kW hp mm mm mm kg 3029DF 128 Diesel 106 5 110 2 9 17 601 26 35 30 41 30 41 34 46 582 888 931 345 14 5 3029TF158 Diesel 106 5 110 2 9 17 8 1 36 49 40 54 40 54 45 61 582 888 979 350 14 5 4039DF008 Diesel 106 5 110 3 9 17 8 1 35 48 38 52 41 56 47 64 588 1016 960 475 12 16 5 Continued on next page 65 1 4039T F008 Diesel 106 5 110 3 9 17 8 1 55 75 61 83 67 91 73 99 588 1016 979 487 12 16 5 DPSG CD03523 55 19 05FEBO7 1 3 061208 PN 127 Specifications ITEM UNIT OF MEASURE 4045DF158 4045HF158 4045TF158 4045TF258 Number of Cylinders 4 4 4 4 Fuel Diesel Diesel Diesel Diesel Bore mm 106 5 106 5 106 5 106 5 Stroke mm 127 127 127 127 Displac
23. in a cool protected location TS1356 UN 18MAR92 Do not incinerate or puncture a starting fluid container DX FIRE3 19 16APR92 1 1 05 4 061208 PN 29 Safety 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 5 061208 PN 30 Safety Handle Chemical Products Safely Direct exposure to hazardous chemicals can cause serious injury Potentially hazardous chemicals used with John Deere equipment include such items as lubricants coolants paints and adhesives A Material Safety Data Sheet MSDS provides specific details on chemical products physical and health hazards safety procedures and emergency response techniques TS1132 UN 26NOV90 Check the MSDS before yo
24. least once a year eCheck belt tension every 500 hours on 3029 and 4039 engines and on 4045 and 6068 engines with manual tensioner Check automatic belt tensioner every 1000 hours 1 year on 4045 and 6068 engines when equipped Have your authorized servicing dealer or engine distributor adjust valve clearance as follows After the first 500 hours of operation then every 1000 hours thereafter on 3029 and 4039 engines Every 2000 hours on 4045 and 6068 engines Have your authorized dealer or engine distributor replace the vibration damper every 4500 hours 5 years Drain and flush cooling system every 2500 hours 3 years when John Deere COOL GARD coolant is used Otherwise every 2000 hours 2 years sContact your dealer when thermostat or injection nozzles are suspected to be defective Replace injection nozzles every 5000 hours and thermostat every 10000 hours DPSG CD03523 26 19 25JAN07 1 1 20 2 061208 PN 78 Maintenance Daily or every 10 hours Daily prestarting checks CD30753 UN 26AUG99 CD30755 UN 24SEP99 D Do the following BEFORE STARTING THE ENGINE for the first time each day IMPORTANT DO NOT add makeup oil until the oil level is BELOW the add mark 1 Check engine oil level on dipstick A Add as required using seasonal viscosity grade oil See 25 1 FD000047 CD30754 UN 26AUG99 FDO00047 UN 13MAR96 DIESEL ENGINE OIL Add oil at rocker arm cover filler cap B IMPO
25. next page OURGP11 00000AB 19 03SEP03 3 6 RG13165 UN 020CT03 15 4 061208 PN 45 Operating the Engine 4 Use the Arrow keys to scroll through the engine ENGINE SPEED PT 1 configuration data 1000 RPM lt NEXT gt OGOO Use Arrow Keys To Scroll OURGP11 00000AB_ 19 03SEP03 4 6 RG13166 UN 29SEP03 5 Press the Menu key to return to the main menu ENGINE SPEED PT 1 1000 RPM lt NEXT gt coDO Return To Main Menu OURGP11 00000AB 19 03SEP03 5 6 RG13167 UN 29SEP03 6 Press the Menu key to exit the main menu and return 98 apna cen to the engine parameter display LOAD RPM ENG RPM 1800 RPM EXeGGI coo TEMP ae a Exit Main Menu RG13159 UN 26SEP03 OURGP11 00000AB_ 19 03SEP03 6 6 15 5 061208 PN 46 Operating the Engine Accessing Stored Trouble Codes 98 1000 RPM LOAD RPM ENG RPM NOTE The engine does not need to be running to 1800 RPM navigate the diagnostic gauge screens If engine COOL TEMP 14 2 pi start up is desired See Starting The Engine All of the engine values illustrated on the diagnostic QC IO gauge indicate the engine is running Q For description of trouble codes see chart in Menu Key Troubleshooting Section RG13159 UN 26SEP03 1 Turn the key switch to the ON position Starting at the single or four engine parameter display press the Menu key OURGP11 00000AC 19 03SEP03 1 6 The main menu will
26. 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 9 061208 PN 34 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 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 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 o
27. specifications or otherwise overpowering will result in loss of warranty protection for this engine Information relative to emissions regulations Depending on final destination this engine can meet the emissions regulations according to the US Environmental Protection Agency EPA California Air Resources Board CARB and for Europe the Directive 97 68 EC relating the measures against the emissions of gaseous and particulates pollutants from internal combustion engines In this case an emission label is stuck on the engine Emission regulations prohibit tampering with the emission related components listed below which would render that component inoperative or to make any adjustment on the engine beyond published specifications It is also illegal to install a part or component where the principal effect of that component is to bypass defeat or render inoperative any engine component or device which would affect the engine conformance to the emissions regulations To summarize it is illegal to do anything except return the engine to its original published specifications DPSG CD03523 1 19 O5JUN08 1 2 061208 PN 2 Introduction List of emission related components 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 Fuel injection pump Intake manifold Turbocharger Charge air cooling
28. system Piston DPSG CD03523 1 19 O5JUN08 2 2 061208 PN 3 Introduction 061208 PN 4 Contents Page Page Identification Views Diesel Engine Break In Oil 10 3 Identification views 0 0 0 eee 01 1 Diesel Engine Oil 000 10 4 Lubricant SIOMOe amp 5 25 0 anaa aaaea 10 5 Maintenance Records Mixing of Lubricants aasa aana ae a 10 5 Using maintenance records 02 1 Diesel Engine Coolant 10 6 100 Hours of operation 02 1 Operating in Warm Temperature Climates 10 6 500 Hours of ODETAllON 6 4 4 4 4 4 908 8 er ew ee ae 02 2 1000 Hours of operation n aaan aaan 02 2 Operating the Engine 1500 Hours of operation siri ieriiuraraaiass 02 3 Using Diagnostic Gauge to Access 2000 Hours of operation 02 3 Engine Information Optional equipment 15 1 2500 Hours of operation a a asana anaana 02 4 Main Menu Navigation 15 2 3000 Hours of operation 3 oc oe 45 exes ese ees 02 4 Engine Configuration Data 15 4 3500 Hours of operation 02 5 Accessing Stored Trouble Codes 15 6 4000 Hours of operation 02 5 Accessing Active Trouble Codes 15 8 4500 Hours of operation 02 6 Engine Shutdown Codes 15 10 5000 Hours of operation 02 6 Adjusting Backlighting
29. 0 hours thereafter Change oil and filter at leat once a year CD30758 UN 26AUG99 1 Run engine approximately 5 minutes to warm up oil Shut engine off 2 Open oil pan drain valve A 3 Drain crankcase oil from engine while warm DPSG CD03523 29 19 06FEB07 1 4 am OD O O D lt a Z D l O m Q O CD30926 UN 30JANO7 gt a i Oil filter on 3029 and 4039 engine Oil new filter element packing 4 Replace oil filter values printed on filter element If values are not provided tighten element approximately e 3029 and 4039 engines 3 4 1 1 4 turn after packing contacts filter a Remove and discard oil filter element B housing DO NOT overtighten filter element using a suitable filter wrench b Oil new packing C and install new filter element Hand tighten element according to Continued on next page DPSG CD03523 29 19 O6FEBO7 2 4 30 1 061208 PN 82 Maintenance 500 hours UN 29JANO7 RG11617 UN 240CT01 D30759A am E I Oil filter seals ha me CD30759A 8 Oil filter on 4045 and 6068 engines e 4045 and 6068 engines Remove and discard oil filter element A using a suitable filter wrench Apply clean engine oil to inner B and outer C seals and to filter threads Wipe both sealing surfaces of the header D E with a clean rag Ensure notches in dust seal F are properly installed in the slots in the housing Replace dust seal if damaged
30. 0 is a trademark of Deere amp Company 10 3 After the break in period use John Deere PLUS 50 or other diesel engine oil as recommended in this manual IMPORTANT Do not use PLUS 50 oil or engine oils meeting any of the following during the first 100 hours of operation of a new or rebuilt engine ACEA E7 ACEA E6 ACEA E5 ACEA E4 ACEA E3 API CJ 4 API Cl 4 PLUS API Cl 4 API CH 4 API CG 4 API CF 4 API CF 2 API CF These oils will not allow the engine to break in properly DX ENOIL4 19 13SEP06 1 1 061208 PN 38 Fuels Lubricants and Coolant Diesel Engine Oil Use oil viscosity based on the expected air temperature range during the period between oil changes Depending on Emission Regulation requirements the oil recommendations are different Refer to the chart to identify the proper oil to be used Non Emission Certified Engines Stage II Emission Certified Engines John Deere PLUS 50 John Deere PLUS 50 Preferred Preferred John Deere TORQ GARD John Deere TORQ GARD SUPREME SUPREME ACEA E3 ACEA E2 ACEA E7 ACEA E6 ACEA E5 ACEA E4 ACEA E3 API CH4 API CG4 API CF4 API CJ4 API Cl4 PLUS API Cl4 API CH4 Multi viscosity diesel engine oils are preferred If diesel fuel with sulfur content greater than 0 5 is used or if oil does not meet the classification above reduce the service interval by 50 DO NOT use diesel fuel with sulfur content greater than 1
31. 1137 1381 1137 1381 1200 Weight dry kg 764 764 764 764 764 Engine oil quantity L 32 32 32 32 32 Engine coolant L 32 35 32 35 32 quantity aWith Fan bApproximate CD03523 0000194 19 06JUN08 5 5 65 8 061208 PN 134 Specifications Unified Inch Bolt and Screw Torque Values TS1671 UN 01MAY03 SAE Grade 1 SAE Grade 2 Dry Lubricated a J lt O O1 ESH X oo O N O o Pa wlolo D On N ol lo ololal lN iN on NO N GO NO on ON Flo OJN N 00 O1 oO oO OoO oO oO oO O1 O O1 O 1250 930 Torque values listed are for general use only based on the strength of the bolt or screw DO NOT use these values if a different torque value or tightening procedure is given for a specific application For plastic insert or crimped steel type lock nuts for stainless steel fasteners or for nuts on U bolts see the tightening instructions for the specific application Shear bolts are designed to fail under predetermined loads Always replace shear bolts with identical grade O1 ale 4Grade 2 applies for hex cap screws not hex bolts up to 6 in 152 mm long and for all other types of bolts and screws of any length a E 1c 700 IE Lubricated Ce tn 17 150 een ee LL 100 74 a ans aas 1g00 s60 1920 SAE Grade 5 5 1 or 5 2 ubricated biin T so a a an os 945 J lt O L on anu O WwW N co l N
32. 3 9 19 22JANO7 1 1 02 2 061208 PN 11 Maintenance Records 1500 Hours of operation J Engine oil drain J Engine oil filter replace g Fuel filter replace J Belt check tension and wear 3800 Series and POWERTech with manual tensioner g Valve clearance adjust 300 Series Number of hours Observation Dealer or distributor stamp Job done by DPSG CD03523 10 19 22JAN07 1 1 2000 Hours of operation J Engine oil drain J Cooling system drain and flush if COOL GARD is not used J Engine oil filter replace g Valve clearance adjust POWERTech g Fuel filter replace g Air intake system check J Check belt and tensioning system J Vibration damper check J Crankcase vent tube clean Number of hours Observation Dealer or distributor stamp Job done by DPSG CD03523 59 19 22JAN07 1 1 02 3 061208 PN 12 Maintenance Records 2500 Hours of operation J Engine oil drain O Cooling system drain and flush if COOL GARD is used J Engine oil filter replace g Fuel filter replace J Belt check tension and wear 800 Series and POWERTech with manual tensioner g Valve clearance adjust 300 Series Number of hours Observation Dealer or distributor stamp Job done by DPSG CD03523 60 19 22JAN07 1 1 3000 Hours of operation J Engine oil drain g Air intake system check J Engine oil filter replace g Fuel filter replace J Check belt and tensioning system
33. 3159 UN 26SEP03 OURGP11 00000B1 19 03SEP03 18 18 Setup 4 Up Display 98 1000 RPM LOAD RPM ENG RPM 1 Turn the key switch to the ON position From the single 1800 RPM or four engine parameter display press the Menu CIUIN Coot Temp ae ih key Menu Key RG13159 UN 26SEP03 Continued on next page OURGP11 00000B2 19 O03SEP03 1 14 15 24 061208 PN 65 Operating the Engine 2 The main menu will be displayed Use the Arrow keys feo Tto TUP DISPLAY to scroll through the menu until Setup 4 Up Display iS jisTgoRED CODES highlighted ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT OCHO Select Setup 4 Up Display RG13225 UN 02O0CT03 OURGP11 00000B2 19 03SEP03 2 14 3 Once the Setup 4 Up Display menu item has been GO TO 1 UP DISPLAY highlighted press the Enter key to activate the Setup listoRED CODES 4 Up Display menu ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT Oc 0 Press Enter Key RG13226 UN 020CT03 Continued on next page OURGP11 00000B2 19 03SEP03 3 14 15 25 061208 PN 66 Operating the Engine 4 Two options are available for the 4 Up Display USE DEFAULTS a Use Defaults This option contains the following CUSTOM SETUP engine parameters for display Engine Speed Battery Voltage Coolant Temperature and Oil Pressure Custom Setup This option co
34. 32 32 28 28 quantity aWith Fan bApproximate DPSG CD03523 55 19 05FEB07 3 3 65 3 061208 PN 129 Specifications General engine pack specifications Stage Il Emission Certified Engines ITEM UNIT OF 3029HFS70 3029HFU70 3029TFS70 3029TFU70 MEASURE Number of 3 3 3 3 Cylinders Fuel Diesel Diesel Diesel Diesel Bore mm 106 5 106 5 106 5 106 5 Stroke mm 110 110 110 110 Displacement L 2 9 2 9 2 9 2 9 Compression 17 2 1 17 21 T72 17 2 1 Ratio POWER 1500 kW hp 37 50 37 50 28 37 28 37 rom Prime POWER 1500 kW hp 41 56 41 56 31 41 31 41 rom Standby POWER 1800 kW hp rpm Prime POWER 1800 kW hp rom Standby Width overall mm 582 582 582 582 Length overall mm 888 888 888 888 Height overall mm 974 974 974 974 Weight dry kg 350 350 350 350 Engine oil quantity L 8 8 8 8 Engine coolant L 14 5 14 5 14 5 14 5 quantity aWith Fan Approximate Continued on next page 65 4 CD03523 0000194 19 O6JUN08 1 5 061208 PN 130 Specifications ITEM UNIT OF 4045HFS72 4045HFS73 4045HFS80 4045HFS82 MEASURE Number of 4 4 4 4 Cylinders Fuel Diesel Diesel Diesel Diesel Bore mm 106 5 106 5 106 5 106 5 Stroke mm 110 110 127 127 Displacement L 4 5 4 5 4 5 4 5 Compression 17 0 1 19 0 1 19 0 1 19 0 1 Ratio POWER 1500 kW hp 75 100 94 126 rpm Prime POWER 1500 kW hp 83 111 103 138 rom Standby POWER 1800 kW hp 67 90 85 11
35. 4 Maintenance 500 hours Replacing fuel filter element s F i E2 ii r A i Ons SA B JOHN DEE J JOHN DEE r N i TR j s i s O Hs F O z0 iin parn E 2 5 l x 8 2 COS0930 A r O Fuel filters A Retaining ring C Drain plug E Water separator bowl F Primary fuel filter element B Final fuel filter element D Bleed plug 1 Thoroughly clean fuel filter assembly and CAUTION Escaping fluid under pressure surrounding area 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 2 Loosen drain plug C and drain fuel into a suitable container NOTE Lifting up on retaining ring as it is rotated helps to get it past raised locators 3 Firmly grasp the retaining ring A and rotate it clockwise 1 4 turn Remove ring with filter element B IMPORTANT Do not dump the old fuel into the new filter element This could cause fuel injection problem 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
