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John Deere CD4039DF008 Automobile Parts User Manual

1. 30 4 Replace fuel filter 30 3 As required F Additional service information 50 1 Clean or replace air filter one piece 50 2 Fuel filter Clean or replace air filter element 50 3 Replacement 30 3 Do not modify fuel system 50 1 Index 1 112699 PN 1 Index Page Page Replace fan and alternator belts V POWERTech 50 4 Daily or every 10 hours 25 1 Valve clearance Observe service intervals 20 1 Adjust 300 Series 35 3 Use correct fuel lubricant and coolant 20 1 Adjust POWERTech 40 1 Metric torque values 65 5 Mixing lubricants 10 4 O Operating the engine Break in period 15 1 Engine operation 15 4 Standby power units 15 4 Starting the engine 15 1 Stopping the engine 15 5 Using a booster battery or charger 15 3 R Record keeping Engine option codes 03 3 Engine serial number plate 03 1 POWERTech medallion 03 1 Record engine serial number 03 2 Record fuel injection pump model number 03 5 S Specifications ENG 22ckeseen neue eee eee eee ES 65 1 Storage ENJO ee ae nee Aes Ane Ane Ane
2. 35 2 Check tension 30 4 Replace POWERTech 50 4 L Break in engine oil 10 2 Lubricant MIXING mn cn en en en cle ETE a ter 10 4 C Storage 10 3 Coolant Diesel engine 10 4 M Drain and flush cooling system 45 1 Wal il Temipelatlie CMS ists seen ses 2 Maintenance records 02 1 Crankcase vent tube Cleaning 03 1 35 1 VEINIENANSE DD A D DD Re ee ne 1000 hours 1 year Check and adjust valve clearance 800 SerieS sc raa esvvaagadese datas 35 3 D Checking air intake system 35 1 Checking automatic belt tensioner Damper 40 4 POWERTech 35 2 Diesel engine oil 10 3 Cleaning crankcase vent tube 03 1 35 1 Di s liuel ses mans nemnmamenemanetE 10 1 2000 hours 2 years Adjust speed droop governor 40 3 Adjust valve clearance POWERTech 40 1 Check engine speed 40 3 E Damper check 40 4 2500 hours 3 years Engine oil Drain and flush cooling system 45 1 Break Dae 2 te tee bee een ee ee ne 10 2 50 hours 2 weeks LI E PR PR EEE NE ARE 10 3 Checking Users ss ss 50 5 Disining 245242 mrrinimanmanananenstene 30 1 500 hours Engine speed 40 3 Changing engine oil and filter 30 1 Checking belt
3. Unified Inch Bolt and Cap Screw Torque Vales 62324348 vo 5 SONG aa 545545 Metric Bolt and Cap Screw Torque Values Page 40 4 45 1 50 1 50 1 50 2 50 3 50 4 50 5 50 6 55 1 55 6 60 1 60 1 60 2 60 3 65 1 65 4 65 5 112699 PN 2 Identification Views IDENTIFICATION VIEWS A Ha rs T i ti D Len i a oo Q 10 gt lt x ise zZ 5 T KR O se a O 4045HF158 Continued on next page DPSG CD03523 3 19 05JUL99 1 2 01 1 112699 PN 5 Identification Views CD30745 UN 23AUG99 6068HF158 DPSG CD03523 3 19 05JUL99 2 2 01 2 112699 PN 6 Maintenance Records USING MAINTENANCE RECORDS To obtain the best performance economy and service life from your engine ensure service is carried out according to this present manual and recorded in the following pages It is recommended that your engine Distributor or your Dealer carry out this service work and stamp the appropriate case Keeping an accurate account of all service performed on your engine will give more value to the machine when you resell it John Deere oils and coolants have been formulated to give maximum protection and performance to your engine We recommend only genuine John Deere service products and replacement parts To protect your rights under the warranty ensure all scheduled services are carried out and recorded If your en
4. Clean air filter element when restriction indicator is red Replace filter element after 6 cleanings or once a year bChange oil and filter after the first 100 hours of operation then every 500 hours thereafter Change oil and filter at least once a year Check belt tension every 500 hours on 300 Series engines and on POWERTech engines with manual tensioner Check automatic belt tensioner every 1000 hours 1 year on POWERTech 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 300 Series engines Every 2000 hours on POWERTech 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 Contact 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 09JUL99 1 1 20 2 112699 PN 44 Maintenance Daily or every 10 hours DAILY PRESTARTING CHECKS a D 2 S S Zz I Le le N a Q O CD30755 UN 24SEP99 N Do the following BEFORE STARTING THE ENGINE for the first time each day IMPORTANT DO NOT top up with
5. Maintenance 2000 hours 2 years Check and adjust engine valve clearance POWERTech ENGINE Checking engine speed Adjust speed droop governor 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 re served to make changes at any time without notice COPYRIGHT 1999 DEERE amp COMPANY European Office Mannheim All rights reserved A John Deere ILLUSTRUCTION Manual 112699 PN 1 Contents Checking crankshaft vibration damper 6 CYLINDER ENGINE ONLY Maintenance 2500 hours 3 years Drain and flush cooling system Maintenance As required Additional service information Do not modify fuel system Clean or replace air filter one piece Clean or replace air filter element Replacing fan and alternator belt POWERTech ENGINES Checking fuel filter Bleeding the fuel system Troubleshooting Engine troubleshooting Electrical troubleshooting Storage Engine storage guidelines Use AR41785 engine storage kit Preparing engine for long term storage Removing engine from long term storage Specifications General engine specifications
6. BELT POWERTECH ENGINES WITH MANUAL TENSIONER Inspect belt 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 1 Loosen cap screws B and C 2 Slide alternator in slot by hand to remove all excess slack in belt A Belt gauge B Cap screw IMPORTANT Do not pry against alternator rear frame C Cap screw 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 4 Tighten cap screws B and C RG9132 UN 040CT99 DPSG CD03523 57 19 16AUG99 1 1 30 5 112699 PN 51 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 bore for elbow adapter Tighten hose clamp securely CD30773 UN 27AUG99 DPSG CD03523 32 19 12JUL99 1 1 CHECKING AIR INTAKE SYSTEM D D O 2 lt N ii PA 2 j a oO e D A O IMPORTANT The air intake system must not leak 2 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 en
7. 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 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 13JUL99 4 4 40 2 112699 PN 58 Maintenance 2000 hours 2 years CHECKING ENGINE SPEED NOTE Most engines for generator set application 1500 rom for 50 Hz or 1800 rom for 60 Hz run only at fast idle and therefore they do not have slow idle o i Fast idle Specification zZ 50 Hz Generator S ti essri 1550 1580 rpm 60 HZ Generator Set 2 2225rcremsreterssdrsremmetemerinanse sue 1865 1890 rpm g oO 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 by an authorized fuel system agent DPSG CD03523 38 19 13JUL99 1 1 ADJUST SPEED DROOP GOVERNOR 1 Warm engine to normal operating temperature 2 Run engine at fast idle 3 Apply full load 4 If specified power cannot be obtained turn screw B to adjust droop until the requested power is reached D D a WwW wn Zz gt I Le N re ise A oO NOTE If surging exists upon
8. 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 UN 26AUG99 DPSG CD03523 27 19 12JUL99 3 3 25 2 112699 PN 46 Maintenance 500 hours CHANGING ENGINE OIL AND FILTER NOTE Change engine oil and filter for the first time after 100 hours maximum of operation then every 500 hours thereafter Change oil and filter at least once a year 1 Run engine approximately 5 minutes to warm up oil Shut engine off 2 Open oil pan drain valve A CD30758 UN 26AUG99 3 Drain crankcase oil from engine while warm 4 Remove and discard oil filter element B using a suitable filter wrench 5 Remove oil filter packing and clean filter mounting pad IMPORTANT Filtration of oils is critical to proper lubrication Always change filter regularly Use filters meeting John Deere performance specifications CD30759 UN 26AUG99 6 Oil the new packing and install a new filter element Hand tighten element according to values printed on filter element If values are not provided tighten element approximately 3 4 1 1 4 turn after packing contacts filter housing DO NOT overtighten filter element 7 Close oil pan drain valve CD30760 U
9. correct viscosity Consult fuel supplier use proper type fuel for operating conditions Drain flush fill and bleed system Replace filter element Have authorized servicing dealer or engine distributor check injectors DPSG CD03523 49 19 10AUG99 1 5 55 1 112699 PN 70 Troubleshooting Symptom Engine knocks Engine runs irregularly or stalls frequently Below normal engine temperature Lack of power Problem Injection pump shut off not reset 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 Engine overloaded Intake air restriction Clogged fuel filter Improper type of fuel Overheated engine Below normal engine temperature Improper valve clearance Dirty or faulty injection nozzles Continued on next page Solution Turn key switch to OFF then to ON 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 an
10. 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 Slowly open the radiator cap Remove engine block drain plug A On POWERTech engines remove oil cooler housing drain plug B Open radiator drain valve C Drain all coolant from radiator Close all drain orifices after coolant has drained Fill the cooling system with clean water Run engine until water passes through the thermostat to stir up possible rust or sediment Stop engine and immediately drain the water from system before rust and sediment settle After draining water close all drain orifices and fill the cooling system with clean water and TY15979 John Deere Heavy Duty Cooling System Cleaner or equivalent cleaner Follow manufacturer s directions on label 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 ZX016192 Continued on next page RG4894 UN 14DEC88 TS281 UN 23AUG88 ZX016192 UN 11JAN99 CD30765 UN 27AUG99 DPSG CD03523 41 19 13JUL99 1 3 45 1 112699 PN 61 Maintenance 2500 hours 3 years 10 Check cooling system hoses for proper condition Replace as necessary 11 Close all drain orifices and fill the cooling system with specified coolant see DIESEL E
11. fresh 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 _ CD30754 UN 26AUG99 FD000047 UN 13MAR96 FD000047 DIESEL ENGINE OIL Add oil at rocker arm cover filler cap B IMPORTANT DO NOT fill above the crosshatch area Oil levels anywhere within crosshatch are considered in the acceptable operating range Continued on next page DPSG CD03523 27 19 12JUL99 1 3 112699 PN 45 Maintenance Daily or every 10 hours TS281 UN 23AUG88 CD30756 UN 26AUG99 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 overall cooling system for leaks 2 CAUTION Explosive release of fluids from ressurized cooling system can cause serious burns Only remove filler cap when engine is cold or when cool enough to touch with bare hands Slowly loosen cap to first stop to relieve pressure before removing completely DPSG CD03523 27 19 12JUL99 2 3 3 If air filter has a dust unloading valve C squeeze valve tip to release any trapped dirt particles 4 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
12. of warranty protection for this engine POWERTECH is a trademark of Deere amp Company 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 List of emission related components e Fuel injection pump e Intake manifold e Turbocharger e Charge air cooling system e Piston 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 DPSG CD03523 1 19 01JUL99 1 1 112699 P
13. 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 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 09JUL99 1 1 STARTING THE ENGINE A CAUTION Before starting engine in a confined building install proper outlet exhaust ventilation equipment Always use safety approved fuel storage and piping NOTE If temperature is below 0 C 32 F it may be necessary to use cold weather starting aids See COLD WEATHER OPERATION 1 Perform all prestarting checks outlined in Maintenance Daily Section 2 Open the fuel supply shut off valve if equipped 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 seconds at a time DPSG CD03523 18 19 09JUL99 1 1 COLD WEATHER OPERATION Depending on equipment various cold weather starting aids are available to assist in starting the engine at temperatures below 0 C 32 F Continued on next page DPSG CD03523 19 19 09JUL99 1 4 112699 PN 38 Operating the Engine Air intake heater p DS
14. removing the load turn screw B clockwise to eliminate DPSG CD03523 39 19 13JUL99 1 1 40 3 112699 PN 59 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 3 Check vibration damper radial runout by positioning a dial indicator so probe contacts damper outer circumference 4 With engine at operating temperature rotate crankshaft using JDG820 or JDE83 Flywheel Turning Tool 5 Note dial indicator reading If runout exceeds specifications given below replace vibration damper D gt zZ el Zz j co S D N Oo a Damper Specification Maximum radial runout 1 50 mm 0 060 in DPSG CD03523 40 19 13JUL99 1 1 40 4 112699 PN 60 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 A CAUTION Explosive release of fluids from pressurized cooling system can cause serious burns Shut off
15. storage up to one year After that the crankcase for each 0 95 L 1 at of crankcase oil engine should be started warmed up and retreated for an extended storage period 6 Disconnect air intake piping from the manifold Pour 90 ml 3 oz of inhibitor into intake system and IMPORTANT Any time your engine will not be reconnect the piping used for over six 6 months the following recommendations for 7 Crank the engine several revolutions with starter storing it and removing it from do not allow the engine to start storage will help to minimize corrosion and deterioration Use the 8 Remove fan alternator belt if desired AR41785 Engine Storage Kit Follow recommended service procedure 9 Remove and clean battery Store them in a cool included with storage kit dry place and keep them fully charged 1 Change engine oil and replace filter Used oil will 10 Clean the exterior of the engine with salt free not give adequate protection See CHANGING water and touchup any scratched or chipped ENGINE OIL AND FILTER painted surfaces with a good quality paint Service air cleaner See CLEAN OR REPLACE 11 Coat all exposed machined metal surfaces with AIR FILTER grease or corrosion inhibitor if not feasible to paint Draining and flushing of cooling system is not 12 Seal all openings on engine with plastic bags and necessary if engine is to be stored only for several tape supplied in storage kit Follow instructions months However for ex
16. 0 The following oil is also recommended e John Deere TORQ GARD SUPREME TORQ GARD SUPREME Other oils may be used if they meet one or more of the following API Service Classification CG 4 API Service Classification CF 4 ACEA Specification E3 ACEA Specification E2 Multi viscosity diesel engine oils are preferred If diesel fuel with sulfur content greater than 0 5 is used reduce the service interval by 50 PLUS 50 is a registered trademark of Deere amp Company TORQ GARD SUPREME is a trademark of Deere amp Company SAE 15W 40 SAE 5W 30 SAE OW 40 SAE 10W 40 TS1661 UN 100CT97 CD ENOIL 19 10OCT97 1 1 LUBRICANT STORAGE Your equipment can operate at top efficiency only when clean lubricants are used Use clean containers to handle all lubricants Whenever possible store lubricants and containers in an area protected from dust moisture and other contamination Store containers on their side to avoid water and dirt accumulation Make certain that all containers are properly marked to identify their contents Properly dispose of all old containers and any residual lubricant they may contain DX LUBST 19 18MAR96 1 1 10 3 112699 PN 35 Fuels Lubricants and Coolant MIXING OF LUBRICANTS In general avoid mixing different brands or types of oil Oil manufacturers blend additives in their oils to meet certain specificati
17. 19 16AUG99 1 1 02 4 112699 PN 10 Maintenance Records 3500 HOURS OF OPERATION O Engine oil replace O Engine oil filter replace O Fuel filter replace O Belt check tension and wear 300 Series and POWERTech with manual tensioner g Valve clearance adjust 300 Series Number of hours Comments Date Job done by Dealer or distributor stamp DPSG CD03523 62 19 16AUG99 1 1 4000 HOURS OF OPERATION O Engine oil replace O Cooling system drain and flush if COOL GARD is not used O Engine oil filter replace g Valve clearance adjust POWERTech Cj Fuel filter replace g Air intake system check O Check belt and tensioning system O Vibration damper check O Crankcase vent tube clean Number of hours Comments Date Job done by Dealer or distributor stamp DPSG CD03523 63 19 16AUG99 1 1 02 5 112699 PN 11 Maintenance Records 4500 HOURS OF OPERATION O Engine oil replace O Vibration damper replace 6 cyl O Engine oil filter replace O Fuel filter replace O Belt check tension and wear 300 Series and POWERTech with manual tensioner g Valve clearance adjust 300 Series Number of hours Comments Dealer or distributor stamp Date Job done by DPSG CD03523 64_ 19 16AUG99 1 1 5000 HOURS OF OPERATION O Engine oil replace g Injection nozzle
18. 250 2150 1550 2700 2000 3400 2550 1 1 2 1000 725 1250 925 990 725 1250 930 2250 1650 2850 2100 3600 2650 4550 3350 DO NOT use these values if a different torque value Fasteners should be replaced with the same or or tightening procedure is given for a specific application Torque values listed are for general use only Check tightness of fasteners periodically Shear bolts are designed to fail under predetermined loads Always replace shear bolts with identical grade 4 Lubricated means coated with a lubricant such as engine oil or fasteners with phosphate and oil coatings Dry means plain or zinc plated without any lubrication 5 Grade 2 applies for hex cap screws not hex bolts up to 152 mm 6 in long Grade 1 applies for hex cap screws over 152 mm 6 in long and for all other types of bolts and screws of any length higher grade if higher grade fasteners are used these should only be tightened to the strength of the original Make sure fasteners threads are clean and that you properly start thread engagement This will prevent them from failing when tightening Tighten plastic insert or crimped steel type lock nuts to approximately 50 percent of the dry torque shown in the chart applied to the nut not to the bolt head Tighten toothed or serrated type lock nuts to the full torque value TS1656_ 19 02APR97 DX TORQ1_ 19 20JUL94 1 1 65 4 112699 PN 83 Specifica
19. 60 1 Storing fuel 10 1 Storing lubricants 10 3 T Torque values ARR E E E E E 65 4 MEO Ipina ate e arae ai ae aa ana ana des 65 5 Troubleshooting l ctrical zz zasesssessesemauemaueree 55 6 ENGING 22222223 oe E55 BESS TESS TESS TESS 55 1 Index 2 112699 PN 2