36. 4 rpm Prime POWER 1800 kW hp 74 99 94 126 rom Standby Width overall mm 751 765 600 765 Length overall mm 1362 1365 1230 1365 Height overall mm 1137 1162 1010 1162 Weight dry kg 505 505 505 505 Engine oil quantity L 16 16 12 16 Engine coolant L 28 32 25 32 quantity aWith Fan bApproximate Continued on next page 65 5 CD03523 0000194 19 06JUN08 2 5 061208 PN 131 Specifications ITEM UNIT OF 4045HFS83 4045HFU72 4045HFU79 4045TFU70 MEASURE Number of 4 4 4 4 Cylinders Fuel Diesel Diesel Diesel Diesel Bore mm 106 5 106 5 106 5 106 5 Stroke mm 110 127 127 127 Displacement L 4 5 4 5 4 5 4 5 Compression 19 0 1 17 071 19 0 1 170 1 Ratio POWER 1500 kW hp 75 100 94 126 55 75 rom Prime POWER 1500 kW hp 83 111 103 138 61 83 rom Standby POWER 1800 kW hp 107 143 rpm Prime POWER 1800 kW hp 118 158 rpm Standby Width overall mm 765 751 765 600 Length overall mm 1365 1362 1365 1230 Height overall mm 1162 1137 1162 1010 Weight dry kg 505 505 505 505 Engine oil quantity L 16 16 16 12 Engine coolant L 32 28 32 25 quantity aWith Fan bApproximate Continued on next page 65 6 CD03523 0000194 19 06JUN08 3 5 061208 PN 132 Specifications ITEM UNIT OF 6068HFS72 6068HFS73 6068HFS76 6068HFS77 6068HFS82 MEASURE Number of 6 6 6 6 6 Cylinders Fuel Diesel Diesel Diesel Diesel Diesel Bore mm 106 5 106
37. 4 Up Custom Setup OURGP11 00000B2 19 03SEP03 11 14 12 The selected quadrant has now changed to the new selected parameter 125 F 1000 RPM COOL TEMP ENG RPM 143 F 57 PSI OIL TEMP OIL PRES 4 Up Display Continued on next page OURGP11 00000B2 19 03SEP03 12 14 RG13153 UN 24SEP03 15 28 061208 PN 69 Operating the Engine 13 Repeat the parameter selection process until all spaces are as desired 14 Press the Menu key to return to the main menu 15 Press the Menu key to exit the main menu and return to the engine parameter display Break in period Within first 100 hours of operation During the first 100 hours of operation avoid overloading excessive idling and no load operation If oil has to be added during this time see ENGINE BREAK IN OIL NOTE During the break in period a higher than usual oil consumption should be considered as normal After first 100 hours of operation After the first 100 hours drain the crankcase and 125 F 1000 RPM COOL TEMP ENG RPM 143 F 57 PSI OIL TEMP OIL PRES Return To Main Menu RG13154 UN 24SEP03 OURGP11 00000B2 19 03SEP03 13 14 STORED CODES 125 1000 RPM ENGINE CONFIG COOL TEMP ENG RPM SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS 143 F 57 PSI ADJUST BACKLIGHT OIL TEMP OIL PRES ooe Select Remaining Parameters oO O H O O N T Z D l LO LO n O a OURGP11 00000B2 19 03SEP03 14 14
38. 45 and 6068 engine plate DPSG CD03523 13_ 19 22JAN07 1 1 03 2 061208 PN 22 Serial Numbers Engine option codes JOHN DEERE NUMBER CD6068H123456 Order 2B0000000 6068HF158 6 8L 1 71ECD 1100 1200 1300 1400 1500 1600 1700 1800 1900 2100 2300 2400 2500 2700 2800 2900 3000 3100 3500 4000 4300 5200 5500 5600 5700 6000 6200 6400 6500 6600 7500 7600 8600 8700 8800 000000 OPTION CODES UN 26AUG99 I CD30748A Engine option code label In addition to the serial number plate OEM engines have an engine option code label affixed to the rocker arm cover These codes indicate which of the engine options were installed on your engine at the factory When in need of parts or service furnish your authorized servicing dealer or engine distributor with these numbers An additional sticker may be also delivered in a plastic bag attached to the engine or inserted in the machine documentation It is recommended to stick this option code list sticker either e On this page of your Operators manual below this section or e On the Engine Owners Warranty booklet under the tite OPTION CODES Engine manufacturing configuration NOTE The Machine Manufacturer may have already stuck it at a specific accessible place inside the enclosure or close to a maintenance area The engine option code label includes an engine base code A This base code must also be recorded along with the option codes At tim
39. Filter and mounting header Install and tighten oil filter by hand until firmly against dust seal F DO NOT overtighten IE O O i Z 00 X A Oil filter element B Inner seal C Outer seal 5 Close oil pan drain valve D Sealing surface E Sealing surface F Dust seal Continued on next page DPSG CD03523 29 19 O6FEBO7 3 4 30 2 061208 PN 83 Maintenance 500 hours CD30761 UN 24SEP99 CD30927 UN 01FEB07 A een ee a a Oil filler cap on rocker arm cover Oil filler neck on engine side 6 Fill engine crankcase with correct John Deere engine oil through opening on rocker arm cover C or on the side of the engine D See DIESEL ENGINE OIL Section for determining correct engine oil To determine the correct oil fill quantity for your engine see the Specifications Section NOTE Crankcase oil capacity may vary slightly ALWAYS fill crankcase to full mark or within crosshatch on dipstick whichever is present DO NOT overfill puree FDO00047 UN 13MAR96 Oil dipstick IMPORTANT Immediately after completing any oil change crank engine for 30 seconds without permitting engine to start This will help insure adequate lubrication to engine components before engine starts 7 Start engine and run to check for possible leaks 8 Stop engine and check oil level after 10 minutes If necessary top up DPSG CD03523 29 19 06FEB07 4 4 30 3 061208 PN 8
40. Fuel Pump Not Able to Meet Required Rail Pressure Requested Torque Curve Signal Unreliable Engine in Derate Condition Continued on next page 55 14 Corrective Action Reduce Engine Speed Reduce Engine Speed Check Wiring Check Wiring Check Wiring Check Wiring Check Battery Voltage and Wiring Contact Service Dealer Check Sensor and Wiring Check Sensor and Wiring Check Sensor and Wiring Check Sensor and Wiring Check Sensor and Wiring Check Sensor and Wiring Check Sensor and Wiring Contact Servicing Dealer Check Injector Wiring or Injector Solenoid Check Injector Wiring or Injector Solenoid Injector Failed or Flow Limiter Closed Check Injector Wiring or Injector Solenoid Check Injector Wiring or Injector Solenoid Injector Failed or Flow Limiter Closed Check Injector Wiring or Injector Solenoid Check Injector Wiring or Injector Solenoid Injector Failed or Flow Limiter Closed Check Injector Wiring or Injector Solenoid Check Injector Wiring or Injector Solenoid Injector Failed or Flow Limiter Closed Check Injector Wiring or Injector Solenoid Check Injector Wiring or Injector Solenoid Injector Failed or Flow Limiter Closed Check Injector Wiring or Injector Solenoid Check Injector Wiring or Injector Solenoid Injector Failed or Flow Limiter Closed Contact Servicing Dealer Not Engine Fault Check Other Shutdown Devices Not Engine Fault Check Other Shutdown Devices Contact Servicing Dealer Contact Servicing Dealer Chec
41. G CD03523 36 19 31JAN07 3 4 e 6 Cylinder Engine NOTE Firing order is 1 5 3 6 2 4 Lock No 1 piston at TDC compression stroke B Adjust valve clearance on No 1 3 and 5 exhaust valves and No 1 2 and 4 intake valves Rotate flywheel 360 Lock No 6 piston at TDC compression stroke C Adjust valve clearance on No 2 4 and 6 exhaust valves and No 3 5 and 6 intake valves RG4777 UN 310CT97 A Front of engine B No 1 Piston at TDC compression stroke C No 6 Piston at TDC compression stroke E Exhaust valve I Intake valve DPSG CD03523 36 19 31JAN07 4 4 40 2 061208 PN 96 Maintenance 2000 hours 2 years Checking engine speed Mechanical fuel system NOTE Most engines for generator set application 1500 rom for 50 Hz or 1800 rpm for 60 Hz run only at fast idle and therefore they do not have slow idle Specification Fast idle 50 Hz Generator set 1550 1580 rpm 60 Hz Generator set 1865 1890 rpm CD30763 UN 24SEP99 NOTE Fast idle is settled by the factory then the idle adjusting screw A is sealed to prevent from tampering Fast idle adjustment can only be done A Fast idle adjusting screw by an authorized fuel system agent DPSG CD03523 38 19 31JAN07 1 1 Adjust speed droop governor Mechanical fuel system Warm engine to normal operating temperature Run engine at fast idle Apply full load If specified power cannot be obtained turn screw
42. HFS83 HPCR System 2 Valve Head CD4045HFU72 DE10 Fuel System CD4045HFU79 HPCR System 2 Valve Head CD4045TFU70 Mechanical Fuel System CD6068HFS72 DE10 Fuel System CD6068HFS73 HPCR System 2 Valve Head CD6068HFS76 HPCR System 4 Valve Head CD6068HFS77 HPCR System 4 Valve Head CD6068HFS82 HPCR System 2 Valve Head CD6068HFS83 HPCR System 2 Valve Head CD6068HFS89 HPCR System 4 Valve Head CD6068HFU72 DE10 Fuel System CD6068HFU74 HPCR System 4 Valve Head CD6068HFU79 HPCR System 2 Valve Head ON mama lst READ THIS MANUAL carefully to learn how to operate and service your engine correctly Failure to do so could result in personal injury or equipment damage THIS MANUAL SHOULD BE CONSIDERED a permanent part of your engine and should remain with the engine when you sell it MEASUREMENTS IN THIS MANUAL are given in metric Use only correct replacement parts and fasteners Metric and inch fasteners may require a specific metric or inch wrench WRITE ENGINE SERIAL NUMBERS and option codes in the spaces indicated in the Serial Number 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 or machine RIGHT HAND AND LEFT HAND sides are determined by standing at the drive or flywheel end rear of the engine and facing toward the front of the engine SETTING FUEL DELIVERY beyond published factory
43. IMPORTANT Ignoring active trouble codes can result in severe engine damage 4 To acknowledge and hide the code and return to the single or four parameter display press the Enter Key 5 The display will return to the single or four parameter display but the display will contain the warning icon Pressing the Enter key will redisplay the hidden trouble code IMPORTANT Ignoring active trouble codes can result in severe engine damage 6 Pressing the Enter key once again will hide the trouble code and return the screen to the single or four parameter display 1 of x WARNING SPN 94 FMI 18 FAULT FUEL DELIVERY PRESSURE CORRECTIVE ACTION CHECK FUEL FILTER AND LINES lt NEXT gt Use Arrow Keys To Scroll RG13241 UN 30SEP03 OURGP11 00000AD 19 03SEP03 3 7 1 of x WARNING SPN 94 FMI 18 FAULT FUEL DELIVERY PRESSURE CORRECTIVE ACTION CHECK FUEL FILTER AND LINES lt NEXT gt Hide Trouble Codes RG13242 UN 30SEP03 OURGP11 00000AD 19 03SEP03 4 7 98 LOAD RPM 1800 RPM aeia COOL TEMP BAT VOLT 14 2 1000 RPM ENG RPM 57 PSI Olt PRES OCO OCD Active Trouble Code Icon RG13176 UN 26SEP03 OURGP11 00000AD 19 03SEP03 5 7 WARNING SPN 94 FMI 18 CORRECTIVE ACTION CHECK FUEL FILTER AND LINES lt NEXT gt Enter Key RG13242 UN 30SEP03 Continued on next page OURGP11 00000AD 19 03SEP03 6 7 15 9 061208 PN 50 Op
44. In oe eee 10 3 D ee ase a a m cae ee eee ee ese ve nee 10 4 Bicily ee ee ee ee ee ee re 30 1 Engine speed Mechanical fuel system 40 3 B Engine wiring layout With Denso High Pressure Common Rail 55 3 aa With Stanadyne DE10 pump 55 2 elt Check automatic tensioner 35 2 Check TENSION sc oa ore a aaa anana 30 6 Replace 4045 and 6068 engines 50 5 F Break in engine oil cn eesoond eden e saw ewes 10 3 Fuel PG SOI ae acs peas act Se Ee Sh Ms sg we 10 1 Handling and StIOMNGs oa ou 2c oo a a ems suas 10 2 C Fuel filter Replacement nannan anana 30 4 Sa Fuel pump model number 03 5 Configuration data viewing 15 4 Fuel system Coolant Bleeding 0 0 c eee e cece eee e es 50 6 Diesel engine 0 cee ee 10 6 Drain and flush cooling system 45 1 Pressure testing cooling system 35 6 Warm temperature climates 10 6 Crankcase vent tube Aedan ecae ae care a A 35 1 Identification views 01 1 01 2 Instrument panel Adjust backlighting 05 15 11 Adjust contrast o oc5cce2e4eeeee02244748 15 13 D Changing units of measure 15 15 Main menu navigation 06 15 2 Setup 1 up display 15 18 Damper CEPET 40 4 Setup 4 up display o o uouo 15 24 Diagnostic procedure 00008 55 12 Chili dow GOGGS da oc ac a oc c
45. JN N Q Olojo jojo O O1 O F oO nyo MNIAINJOJO N io ao o o a o O1 N o_o O N N OJo o_o O O1 CO O o O _ o_o s N O O 1625 2325 29 215 2100 3200 2350 4050 3000 3750 2770 4750 3500 Shear bolts are designed to fail under predetermined loads Always replace shear bolts with identical property class Replace fasteners with the same or higher property class If higher property class fasteners are used tighten these to the strength of the original Make sure fastener threads are clean and that you properly start thread engagement When possible lubricate plain or zinc plated fasteners other than lock nuts wheel bolts or wheel nuts unless different instructions are given for the specific application O O O l AA Lubricated means coated with a lubricant such as engine oil fasteners with phosphate and oil coatings or M20 and larger fasteners with JDM F13C zinc flake coating Dry means plain or zinc plated without any lubrication or M6 to M18 fasteners with JDM F13B zinc flake coating 65 DX TORQ2 19 24APR03 1 1 10 061208 PN 136 Index Page Page A E Air filter Engine Clean or replace element 50 4 Operation irae areas Saas Si 15 34 Clean or replace one piece 50 3 Engine Control Unit ECU serial number 03 5 Air intake system Engine oll CHECKING 254554554552 5045o7eRn0ene05 35 1 Break
46. N 26AUG99 Continued on next page DPSG CD03523 27 19 07FEBO7 3 4 25 2 061208 PN 80 Maintenance Daily or every 10 hours 6 NOTE Engines with mechanical fuel system have a single fuel filter while electronically controlled i engines DE10 and HPCR fuel systems have two P fuel filters primary and final Moreover these a JOHN DEEF electronically controlled engines may be equipped with a water sensor at the fuel filters An indicator D gt es light on the instrument panel will signal the Ban aren operator that water should be drained from filter f bowls CD30929 UN 07FEB07 Check fuel filters C and D for water and debris as i g 4 n 4 5 meco30929 follows Drain fuel filter s a Loosen drain plug s A at bottom of fuel filter s or A Drain plug bowl s two or three turns B Air bleed plug C Primary fuel filter D Final fuel filter Loosen air bleed plug s B two full turns and drain water into a suitable container When fuel starts to drain out tighten drain plug s securely Bleed fuel system DPSG CD03523 27 19 07FEB07 4 4 25 3 061208 PN 81 Maintenance 500 hours Changing engine oil and filter IMPORTANT Filtration of oils is critical to proper lubrication Always change filter regularly Use filter meeting John Deere performance specifications NOTE Change engine oil and filter for the first time after 100 hours maximum of operation then every 50
47. NGER identifies the most serious hazards DANGER or WARNING safety signs are located near A WARNING specific hazards General precautions are listed on CAUTION safety signs CAUTION also calls attention to safety messages in this manual A CAUTION DX SIGNAL 19 O3MAR93 1 1 TS187 19 30SEP88 Do Not Open High Pressure Fuel System High pressure fluid remaining in fuel lines can cause serious injury Do not disconnect or attempt repair of fuel lines sensors or any other components between the high pressure fuel pump and nozzles on engines with High Pressure Common Rail HPCR fuel system Only technicians familiar with this type of system can perform repairs See your John Deere dealer a TS1343 UN 18MAR92 DX WW HPCR1 19 07JANO3 1 1 05 1 061208 PN 26 Safety Engine lifting procedure CAUTION The only recommended method for lifting the engine is with JDG23 Engine Lifting Sling A and safety approved lifting straps B that come with engine Use extreme caution when lifting and NEVER permit any part of the body to be positioned under an engine being lifted or suspended RG7784 UN 11NOV97 Lift engine with longitudinal loading on lifting sling and lifting straps only Angular loading greatly reduces lifting capacity of sling and straps NOTE If engine does not have lifting straps universal straps can be procured through service parts under part numbers JD 244 1 and JD 244 2 1 If not