20. 93 Engine oil quantity L 19 5 19 5 19 5 Engine coolant L 29 26 26 quantity aWith Fan PApproximate DPSG CD03523 55 19 10AUG99 3 3 65 3 112699 PN 82 Specifications UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUES SAE Grade and Head Markings SAE Grade and Nut Markings 1 or 2 5 5 1 5 2 8 NO MARK 63 2 5 Grade 1 Grade 2 Grade 5 5 1 or 5 2 Grade 8 or 8 2 Size Lubricated Dry2 Lubricateda Drys Lubricateda Drys Lubricated Dry2 4 L Nm Ib ft Nm lb ft Nm Ib ft Nm lb ft Nm lb ft Nm Ib ft Nem lb ft Nem Ib ft T 1 4 37 28 47 35 6 45 75 55 9 5 7 12 9 135 10 17 125 5 16 77 55 10 7 12 9 15 11 20 15 25 18 28 21 35 26 3 8 14 10 17 13 22 16 27 20 35 26 44 33 50 36 63 46 7 16 22 16 28 20 35 26 44 32 55 41 70 52 80 58 100 75 1 2 33 25 42 31 53 39 67 50 85 63 110 80 120 90 150 115 9 16 48 36 60 45 75 56 95 70 125 90 155 115 175 130 225 160 5 8 67 50 85 62 105 78 135 100 170 125 215 160 240 175 300 225 3 4 120 87 150 110 190 140 240 175 300 225 375 280 425 310 550 400 7 8 190 140 240 175 190 140 240 175 490 360 625 450 700 500 875 650 1 290 210 360 270 290 210 360 270 725 540 925 675 1050 750 1300 975 1 1 8 400 300 510 375 400 300 510 375 900 675 1150 850 1450 1075 1850 1350 1 1 4 570 425 725 530 570 425 725 530 1300 950 1650 1200 2050 1500 2600 1950 1 3 8 750 550 950 700 750 550 950 700 1700 1
21. E GUIDELINES 1 John Deere engines can be stored outside for up to MUST BE taken See PREPARING ENGINE FOR three 3 months with no long term preparation IF LONG TERM STORAGE COVERED BY WATERPROOF COVERING 5 For John Deere engines not yet installed in 2 John Deere engines can be stored in a standard machines run a line from a container of AR41937 overseas shipping container for up to three 3 Nucle Oil from AR41785 Engine Storage Kit to the months with no long term preparation fuel transfer pump intake and another line from the fuel return manifold to the tank so that Nucle Oil is 3 John Deere engines can be stored inside circulated through the injection system during warehoused for up to six 6 months with no long cranking term preparation 4 John Deere engines expected to be stored more than six 6 months long term storage preparation DPSG CD03523 51 19 10AUG99 1 1 USE AR41785 ENGINE STORAGE KIT See your John Deere servicing dealer or engine distributor for an AR41785 Engine Storage Kit Closely follow instructions provided with this kit IMPORTANT Inhibitors can easily change to gas 8 Seal or tape each opening immediately S after adding inhibitor 2 I 2 DPSG CD03523 52 19 10AUG99 1 1 60 1 112699 PN 77 Storage PREPARING ENGINE FOR LONG TERM STORAGE The following storage preparations are good for long 5 Add 30 ml 1 oz of inhibitor to the engine term engine
22. ICE 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 amp ground Stop the engine Remove the key Allow machine to cool Securely support any machine elements that must be raised for service work Keep all parts in good condition and properly installed Fix damage immediately Replace worn or broken parts Remove any buildup of grease oil or debris On self propelled equipment disconnect battery ground cable before making adjustments on electrical systems i i 8 or welding on machine lo On towed implements disconnect wiring harnesses from 5 tractor before servicing electrical system components or welding on machine D 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 2 doors and get outside air into the area i D Oo A D DX AIR 19 17FEB99 1 1 05 7 112699 PN 29 Safety AVOID HIGH PRESSURE FLUIDS Escaping fluid under pressure can penetrate the skin causing serious injury Avoid the hazard
23. IONS Carefully read all safety messages in this manual and on your machine safety signs Keep safety signs in good condition Replace missing or damaged safety signs Be sure new equipment components and repair parts include the current safety signs Replacement safety signs are available from your John Deere dealer Learn how to operate the machine and how to use controls properly Do not let anyone operate without instruction TS201 UN 23AUG88 Keep your machine in proper working condition Unauthorized modifications to the machine may impair the function and or safety and affect machine life If you do not understand any part of this manual and need assistance contact your John Deere dealer DX READ 19 03MAR93 1 1 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 112699 PN 25 Safety HANDLE FUEL SAFELY AVOID FIRES Handle fuel with care it is highly flammable Do not refuel the machine while smoking or when near open flame or sparks Always stop engine before refueling machine Fill fuel tank 8 outdoors 2 Prevent fires by keeping
24. N 2 Contents Page Identification Views Identification views 01 1 Maintenance Records Using maintenance records 02 1 100 Hours of operation 02 1 500 Hours of operation 02 2 1000 Hours of operation 02 2 1500 Hours of operation 02 3 2000 Hours of operation 02 3 2500 Hours of operation 02 4 3000 Hours of operation 02 4 3500 Hours of operation 02 5 4000 Hours of operation 02 5 4500 Hours of operation 02 6 5000 Hours of operation 02 6 5500 Hours of operation 02 7 6000 Hours of operation 02 7 6500 Hours of operation 02 8 7000 Hours of operation 02 8 7500 Hours of operation 02 9 8000 Hours of operation 02 9 8500 Hours of operation 02 10 9000 Hours of operation 02 10 9500 Hours of operation 02 11 10000 Hours of operation 02 11 Record Keeping POWERTech medallion 03 1 Engine serial number plate 03 1 Record engine serial number 03 2 Engine option codes 03 3 Record fuel injection pump model number 03 5 Safety 4 22rea0ctsirsiuseini
25. N 26AUG99 300 Series engine Continued on next page DPSG CD03523 29 19 12JUL99 1 2 30 1 112699 PN 47 Maintenance 500 hours 8 Fill engine crankcase with correct John Deere engine oil through rocker arm cover opening C see DIESEL ENGINE OIL To determine the correct oil fill quantity for your engine see Engine Oil Quantities in 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 IMPORTANT Immediately after completing any oil change crank engine for 30 seconds without permitting engine to start This will help insure adequate lubrication to engine components before engine starts 9 Start engine and run to check for possible leaks 10 Stop engine and check oil level after 10 minutes If necessary top up FD000047 fo bes rm E gt CD30761 UN 24SEP99 FD000047 UN 13MAR96 DPSG CD03523 29 19 12JUL99 2 2 30 2 112699 PN 48 Maintenance 500 hours REPLACING FUEL FILTER ELEMENT X9811 UN 23AUG88 RG7721 UN 15JAN99 A Retaining ring B Filter element C Drain plug D Bleed plug IMPORTANT Do not dump the old fuel into the new filter element This could cause fuel injection problem CAUTION CAUTION Escaping fluid under pressure can penetrate the skin causing serious injury Reli
26. NGINE COOLANT Cooling system capacity Specification CD3029DF128 14 5 L 15 5 at CD4039DF008 16 5 L 17 5 at CD4039TFO08 16 5 L 17 5 at 01D 107 1ed a ke1 20 L 21 qt CD4045HFA158 cccsccsseccssesecessesccssecssssscsesseceesevecsssvceesseeeeseees 25 L 26 5 at CD4045TF 158 25 L 26 5 at CD4045TF258 25 L 26 5 at CD6068HF 158 29 L 30 5 at CD6068TF158 26 L 27 5 at CD6068TF258 26 L 27 5 at DPSG CD03523 41 19 13JUL99 2 3 12 When refilling cooling system loosen temperature sensor B or plug at the rear of cylinder head to allow air to escape 13 Run engine until it reaches operating temperature then check coolant level and entire cooling system for leaks o gt x Si Zz j Ce oO a Q oO DPSG CD03523 41 19 13JUL99 3 3 45 2 112699 PN 62 Maintenance As required ADDITIONAL SERVICE INFORMATION This manual does not allow a complete repair of your engine If you want want more detailled service information the following publications are available from your regular parts channel e PC2451 Parts Catalog e CTM3274 Component Technical Manual for 300 Series engines English e CTM104 Component Technical Manual for POWERTech engines English e CTM67 Component Technical Manual for OEM Engine accessories English only e CTM77 Component Technical Manual for Alternators and Star
27. PN 65 Maintenance As required REPLACING FAN AND ALTERNATOR BELT POWERTECH 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 N 2 On engines with automatic belt tensioner release tension on belt using a breaker bar and socket on 5 tension arm S On engines with manual tensioner loosen cap screws Installation on 4 cyl engines holding the alternator 3 Remove poly vee belt from pulleys and discard belt 9 4 Install new belt making sure belt is correctly seated in all pulley grooves Refer to belt routing at right for your 1 application 5 Apply tension to belt see CHECKING BELT wr gt 6 Start engine and check belt alignment 5 I Installation on 6 cyl engines ALT Alternator CP Crankshaft Pulley FD Fan Drive I Idler Pulley T Tensioner WP Water Pump DPSG CD03523 45 19 15JUL99 1 1 50 4 112699 PN 66 Maintenance As required CHECKING FUEL FILTER Periodically the fuel filter should be checked for water or debris IMPORTANT Drain water into a suitable container and dispose of properly 1 Loosen drain plug B at bottom of fuel filter two or three turns RG9868 UN 15JAN99 2 Loosen air bleed plug two full turns A on fuel filter base and drain water from bottom until fuel
28. POWER Units for Gensets Saran 2 9L 4039 4 5 6 8L 128 008 158 258 OPERATOR S MANUAL John Deere Usine de Saran OMCD16564 03JANO00 in Germany ENGLISH DEERE Scene MTL POWER Introduction THIS MANUAL COVERS the following engines for generator sets ENGINE FAMILY 300 SERIES ENGINE MODEL CD3029DF 128 CD4039DF008 CD4039TF008 CD4045DF 158 CD4045HF158 CD4045TF158 CD4045TF258 CD6068HF 158 CD6068TF158 CD6068TF258 POWERTECH 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 Record Keeping Section Accurately record all the numbers Your dealer also needs these numbers when you order parts File the identification numbers in a secure place off the engine 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 specifications or otherwise overpowering will result in loss
29. S iro 0 oc Continued on next page DPSG CD03523 34 19 13JUL99 1 2 35 2 112699 PN 53 Maintenance 1000 hours 1 year e Checking tensioner spring tension A belt tension gauge will not give an accurate measure of the belt tension when automatic spring tensioner is used Measure tensioner spring tension using a torque wrench and procedure outlined below a Release tension on belt using a breaker bar and socket on tension arm Remove belt from pulleys b Release tension on tension arm and remove breaker bar c Put a mark A on swing arm of tensioner as shown d Measure 21 mm 0 83 in from A and put a mark B on tensioner mounting base e Rotate the swing arm using a torque wrench until marks A and B are aligned f Record torque wrench measurement and compare with specification below Replace tensioner assembly as required RG7977 UN 14NOV97 Spring Specification FOMC sete ns nie E T 18 22 Nem 13 16 lb ft DPSG CD03523 34 19 13JUL99 2 2 CHECK AND ADJUST ENGINE VALVE CLEARANCE 300 SERIES 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 distributor adjust the engine valve clearance CD30544 UN 19MAY98 1 Remove rocker arm cover and crankcase vent tube 2 Using JDE83 or JDG820 Fl
30. Tech Cj Fuel filter replace O Thermostat replace O Check belt and tensioning system O Vibration damper check O Crankcase vent tube clean O Injection nozzles replace g Air intake system check Number of hours Comments Dealer or distributor stamp Date Job done by DPSG CD03523 75 19 16AUG99 1 1 02 11 112699 PN 17 Record Keeping POWERTECH MEDALLION A medallion is located on the rocker arm cover which identifies each engine as a John Deere POWERTECH engine POWERTECH is a trademark of Deere amp Company JOHN DEERE 8 Z xt B i F a 45 liter 2 O a DPSG CD03523 11 19 O05JUL99 1 1 ENGINE SERIAL NUMBER PLATE POWERTech engine Each engine has a 13 digit John Deere serial number The first two digits identify the factory that produced the engine CD indicates the engines was built in Saran France CD30746 UN 24SEP99 300 Series engine Your engine s serial number plate A is located on the right hand side of cylinder block behind the fuel filter for POWERTech engines and near the fuel supply pump on 300 Series engines DPSG CD03523 12 19 05JUL99 1 1 112699 PN 18 Record Keeping 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 O bi D4039D1 23 56 This information is
31. ain 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 DPSG CD03523 49 19 10AUG99 3 5 55 3 112699 PN 72 Troubleshooting Symptom Engine emits black or grey exhaust smoke Engine overheats High fuel consumption Problem Improper type of fuel Clogged or dirty air cleaner Engine overloaded Injection nozzles dirty Engine out of time Turbocharger not functioning Engine overloaded Low coolant level Faulty radiator cap Stretched poly vee belt or defective belt tensioner Low engine oil level Cooling system needs flushing Defective thermostat Defective temperature gauge or sender Incorrect grade of fuel Improper type of fuel Clogged or dirty air cleaner Continued on next page Solution Use proper fuel Service air cleaner Reduce load See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor Reduce load Fill radiator to proper level check radiator and hoses for loose connections or leaks Have serviceman check Check automatic belt tensioner and check belts for
32. asteners periodically Shear bolts are designed to fail under predetermined loads Always replace shear bolts with identical property class Fasteners should be replaced with the same or higher property class If higher property class fasteners are used these should only be tightened to the strength of the original Make sure fasteners threads are clean and that you properly start thread engagement This will prevent them from failing when tightening Tighten plastic insert or crimped steel type lock nuts to approximately 50 percent of the dry torque shown in the chart applied to the nut not to the bolt head Tighten toothed or serrated type lock nuts to the full torque value Lubricated means coated with a lubricant such as engine oil or fasteners with phosphate and oil coatings Dry means plain or zinc olated without any lubrication TS1657_ 19 02APR97 DX TORQ2 19 20JUL94 1 1 65 5 112699 PN 84 Index Page Page A Fuel system Bleeding 50 6 Air filter Fuel Clean or replace one piece 50 2 Digole ene TE Eara 40e 14494 1444 Jagat 10 1 Clean or replace element 50 3 Handling and storing 10 1 Air intake system Checking aes icban sat eee eee te yee pa eW 35 1 l B Identification views 01 1 Inch torque values 65 4 Belt Check automatic tensioner
33. b done by DPSG CD03523 71 19 16AUG99 1 1 02 9 112699 PN 15 Maintenance Records 8500 HOURS OF OPERATION O Engine oil replace O Engine oil filter replace O Fuel filter replace O Belt check tension and wear 300 Series and POWERTech with manual tensioner g Valve clearance adjust 300 Series Number of hours Comments Dealer or distributor stamp Date Job done by DPSG CD03523 72 19 16AUG99 1 1 9000 HOURS OF OPERATION O Engine oil replace g Air intake system check O Engine oil filter replace O Vibration damper replace 6 cyl O Fuel filter replace O Check belt and tensioning system O Crankcase vent tube clean Number of hours Comments Dealer or distributor stamp Date Job done by DPSG CD03523 73 19 16AUG99 1 1 02 10 112699 PN 16 Maintenance Records 9500 HOURS OF OPERATION O Engine oil replace O Engine oil filter replace O Fuel filter replace O Belt check tension and wear 300 Series and POWERTech with manual tensioner g Valve clearance adjust 300 Series Number of hours Comments Dealer or distributor stamp Date Job done by DPSG CD03523 74 19 16AUG99 1 1 10000 HOURS OF OPERATION O Engine oil replace g Cooling system drain and flush O Engine oil filter replace g Valve clearance adjust POWER
34. by relieving pressure before disconnecting hydraulic or other lines Tighten all connections before applying pressure Search for leaks with a piece of cardboard Protect hands and body from high pressure fluids X9811 UN 23AUG88 If an accident occurs see a doctor immediately Any fluid injected 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 DX FLUID 19 03MAR93 1 1 AVOID HEATING NEAR PRESSURIZED FLUID LINES Flammable spray can be generated by heating near pressurized fluid lines resulting in severe burns to yourself and bystanders Do not heat by welding soldering or using a torch near pressurized fluid lines or 8 other flammable materials Pressurized lines can be accidentally cut when heat goes beyond the immediate 1 flame area 7 sl a p DX TORCH 19 03MAR93 1 1 05 8 112699 PN 30 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 8 lt Do all work outside or in a well ventilated area Dispose of a paint and solvent properly 7 Remove paint before welding or heating 4 e f you sand or grind pa
35. d connections Reduce load Service air cleaner Replace filter element 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 DPSG CD03523 49 19 10AUG99 2 5 55 2 112699 PN 71 Troubleshooting Symptom Low oil pressure High oil consumption Engine emits white smoke Problem 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 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 Continued on next page Solution 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 and fill crankcase with oil of proper viscosity and quality Use oil of correct viscosity Check for leaks in lines gaskets and dr
36. e Records Section engine DPSG CD03523 24 19 09JUL99 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 3 Engine 3 Consult your John Deere engine distributor servicing dealer or your nearest John Deere Parts Network for 8 recommended fuels lubricants and coolant Also available are necessary additives for use when operating engines in tropical arctic or any other adverse conditions DPSG CD03523 25 19 09JUL99 1 1 20 1 112699 PN 43 Maintenance MAINTENANCE INTERVAL CHART Item 10H 500 H 1000 H 2000 H 2500 H As daily 1 year 2 years 3 years required Check engine oil and coolant level Check air filter restriction indicator Change engine oil and filter e Replace fuel filter element Check belt tension and automatic tensioner e Check and adjust valve clearance e e Clean crankcase vent tube Check air intake hoses connections and system Check vibration damper 6 cyl e Check engine speed and speed droop governor Drain and flush cooling system Drain water and sediment from fuel filter Clean filter element see note a Test thermostat and injection nozzles see your dealer e
37. e clearance engine cold Specification Intake s ceccscewsccitcencseecescvvsinecbeces ense nice ieuna 0 35 mm 0 014 in ExMaUSt nn Rae 0 45 mm 0 018 in 4 If valves need adjusting loosen the lock nut 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 lock nut to 27 Nem 20 lb ft Recheck clearance again after tightening lock nut Readjust clearance as necessary a 0 D lt re aT Z D T a 36 nN o a 5 Reinstall rocker arm cover and crankcase vent tube Continued on next page DPSG CD03523 36 19 13JUL99 2 4 40 1 112699 PN 57 Maintenance 2000 hours 2 years e 4 Cylinder Engine NOTE Firing order is 1 3 4 2 a b Rotate flywheel 360 Lock No 4 piston at TDC 4 Eri E 2 el Adjust valve clearance on No 2 and 4 exhaust 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 compression stroke C 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 36 19 13JUL99 3 4 e 6 Cylinder Engine NOTE Firing order is 1 5 3 6 2 4 a b C Adjust valve clearance on No 2 4 and 6 exhaust Lock