48. O o O O l on NO on O O 155 175 3 N oO oO OJS olola oO O O1 Ce O O O O1 3 oO N O O oh O1 O O a o O 0 O O G 75 1280 O Q O 3 1200 70 1250 214 1580 2000 3400 2500 2250 1650 2850 2100 3600 2650 4550 3350 Replace fasteners with the same or higher grade If higher grade fasteners are used tighten these to the strength of the original Make sure fastener threads are clean and that you properly start thread engagement When possible lubricate plain or zinc plated fasteners other than lock nuts wheel bolts or wheel nuts unless different instructions are given for the specific application 5 D N S co D No A ho S o O co on al BEE Grade 1 applies for hex cap screws over 6 in 152 mm long Lubricated means coated with a lubricant such as engine oil fasteners with phosphate and oil coatings or 7 8 in and larger fasteners with JDM F13C zinc flake coating Dry means plain or zinc plated without any lubrication or 1 4 to 3 4 in fasteners with JDM F13B zinc flake coating 65 9 DX TORQ1 19 24APR03 1 1 061208 PN 135 Specifications Metric Bolt and Screw Torque Values TS1670 UN 01MAY03 Lubricated UO lt o Class 8 8 or 9 8 Lubricated UO lt o Class 10 9 Lubricated Class 12 9 Lubricated J
49. ODES Some engines display Service Codes or DTCs as 2 digit codes read from a fault lamp which gives blink codes SPN FMI CODES Stored and active diagnostic trouble codes are output on the diagnostic gauge on the Deere electronic instrument panel according to the J1939 standard as a two part code as shown on the tables on the following pages The first part is a six digit Suspect Parameter Number SPN followed by a two digit Failure Mode Identifier FMI code In order to determine the exact failure both parts SPN and FMI of the code are needed 55 10 The SPN identifies the system or the component that has the failure for example SPN 000110 indicates a failure in the engine coolant temperature circuit The FMI identifies the type of failure that has occurred for example FMI 03 indicates value above normal Combining SPN 000110 with FMI 03 yields engine coolant temperature input voltage too high or the equivalent of 2 digit fault code 18 If diagnosing an application that shows DTCs as SPNs and FMls using the following list determine the equivalent 2 digit code and have your dealer use the diagnostic procedure in the component technical manual for that 2 digit code Always contact your servicing dealer for help in correcting diagnostic trouble codes which are displayed for your engine CD03523 0000190 19 O2FEBO7 1 1 061208 PN 119 Troubleshooting Using blink code method for retrieving Diagnostic Troub
50. Oil Filler Neck Cylinder Head With Valves i _ Crankshaft Pulley 52 Auxiliary Gear Drive 14 Flywheel Housing 53 Fuel Heater 15 Flywheel 54 Oil heater 16_ Fuel Injection Pump 55 Shipping stand 17 Air inlet 56 Paint Option 18 Air cleaner 57 Coolant Inlet 19 Oil pan 59 Oil Cooler 20 Coolant pump 60_ Add on Auxiliary Drive Pulley a1 Thermostat Cover 62 Alternator Mounting 22 Thermostat 63 Low Pressure Fuel Line ie Fan Drive 64 Exhaust Elbow 24 Fan Belt 65 Turbocharger 25 Fan 66 Temperature Switch 260 Engine Coolant Heater 67_ Electronic Tachometer Sensor al Radiator 68 Damper 26 Exhaust Manifold 69 Engine Serial Number Plate 29 Ventilator System 72 ECU Electronic Software Option 30 Starting Motor 74_ Air conditioner Compressor Mounting 31 Alternator 75 Air Restriction Indicator 32 Instrument Panel 76 Oil Pressure Switch 39 Fuel Filter Sot Primary Fuel Filter 36 Front Plate 83 Electronic Software 37 Fuel Transfer Pump 84 Electrical Wiring Harness 39 Thermostat Housing 86 Fan Pulley 40 Oil Dipstick 87_ Automatic Belt Tensioner 41 Belt Driven Front Auxiliary Drive 88 Oil Filter 43 Starting Aid 91 Special Equipment Factory Installed 44 Timing Gear Cover with Gears 94 Vehicle Timing 45 Balancer Shaft 95 Identification label 46_ Cylinder Block With Liners and Camshaft 97 Special Equipment Field Installed 47 Crankshaft and Bearings 98 Shipping 48 Connecting Rods and Pistons 49 Valve Actuating Mechanism
51. Power Units for Generator Sets Stage Il and Non Certified Engines Saran Built OPERATOR S MANUAL Power Units for Generator Sets Stage Il and Non Certified Engines Saran Built OMCD16564 Issue F8 ANGLAIS CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm If this product contains a gasoline engine A WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm The State of California requires the above two warnings John Deere Usine De Saran This manual replaces OMCD16564 B7 European Version Printed in Germany Introduction Foreword THIS MANUAL COVERS the following engines for generator sets Non Emission Certified Engines Mechanical Fuel System CD3029DF 128 CD3029TF158 CD4039DF008 CD4039TF008 CD4045DF 158 CD4045HF 158 CD4045TF158 CD4045TF258 CD6068HF 158 CD6068HF258 CD6068TF158 CD6068TF258 Emission Certified Engines Stage Il according to Directive 97 68 EC CD3029HFS70 Mechanical Fuel System CD3029HFU70 Mechanical Fuel System CD3029TFS70 Mechanical Fuel System CD3029TFU70 Mechanical Fuel System CD4045HFS72 DE10 Fuel System CD4045HFS73 HPCR System 2 Valve Head CD4045HFS80 Mechanical Fuel System CD4045HFS82 HPCR System 2 Valve Head CD4045
52. RPM 57 PSI BAT VOLT OIL PRES RG13229 UN 26SEP03 List Of Engine Parameters OURGP11 00000B2_ 19 03SEP03 8 14 9 The parameter that is highlighted is the selected ENGINE SPEED 3 The number to the right of the parameter for the screen Use the arrow keys to ENGINE HOURS parameter indicates the quadrant abst i ENGINE COOLANT TEMPERATURE 1 in which it is displayed highlight the new parameter to be placed in the 4 Up BATTERY POTENTIAL 1 Upper Left Quadrent Display ENGINE OIL TEMPERATURE 2 Lower Left Quadrent ENGINE OIL PRESSURE 3 Upper Right Quadrent 4 Lower Right Quadrent RG13230 UN 26SEP03 OGP Select Desired Engine Parameter Continued on next page OURGP11 00000B2 19 03SEP03 9 14 15 27 061208 PN 68 Operating the Engine 10 Press the Enter key to change the selected ENGINE SPEED 3 parameter in the quadrant to the new parameter ENGINE HOURS ENGINE COOLANT TEMPERATURE 1 BATTERY POTENTIAL 2 ENGINE OIL TEMPERATURE ENGINE OIL PRESSURE coq Enter Selected Parameter OURGP11 00000B2 19 03SEP03 10 14 RG13231 UN 26SEP03 11 Use the Menu keys to return to the 4 Up Custom ENGINE SPEED 3 Setup screen ENGINE HOURS ENGINE COOLANT TEMPERATURE 1 BATTERY POTENTIAL ENGINE OIL TEMPERATURE Note the number to the right of ENGINE OIL PRESSURE the selected parameter indicating that the parameter is now assigned to that display location RG13232 UN 26SEP03 QOO Return To
53. RTANT Continued on next page DO NOT fill above the crosshatch area Oil levels anywhere within crosshatch are considered in the acceptable operating range DPSG CD03523 27 19 07FEBO7 1 4 061208 PN 79 Maintenance Daily or every 10 hours TS281 UN 23AUG88 CD30756 UN 26AUG99 hands Slowly loosen cap to first stop to relieve pressure before removing completely CAUTION Explosive release of fluids from pressurized cooling system can cause serious burns Remove radiator cap E and check coolant level which should be at bottom of filler neck Fill radiator with proper coolant solution if level is low See DIESEL ENGINE COOLANT Check entire cooling Only remove filler cap when engine is cold system for leaks or when cool enough to touch with bare DPSG CD03523 27 19 07FEB07 2 4 If air filter has a dust unloader valve C squeeze valve tip to release any trapped dirt particles Check air intake restriction indicator D When indicator is red air filter needs to be cleaned IMPORTANT Maximum air intake restriction is 6 25 kPa 0 06 bar 1 0 psi 25 in H20 A clogged air cleaner element will cause excessive intake restriction and a reduced air supply to the engine RG4687 UN 20DEC88 5 Make a thorough inspection of the engine compartment NOTE Wipe all fittings caps and plugs before performing any maintenance to reduce the chance of system contamination CD30757 U
54. System voltage Percent engine load at the current rom Coolant temperature Oil pressure Throttle position Intake manifold temperature Current fuel consumption Active service diagnostic codes Stored service diagnostic codes from the engine Set the units for display View the engine configuration parameters 15 1 S m ep S Zz T D 2 O Diagnostic Gauge A Diagnostic Gauge B Menu Key C Arrow Keys D Enter Key E Red STOP ENGINE Indicator Light F Amber WARNING Indicator Light Continued on next page CD03523 000018B 19 22JANO07 1 2 061208 PN 42 Operating the Engine NOTE Engine parameters which can be accessed will vary with the engine application Six languages for readouts are available and can be selected during setup of gauge The diagnostic gauge includes a graphical backlit Liquid Crystal Display LCD screen The display can show either a single parameter or a quadrant display showing four parameters simultaneously The diagnostic gauge uses two arrow keys C for scrolling through the engine parameter list and viewing the menu list and an enter key D for selecting highlighted items The red E and amber F lights are used to signal active trouble code received by the diagnostic gauge Main Menu Navigation NOTE The engine does not need to be running to navigate the diagnostic gauge screens If engine start up is desired See Starting The Engine All of the
55. TC s 55 12 Listing of Diagnostic Trouble Codes DTCs 55 13 Intermittent Fault Diagnostics With Electronic Controls 22s0 eensavaneenct 55 15 Page Storage Engine storage guidelines 60 1 Preparing engine for long term storage 60 1 Removing engine from long term storage 60 2 Specifications General engine pack specifications Non Emission Certified Engines 65 1 General engine pack specifications Stage Il Emission Certified Engines 65 4 Unified Inch Bolt and Screw Torque Values 65 9 Metric Bolt and Screw Torque Values 65 10 061208 PN 2 Identification Views Identification views OJANO D30840 UN CD30840 3029DF 128 Continued on next page DPSG CD03523 3 19 22JAN07 1 3 01 1 061208 PN 7 CD30841 Identification Views 4045HF 158 Continued on next page 01 2 UN 10OJANO DPSG CD03523 3 19 22JAN07 2 3 061208 PN 8 CD30842 Identification Views 6068HF258 01 3 UN 10OJANO DPSG CD03523 3 19 22JANO07 3 3 061208 PN 9 Maintenance Records Using maintenance records To obtain the best performance economy and service John Deere oils and coolants have been formulated to life from your engine ensure service is carried out give maximum protection and performance to your according to this present manual and recorded in the engine We recommend only genuine John Deere fo
56. ad an active DTC 18 and stored DTC 53 the flashing sequence would be flash three times short pause flash two times long pause flash one time short pause flash eight times long pause flash three times short pause flash three times long pause flash five times short pause flash three times CD03523 0000191 19 O2FEBO7 1 1 061208 PN 120 Troubleshooting Using diagnostic gauge for retrieving Diagnostic Trouble Codes DTC s NOTE The method below applies on applications having the optional diagnostic gauge shown refer to the generator documentation for more information 1 Make sure all engine mechanical and other systems not related to the electronic control system are operating properly See ENGINE TROUBLESHOOTING in this section NOTE Diagnostic gauge A uses the menu key B to access various engine functions two arrow keys RG13740 UN 11NOV04 C to scroll through the engine parameter list and Trouble Code Display On Instrument Panel view the menu list and an enter key D for selecting highlighted items A Diagnostic Gauge B Menu Key C Arrow Keys 2 Read and record DTC s displayed on LCD of D Enter Key diagnostic gauge A For procedure to access diagnostic trouble codes refer to Using Diagnostic Gauge to Access Engine Information earlier in this manual 3 Go to the LISTING OF DIAGNOSTIC TROUBLE CODES DTCs later in this section to interpret
57. anister IMPORTANT Do not attempt to clean the secondary safety element B It must be only replaced as recommended 3 Thoroughly clean all dirt from inside canister IMPORTANT If primary element shows evidence of bad condition punched CD30772 UN 27AUG99 C Air restriction indicator D Wing nut 50 4 dented replace both the primary and the secondary elements 4 Clean primary element with compressed air working from clean to dirty side NOTE Compressed air pressure must not exceed 600 kPa 6 bar 88 psi 5 Mark air filter to keep track of each cleaning operation 6 Fully depress air restriction indicator reset button and release to reset indicator 7 Check air system entirely for proper condition see CHECKING AIR INTAKE SYSTEM DPSG CD03523 58 19 22JAN07 1 1 061208 PN 105 Maintenance As required Replacing fan and alternator belt 4045 and 6068 Engines NOTE Refer to CHECKING BELT TENSIONER SPRING TENSION AND BELT WEAR for additional information on the belt tensioner 1 Inspect belts for cracks fraying or stretched out areas Replace if necessary 2 op 2 On engines with automatic belt tensioner release 5 tension on belt using a breaker bar and socket on tension arm gt O On engines with manual tensioner loosen cap screws Installation on 4045 engines holding the alternator 3 Remove poly V belt from pulleys and discard belt 4 Install new b
58. ar frame 3 Using the gauge A on the alternator bracket stretch belt by prying outward on alternator front frame Stretch the belt 1 gauge unit for a used belt and 1 5 gauge units for a new belt Tighten cap screws B and C A Belt gauge B Cap screw C Cap screw CD30843 D Reference mark E Alternator upper bracket notch Reference marks rick 3 Nt f a Y RG9132 UN 040CT99 CD30843 UN 10JAN03 DPSG CD03523 57 19 30JAN07 1 1 30 7 061208 PN 88 Maintenance 1000 hours 1 year Cleaning crankcase vent tube If you operate the engine in dusty conditions clean the tube at shorter intervals 1 Remove and clean crankcase vent tube A 2 Install the vent tube Be sure the O ring fits correctly in the rocker arm cover for elbow adapter Tighten hose clamp securely CD30773 UN 27AUG99 ii DPSG CD03523 32 19 22JAN07 1 1 Checking air intake system O O oO D lt N a Z D l N N m Q O IMPORTANT The air intake system must not leak Check clamps on piping A which connect the air Any leak no matter how small may filter engine and if present turbocharger and result in engine failure due to air to air radiator Tighten clamps as necessary abrasive dirt and dust entering the intake system Test air restriction indicator B for proper operation Replace indicator as necessary 1 Inspect all intake hoses piping for cracks Replace as necessary