38. e for remaining injection nozzles if necessary until all air has been removed from fuel system If engine still will not start see your authorized servicing dealer or engine distributor D D A W N D Zz l N o a Q O RG7725 UN 08JAN97 DPSG CD03523 46 19 10AUG99 2 2 50 7 112699 PN 69 Troubleshooting ENGINE TROUBLESHOOTING Symptom Engine cranks but will not start Engine hard to start or will not start Problem Incorrect starting procedure No fuel Exhaust restricted Fuel filter plugged or full of water Injection pump not getting fuel or air in 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 Continued on next page 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
39. e such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises TS207 UN 23AUG88 DX NOISE _ 19 03MAR93 1 1 05 5 112699 PN 27 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 you start any job using a hazardous chemical That way you will know exactly what the risks are and how to do the job safely Then follow procedures and recommended equipment See your John Deere dealer for MSDS s on chemical products used with John Deere equipment DX MSDS NA 19 03MAR93 1 1 STAY CLEAR OF ROTATING DRIVELINES Entanglement in rotating driveline can cause serious injury or death Keep master shield and driveline shields in place at all 6 times Make sure rotating shields turn freely A 3 2 lt Wear close fitting clothing Stop the engine and be sure Pe i 2 the PTO driveline is stopped before making adjustments or performing any type service on the engine or PTO driven equipment 2 CD PTO 19 12SEP95 1 1 05 6 112699 PN 28 Safety PRACT
40. ed 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 09JUL99 1 1 STANDBY POWER UNITS To assure that your engine will deliver efficient standby operation when needed start engine and run at rated speed with 50 70 load for 30 minutes every 2 weeks DO NOT allow engine to run an extended period of time with no load DPSG CD03523 22 19 09JUL99 1 1 1 5 4 112699 PN 41 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 09JUL99 1 1 15 5 112699 PN 42 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 under 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 Maintenanc
41. es Number of hours Comments Date Job done by Dealer or distributor stamp DPSG CD03523 10 19 05JUL99 1 1 2000 HOURS OF OPERATION O Engine oil replace O Cooling system drain and flush if COOL GARD is not used O Engine oil filter replace g Valve clearance adjust POWERTech Cj Fuel filter replace g Air intake system check O Check belt and tensioning system O Vibration damper check O Crankcase vent tube clean Number of hours Comments Date Job done by Dealer or distributor stamp DPSG CD03523 59 19 16AUG99 1 1 02 3 112699 PN 9 Maintenance Records 2500 HOURS OF OPERATION O Engine oil replace O Engine oil filter replace O Fuel filter replace manual tensioner g Valve clearance adjust 300 Series O Belt check tension and wear 300 Series and POWERTech with O Cooling system drain and flush if COOL GARD is used Number of hours Date Job done by Comments Dealer or distributor stamp DPSG CD03523 60 _ 19 16AUG99 1 1 3000 HOURS OF OPERATION O Engine oil replace O Engine oil filter replace O Fuel filter replace O Check belt and tensioning system O Crankcase vent tube clean O Air intake system check Number of hours Date Job done by Comments Dealer or distributor stamp DPSG CD03523 61
42. eve 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 A plug is provided with the new element for plugging the used element 4 Inspect filter mounting base for cleanliness Clean as required If any fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result Doctors unfamiliar with this type of injury may call the Deere amp Company Medical Department in Moline Illinois or other knowledgeable medical source NOTE Raised locators on fuel filter canister must be indexed properly with slots in mounting base for correct installation 5 Install new filter element dry onto mounting base Be sure element is properly indexed and firmly seated on base It may be necessary to rotate filter for correct alignment 1 Thoroughly clean fuel filter assembly and surrounding area 6 Install retaining ring onto mounting base making certain dust seal is in place on filter base Hand tighten ring about 1 3 turn until it snaps into the 2 Loosen drain plug C and drain fuel into a suitable detent DO NOT overtighten retaining ring container NOTE The proper installation is indicated when a click is heard and a release o
43. f the retaining ring is felt 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 7 Bleed the fuel system DPSG CD03523 30 19 12JUL99 1 1 30 3 112699 PN 49 Maintenance 500 hours CHECKING BELT 300 SERIES ENGINES 1 Inspect belt for cracks fraying or stretched out areas Replace as necessary 2 Check belt tension using one of following methods ce z a Use of JDG529 Tension Gauge A k IZ i gt Belt tension Specification NOW Delt sirasinda sekssana 578 622 N 130 140 lb force S WSCGIDGM 23cm 378 423 N 85 94 lb force 2 NOTE Belt is considered used after 10 minutes of operation b Use of tension tester B and straight edge 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 04MAY98 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 CD30646 UN 04MAY98 DPSG CD03523 31 19 12JUL99 1 1 30 4 112699 PN 50 Maintenance 500 hours CHECKING
44. fr A Air intake heater is either a grid type A for POWERTech Po fn ooo te engines or a glow plug type B for 300 Series engines Beppe d installed in the air intake channel 9 CE CAUTION NEVER use Ether Starting Fluid when air intake heater is used to start the engine y Sh 8 one ee 2 Activate the heating element preheater position for B OR LT F i Pen Z 30 seconds maximum then start the engine ai ee S 8 oO DPSG CD03523 19 19 09JUL99 2 4 Coolant heater Connect plug of coolant heater A to a 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 to the ambient temperature 19 HN DEERE PAL FILTER LX1017708 UN 090CT97 DPSG CD03523 19 19 0O9JUL99 4 4 15 2 112699 PN 39 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 CAUTION Gas given off by batteries is explosive Keep sparks and flames away from batteries Before connecting or disconnecting a battery charger turn charger off Make last connection and first disconnection at a point away from battery Always connec
45. gine failure due to air to air radiator Tighten clamps as necessary abrasive dirt and dust entering the intake system 3 Test air restriction indicator B for proper operation Replace indicator as necessary 1 Inspect all intake hoses piping for cracks Replace as necessary Continued on next page DPSG CD03523 33 19 12JUL99 1 2 35 1 112699 PN 52 Maintenance 1000 hours 1 year 4 If engine has a rubber dust unloading valve C inspect the valve on bottom of air filter for cracks or plugging Replace as necessary 5 Service air filter as necessary G4687 UN 20DEC88 R DPSG CD03523 33 19 12JUL99 2 2 CHECKING AUTOMATIC BELT TENSIONER POWERTECH 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 D gt Z T Zz 2 I co a 3
46. gine is covered by extended warranty it is important to maintain this record for the duration of the warranty DPSG CD03523 6 19 05JUL99 1 1 100 HOURS OF OPERATION O Engine oil replace O Engine oil filter replace g Hose connections check Number of hours Comments Date Job done by Dealer or distributor stamp DPSG CD03523 7__ 19 05JUL99 1 1 112699 PN 7 Maintenance Records 500 HOURS OF OPERATION O Engine oil replace O Engine oil filter replace O Fuel filter replace O Belt check tension and wear 300 Series and POWERTech with manual tensioner g Valve clearance adjust 300 Series Number of hours Comments Dealer or distributor stamp Date Job done by DPSG CD03523 8 19 05JUL99 1 1 1000 HOURS OF OPERATION O Engine oil replace O Air intake system check O Engine oil filter replace O Fuel filter replace O Check belt and tensioning system O Crankcase vent tube clean Number of hours Comments Dealer or distributor stamp Date Job done by DPSG CD03523 9 19 05JUL99 1 1 02 2 112699 PN 8 Maintenance Records 1500 HOURS OF OPERATION O Engine oil replace O Engine oil filter replace O Fuel filter replace O Belt check tension and wear 300 Series and POWERTech with manual tensioner g Valve clearance adjust 300 Seri
47. heck air system entirely for proper condition see CHECKING AIR INTAKE SYSTEM CD30766 UN O6SEP99 RG9912 UN 25FEB99 DPSG CD03523 44 19 15JUL99 1 1 50 2 112699 PN 64 Maintenance As required CLEAN OR REPLACE AIR FILTER ELEMENT C Air restriction indicator D Wing nut 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 every 6 primary element cleaning or at least once a year Proceed as follows 1 Thoroughly clean all dirt around air filter area CD30772 UN 27AUG99 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 must not exceed 600 kPa 6 bar 88 psi 2 Remove wing nut D and remove primary element 5 Mark air filter to keep track of each cleaning A from canister operation IMPORTANT Do not attempt to clean the 6 Fully depress air restriction indicator reset button secondary safety element B It and release to reset indicator must be only replaced as recommended 7 Check air system entirely for proper condition see CHECKING AIR INTAKE SYSTEM 3 Thoroughly clean all dirt from inside canister IMPORTANT If primary element shows evidence of bad condition punched DPSG CD03523 58 19 16AUG99 1 1 50 3 112699
48. ing 87 Automatic Belt Tensioner 40 Oil Dipstick 88 _ __ Oil Filter A1 Belt Driven Front Auxiliary Drive 91 Special Equipment Factory Installed 430 Starting Aid 97 Special Equipment Field Installed 44 Timing Gear Cover with Gears 98 Shipping DPSG CD03523 14 19 05JUL99 2 2 03 4 112699 PN 21 Record Keeping RECORD FUEL INJECTION PUMP MODEL NUMBER Record the fuel injection pump model and serial information found on the serial number plate A Model No RPM Manufacturer s No Serial No D D a W N D Zz D l D o Oo Q O DPSG CD03523 15 19 07JUL99 1 1 03 5 112699 PN 22 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 8 practices a 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 DANGER identifies the most serious hazards DANGER or WARNING safety signs are located near A WARNING g specific hazards General precautions are listed on in CAUTION safety signs CAUTION also calls attention to S safety messages in this manual A CAUTION 7 DX SIGNAL _ 19 03MAR93 1 1 05 1 112699 PN 23 Safety ENGINE LIFTING PROCEDURE CAUTION The only reco
49. int avoid breathing the dust Wear an approved respirator e f you use solvent or paint stripper remove stripper with soap and water before welding Remove solvent or paint stripper containers and other flammable material from area Allow fumes to disperse at least 15 minutes before welding or heating DX PAINT 19 03MAR93 1 1 SERVICE COOLING SYSTEM SAFELY Explosive release of fluids from pressurized cooling system can cause serious burns Shut off engine Only remove filler cap when cool enough to touch with bare hands Slowly loosen cap to first stop 8 to relieve pressure before removing completely 2 3 7 DX RCAP 19 04JUN90 1 1 05 9 112699 PN 31 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 8 are brake pads brake band and lining assemblies clutch 2 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 g airborne dust containing asbestos is not generated 2 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 app
50. ive belt tensioner Engine under load Loose or corroded connections Low battery output voltage Faulty start circuit relay Blown fuse Continued on next page Solution Remove accessories or install higher output alternator Increase engine rpm when heavy electrical load is used Inspect and clean as necessary Test battery Test charging system Check for moisture and replace as necessary Test battery Test charging system Clean and tighten connections See your authorized servicing dealer or engine distributor Adjust belt tension or replace belts 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 10AUG99 1 2 55 6 112699 PN 75 Troubleshooting Symptom Starter cranks slowly Entire electrical system Problem Low battery output Crankcase oil too heavy Loose or corroded connections Faulty battery connection Sulfated or worn out battery Blown fuse 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 10AUG99 2 2 55 7 112699 PN 76 Storage ENGINE STORAG
51. ize the fuel and prevent water condensation Contact your fuel supplier for recommendations DX FUEL4 19 18MAR96 1 1 112699 PN 33 Fuels Lubricants and Coolant ENGINE BREAK IN OIL New engines are filled at the factory with John Deere ENGINE BREAK IN OIL During the break in period 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 PLUS 50 is a registered trademark of Deere amp Company e ACEA Specification E1 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 API CG4 API CF4 ACEA E3 or ACEA E2 performance levels during the first 100 hours of operation of a new or rebuilt engine These oils will not allow the engine to break in properly DX ENOIL4 19 10OCT97 1 1 10 2 112699 PN 34 Fuels Lubricants and Coolant DIESEL ENGINE OIL Use oil viscosity based on the expected air temperature range during the period between oil changes The following oil is preferred e John Deere PLUS 5
52. ll with new coolant after the first 3 years or 3000 hours of operation Subsequent drain intervals are determined by the coolant used for service At each interval drain the coolant flush the cooling system and refill with new coolant When John Deere COOL GARD is used the coolant drain interval is 3 years or 3000 hours of operation If COOL GARD is not used the drain interval is reduced to 2 years or 2000 hours of operation DX COOL8 19 12FEB99 1 1 10 4 112699 PN 36 Fuels Lubricants and Coolant OPERATING IN WARM TEMPERATURE CLIMATES John Deere engines are designed to operate using glycol base engine coolants Always use a recommended glycol base engine coolant even when operating in geographical areas where freeze protection is not required IMPORTANT Water may be used as coolant in emergency situations only Foaming hot surface aluminum and iron corrosion scaling and cavitation will occur when water is used as the coolant even when coolant conditioners are added Drain cooling system and refill with recommended glycol base engine coolant as soon as possible DX COOL6 19 18MAR96 1 1 10 5 112699 PN 37 Operating the Engine BREAK IN PERIOD Within first 100 hours of operation During the first 100 hours of operation avoid overloading excessive idling and no load operation See ENGINE BREAK IN OIL for eventual addition of oil NOTE During the break in
53. ly 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 S Use leakproof containers when draining fluids Do not use 2 food or beverage containers that may mislead someone Z into drinking from them l Do not pour waste onto the ground down a drain or into D 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 10 112699 PN 32 Fuels Lubricants and Coolant DIESEL FUEL Consult your local fuel distributor for properties of the diesel fuel available in your area In general diesel fuels are blended to satisfy the low temperature requirements of the geographical area in which they are marketed Diesel fuels specified to EN 590 or ASTM D975 are recommended In all cases the fuel shall meet the following properties Cetane number of 40 minimum Cetane nu
54. machine clean of accumulated 5 trash grease and debris Always clean up spilled fuel 3 DX FIRE1 19 03MAR93 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 8 hospital and fire department near your telephone z 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 2 To prevent accidental discharge when storing the pressurized can keep the cap on the container and store 2 in a cool protected location Do not incinerate or puncture a starting fluid container 2 DX FIRE3 19 16APR92 1 1 05 4 112699 PN 26 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 devic
55. mber greater than 50 is preferred especially for temperatures below 20 C 4 F or elevations above 1500 m 5 000 ft Cold Filter Plugging Point CFPP below the expected low temperature OR Cloud Point at least 5 C 9 F below the expected low temperature Fuel lubricity should pass a minimum of 3100 gram load level as measured by the BOCLE scuffing test Sulfur content Sulfur content should not exceed 0 5 Sulfur content less than 0 05 is preferred If diesel fuel with sulfur content greater than 0 5 sulfur content is used reduce the service interval for engine oil and filter by 50 e DO NOT use diesel fuel with sulfur content greater than 1 0 Bio diesel fuels may be used ONLY if the fuel properties meet DIN 51606 or equivalent specification DO NOT mix used engine oil or any other type of lubricant with diesel fuel DX FUEL1 19 17FEB99 1 1 HANDLING AND STORING DIESEL FUEL A CAUTION Handle fuel carefully Do not fill the fuel tank when engine is running DO NOT smoke while you fill the fuel tank or service the fuel system Fill the fuel tank at the end of each day s operation to prevent 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 original vented cap When fuel is stored for an extended period or if there is a slow turnover of fuel add a fuel conditioner to stabil
56. mmended 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 Ki y l 1 U 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 equipped install lifting straps and torque to 200 Nem 145 lb 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 060CT99 1 1 05 2 112699 PN 24 Safety FOLLOW SAFETY INSTRUCT
57. nd POWERTech with manual tensioner g Valve clearance adjust 300 Series Number of hours Comments Dealer or distributor stamp Date Job done by DPSG CD03523 68 19 16AUG99 1 1 7000 HOURS OF OPERATION O Engine oil replace O Air intake system check O Engine oil filter replace O Fuel filter replace O Check belt and tensioning system O Crankcase vent tube clean Number of hours Comments Dealer or distributor stamp Date Job done by DPSG CD03523 69 19 16AUG99 1 1 02 8 112699 PN 14 Maintenance Records 7500 HOURS OF OPERATION O Engine oil replace O Cooling system drain and flush if COOL GARD is used O Engine oil filter replace O Fuel filter replace O Belt check tension and wear 300 Series and POWERTech with manual tensioner g Valve clearance adjust 300 Series Number of hours Comments Dealer or distributor stamp Date Job done by DPSG CD03523 70 19 16AUG99 1 1 8000 HOURS OF OPERATION O Engine oil replace O Cooling system drain and flush if COOL GARD is not used O Engine oil filter replace g Valve clearance adjust POWERTech Cj Fuel filter replace g Air intake system check O Check belt and tensioning system O Vibration damper check O Crankcase vent tube clean Number of hours Comments Dealer or distributor stamp Date Jo