59. ast 5 C 9 F below the expected lowest temperature or Cloud Point below the expected lowest ambient temperature Fuel lubricity should pass a maximum scar diameter of 0 45 mm as measured by ASTM D6079 or ISO 12156 1 Sulfur content Diesel fuel quality and fuel sulfur content must comply with all existing emissions regulations for the area in which the engine operates e Use of diesel fuel with sulfur content less than 0 10 1000 ppm is STRONGLY recommended e Use of diesel fuel with sulfur content 0 10 1000 ppm to 0 50 5000 ppm may result in REDUCED oil and filter change intervals as shown in the table e BEFORE using diesel fuel with sulfur content greater than 0 50 5000 ppm contact your John Deere dealer IMPORTANT Do not mix used diesel engine oil or any other type of lubricating oil with diesel fuel IMPORTANT Improper fuel additive usage may cause damage on fuel injection equipment of diesel engines DX FUEL1 19 050CT07 1 1 10 1 061208 PN 36 Fuels Lubricants and Coolant Handling and Storing Diesel Fuel When using bio diesel fuel the fuel filter may require CAUTION Handle fuel carefully Do not fill more frequent replacement due to premature plugging the fuel tank when engine is running Check engine oil level daily prior to starting engine A rising oil level may indicate fuel dilution of the engine oil DO NOT smoke while you fill the fuel tank or service the fuel system
60. ausing at each OURGP11 00000B1 19 03SEP03 4 18 5 Use Defaults To select Use Defaults use the Arrow maaa f as USE DEFAULTS keys to scroll to and highlight Use Defaults in the CUSTOM SETUP menu display AUTOMATIC SCAN OFF RG13195 UN 26SEP03 Select Defaults Continued on next page OURGP11 00000B1 19 O3SEP03 5 18 15 19 061208 PN 60 Operating the Engine 6 Press the Enter key to activate the Use Defaults USE DEFAULTS function CUSTOM SETUP AUTOMATIC SCAN OFF RG13197 UN 29SEP03 Defaults Selected OURGP11 00000B1 19 03SEP03 6 18 7 The display parameters are reset to the factory defaults then the display will return to the Setup 1 Up Display menu RESTORED TO DEFAULTS Restored To Defaults RG13149 UN 24SEP03 OURGP11 00000B1 19 03SEP03 7 18 8 Custom Setup To perform a custom setup of the USE DEFAULTS 1 Up Display use the arrow buttons to scroll to and CUSTOM SETUP highlight Custom Setup on the display AUTOMATIC SCAN OFE RG13198 UN 26SEP03 OGPO Select Custom Setup Continued on next page OURGP11 00000B1 19 03SEP03 8 18 15 20 061208 PN 61 Operating the Engine 9 Press the Enter key to display a list of engine parameters IUSE DEFAULTS CUSTOM SETUP AUTOMATIC SCAN OFF RG13199 UN 26SEP03 OTO Engine Parameters OURGP11 00000B1 19 03SEP03 9 18 10 Use the Arrow keys to scroll to and highlight a ENGINE SPEED sel
61. be displayed Use the Arrow keys GO TO 1 UP DISPLAY to scroll through the menu until Stored Codes is STORED CODES highlighted ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT Select Stored Codes RG13168 UN 02OCT03 Continued on next page OURGP11 00000AC 19 03SEP03 2 6 15 6 061208 PN 47 Operating the Engine 3 Once the Stored Codes menu item has been GO TO 1 UP DISPLAY highlighted press the Enter key to view the stored STORED CODES codes ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT TT Enter Key RG13169 UN 02O0CT03 OURGP11 00000AC 19 03SEP03 3 6 4 If the word Next appears above the Arrow keys dofx there are more stored codes that may be viewed Use SPN 94 FMI 18 the Arrow key to scroll to the next stored code PAULE FUEL DELIVERY PRESSURE CORRECTIVE ACTION CHECK FUEL FILTER AND LINES lt NEXT gt OCPO Use Arrow Keys To Scroll RG13245 UN 020CT03 OURGP11 00000AC 19 03SEP03 4 6 5 Press the Menu key to return to the main menu dofx SPN 110 FMI 16 FAULT ENGINE COOLANT TEMERATURE HIGH CORRECTIVE ACTION CHECK COOLING SYSTEM REDUCE POWER lt NEXT gt HIDE ooO Return To Main Menu RG13246 UN 020CT03 Continued on next page OURGP11 00000AC 19 03SEP03 5 6 15 7 061208 PN 48 Operating the Engine 6 Press the Menu key to exit t
62. case oil dilution due to incomplete fuel combustion and permits formation of gummy deposits on valves pistons and piston rings It also promotes rapid accumulation of engine sludge and unburned fuel in the exhaust system If an engine will be idling for more than 5 minutes stop and restart later NOTE Generator set applications have the governor locked at a specified speed and do not have a Slow idle function These engines idle at no load governed speed fast idle DPSG CD03523 21 19 22JAN07 1 1 weeks DO NOT allow engine to run extended period of time with no load DPSG CD03523 22 19 22JAN07 1 1 061208 PN 75 Operating the Engine Stopping the engine 1 Before stopping run engine for at least 2 minutes at fast idle and no load 2 Stop the engine DPSG CD03523 23 19 22JAN07 1 1 Changing Generator Frequency Generator sets powered by 6068HFU74 engine are dual frequency 50 Hz 1500 rpm or 60 Hz 1800 rpm Refer to the generator set documentation for more information CD03523 000018C 19 26JAN07 1 1 15 35 061208 PN 76 Maintenance Observe service intervals Using hour meter as a guide perform all services at IMPORTANT Recommended service intervals are the hourly intervals indicated on following pages At for normal operating conditions each scheduled maintenance interval perform all Service MORE OFTEN if engine is previous maintenance operations in addition to the operated u
63. cec ncec ces 15 10 Using diagnostic gauge 15 1 Using diagnostic gauge 15 1 Diagnostic Trouble Codes DTCs 55 13 Viewing active service codes 15 8 Diagnostic trouble codes DTCs Viewing configuration data 15 4 Active engine service codes viewing 15 8 Viewing stored service codes 15 6 Diagnostic Trouble Codes DTCs Intermittent fault diagnostics 55 15 Diagnostic gauge 00 e eee 55 12 Diagnostic trouble codes DTCs Stored service codes viewing 15 6 Diesel engine Oil 2 2 0 00 eee eee 10 4 L Diesel WC cccce nee ee opera peeks 10 1 DTCs Diagnostic Trouble Codes Listing of DTCs os sa58 o8 2 a eee one ee 55 13 View active service codes 15 8 Lubricant View stored service codes 15 6 PVCU eg se est ee et Gre en posi ate ae ae Sar 10 5 Index 1 061208 PN 1 Index Page Page Slorag s teen ee ewes ea A 10 5 S Serial number Wi Engine Control Unit ECU 03 5 High pressure fuel pump 03 5 Serial numbers Maintenance Engine Control Unit ECU serial number 03 5 AS required i l Engine option codes 00008 03 3 Additional service information Tere re 50 1 Engine serial number plate 03 1 Clean or replace air filter element EEE 50 4 Fuel pump model number 03 5 Clean or replace air filter o
64. cement is thought to be required NOTE The engine control unit ECU is the component LEAST likely to fail Suggestions for diagnosing intermittent faults 55 15 e If the problem is intermittent try to reproduce the operating conditions that were present when the diagnostic trouble code DTC set If a faulty connection or wire is suspected to be the cause of the intermittent problem clear DTCs then check the connection or wire by wiggling it while watching the diagnostic gauge to see if the fault resets Possible causes of intermittent faults Faulty connection between sensor or actuator harness e Faulty contact between terminals in connector e Faulty terminal wire connection e Electromagnetic interference EMI from an improperly installed 2 way radio etc can cause faulty signals to be sent to the ECU NOTE Refer also to generator documents for more information about connections and wirings CD03523 0000193 19 O5FEBO7 1 1 061208 PN 124 Storage Engine storage guidelines 1 John Deere engines can be stored outside for up to John Deere engines expected to be stored more three 3 months with no long term preparation IF than six 6 months long term storage preparation COVERED BY WATERPROOF COVERING MUST BE taken See PREPARING ENGINE FOR LONG TERM STORAGE John Deere engines can be stored in a standard overseas shipping container for up to three 3 months with no long term preparation
65. change the oil filter see CHANGING ENGINE OIL AND FILTER Fill crankcase with seasonal viscosity grade oil see DIESEL ENGINE OIL Check tension of alternator belt Check connections of air intake hoses Check for proper tightening of cap screws all around the engine DPSG CD03523 17 19 22JAN07 1 1 15 29 061208 PN 70 Operating the Engine Starting the engine f CAUTION Before starting engine in a 2 Open the fuel supply shut off valve if equipped confined building install proper outlet exhaust ventilation equipment Always use safety approved fuel storage and piping 3 Activate the starter motor switch to crank the engine and release it as soon as engine starts NOTE Do not operate the starter motor more than 20 NOTE If temperature is below 0 C 32 F it may seconds Fane be necessary to use cold weather starting aids See COLD WEATHER OPERATION 1 Perform all prestarting checks outlined in Maintenance Daily Section DPSG CD03523 18 19 22JAN07 1 1 Cold weather operation Depending on equipment various cold weather starting aids are available to assist in starting the engine at temperature below 0 C 32 F Continued on next page DPSG CD03523 19 19 O6FEBO7 1 4 1 5 30 061208 PN 71 Operating the Engine Air intake heater CAUTION DO NOT use starting fluid on D SG engines equipped with grid type air intake heater or glow plug s Ether starting fluid is highly flam
66. ck Sensor and Wiring Check Air Cleaner Aftercooler or Room Temperature Check for plugged air filter Check Cooling System Reduce Power Check Sensor and Wiring Check Sensor and Wiring Check Cooling System Reduce Power Check Cooling System Reduce Power Check Operators Manual Adding Coolant Contact Servicing Dealer Contact Servicing Dealer Add Fuel or Switch Fuel Tanks Check Sensor and Wiring Check Sensor and Wiring Add Fuel or Switch Fuel Tanks Check Fault Codes or Contact Servicing Dealer Continued on next page OURGP12 00001E2 19 15MAR06 1 3 55 13 061208 PN 122 SPN 000190 000611 000620 000627 000629 000636 000637 000639 000651 000652 000653 000654 000655 000656 000898 000970 000971 001069 001079 001080 001109 001110 001347 001568 001569 FMI 00 16 03 04 03 04 01 13 02 08 10 02 07 08 10 13 05 06 07 05 06 07 05 06 07 05 06 07 05 06 07 05 06 07 09 31 31 09 31 03 04 03 04 31 31 03 05 07 02 31 Troubleshooting Description of Fault Engine Speed Extremely High Engine Speed Moderately High Injector Shorted to Power Injector Shorted to Ground Sensor Supply 2 Voltage High Sensor Supply 2 Voltage Low All Injector Currents Are Low ECU Programming Error Engine Position Sensor Signal Unreliable Engine Position Sensor Signal Missing Engine Position Sensor Signal Rate of Change Abnormal Engine Tim
67. d 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 accidentally burst when heat goes beyond the immediate flame area 05 8 X9811 UN 23AUG88 DX FLUID 19 O3MAR93 1 1 TS953 UN 15MAY90 DX TORCH 19 10DEC04 1 1 061208 PN 33 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 100 mm 4 in from area to be affected by heating If paint cannot be removed wear an approved respirator before heating or welding lf you sand or grind paint avoid breathing the dust Wear an approved respirator 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 not use a chlorinated solvent in areas where welding will take place Do all work in an area that is well ventilated to carry toxic fumes and dust away Dispose of paint and solvent properly DX PAINT 19 24JULO2 1 1 Service Cooling System Safely Explosive release of fluids from pressurized cooling system can cause
68. d on next page 95 9 Solution Remove accessories or install higher output alternator Increase engine rom when heavy electrical load is used Inspect and clean as necessary Test battery Test charging system Check for moisture and replace as necessary Test battery Test charging system Clean and tighten connections See your authorized servicing dealer or engine distributor Adjust belt tension or replace belts Remove load Clean and tighten loose connections See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor Replace fuse DPSG CD03523 50 19 22JANO07 1 2 061208 PN 118 Troubleshooting Symptom Problem Starter cranks slowly Crankcase oil too heavy Loose or corroded connections Entire electrical system Sulfated or worn out batteries Blown fuse Low battery output Faulty battery connection 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 DPSG CD03523 50 19 22JAN07 2 2 Displaying Of Diagnostic Trouble Codes DTCs There are several different methods for displaying both stored and active DTCs from the ECU via a fault lamp or a diagnostic gauge on the electronic instrument panel 2 DIGIT C
69. e Connector Panel Connections Solenoid C Manifold Air Temperature F Engine Wiring Harness I Fuel Rail Pressure Sensor M Fuel Temperature Sensor MAT Sensor CD03523 000018F 19 02FEBO7 1 1 55 3 061208 PN 112 Engine troubleshooting Symptom Engine cranks but will not start Engine hard to start or will not start Troubleshooting Problem Incorrect starting procedure No fuel Exhaust restricted Fuel filter plugged or full of water Injection pump not getting fuel or air in fuel system Faulty injection pump or nozzles Engine starting under load Improper starting procedure No fuel Air in fuel line Cold weather Slow starter speed Crankcase oil too heavy Improper type of fuel Water dirt or air in fuel system Clogged fuel filter Dirty or faulty injection nozzles Injection pump shut off not reset Continued on next page 55 4 Solution Verify correct starting procedure Check fuel in tank and manual shut off valve Check and correct exhaust restriction Replace fuel filter or drain water from filter Check fuel flow at supply pump or bleed fuel system Consult authorized diesel repair station for repair or replacement Remove load Review starting procedure Check fuel tank Bleed fuel line Use cold weather starting aids See Starter Cranks Slowly Use oil of proper viscosity Consult fuel supplier use proper type fuel for op
70. ected or filters removed it will be necessary to bleed air from the system On dual fuel filter system bleed air only from final filter RG7947 UN 13NOV97 Y 1 Loosen the air bleed screw A two full turns On DE10 ES S 7 fuel system loosen only air bleed screw on final fuel a 4 filter O a aa y 2 Operate supply pump primer lever B until fuel flow is o BY aX free from air bubbles id A Mechanical and DE10 fuel systems al i UN 15JAN99 RG8013A Fuel pump primer lever 3 Tighten bleed screw securely continue operating hand primer until pumping action is not felt 4 Start engine and check for leaks If engine does not start it will be necessary to bleed air from fuel system at fuel injection pump or injection nozzles as explained next Continued on next page DPSG CD03523 46 19 O9FEBO7 1 4 50 6 061208 PN 107 Maintenance As required CD30928 CD30771 UN 24SEP99 T piri CD30928 UN 02FEB07 Mechanical injection pump return line DE10 Fuel return line e At Fuel Injection Pump c Securely tighten return line connector a Slightly loosen fuel return line connector C at fuel injection pump b Operate fuel supply pump primer lever until fuel without air bubbles flows from fuel return line connection DPSG CD03523 46 19 O09FEBO7 2 4 At Fuel Injection Nozzles a Using two open end wrenches loosen fuel line connection at injection nozzle b Crank