58. ng engine Operate engine at high idle for 1 to 2 minutes 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 Minimum oil pressure at full load rated speed Specification PIOSSUTE ie 275 kPa 2 75 bar 40 psi Coolant temperature range Specification WOMPSlALUNG near unes 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 Oil at normal operating temperature of 115 C 240 F Unusual noise or vibration Excessive black exhaust fumes Excessive fuel consumption Excessive oil consumption 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 crankcase oil dilution due to incomplete fuel combustion and permits formation of gummy deposits on valves pistons and piston rings It also promotes rapid accumulation of engine sludge and unburn
59. nteietn s 05 1 Fuels Lubricants and Coolant Diesel Fuel 10 1 Handling and Storing Diesel Fuel 10 1 Engine Break In Oil 10 2 Diesel Engine Oil 10 3 Lubricant Storage 10 3 Mixing of Lubricants 10 4 Diesel Engine Coolant Operating in Warm Temperature Climates Operating the Engine Break in period Starting the engine Cold weather operation Using a booster battery or charger Engine operation Standby power units Stopping the engine Maintenance Observe service intervals Use correct fuels lubricants and coolant Maintenance interval chart Maintenance Daily or every 10 hours Daily prestarting checks Maintenance 500 hours Changing engine oil and filter Replacing fuel filter element Checking belt 300 SERIES ENGINES Checking belt POWERTech ENGINES with manual tensioner Maintenance 1000 hours 1 year Cleaning crankcase vent tube Checking air intake system Checking automatic belt tensioner POWERTech ENGINES Check and adjust engine valve clearance 300 SERIES ENGINES
60. odes if an option has been added after the engine left the producing factory If option code label is lost or destroyed consult your servicing dealer or engine distributor selling the engine for a replacement Continued on next page DPSG CD03523 14 19 O05JUL99 1 2 03 3 112699 PN 20 Record Keeping Option Description Option Description Codes Codes Engine Base Code TI Rocker Arm Cover 45 Balancer Shaft 12 Oil Filler Neck 46 Cylinder Block With Liners and Camshaft 19 Crankshaft Pulley 47 Crankshaft and Bearings 14 Flywheel Housing 48 Connecting Rods and Pistons 15 Flywheel 49 Valve Actuating Mechanisms 16 Fuel Injection Pump 50 Oil Pump 17 Air inlet Sio Cylinder Head With Valves te Air cleaner 52 Auxiliary Gear Drive 19 Oil pan 54 Oil heater 20 Coolant pump 55 Shipping stand 21 Thermostat Cover 56 Paint Option 22 Thermostat 57 Coolant Inlet 23 Fan Drive 59 Oil Cooler 24 Fan Belt 60_ Add on Auxiliary Drive Pulley 25 Fan 62 Alternator Mounting 26 Engine Coolant Heater 64 Exhaust Elbow 27 Radiator 65 Turbocharger 280 Exhaust Manifold 66 Temperature Switch 2905 o Ventilator System 67 Electronic Tachometer Sensor 30 Starting Motor 68 Damper Alternator 69 Engine Serial Number Plate 382 Instrument Panel 74 Air Conditioning System Compressor Mounting 35 Fuel Filter 19e Air Restriction Indicator 36 Front Plate 76 Oil Pressure Switch 87 Fuel Transfer Pump 86 Fan Pulley 89 Thermostat Hous
61. ons and performance requirements Mixing different oils can interfere with the proper functioning of these additives and degrade lubricant performance Consult your John Deere dealer to obtain specific information and recommendations DX LUBMIX 19 18MAR96 1 1 DIESEL ENGINE COOLANT The engine cooling system is filled to provide year round protection against corrosion and cylinder liner pitting and winter freeze protection to 37 C 34 F John Deere COOL GARD is preferred for service If John Deere COOL GARD is not available use a low silicate ethylene 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 A 50 mixture of ethylene glycol engine coolant in water provides freeze protection to 37 C 34 F If protection at lower temperatures is required consult your John Deere dealer for recommendations Water quality is important to the performance of the cooling system Distilled deionized or demineralized water is recommended for mixing with ethylene glycol base engine coolant concentrate IMPORTANT Do not use cooling system sealing additives or antifreeze that contains sealing additives COOLANT DRAIN INTERVALS Drain the factory fill engine coolant flush the cooling system and refi
62. p carefully and check all gauges before 3 Install fan alternator belt if removed placing engine under load 4 Fill fuel tank 8 On the first day of operation after storage check overall engine for leaks and check all gauges for 5 Perform all appropriate prestarting checks See correct operation DAILY PRESTARTING CHECKS DPSG CD03523 54 19 10AUG99 1 1 60 3 112699 PN 79 Specifications GENERAL ENGINE SPECIFICATIONS ITEM UNIT OF MEASURE 3029DF128 4039DF008 4039TF008 Number of Cylinders 3 4 4 Fuel Diesel Diesel Diesel Bore mm 106 5 106 5 106 5 Stroke mm 110 110 110 Displacement 2 9 3 9 3 9 Compression Ratio 17 8 1 17 8 1 17 8 1 POWER KW hp 26 35 35 48 55 75 1500 rpm Prime POWER KW hp 30 41 38 52 61 83 1500 rpm Standby POWER kW hp 30 41 41 56 67 91 1800 rpm Prime POWER kW hp 34 46 47 64 73 99 1800 rpm Standby Width overall mm 582 588 588 Length overall mm 888 1016 1016 Height overall mm 931 960 979 Weight dry kg 345 410 455 Engine oil quantity LE 6 12 12 Engine coolant L 14 5 16 5 16 5 quantity aWith Fan PApproximate Continued on next page DPSG CDO03523 55 19 10AUG99 1 3 65 1 112699 PN 80 Specifications ITEM Number of Cylinders Fuel Bore Stroke Displacement Compression Ratio POWER 1500 rpm Prime POWER 1500 rpm Standby POWER 1800 rpm Prime POWER 1800 rpm Standby Width o
63. r s manual below this section or e On the Engine Owner s Warranty booklet under the title 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 times it will be necessary to furnish this base code to differentiate two identical option codes for the same engine model The first two digits of each code identify a specific group such as alternators The last two digits of each code identify one specific option provided on your engine such as a 12 volt 55 amp alternator NOTE These option codes are based on the latest 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 NOTE Your engine option code label may not contain all option c
64. s replace O Engine oil filter replace O Air intake system check g Fuel filter replace O Cooling system drain and flush if COOL GARD is used O Check belt and tensioning system O Crankcase vent tube clean Number of hours Comments Dealer or distributor stamp Date Job done by DPSG CD03523 65 19 16AUG99 1 1 02 6 112699 PN 12 Maintenance Records 5500 HOURS OF OPERATION O Engine oil replace O Engine oil filter replace O Fuel filter replace O Belt check tension and wear 300 Series and POWERTech with manual tensioner g Valve clearance adjust 300 Series Number of hours Comments Date Job done by Dealer or distributor stamp DPSG CD03523 66 19 16AUG99 1 1 6000 HOURS OF OPERATION O Engine oil replace O Cooling system drain and flush if COOL GARD is not used O Engine oil filter replace g Valve clearance adjust POWERTech Cj Fuel filter replace g Air intake system check O Check belt and tensioning system O Vibration damper check O Crankcase vent tube clean Number of hours Comments Date Job done by Dealer or distributor stamp DPSG CD03523 67 19 16AUG99 1 1 02 7 112699 PN 13 Maintenance Records 6500 HOURS OF OPERATION O Engine oil replace O Engine oil filter replace O Fuel filter replace O Belt check tension and wear 300 Series a
65. s been opened up for service lines disconnected or filters removed it will be necessary to bleed air from the system RG7947 UN 13NOV97 1 Loosen the air bleed screw A two full turns by hand on fuel filter base 2 Operate supply pump primer lever B until fuel flow is free from air bubbles 3 Tighten bleed plug securely continue operating hand primer until pumping action is not felt Push hand primer inward toward engine as far as it will go a D Z lt x B zZ T 4 Start engine and check for leaks RG8013A If engine will not start it may be necessary to bleed air from fuel system at fuel injection pump or injection nozzles as explained next Continued on next page DPSG CD03523 46 19 10AUG99 1 2 50 6 112699 PN 68 Maintenance As required e At Fuel Injection Pump 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 c Tighten return line connector to 16 Nem 12 lb ft d Leave hand primer in the inward position toward cylinder block e At Fuel Injection Nozzles a Using two open end wrenches loosen fuel line connection at injection nozzle b Crank 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 lb ft c Repeat procedur
66. starts to drain out 3 When fuel starts to drain out tighten drain plug securely 4 After draining water from the fuel filter the filter must be primed by bleeding all air from the fuel system Operate primer lever of the fuel supply pump C until fuel flow is free from air bubbles 5 Tighten bleed plug securely continue operating hand primer until pumping action is not felt Push hand primer inward toward engine as far as it will go a fez Z lt x B 7 Iz I a oO pe re a If the fuel system needs further bleeding of air see BLEEDING THE FUEL SYSTEM DPSG CD03523 28 19 12JUL99 1 1 50 5 112699 PN 67 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 surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result Doctors unfamiliar with this type of injury may call the Deere amp Company Medical Department in Moline Illinois or other knowledgeable medical source Whenever the fuel system ha
67. stretching Replace as required Check oil level Add oil as required Flush cooling system Remove and check thermostat Check coolant temperature with thermometer and replace if necessary Use correct grade of fuel Use proper type of fuel Service air cleaner DPSG CD03523 49 19 10AUG99 4 5 55 4 112699 PN 73 Troubleshooting Symptom Problem Engine overloaded Improper valve clearance Injection nozzles dirty Engine out of time Defective turbocharger Low engine temperature Solution 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 10AUG99 5 5 55 5 112699 PN 74 Troubleshooting ELECTRICAL TROUBLESHOOTING Symptom Undercharged system Battery uses too much water Battery will not charge Starter will not crank Problem Excessive electrical load from added accessories Excessive engine idling Poor electrical connections on battery ground strap starter or alternator Defective battery Defective alternator Cracked battery case Defective battery Battery charging rate too high Loose or corroded connections Sulfated or worn out battery Stretched poly vee belt or defect
68. t NEGATIVE cable last and disconnect this cable first TS204 UN 23AUG88 IMPORTANT Be sure polarity is correct before making connections Reversed polarity will damage electrical system Always connect positive to positive and negative to ground Always use 12 volt booster battery for 12 volt electrical systems and 24 volt booster battery batteries for 24 volt electrical systems RG4678 UN 14DEC88 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 gt post of the booster battery RG4698 UN 14DEC88 24 Volts System 5 ALWAYS complete the hookup by making the last A 18 Voik Machine batteryibatiaries connection of the NEGATIVE gt cable to a good B 12 Volt Booster battery batteries ground on the engine frame and away from the C Booster cable battery ies D Cable to starter motor 6 Start the engine Disconnect jumper cables immediately after engine starts Disconnect NEGATIVE cable first DPSG CD03523 20 19 09JUL99 1 1 15 3 112699 PN 40 Operating the Engine ENGINE OPERATION Warmi
69. tended storage periods of a supplied in kit year or longer it is recommended that the cooling system be drained flushed and refilled Refill with 13 Store the engine in a dry protected place If appropriate coolant See DIESEL ENGINE engine must be stored outside cover it with a COOLANT waterproof canvas or other suitable protective material and use a strong waterproof tape 4 Drain fuel tank and add 30 ml 1 oz of inhibitor to the fuel tank for each 15 L 4 U S gal of tank capacity Completely drain fuel filter and close fuel valve if equipped DPSG CD03523 53 19 10AUG99 1 1 60 2 112699 PN 78 Storage REMOVING ENGINE FROM LONG TERM STORAGE Refer to the appropriate section for detailed services IMPORTANT DO NOT operate starter more than listed below or have your authorized servicing dealer 30 seconds at a time Wait at least 2 or engine distributor perform services that you may not minutes for starter to cool before be familiar with trying again 1 Remove all protective coverings from engine 6 Crank engine for 20 seconds with starter do not Unseal all openings in engine and remove covering allow the engine to start Wait 2 minutes and crank from electrical systems engine an additional 20 seconds to assure bearing surfaces are adequately lubricated 2 Remove the battery from storage Install battery fully charged and connect the terminals 7 Start engine and run at no load for several minutes Warm u
70. ter Motors English only RG4624 UN 15DEC88 DPSG CD03523 42 19 15JUL99 1 1 DO NOT MODIFY FUEL SYSTEM IMPORTANT Modification or alteration of the injection pump the injection pump timing or the fuel injectors in ways not recommended by the manufacturer will terminate the warranty obligation to the purchaser 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 D D oa W A Zz I 2 N re a Q oO DPSG CD03523 43 19 15JUL99 1 1 50 1 112699 PN 63 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 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 must not exceed 600 kPa 6 bar 88 psi 4 Mark air filter to keep track of each cleaning operation 5 Fully depress air restriction indicator reset button and release to reset indicator 6 C
71. tions METRIC BOLT AND CAP SCREW TORQUE VALUES Class 4 8 Class 8 8 or 9 8 Class 10 9 Class 12 9 Size Lubricated Dry2 Lubricateda Drya Lubricateda Drya Lubricateda Drys Nm Ib ft Nm lb ft N m Ib ft Nm lb ft Nm lb ft N m lb ft Nm 1b ft Nm Ib ft M6 4 8 3 5 6 45 9 6 5 11 8 5 13 9 5 17 12 15 11 5 19 14 5 M8 12 8 5 15 11 22 16 28 20 32 24 40 30 37 28 47 35 M10 23 17 29 21 43 32 55 40 63 47 80 60 75 55 95 70 M12 40 29 50 37 75 55 95 70 110 80 140 105 130 95 165 120 M14 63 47 80 60 120 88 150 110 175 130 225 165 205 150 260 190 M16 100 73 125 92 190 140 240 175 275 200 350 255 320 240 400 300 M18 135 100 175 125 260 195 330 250 375 275 475 350 440 325 560 410 M20 190 140 240 180 375 275 475 350 530 400 675 500 625 460 800 580 M22 260 190 330 250 510 375 650 475 725 540 925 675 850 625 1075 800 M24 330 250 425 310 650 475 825 600 925 675 1150 850 1075 800 1350 1000 M27 490 360 625 450 950 700 1200 875 1350 1000 1700 1250 1600 1150 2000 1500 M30 675 490 850 625 1300 950 1650 1200 1850 1350 2300 1700 2150 1600 2700 2000 M33 900 675 1150 850 1750 1300 2200 1650 2500 1850 3150 2350 2900 2150 3700 2750 M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2750 4750 3500 DO NOT use these values if a different torque value or tightening procedure is given for a specific application Torque values listed are for general use only Check tightness of f
72. troke Continued on next page DPSG CD03523 35 19 13JUL99 3 4 35 4 112699 PN 55 Maintenance 1000 hours 1 year e 4 Cylinder Engine NOTE Firing order is 1 3 4 2 a Lock No 1 piston at TDC compression stroke B b Adjust valve clearance on No 1 and 3 exhaust valves and No 1 and 2 intake valves c Rotate flywheel 360 Lock No 4 piston at TDC 4 3 e g compression stroke C d 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 13JUL99 4 4 35 5 112699 PN 56 Maintenance 2000 hours 2 years CHECK AND ADJUST ENGINE VALVE CLEARANCE POWERTECH ENGINE 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 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 B into flywheel bore CD30544 UN 19MAY98 DPSG CD03523 36 19 13JUL99 1 4 3 Check and adjust valve clearance to specifications according to following procedures Valv
73. verall Length overall Height overall Weight dry Engine oil quantity Engine coolant quantity aWith Fan PApproximate UNIT OF MEASURE mm mm kW hp kW hp kW hp kW hp mm mm mm kg 4045HF158 4 Diesel 106 5 127 4 5 17 0 1 88 120 96 131 108 147 120 163 798 1356 1136 446 12 25 4045TF158 4 Diesel 106 5 127 4 5 17 0 1 61 83 68 92 72 98 79 107 668 1219 1010 436 25 Continued on next page 4045TF258 4 Diesel 106 5 127 4 5 17 0 1 72 98 80 109 80 109 88 120 668 1219 1010 436 12 25 4045DF158 4 Diesel 106 5 127 4 5 17 6 1 41 56 42 57 48 65 51 69 668 1219 1010 391 20 DPSG CD03523 55 19 10AUG99 2 3 65 2 112699 PN 81 Specifications ITEM UNIT OF 6068HF158 6068TF158 6068TF258 MEASURE Number of Cylinders 6 6 6 Fuel Diesel Diesel Diesel Bore mm 106 5 106 5 106 5 Stroke mm 127 127 127 Displacement L 6 8 6 8 6 8 Compression Ratio 17 01 17 0 1 17 0 1 POWER 1500 rpm kW hp 134 182 92 125 105 143 Prime POWER 1500 rpm kW hp 148 201 101 137 116 158 Standby POWER 1800 rpm kW hp 164 223 108 147 124 169 Prime POWER 1800 rpm kW hp 187 254 119 162 137 186 Standby Width overall mm 798 668 668 Length overall mm 1476 1383 1383 Height overall mm 1136 1032 1032 Weight dry kg 613 593 5
74. very important for repair parts or N 4039D F008 coor Abs vA warranty information D P S G SARAN MADE IN FRANCE UN 24AUG99 CD30705B Engine Model Number C 300 Series engine plate JOHN DEERE Coefficient of Absorption Value D Engine Serial Number CD4045T 123456 Abs CD4045TF158 Coeff X XX DEERE amp COMPANY MOLINE ILLINOIS MADE IN FRANCE UN 23AUG99 CD30747 POWERTech engine plate DPSG CD03523 13 19 05JUL99 1 1 03 2 112699 PN 19 Record Keeping ENGINE OPTION CODES JOHN DEERE 6068H F158 0 1300 1 400 1500 Order 2B0000000 1100 120 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 NUMBER CD6068H123456 6 8L 171ECD 000000 OPTION CODES UN 26AUG99 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 Operato
75. ywheel 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 B into flywheel bore Continued on next page DPSG CD03523 35 19 13JUL99 1 4 35 3 112699 PN 54 Maintenance 1000 hours 1 year 3 Check and adjust valve clearance to specifications according to following procedures Valve clearance engine cold Specification Mtaki screen rent 0 35 mm 0 014 in EXN USL cssscsscsvccscsecessevascessbecotenycanesbenviesvsivessevseceverresses 0 45 mm 0 018 in NOTE If rocker arm is equipped with adjusting screw and lock nut A tighten lock nut to 27 Nem 20 Ib ft after adjusting valve clearance CD30545 UN 19MAY98 4 Reinstall rocker arm cover and crankcase vent tube RG6307 UN 03AUG92 DPSG CD03523 35 19 13JUL99 2 4 e 3 Cylinder Engine A 1 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 8 Zz 2 e T 2 I oo 3 8 Q oO A Front of engine B Exhaust valve C Intake valve D No 1 Piston at TDC compression stroke E No 1 Piston at TDC exhaust s

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