71. ected parameter parameter with a number to right PERCENT LOAD AT CURRENT RPM 3 of it ENGINE OIL PRESSURE This number indicates ENGINE COOLANT TEMPERATURE the order of display for the parameters and that the parameter is selected for display OGO Select Parameters RG13150 UN 24SEP03 OURGP11 00000B1 19 03SEP03 10 18 11 Press the Enter key to deselect the selected parameter removing it from the list of parameters being displayed on the 1 Up Display ENGINE SPEED PERCENT LOAD AT CURRENT RPM 3 ENGINE OIL PRESSURE 2 ENGINE COOLANT TEMPERATURE Deselect Parameters RG13219 UN 26SEP03 Continued on next page OURGP11 00000B1 19 03SEP03 11 18 15 21 061208 PN 62 Operating the Engine 12 Use the Arrow keys to scroll and highlight the ENGINE SPEED desired parameter that has not been selected for PERCENT LOAD AT CURRENT RPM 2 display parameter without a number to right of it ENGINE OIL PRESSURE 1 f Note that the numbers ENGINE COOLANT TEMP now indicate the new order of display for the parameters Select Desired Parameters RG13151 UN 24SEP03 OURGP11 00000B1 19 03SEP03 12 18 13 Press the Enter key to select the parameter for inclusion in the Single Engine Parameter Display eee PERCENT LOAD AT CURRENT RPM 2 14 Continue to scroll through and select additional ENGINE OIL PRESSURE 1 parameters for the custom 1 Up Display Press the ENGINE COOLANT TEMP Menu key at a
72. ed cooling system can cause serious burns TS281 UN 23AUG88 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 1 Slowly open the radiator cap 2 Remove engine block drain plug A 3 On POWERTech engines remove oil cooler housing drain plug B 4 Open radiator drain valve C Drain all coolant from radiator RG4894 UN 14DEC88 5 Close all drain orifices after coolant has drained 6 Fill the cooling system with clean water Run engine until water passes through the thermostat to stir up possible rust or sediment 7 Stop engine and immediately drain the water from system before rust and sediment settle 8 After draining water close all drain orifices and fill the cooling system with cleaning product such as ZX016192 PMCC2610 or PMCC2638 Cooling System Cleaners available from your John Deere Dealer Follow manufacturer s directions on label ZX016192 UN 11JAN99 9 After cleaning the cooling system drain cleaner and fill with water to flush the system Run engine until water passes through the thermostat then drain out flushing water CD30765 UN 27AUG99 Continued on next page DPSG CD03523 41 19 O6JUN08 1 3 45 1 061208 PN 99 Maintenance 2500 hours 3 years 10 Check cooling system hoses for proper condition Replace as necessary 11 Close all drain orifices a
73. ee mre ee manne rt Meme meet re EMM nent antennae ere 28 L 29 5 qt G8 e 8 cl ol ce 1 eee manner ene neem een ener team oe eee meee eae 32 L 34 qt EDOS E a oY cc PE eee en eee eee ene AAAA eer nee 32 L 34 qt B S81 ole a aie ZG Renee nen nee ne ere neo aa Ea aii n are eee em 35 L 37 qt GDGOGSHES TT rresten ora e a 35 L 37 qt COCOG elo ae innne aia aR 32 L 34 qt CDCOCORE SO E orreee E E 32 L 34 qt C DGOGSHP OI ososi AAEE 35 L 37 qt GOCOCOSRHPUT 2 erase cect ee aea e ra a a 32 L 34 qt GDGOGORHFU TA sisia aat 35 L 37 qt CD6068HFU79 cree sates recess teceeeceomeemneeseeiessebeveestonsaceenene 32 L 34 qt Continued on next page 45 2 DPSG CD03523 41 19 O6JUN08 2 3 061208 PN 100 Maintenance 2500 hours 3 years 12 When refilling cooling system loosen temperature sensor B or plug at the rear of cylinder head to allow air to escape Run engine until it reaches operating temperature then check coolant level and entire cooling system for leaks ee ro gt lt x t T Xz gt op lt i 9 Q O DPSG CD03523 41 19 06JUN08 3 3 45 3 061208 PN 101 Maintenance As required Additional service information This manual does not allow a complete repair of your Lo SZ Ss engine If you want want more detailed service information ao NGS GE ERS the following publications are available from your regular parts channel amp e PC2451 Parts Catalog for Non Emis
74. elt making sure belt is correctly seated in all pulley grooves Refer to belt routing at right for your application 5 Apply tension to belt See CHECKING BELT gt 6 Start engine and check belt alignment 5 ALT Alternator R CP Crank Pulley S FD Fan Drive O I Idler Pulley Installation on 6068 engines T Tensioner WP Water Pump DPSG CD03523 45 19 31JAN07 1 1 50 5 061208 PN 106 Maintenance 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 X9811 UN 23AUG88 If ANY fluid is injected into the skin it must be i F surgically removed within a few hours by a erf doctor familiar with this type injury or gangrene gq may result Doctors unfamiliar with this type of J A injury may call the Deere amp Company Medical m F Department in Moline Illinois or other knowledgeable medical source Y NOTE Engines with mechanical fuel system have a single fuel filter while electronically controlled engines DE10 and HPCR fuel systems have two fuel filters primary and final Whenever the fuel system has been opened up for service lines disconn
75. ement L 4 5 4 5 4 5 4 5 Compression Ratio 17 6 1 17 0 1 17 0 1 17 0 1 POWER 1500 kW hp 41 56 88 120 61 83 72 98 rom Prime POWER 1500 kW hp 42 57 96 131 68 92 80 109 rom Standby POWER 1800 kW hp 48 65 108 147 72 98 80 109 rom Prime POWER 1800 kW hp 51 69 120 163 79 107 88 120 rom Standby Width overall mm 606 798 606 652 Length overall mm 1038 1209 1191 1225 Height overall mm 959 1197 1027 1027 Weight dry kg 493 599 505 520 Engine oil quantity L 8 12 12 12 Engine coolant L 20 28 25 25 quantity aWith Fan Approximate Continued on next page DPSG CD03523 55 19 05FEB07 2 3 65 2 061208 PN 128 Specifications ITEM UNIT OF 6068HF158 6068HF258 6068TF158 6068TF258 MEASURE Number of 6 6 6 6 Cylinders Fuel Diesel Diesel Diesel Diesel Bore mm 106 5 106 5 106 5 106 5 Stroke mm 127 127 127 127 Displacement L 6 8 6 8 6 8 6 8 Compression 17 0 1 17 0 1 17 0 1 17 0 1 Ratio POWER 1500 kW hp 134 182 160 218 92 125 105 143 rpm Prime POWER 1500 kW hp 148 201 177 241 101 137 116 158 rom Standby POWER 1800 kW hp 164 223 179 243 108 147 124 169 rpm Prime POWER 1800 kW hp 187 254 200 272 119 162 137 186 rom Standby Width overall mm 798 798 652 652 Length overall mm 1500 1500 1364 1364 Height overall mm 1136 1204 1070 1070 Weight dry kg 705 764 651 651 Engine oil quantity L 20 32 20 20 Engine coolant L
76. engine over with starting motor but do not start engine until fuel free from bubbles flows out of loosened connection Retighten connection to 27 Nem 20 Ib ft Repeat procedure for remaining injection nozzles if necessary until all air has been removed from fuel system RG7725 UN O8JAN97 If engine still will not start see your authorized servicing wma AX dealer or engine distributor Bleed fuel system at fuel injection nozzles Continued on next page DPSG CD03523 46 19 O9FEBO7 3 4 50 7 061208 PN 108 Maintenance As required TS1343 UN 18MAR92 RG12220 UN 24MAY02 Po Final fuel filter bleed screw B HPCR fuel system 2 or 4 valve head i lg CAUTION High pressure fluid remaining in fuel lines can cause serious injury Do not disconnect fuel lines between the high pressure fuel pump and nozzles Only bleed the fuel system at the fuel filter bleed screw A a A 1 a 1 Loosen the air bleed screw A two full turns on final filter base only 2 Operate fuel supply pump primer lever B until fuel flow is free from air bubbles RG12221 UN 24MAY02 3 Tighten bleed screw securely Continue operating primer until pumping action is not felt a Fuel supply pump primer lever 4 Start engine and check for leaks If engine will not start repeat steps 1 4 DPSG CD03523 46 19 O09FEBO7 4 4 50 8 061208 PN 109 Troubleshooting General troubleshooting info
77. equipped install lifting straps and torque to 200 Nem 145 Ib ft 2 Attach JDG23 Engine Lifting Sling A to engine lifting straps B and overhead hoist IMPORTANT Lifting straps are designed to lift the engine and accessories such as radiator air filter and other small components If larger components such as power take off transmission generator air compressor etc are attached to engine the lifting straps provided with engine or through parts channel are not intended for this purpose Technician is responsible for providing adequate lifting devices under these situations See machine manuals for additional information on removing engine from machine 3 Carefully move engine to desired location DPSG CD03523 95 19 22JAN07 1 1 05 2 061208 PN 27 Safety 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 par
78. erating 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 DPSG CD03523 49 19 22JAN07 1 5 061208 PN 113 Symptom Engine knocks Engine runs irregularly or stalls frequently Below normal engine temperature Troubleshooting Problem Low engine oil level Injection pump out of time Low coolant temperature Engine overheating Low coolant temperature Clogged fuel filter Water dirt or air in fuel system Dirty or faulty injection nozzles Defective thermostat Defective temperature gauge or sender Continued on next page 95 5 Solution Add oil to engine crankcase See your authorized servicing dealer or engine distributor Remove and check thermostat See Engine Overheats Remove and check thermostat Replace fuel filter element Drain flush fill and bleed system Have authorized servicing dealer or engine distributor check injectors Remove and check thermostat Check gauge sender and connections DPSG CD03523 49 19 22JAN07 2 5 061208 PN 114 Symptom Lack of power Low oil pressure Troubleshooting Problem Engine overloaded Intake air restriction Clogged fuel filter Improper type of fuel Overheated engine Below normal engine temperature Improper valve clearance Dirty or
79. erating the Engine Press the Menu key to return to the main menu 2 E ADJUST CONTRAST RG13187 UN 26SEP03 Return To Main Menu OURGP11 00000AF 19 O03SEP03 5 6 6 Press the Menu key to exit the main menu and return l 98 to the engine parameter display eLA Se 1800 RPM EXeGGI coo TEMP aly a Exit Main Menu RG13159 UN 26SEP03 OURGP11 00000AF 19 O03SEP03 6 6 Selecting Units Of Measurement 98 1000 RPM LOAD RPM ENG RPM 1 Turn the key switch to the ON position Starting at the 1800 RPM single or four engine parameter display press the CIUIN Coot Temp ae gis Menu key Menu Key RG13159 UN 26SEP03 Continued on next page OURGP11 00000BO 19 03SEP03 1 7 15 15 061208 PN 56 Operating the Engine 2 The main menu will be displayed Use the Arrow keys to scroll through the menu until Select Units is highlighted 3 Once the Select Units menu item has been highlighted press the Enter key to access the Select Units function 4 There are three choices for units of measurement English Metric kPa or Metric Bar English is for Imperial units with pressures displayed in PSI and temperatures in F Metric kPa and Metric bar are for IS units with pressures displayed in kPa and bar respectively and temperatures in C Use the Arrow keys to highlight the desired units of measurement GO TO 1 UP DISPLAY STORED CODES ENGINE CONFIG SETUP 1
80. erating the Engine 7 The single or four parameter screen will display the A 98 1000 RPN warning icon until the trouble code condition is LOAD RPN ENG RPM corrected 1800 RPM i 14 2 57 PSI ENG RPM COOL TEMP l BAT VOLT OIL PRES Active Trouble Code Condition RG13243 UN 010CT03 OURGP11 00000AD 19 03SEP03 7 7 Engine Shutdown Codes 98 1000 RPM LOAD RPM ENG RPM 1 During normal operation the single or four parameter 1800 RPM screen will be displayed 57 PSI BAT VOLT OIL PRES Normal Operation RG13172 UN 26SEP03 OURGP11 00000AE 19 03SEP03 1 6 When the diagnostic gauge receives a severe trouble SHUTDOWN 1 of x code from an engine control unit the single or four parameter screen will be replaced with the Shutdown we 199 EM message The SPN and FMI number will be displayed ENGINE OIL PRESSURE LOW along with a description of the problem and the AAV corrective action needed ines TE If the word Next appears above the arrow keys there are more trouble codes that can be viewed by using the arrow keys to scroll to the next trouble code RG13238 UN 29SEP03 Shutdown Message OURGP11 00000AE_ 19 03SEP03 2 6 To acknowledge and hide the trouble code and return SHUTDOWN to the single or four parameter display press the Enter key woo 100 FMI 1 ENGINE OIL PRESSURE LOW CORRECTIVE ACTION o 0 Ge H E7 IMPORTANT Ignoring the shutdown message can result i
81. es it will be necessary to furnish this base code to differentiate two identical option codes for the same engine model The first two digits of each code identify a specific group such as alternators The last two digits of each code identify one specific option provided on your engine such as a 12 volt 55 amp alternator NOTE These option codes are based on the latest information available at the time of publication The right is reserved to make changes at any time without notice If an engine is ordered without a particular component the last two digits of that functional group option code will be 99 00 or XX The list on the next page shows only the first two digits of the code numbers For future reference such as ordering repair parts it is important to have these code numbers available To ensure this availability enter the third and fourth digits shown on your engine option code label in the spaces provided on the following page Continued on next page DPSG CD03523 14 19 22JANO07 1 2 03 3 061208 PN 23 Serial Numbers NOTE NOTE Your engine option code label may not If option code label is lost or destroyed contain all option codes if an option has been consult your servicing dealer or engine added after the engine left the producing distributor selling the engine for a replacement factory Option Description Option Description Codes Codes Engine Base Code 11 Rocker Arm Cover 50 Oil Pump 12
82. evel check radiator and hoses for loose connections or leaks Have serviceman check Check automatic belt tensioner and check belts for stretching Replace as required Check oil level Add oil as required Flush cooling system Remove and check thermostat Check water temperature with thermometer and replace if necessary Use correct grade of fuel 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 DPSG CD03523 49 19 22JAN07 5 5 061208 PN 117 Electrical troubleshooting Symptom Undercharged system Battery uses too much water Batteries will not charge Starter will not crank Troubleshooting Problem Excessive electrical load from added accessories Excessive engine idling Poor electrical connections on battery ground strap starter or alternator Defective battery Defective alternator Cracked battery case Defective battery Battery charging rate too high Loose or corroded connections Sulfated or worn out batteries Stretched poly V belt or defective belt tensioner Engine under load Loose or corroded connections Low battery output voltage Faulty start circuit relay Blown fuse Continue
83. faulty injection nozzles Injection pump out of time Turbocharger not functioning Leaking exhaust manifold gasket Defective aneroid control line Restricted fuel hose Low fast idle speed Low oil level Improper type of oil Continued on next page 55 6 Solution Reduce load Service air cleaner Replace filter elements Use proper fuel See Engine Overheats Remove and check thermostat See your authorized servicing dealer or engine distributor Have authorized servicing 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 Add oil Drain fill crankcase with oil of proper viscosity and quality DPSG CD03523 49 19 22JAN07 3 5 061208 PN 115 Symptom High oil consumption Engine emits white smoke Engine emits black or gray exhaust smoke Troubleshooting Problem 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 Improper type of fuel Clogged or dirty air c
84. he main menu and return 98 4000 Ben to the engine parameter display LOADGRPM ENG RPM 1800 RPM COOL TEMP 14 2 of PSI Exit Main Menu RG13159 UN 26SEP03 OURGP11 00000AC 19 03SEP03 6 6 Accessing Active Trouble Codes 98 1000 RPM LOAD RPM ENG RPM NOTE The engine does not need to be running to 1800 RPM navigate the diagnostic gauge screens If engine 14 2 57 PSI start up is desired See Starting The Engine All of A ee i aaa Normal Operation RG13172 UN 26SEP03 For description of trouble codes see chart in Troubleshooting Section 1 During normal operation the single or four parameter screen will be displayed OURGP11 00000AD 19 03SEP03 1 7 2 When the diagnostic gauge receives a trouble code o WARNING from an engine control unit the single or four SPN 94 FMI 18 parameter screen will be replaced with the Warning FAUT message The SPN and FMI number will be displayed bee OE ENE SURE along with a description of the problem and the sadia sA NAAA NSA corrective action needed T GDE IMPORTANT Ignoring active trouble codes can result in severe engine damage Active Trouble Codes Displayed RG13240 UN 30SEP03 Continued on next page OURGP11 00000AD 19 03SEP03 2 7 15 8 061208 PN 49 Operating the Engine 3 If the word Next appears above the arrow keys there are more trouble codes that can be viewed by using the arrow keys to scroll to the next trouble code
85. ing Sensor Signal Unreliable Engine Timing and Position Sensors Out of Sync Engine Timing Sensor Signal Missing Engine Timing Signal Rate of Change Abnormal CAN Bus Error Communication network problem Injector Number 1 Circuit Has High Resistance Injector Number 1 Circuit Has Low Resistance Injector Number 1 Not Responding Injector Number 2 Circuit Has High Resistance Injector Number 2 Circuit Has Low Resistance Injector Number 2 Not Responding Injector Number 3 Circuit Has High Resistance Injector Number 3 Circuit Has Low Resistance Injector Number 3 Not Responding Injector Number 4 Circuit Has High Resistance Injector Number 4 Circuit Has Low Resistance Injector Number 4 Not Responding Injector Number 5 Circuit Has High Resistance Injector Number 5 Circuit Has Low Resistance Injector Number 5 Not Responding Injector Number 6 Circuit Has High Resistance Injector Number 6 Circuit Has Low Resistance Injector Number 6 Not Responding Vehicle Speed or Torque Message Unreliable External Shutdown Commanded External Fuel Derate Switch Active Tire Size Invalid Tire Size Error Sensor Supply 1 Voltage High Sensor Supply 1 Voltage Low Fuel Rail Pressure Sensor Supply Voltage High Fuel Rail Pressure Sensor Supply Voltage Low Engine Protection Shutdown Warning Engine Protection Shutdown High Pressure Fuel Pump Control Valve Signal Out of Range High High Pressure Fuel Pump Solenoid Number 1 Circuit Has High Resistance High Pressure
86. ing at the 1800 RPM single or four engine parameter display press the CIUIN coot TEMP Le A Menu key Menu Key RG13159 UN 26SEP03 Continued on next page OURGP11 0000237 19 210CT03 1 6 15 11 061208 PN 52 Operating the Engine 2 The main menu will be displayed Use the Arrow keys GO TO 1 UP DISPLAY to scroll through the menu until Adjust Backlight is STORED CODES highlighted ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT RG13181 UN 020CT03 Select Adjust Backlight OURGP11 0000237__ 19 210CT03 2 6 3 Once the Adjust Backlight menu item has been GO TO 1 UP DISPLAY highlighted press the Enter key to activate the STORED CODES Adjust Backlight function ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT COO Press Enter Key 2 r H O O A 1 Z l a a n O o OURGP11 0000237 19 210CT03 3 6 4 Use the Arrow keys to select the desired backlight intensity ADJUST BACKLIGHT Om 1c lt gt OWO Adjust Backlight Intensity Continued on next page OURGP11 0000237 19 210CT03 4 6 RG13183 UN 29SEP03 15 12 061208 PN 53 Operating the Engine Press the Menu key to return to the main menu j d y d ADJUST CONTRAST RG13184 UN 26SEP03 Return To Main Menu OURGP11 0000237 19 210CT03 5 6 6 Press the Menu key to exit the main menu and return l 98 to the engi
87. ion and wear 800 Series and POWERTech with manual tensioner g Valve clearance adjust 300 Series Number of hours Observation Dealer or distributor stamp Job done by DPSG CD03523 72 19 22JAN07 1 1 9000 Hours of operation J Engine oil drain g Air intake system check J Engine oil filter replace g Fuel filter replace J Check belt and tensioning system J Crankcase vent tube clean Number of hours Observation Dealer or distributor stamp Job done by DPSG CD03523 73 19 22JAN07 1 1 02 10 061208 PN 19 Maintenance Records 9500 Hours of operation J Engine oil drain J Engine oil filter replace g Fuel filter replace J Belt check tension and wear 800 Series and POWERTech with manual tensioner g Valve clearance adjust 300 Series Number of hours Observation Dealer or distributor stamp Job done by DPSG CD03523 74 19 22JAN07 1 1 10000 Hours of operation J Engine oil drain J Cooling system drain and flush J Engine oil filter replace g Valve clearance adjust POWERTech g Fuel filter replace J Thermostat replace J Check belt and tensioning system g Vibration damper check g Crankcase vent tube clean g Injection nozzles replace g Air intake system check Number of hours Observation Dealer or distributor stamp Job done by DPSG CD03523 75 19 22JAN07 1 1 02 11 061208 PN 20 Serial Numbers POWERTech label A label
88. is located on the rocker arm cover which identifies each engine as a John Deere POWERTECH engine LPOMMTERIECH 4 5 liter POWERTECH is a trademark of Deere amp Company DPSG CD03523 11 19 22JAN07 1 1 RG8041 UN 15JAN99 Engine serial number plate O oD 1D O A Z LU 7 i l Z Z 3 5 g Q O O 39 Q o O 4045 and 6068 Engines Each engine has a 13 digit John Deere serial number Your engine s serial number plate A is located on the The first two digits identify the factory that produced right hand side of cylinder block behind the fuel filter the engine for 4045 and 6068 engines and near the fuel supply pump on 3029 and 4039 engines CD indicates the engine was built in Saran France DPSG CD03523 12 19 22JAN07 1 1 03 1 061208 PN 21 Serial Numbers Record engine serial number JOHN DEERE Record all of the numbers and letters found on your ENGINE SERIAL NUMBER engine serial number plate in the spaces provided below al D4039D1 23 5G D This information is very important for repair parts or _ 40 39 D FO 08 Coeff Abs A warranty information Engine Serial Number B D P S G SARAN MADE IN FRANCE CD30705B UN 24AUG99 Engine Model Number C 3029 and 4039 engine plate Coefficient of Absorption Value D J O H N D R E Engine Serial Number o CD6068G123450 oe O DEERE amp COMPANY MOLINE ILLINOIS MADE IN FRANCE UN 22JAN07 CD30747A 40
89. istributor stamp Job done by DPSG CD03523 68 19 22JAN07 1 1 7000 Hours of operation J Engine oil drain g Air intake system check J Engine oil filter replace g Fuel filter replace J Check belt and tensioning system J Crankcase vent tube clean Number of hours Observation Dealer or distributor stamp Job done by DPSG CD03523 69 19 22JAN07 1 1 02 8 061208 PN 17 Maintenance Records 7500 Hours of operation J Engine oil drain J Engine oil filter replace g Fuel filter replace J Belt check tension and wear 800 Series and POWERTech with manual tensioner g Valve clearance adjust 300 Series Number of hours Observation Job done by 8000 Hours of operation J Engine oil drain J Engine oil filter replace g Fuel filter replace J Check belt and tensioning system J Crankcase vent tube clean Number of hours Observation Job done by O Cooling system drain and flush if COOL GARD is used Dealer or distributor stamp DPSG CD03523 70 19 22JAN07 1 1 J Cooling system drain and flush if COOL GARD is not used g Valve clearance adjust POWERTech g Air intake system check g Vibration damper check Dealer or distributor stamp DPSG CD03523 71 19 22JAN07 1 1 02 9 061208 PN 18 Maintenance Records 8500 Hours of operation J Engine oil drain J Engine oil filter replace g Fuel filter replace J Belt check tens
90. k Wiring Check Wiring Check Wiring Check Wiring Shut Down Engine Check Fault Codes Shut Down Engine Check Fault Codes Contact Servicing Dealer Check Pump Wiring Check Fuel Filter and Lines Contact Servicing Dealer Check Fault Codes OURGP12 00001E2 19 15MAR06 2 3 061208 PN 123 Troubleshooting SPN FMI 002000 13 Description of Fault Security Violation Corrective Action Contact Servicing Dealer OURGP12 00001E2 19 15MAR06 3 3 Intermittent Fault Diagnostics With Electronic Controls Intermittent faults are problems that periodically go away A problem such as a terminal that intermittently doesn t make contact can cause an intermittent fault Other intermittent faults may be set only under certain operating conditions such as heavy load extended idle etc When diagnosing intermittent faults take special note of the condition of wiring and connectors since a high percentage of intermittent problems originate here Check for loose dirty or disconnected connectors Inspect the wiring routing looking for possible shorts caused by contact with external parts for example rubbing against sharp sheet metal edges Inspect the connector vicinity looking for wires that have pulled out of connectors poorly positioned terminals damaged connectors and corroded or damaged splices and terminals Look for broken wires damaged splices and wire to wire shorts Use good judgement if component repla
91. le Codes DTC s NOTE The method below applies to applications having a fault lamp on instrument panel refer to the generator documentation for more information The Electronic Control Unit ECU has the ability to display DTCs using blinking sequence of the fault lamp NOTE The ECU blinks the codes in 2 digit codes only See LISTING OF DIAGNOSTIC TROUBLE CODES DTCS later in this Group Press down Override Shutdown Switch while turning the ignition switch ON The Fault Lamp will begin to flash a code number For example flash three times short pause flash two times long pause This example is code 32 The ECU begins the flashing sequence by flashing a code 32 this indicates the start of blinking active codes If there are any active DTCs the ECU will flash its 2 digit number If there is more than one 55 11 active DTC the ECU will flash each code in numerical order If there are no active DTCs the Fault Lamp will flash a code 88 Following the active codes the Fault Lamp will flash a code 33 This indicates the start of blinking stored codes If there are any stored DTCs the Fault Lamp will flash its 2 digit number If there is more than one stored DTC the ECU will flash each code in numerical order If there are no stored DTCs the Fault Lamp will flash a code 88 5 Once complete this sequence will repeat 6 When complete turn ignition OFF As an example if an engine h
92. leaner Engine overloaded Injection nozzles dirty Engine out of time Turbocharger not functioning Continued on next page 55 7 Solution 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 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 DPSG CD03523 49 19 22JAN07 4 5 061208 PN 116 Symptom Engine overheats High fuel consumption Troubleshooting Problem Engine overloaded Low coolant level Faulty radiator cap Stretched poly V belt or defective belt tensioner Low engine oil level Cooling system needs flushing Defective thermostat Defective temperature gauge or sender Incorrect grade of fuel Improper type of fuel Clogged or dirty air cleaner Engine overloaded Improper valve clearance Injection nozzles dirty Engine out of time Defective turbocharger Low engine temperature 95 8 Solution Reduce load Fill radiator to proper l
93. lled to provide year round protection against corrosion and cylinder liner pitting and winter freeze protection to 37 C 34 F John Deere COOL GARD is preferred for service If John Deere COOL GARD is not available use a low silicate ethylene glycol or propylene glycol base coolant concentrate in a 50 mixture of concentrate with quality water The coolant concentrate shall be of a quality that provides cavitation protection to cast iron and aluminum parts in the cooling system John Deere COOL GARD meets this requirement Freeze protection A 50 mixture of ethylene glycol engine coolant in water provides freeze protection to 37 C 34 F 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 10 6 A 50 mixture of propylene glycol engine coolant in water provides freeze protection to 33 C 27 F If protection at lower temperatures is required consult your John Deere dealer for recommendations 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 and propylene glycol base engine coolant concentrate IMPORTANT Do n
94. llowing pages It is recommended that your engine service products and replacement parts Distributor or your Dealer carry out this service work and stamp the appropriate case To protect your rights under the warranty ensure all scheduled services are carried out and recorded If Keeping an accurate account of all service performed your engine is covered by extended warranty it is on your engine will give more value to the machine important to maintain this record for the duration of the when resell it warranty DPSG CD03523 6 19 22JANO7 1 1 100 Hours of operation J Engine oil drain J Engine oil filter replace Hose connections check Number of hours Observation Dealer or distributor stamp Job done by DPSG CD03523 7 19 22JANO7 1 1 02 1 061208 PN 10 Maintenance Records 500 Hours of operation J Engine oil drain J Engine oil filter replace g Fuel filter replace J Belt check tension and wear 3800 Series and POWERTech with manual tensioner g Valve clearance adjust 300 Series Number of hours Observation Dealer or distributor stamp Job done by DPSG CD03523 8 19 22JANO7 1 1 1000 Hours of operation J Engine oil drain g Air intake system check J Engine oil filter replace g Fuel filter replace J Check belt and tensioning system J Crankcase vent tube clean Number of hours Observation Dealer or distributor stamp Job done by DPSG CD0352
95. mable and may explode causing serious injury ws NOTE On engines with electronically controlled fuel 5 system DE10 HPCR the air intake heater o operates automatically controlled by the ECU An Si engine preheater indicator light comes on when Handie starina tind with Gare 7 the key switch is turned ON In warm weather the light comes on briefly for a light check In cold weather the light remains ON during the automatic operation of the air intake heater or glow plug s Operating time depends on temperature Do not crank engine until light goes OFF e 3029 and 4039 engines are optionally equipped with the single glow plug B screwed in cylinder head intake manifold Activate the glow plug preheater position for MGs oh a 30 seconds maximum then start the engine moar a 2 e 4045 and 6068 engines except HPCR 4 valve head Pe oe r are optionally equipped with the grid type air heater A o installed between cylinder head and air intake pipe S For mechanical fuel system activate the heating a element preheater position for 30 seconds maximum Glow Plug or Grid Type air heater then start the engine For electronically controlled engines DE10 HPCR 2 valve head turn key switch ON but DO NOT crank engine until engine preheater indicator light turns OFF e HPCR 4 valve head engines are equipped with glow plugs one per cylinder C Turn key switch ON but DO NOT crank engine until preheater indicat
96. mperature Signal Out of Range High 04 Intake Manifold Air Temperature Signal Out of Range Low 16 Intake Manifold Air Temperature Signal Moderately High 000107 00 Air Filter Pressure Differential Extremely High 000110 00 Engine Coolant Temperature Signal Extremely High 03 Engine Coolant Temperature Signal Out of Range High 04 Engine Coolant Temperature Signal Out of Range Low 15 Engine Coolant Temperature Signal Slightly High 16 Engine Coolant Temperature Signal Moderately High 000111 01 Engine Coolant Level Low 000158 17 ECU Power Down Error Internal ECU Problem 000160 02 Axle Speed Signal Unreliable 000174 00 Fuel Temperature Signal Extremely High 000174 03 Fuel Temperature Signal Out of Range High 04 Fuel Temperature Signal Out of Range Low 16 Fuel Temperature Signal Moderately High 000189 00 Engine Speed Derate Condition Exists Corrective Action Check Sensor and Wiring Check Sensor and Wiring Check Sensor and Wiring Check Sensor and Wiring Contact Servicing Dealer Check Switch and Wiring Check Switch and Wiring Check Sensor and Wiring Check Sensor and Wiring Check Sensor and Wiring Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer Check Sensor and Wiring Check Sensor and Wiring Stop and Drain Water Separator Check Oil Level Check Sensor and Wiring Check Sensor and Wiring Check Oil Level Check Air Cleaner Aftercooler or Room Temperature Check Sensor and Wiring Che
97. n severe engine damage lt NEXT gt HIDE ar Hide Trouble Code Continued on next page OURGP11 00000AE 19 03SEP03 3 6 15 10 061208 PN 51 RG13239 UN 29SEP03 Operating the Engine The display will return to the single or four parameter i 98 display but the display will contain the Shutdown o LOAD amp Rem 1009 REM icon Pressing the Enter key will redisplay the hidden 1800 RPM trouble code ENGIN COOL TEMP oe lt gt IMPORTANT Ignoring the shutdown message can OCO OA result in severe engine damage Flashing Shutdown Icon RG13179 UN 26SEP03 OURGP11 00000AE 19 03SEP03 4 6 5 Pressing the Enter key once again will hide the W trouble code and return the screen to the single or four 10x SHUTDOWN SPN 100 FMI 1 parameter display aia ENGINE OIL PRESSURE LOW CORRECTIVE ACTION o 0 Ge H R lt NEXT gt HIDE aT Redisplay Trouble Code RG13239 UN 29SEP03 OURGP11 00000AE 19 03SEP03 5 6 6 The single or four parameter screen will display the 0 shutdown icon until the trouble code condition is LOAD amp RPM ENG RPM corrected 1800 RPM eRe COOL TEMP BAT VOLT OIL PRES 98 1000 RPM 14 2 57 PSI IMPORTANT Ignoring the shutdown message can result in severe engine damage Shutdown Icon RG13180 UN 26SEP03 OURGP11 00000AE 19 03SEP03 6 6 Adjusting Backlighting re LOAD RPM ENG RPM 1 Turn the key switch to the ON position Start
98. nd fill the cooling system with specified coolant see DIESEL ENGINE COOLANT Specification Cooling system capacity CD3029DF 128 aaeain ene n merece eee nee 14 5 L 15 5 at CBSO TF IEG Renee eee een e ee Cees eee ee ee 14 5 L 15 5 at 2 AO serenigi aa a ean Se hinain 14 5 L 15 5 at GASOA TFE S TO i EE eT ee S nee 14 5 L 15 5 qt CD3029HFU70 po ccdesasiecincetescasenonberaasisncetinetannesntdeSeimncgendsamuimee 14 5 L 15 5 at 1B C6210 9 1 Wig 0 sasesana ea mee tener mele ere eee 14 5 L 15 5 at C DAOSO B 016 acainnean 16 5 L 17 5 qt CD4039 T a 0c aissisinniouunien ninaa niai 16 5 L 17 5 qt ODA0AS DEF T50 nirera E EEEE 20 L 21 qt CD4045SRHF ces aca ees ee aes Ear ESE dn inian 28 L 29 5 qt CD4045 IF IE g enea ae Ranai 25 L 26 5 qt GB arog FF2580 oiiaii E nc nea FE 25 L 26 5 qt CD4045HFS72 cececeedenecocticaseteiorenintonanhnatesdnsdntecunnssaaeiaessiadasans 28 L 29 5 qt CDAQASHPS ZS eee nee eee ee E e iiaa eee ere eee 32 L 34 qt AOI OO mororooo 25 L 26 5 qt Oe arrena ch sed octet see ee eee 32 L 34 qt GRADI HERSO oe eee ete temlln Rar are et sere a ne en ote rinretre eee ree Neer 32 L 34 qt OT aaa encase acresce se casas a DUST aE TS EEE 28 L 29 5 qt CDJ045SHFUT enesenn anan ea RS 32 L 34 qt Gy Bor Sa TFU O ioan ee E E ree ere aren 25 L 26 5 qt CDGOGBHF 158 orrien a eesti tnaaseewtene 32 L 34 qt CDOGOCOHF258 aaas SR 32 L 34 qt CEGOCS TRIE O oona eee eee ee eee ee eee 28 L 29 5 qt CDGOG TF 25E nee
99. nder adverse conditions ones specified Keep a record of hourly intervals and Neglecting maintenance can result in services performed using charts provided in failures or permanent damage to the Maintenance Records Section engine DPSG CD03523 24 19 22JAN07 1 1 Use correct fuels lubricants and coolant IMPORTANT Use only fuels lubricants and coolants meeting specifications outlined in Fuels Lubricants and Coolant Section when servicing your John Deere Engine Consult your John Deere engine distributor servicing dealer or your nearest John Deere Parts Network for recommended fuels lubricants and coolant Also available are necessary additives for use when operating engines in tropical arctic or any other adverse conditions TS100 UN 23AUG88 DPSG CD03523 25 19 22JAN07 1 1 20 1 061208 PN 77 Maintenance Maintenance interval chart Item 10 H 500 H 1000 H 2000 H 2500 H As daily 1 year 2 years 3 years required Check and adjust valve clearance Clean crankcase vent tube Check belt tension and automatic tensioner Check air intake hoses connections and system SE l j e j Test glow plugs HPCR 4 valve head aClean air filter element when restriction indicator is red Replace filter element after 6 cleanings or once a year Change oil and filter after the first 100 hours of operation then every 500 hours maximum thereafter see DIESEL ENGINE OIL information Change oil and filter at
100. ne parameter display eLA Se 1800 RPM EXeGGI coo TEMP aly a Exit Main Menu RG13159 UN 26SEP03 OURGP11 0000237 19 210CT03 6 6 Adjusting Contrast 98 1000 RPM LOAD RPM ENG RPM 1 Turn the key switch to the ON position Starting at the 1800 RPM single or four engine parameter display press the CIUIN Coot Temp ae gis Menu key Menu Key RG13159 UN 26SEP03 Continued on next page OURGP11 00000AF 19 O3SEP03 1 6 1 5 1 3 061208 PN 54 Operating the Engine 2 The main menu will be displayed Use the Arrow keys GO TO 1 UP DISPLAY to scroll through the menu until Adjust Contrast is STORED CODES highlighted ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT RG13161 UN 020CT03 Select Adjust Contrast OURGP11 00000AF 19 O03SEP03 2 6 3 Once the Adjust Contrast menu item has been STORED CODES highlighted press the Enter key to activate the ENGINE CONFIG Adjust Contrast function SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT ADJUST CONTRAST Press Enter Key 0 ro H Q O A I Z LO ee 0 O X OURGP11 00000AF 19 O03SEP03 3 6 4 Use the Arrow keys to select the desired contrast intensity ADJUST CONTRAST Om io gt OOO Adjust Contrast Intensity Continued on next page OURGP11 00000AF 19 O3SEP03 4 6 15 14 061208 PN 55 RG13186 UN 29SEP03 Op
101. ne piece 50 3 POWERTech label ooann 03 1 PONGE OAY ME te i a ae a eet ve Record engine serial number 03 2 Replace fan and alternator belts 4045 and 6068 Record fuel injection pump model number 03 5 21010 0c a a ere 50 5 Sneciicni pecifications Daily or every 10 NOUS ec cg ee es Be eee fee le 25 1 Engine Pack Observe service intervals sh eH Bathe eh Ge ate eros 20 1 Non Emission Certified Engines 65 1 Use correct fuel lubricant and coolant 20 1 Stage II Emission Certified Engines 65 4 1000 hours 1 year Storage Check and adjust valve clearance 3029 and ENGNG 4244646424240 582685 48508 2546505 60 1 BOO a Acca se eaeanen malas BIONNG TUG 2 2 2 24 a2 tatbeeadeeeerseesen 10 2 NECA A Mle OSC a tesa e om Storing lubricants s s s aeaaaee ian de 10 5 Checking automatic belt tensioner 4045 and 6068 Engines n a nnana aana aaan 35 2 Cleaning crankcase vent tube 35 1 Pressure testing cooling system 35 6 T 2000 hours 2 years Adjust speed droop governor Mechanical fuel Trouble codes aia ee a ee 55 13 SVEM sorer gt 44 dar aaa r 40 3 Troubleshooting Adjust valve clearance 4045 and 6068 Electrical nnana rg be Sina gel ge we wane eee wie de 55 9 CNOINGS s dcedc di ddan yaddaudoaud sae 40 1 EDONG sarase raens ra ENTERA AN E ET A S 55 4 Check engine speed Mechanical fuel General information naana aaa aeaaea 55 1 M IOM 2c ne hake Aa eed ee ke 40 3 Damper check
102. ngine must be stored outside cover it with a year or longer it is recommended that the cooling waterproof canvas or other suitable protective system be drained flushed and refilled Refill with material and use a strong waterproof tape DPSG CD03523 53 19 22JAN07 1 1 60 1 061208 PN 125 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 Check for filled fuel tank Perform all appropriate prestarting checks See DAILY PRESTARTING CHECKS 60 2 minutes for starter to cool before trying again Crank engine for 20 seconds with starter do not allow the engine to start Wait 2 minutes and crank engine an additional 20 seconds to assure bearing surfaces are adequately lubricated Start engine and run at 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
103. ntains a list of engine parameters Engine parameters from this list can be selected to replace any or all of the default parameters RG13244 UN 02OCT03 Select Factory Defaults OURGP11 00000B2 19 03SEP03 4 14 5 To reset the display parameters to the factory defaults scroll to and highlight Use Defaults Press the Enter key to activate the Use Defaults function A message RESTORED TO indicating the display parameters are reset to the DEFAULTS factory defaults will be displayed then the display will return to the Setup 4 Up Display menu Restored To Defaults cD A Lu o Z D st cD Oo o OURGP11 00000B2 19 03SEP03 5 14 6 Custom Setup To perform a custom setup of the USE DEFAULTS 4 Up Display use the arrow buttons to scroll to and CUSTOM SETUP highlight Custom Setup on the display OOG Custom Setup Continued on next page OURGP11 00000B2 19 03SEP03 6 14 15 26 061208 PN 67 RG13227 UN 26SEP03 Operating the Engine 7 The quadrant with the highlighted parameter value is the current selected parameter Use the Arrow keys 125 F 4000 RPM to highlight the value in the quadrant you wish to COOL TEMP ENG RPM change to a new parameter 57 PSI BAT VOLT OIL PRES OGP Select Parameters RG13228 UN 26SEP03 OURGP11 00000B2 19 03SEP03 7 14 8 Press the Enter key and a list of engine parameters will be displayed 125 F 1000 RPM COOL TEMP ENG
104. ny time to return to the Custom Setup menu RG13220 UN 26SEP03 Select Parameters For Display OURGP11 00000B1 19 03SEP03 13 18 Automatic Scan Selecting the scan function will USE DEFAULTS allow the 1 Up Display to scroll through the selected set of parameters one at a time Use the Arrow keys CUSTOM SETUP to scroll to the Automatic Scan function AUTOMATIC SCAN OFF RG13221 UN 26SEP03 OOO Automatic Scan Off Continued on next page OURGP11 00000B1 19 03SEP03 14 18 15 22 061208 PN 63 Operating the Engine 16 Press the Enter key to toggle the Automatic Scan function on USE DEFAULTS CUSTOM SETUP AUTOMATIC SCAN ON RG13222 UN 26SEP03 Automatic Scan On OURGP11 00000B1 19 03SEP03 15 18 17 lie ne m again to toggle the Automatic USE DEFAULTS a Manone ne CUSTOM SETUP AUTOMATIC SCAN OFF Automatic Scan Off RG13223 UN 26SEP03 Continued on next page OURGP11 00000B1 19 03SEP03 16 18 15 23 061208 PN 64 Operating the Engine 18 Once the Use Defaults Custom Setup and n n USE DEFAULTS Automatic Scan functions have been set press the CUSTOM SETUP Menu key to return to the main menu AUTOMATIC SCAN ON Menu Key RG13224 UN 26SEP03 OURGP11 00000B1 19 O03SEP03 17 18 19 Press the Menu key to exit the main menu and 98 return to the engine parameter display eLA Se 1800 RPM EXeGGI coo TEMP aly a Exit Main Menu RG1
105. oil filter replace g Air intake system check g Fuel filter replace J Cooling system drain and flush if COOL GARD is used J Check belt and tensioning system J Crankcase vent tube clean Number of hours Observation Dealer or distributor stamp Job done by DPSG CD03523 65 19 22JAN07 1 1 02 6 061208 PN 15 Maintenance Records 5500 Hours of operation J Engine oil drain J Engine oil filter replace g Fuel filter replace J Belt check tension and wear 800 Series and POWERTech with manual tensioner g Valve clearance adjust 300 Series Number of hours Observation Dealer or distributor stamp Job done by DPSG CD03523 66 19 22JAN07 1 1 6000 Hours of operation J Engine oil drain J Cooling system drain and flush if COOL GARD is not used J Engine oil filter replace g Valve clearance adjust POWERTech g Fuel filter replace g Air intake system check J Check belt and tensioning system g Vibration damper check J Crankcase vent tube clean Number of hours Observation Dealer or distributor stamp Job done by DPSG CD03523 67 19 22JAN07 1 1 02 7 061208 PN 16 Maintenance Records 6500 Hours of operation J Engine oil drain J Engine oil filter replace g Fuel filter replace J Belt check tension and wear 800 Series and POWERTech with manual tensioner g Valve clearance adjust 300 Series Number of hours Observation Dealer or d
106. om gauge turn it 180 and retest cap to confirm measurement Test Cooling System NOTE Engine should be warmed up to test overall cooling system RG6557 UN 20JAN93 RG6558 UN 20JAN93 Test cooling system 1 Allow engines 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 specification listed for radiator cap 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 engine distributor or servicing dealer correct this problem immediately CD03523 00000EC 19 22JAN07 1 1 061208 PN 94 Maintenance 2000 hours 2 years Check and adjust engine valve clearance 4045 and 6068 Engines Adjust engine valve clearance as follows or have your authorized servicing dealer or engine distributor adjust the engine valve clearance 1 Remove rocker arm cover and crankcase vent tube 2 Using JDE83 or JDG820 Flywheel Turning Tool A rotate engine flywheel in running direc
107. or light turns OFF A Grid Type heater 4045 and 6068 non HPCR 4 valve head engines B Single Glow Plug 3029 and 4039 engines C Multiple Glow Plugs HPCR 4 valve head engines CD30925 UN 23JANO7 Glow Plugs on HPCR 4 valve head engine Continued on next page DPSG CD03523 19 19 O6FEBO7 2 4 15 31 061208 PN 72 Operating the Engine Coolant heater Connect plug of coolant heater A to a proper power source 110 or 220 V At an ambient temperature of 15 C 5 F the heating process takes approximatively 2 hours Extend heating period if ambient temperature is lower Fuel preheater Fuel preheater A switches ON and OFF automatically in relation with the ambient temperature 15 32 DAAE DPSG CD03523 19 19 06FEB07 3 4 i N X1017768 UN 240CT97 MN DEERE dA ji MaL FILTER e w LX1017708 UN 090CT97 O DPSG CD03523 19 19 06FEB07 4 4 061208 PN 73 Operating the Engine Using a booster battery or charger A 12 volt booster battery can be connected in parallel with battery ies on the unit to aid in cold weather starting ALWAYS use heavy duty jumper cables A CAUTION Gas given off by battery 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
108. ot use cooling system sealing additives or antifreeze that contains sealing additives IMPORTANT Do not mix ethylene glycol and propylene glycol base coolants DX COOL8 19 16NOV01 1 1 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 061208 PN 41 Operating the Engine Using Diagnostic Gauge to Access Engine Information Optional equipment NOTE Generator sets powered by an electronically controlled engine DE10 or HPCR fuel system can be optionally equipped with the diagnostic gauge shown Depending on the generator set manufacturer other instrumentations can be used Refer to the generator set documentation for more information The diagnostic gauge A allows the operator to view many readouts of engine functions and trouble codes DTCs The gauge is linked to the electronic control system and its sensors This allows the operator to monitor engine functions and to troubleshoot the engine systems when needed Press the menu key B to access the various engine functions in sequence The displays can be selected as either customary English or metric units The following menu of engine parameters can be displayed on the diagnostic gauge window Engine hours Engine rpm
109. r beverage containers that may mislead someone into drinking from them TS1133 UN 26NOV90 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 1 0 061208 PN 35 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 Renewable diesel is basically identical to petroleum diesel fuel that is created by Hydrotreating fats and oils Renewable diesel that meets EN 590 or ASTM D975 is acceptable for use at all percentage mixture levels Required fuel properties In all cases the fuel shall meet the following properties Cetane number of 45 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 should be at le
110. rmation A reliable program for troubleshooting engine problems should include the following basic diagnostic thought process Troubleshooting electronically controlled engine problems can be difficult The first thing to do is to identify the type of problem which can be mechanical or electrical An engine wiring layout is provided in this section to identify electrical components engine controller sensors connectors Later in this section is a list of possible engine problems and diagnostic trouble codes that may be encountered accompanied by possible causes and corrections This troubleshooting information is of a general nature See also the generator documentation for a complete information of your application 55 1 e Know the engine and all related systems e Study the problem thoroughly e Relate the symptoms to your knowledge of engine and systems Diagnose the problem starting with the easiest things first Double check before beginning the disassembly e Determine cause and make a thorough repair e After making repairs operate the engine under normal conditions to verify that the problem and Cause was corrected CD03523 000018D 19 08FEBO7 1 1 061208 PN 110 Troubleshooting Engine Wiring Layout Electronic Fuel System With Stanadyne DE10 Injection Pump sone x om air A LO ra Enne Ai J E MS BBG Fj d Beat me FONE aes i he Pron Bs eee
111. s DPSG CD03523 14 19 22JAN07 2 2 03 4 061208 PN 24 Serial Numbers Record fuel injection pump model number Record the fuel injection pump model and serial information found on the serial number plate A Model No RPM Manufacturer s No Serial No CD30749 UN 24SEP99 Record Engine Control Unit ECU Serial Number Record the part number and serial number information found on the serial number label A on the Engine Control Unit ECU mounted on or near the engine Part No Serial No RG14635 UN 13APR06 Record Engine Control Unit ECU Serial Number A Serial Number Label CD03523 0000189 19 O6FEBO7 1 1 Record High Pressure Fuel Pump Model Number Record the high pressure fuel pump model and serial number information found on the serial number plate A Model No gt gt gt RPM Manufacturer s No Serial No RG13718 UN 11NOV04 A Serial Number Plate CD03523 000018A 19 06FEB07 1 1 03 5 061208 PN 25 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 o ee O LU OQ N T Z D O o m o H DX ALERT 19 29SEP98 1 1 Understand Signal Words A DANGER A signal word DANGER WARNING or CAUTION is used with the safety alert symbol DA
112. sion Certified gt engines z e PC3235 Parts Catalog for Stage II Emission Certified engines amp T e CTM3274 Component Technical Manual for 3029 and 4039 engines English e CTM104 Component Technical Manual for 4045 and 6068 base engines English e CTM207 Component Technical Manual for Mechanical Fuel Systems on 4045 and 6068 engines English e CTM320 Component Technical Manual for HPCR Fuel System on 4045 and 6068 with 4 Valve Head Engines English e CTM331 Component Technical Manual for DE10 Fuel Systems on 4045 and 6068 engines English e CTM502 Component Technical Manual for HPCR Fuel System on 4045 and 6068 with 2 Valve Head Engines English e CTM67 Component Technical Manual for OEM Engine accessories English only e CTM77 Component Technical Manual for Alternators and Starter Motors English only DPSG CD03523 42 19 31JAN07 1 1 50 1 061208 PN 102 Maintenance As required 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 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 CD30768 UN 24SEP99 DPSG CD03523 43 19 22JAN07 1 1 50 2 061208
113. t of this manual and need assistance contact your John Deere dealer DX READ 19 03MAR93 1 1 Prevent Machine Runaway Avoid possible injury or death from machinery runaway Do not start engine by shorting across starter terminals Machine will start in gear if normal circuitry is bypassed NEVER start engine while standing on ground Start engine only from operator s seat with transmission in neutral or park TS177 UN 11JAN89 DX BYPAS1 19 29SEP98 1 1 05 3 061208 PN 28 Safety Handle Fuel Safely Avoid Fires Handle fuel with care it is highly flammable Do not refuel 9 the machine while smoking or when near open flame or sparks Always stop engine before refueling machine Fill fuel tank gt outdoors Prevent fires by keeping machine clean of accumulated trash grease and debris Always clean up spilled fuel TS202 UN 23AUG88 DX FIRE1 19 O03MAR93 1 1 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 TS291 UN 23AUG88 DX FIRE2 19 03MAR93 1 1 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
114. the DTC s present 4 Contact your nearest engine distributor or servicing dealer with a list of DTC s so that necessary repairs can be made 55 12 CD03523 0000192 19 O02FEBO7 1 1 061208 PN 121 Troubleshooting Listing of Diagnostic Trouble Codes DTCs NOTE Not all of these codes are used on all OEM engine applications Trouble Codes DTC s Listing in Ascending SPN FMI Codes SPN FMI Description of Fault 000028 03 Throttle 3 Signal Out of Range High 04 Throttle 3 Signal Out of Range Low 000029 03 Throttle 2 Signal Out of Range High 04 Throttle 2 Signal Out of Range Low 000084 31 Vehicle Speed Signal Unreliable 000091 03 Throttle 1 Signal Out of Range High 04 Throttle 1 Signal Out of Range Low 09 Throttle 1 Communication Signal Erratic 000094 03 Low Pressure Fuel Signal Out of Range High 04 Low Pressure Fuel Signal Out of Range Low 10 Low Pressure Fuel Rate of Change Abnormal 13 Low Pressure Fuel Out of Calibration I7 High Pressure Fuel System Pressure Slightly Low 000097 00 Water in Fuel Continuously Detected 03 Water in Fuel Signal Out of Range High 04 Water in Fuel Signal Out of Range Low 16 Water in Fuel Detected 000100 01 Engine Oil Pressure Signal Extremely Low 03 Engine Oil Pressure Signal Out of Range High 04 Engine Oil Pressure Signal Out of Range Low 18 Engine Oil Pressure Signal Moderately Low 000105 00 Intake Manifold Air Temperature Signal Extremely High 03 Intake Manifold Air Te
115. tion clockwise viewed from water pump until No 1 piston front has reached top dead center TDC on compression stroke Insert timing pin JDE81 4 B into flywheel bore CD30544 UN 19MAY98 DPSG CD03523 36 19 31JAN07 1 4 Check and adjust valve clearance to specifications according to following procedures Specification Valve clearance engine cold 0 35 mm 0 014 in 0 45 mm 0 018 in 4 If valves need adjusting loosen the locknut on rocker arm adjusting screw Turn adjusting screw until feeler gauge slips with a slight drag Hold the adjusting screw from turning with screwdriver and tighten locknut to 27 Nem 20 lb ft Recheck clearance after tightening locknut Readjust clearance as necessary RG7409 UN O6AUG96 Reinstall rocker arm cover and crankcase vent tube Continued on next page DPSG CD03523 36 19 31JAN07 2 4 40 1 061208 PN 95 Maintenance 2000 hours 2 years e 4 Cylinder Engine NOTE Firing order is 1 3 4 2 Lock No 1 piston at TDC compression stroke B Adjust valve clearance on No 1 and 3 exhaust valves and No 1 and 2 intake valves Rotate flywheel 360 Lock No 4 piston at TDC compression stroke C Adjust valve clearance on No 2 and 4 exhaust valves and No 3 and 4 intake valves RG4776 UN 310CT97 A Front of engine B No 1 Piston at TDC compression stroke C No 4 Piston at TDC compression stroke E Exhaust valve I Intake valve DPS
116. to scroll through the menu until GO TO 1 UP DISPLAY Setup 1 Up Display is highlighted STORED CODES ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITSD ADJUST BACKLIGHT Setup 1 Up Display oP O H Q O A T Z op O op O o OURGP11 00000B1 19 03SEP03 2 18 3 Once Setup 1 Up Display menu item has been GO TO 7 Y highlighted press the Enter key to access the Setup Een conES 1 Up Display function ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITSD ADJUST BACKLIGHT o0 Press Enter Key Continued on next page OURGP11 00000B1 19 03SEP03 3 18 RG13194 UN 020CT03 15 18 061208 PN 59 Operating the Engine 4 Three options are available for modification of the 1 Up USE DEFAULTS Display CUSTOM SETUP AUTOMATIC SCAN OFF a Use Defaults This option contains the following engine parameters for display Engine Hours Engine Speed Battery Voltage Load Coolant Temperature and Oil Pressure RG13196 UN 26SEP03 Custom Setup This option contains a list of ae f engine parameters Engine parameters from this list can be selected to replace any or all of the default parameters This option can be used to add 1 Up Display Options parameters available for scrolling in the 1 Up Display Automatic Scan Selecting the scan function will allow the 1 Up Display to scroll through the selected set of parameters one at a time momentarily p
117. to the engine parameter display SETUP 4 UP DISPLAY SELECT UNITS 14 2 57 PSI ADJUST BACKLIGHT BAT VOLT OIL PRES Use Arrow Buttons To Scroll Quadrant Display RG13163 UN 02OCT03 OURGP11 00000A9 19 03SEP03 5 5 1 5 3 061208 PN 44 Operating the Engine Engine Configuration Data 98 1000 RPM LOAD RPM ENG RPM NOTE The engine configuration data is a read only 1800 RPM function COOL TEMP 16 2 st NOTE The engine does not need to be running to QC IO navigate the diagnostic gauge screens If engine Start up is desired See Starting The Engine All of l the engine values illustrated on the diagnostic Menu Key gauge indicate the engine is running RG13159 UN 26SEP03 1 Turn the key switch to the ON position Starting at the single or four engine parameter display press the Menu key OURGP11 00000AB 19 03SEP03 1 6 The main menu will be displayed Use the Arrow keys f69 TO T UP DISPLAY to scroll through the menu until Engine Config is STORED CODES highlighted ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT OORO Select Engine Configuration OURGP11 00000AB_ 19 03SEP03 2 6 3 Once Engine Config menu item has been highlighted GO TO 1 UP DISPLAY press the Enter key to view the engine configuration data ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT RG13164 UN 070OCT03 Oco Enter Key Continued on
118. u 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 O03MAR93 1 1 Stay Clear of Rotating Drivelines Entanglement in rotating driveline can cause serious injury or death Keep master shield and driveline shields in place at all times Make sure rotating shields turn freely aa Wear close fitting clothing Stop the engine and be sure Ba the PTO driveline is stopped before making adjustments or performing any type service on the engine or PTO driven equipment hY TS1644 UN 22AUG95 CD PTO 19 22JANO7 1 1 05 6 061208 PN 31 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 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 batter
119. utes before applying the load NOTE This procedure does not apply to standby generator sets where the engine is loaded immediately upon reaching rated speed Normal engine operation Compare engine coolant temperature and engine oil pressure with specifications below Specification Minimum oil pressure at full load rated speed Pressure 0000 275 kPa 2 75 bar 40 psi Coolant temperature range Temperature ae sieusencescnsuacteoccnammnceretinaeicnvenacs 82 94 C 180 202 F Stop engine immediately if coolant temperature is above or oil pressure below specifications or if there are any signs of part failure Symptoms that may be early signs of engine problems could be e Sudden loss of power e Unusual noise or vibration e Excessive black exhaust Oil at normal operating temperature of 115 C 240 F Standby power units To assure that your engine will deliver efficient standby operation when needed start engine and run at rated speed with 50 70 load for 30 minutes every 2 15 34 e Excessive fuel consumption e Excessive oil consumption e Fluid leaks Recommendation for turbocharger engines Should the engine stall when operating under load IMMEDIATELY restart it to prevent overheating of turbocharger components Idling engine Avoid excessive engine idling Prolonged idling may cause the engine coolant temperature to fall below its normal range This in turn causes crank
120. utor adjust the engine valve clearance CD30544 UN 19MAY98 1 Remove rocker arm cover and crankcase vent tube 2 Using JDE83 or JDG820 Flywheel Turning Tool A rotate engine flywheel in running direction clockwise viewed from water pump until No 1 piston front has reached top dead center TDC on compression stroke Insert timing pin JDE81 4 or JDG1571 B into flywheel bore DPSG CD03523 35 19 31JAN07 1 4 3 Check and adjust valve clearance to specifications according to following procedures Specification Valve clearance engine cold 0 35 mm 0 014 in 0 45 mm 0 018 in NOTE If rocker arm is equipped with adjusting screw and i jam nut A tighten jam nut to 27 Nem 20 lb ft after adjusting valve clearance CD30545 UN 19MAY98 4 Reinstall rocker arm cover and crankcase vent tube RG6307 UN 03AUG92 Continued on next page DPSG CD03523 35 19 31JAN07 2 4 35 4 061208 PN 92 Maintenance 1000 hours 1 year e 3 Cylinder Engine NOTE Firing order is 1 2 3 a Lock No 1 piston at TDC compression stroke D b Adjust valve clearance on No 1 and 2 exhaust valves and No 1 and 3 intake valves c Rotate flywheel 360 Lock No 1 piston at TDC exhaust stroke E d Adjust valve clearance on No 3 exhaust valve and No 2 intake valve A Front of engine B Exhaust valve C lIntake valve D No 1 Piston at TDC compression stroke E No 1 Piston at TDC exhaust stroke co
121. y 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 the exhaust fumes from the area with an exhaust pipe extension If you do not have an exhaust pipe extension open the doors and get outside air into the area TS220 UN 23AUG88 DX AIR 19 17FEB99 1 1 05 7 061208 PN 32 Safety 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 lf an accident occurs see a doctor immediately Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result Doctors unfamiliar with this type of injury should reference a knowledgeable medical source Such information is available from Deere amp Company Medical Department in Moline Illinois U S A Avoid Heating Near Pressurized Fluid Lines Flammable spray can be generated by heating near pressurized flui

Manual - KVA Diesel-EL

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