John Deere CD4039DF008 OPERATOR’S MANUAL

4 (1)

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 (03JAN00)

Printed in Germany

ENGLISH

Introduction

THIS MANUAL COVERS the following engines for generator sets:

ENGINE FAMILY

ENGINE MODEL

300-SERIES

CD3029DF128

 

CD4039DF008

 

CD4039TF008

POWERTECH

CD4045DF158

 

CD4045HF158

 

CD4045TF158

 

CD4045TF258

 

CD6068HF158

 

CD6068TF158

 

CD6068TF258

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 of warranty protection for this engine.

Information relative to emissions regulations

Depending on final destination, this engine can meet the emissions regulations according to the US Environmental Protection Agency (EPA), California Air Resources Board (CARB) and for Europe, the Directive 97/68/EC relating the measures against the emissions of gaseous and particulates pollutants from internal combustion engines. In this case an emission label is stuck on the engine.

Emission regulations prohibit tampering with the emission-related components listed below which would render that component inoperative or to make any adjustment on the engine beyond published specifications. It is also illegal to install a part or component where the principal effect of that component is to bypass, defeat, or render inoperative any engine component or device which would affect the engine conformance to the emissions regulations. To summarize, it is illegal to do anything except return the engine to its original published specifications.

List of emission-related components:

Fuel injection pump

Intake manifold

Turbocharger

Charge air cooling system

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.

POWERTECH is a trademark of Deere & Company

DPSG,CD03523,1 –19–01JUL99–1/1

 

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Contents

Page

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . 10-4

Operating in Warm Temperature Climates . . . . . 10-5

Operating the Engine

Break-in period . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1 Starting the engine . . . . . . . . . . . . . . . . . . . . . . . 15-1 Cold weather operation . . . . . . . . . . . . . . . . . . . 15-1 Using a booster battery or charger . . . . . . . . . . . 15-3 Engine operation . . . . . . . . . . . . . . . . . . . . . . . . 15-4 Standby power units. . . . . . . . . . . . . . . . . . . . . . 15-4 Stopping the engine . . . . . . . . . . . . . . . . . . . . . . 15-5

Maintenance

Observe service intervals . . . . . . . . . . . . . . . . . . 20-1 Use correct fuels, lubricants and coolant . . . . . . 20-1 Maintenance interval chart . . . . . . . . . . . . . . . . . 20-2

Maintenance/Daily or every 10 hours

Daily prestarting checks . . . . . . . . . . . . . . . . . . . 25-1

Maintenance/500 hours

Changing engine oil and filter . . . . . . . . . . . . . . 30-1 Replacing fuel filter element . . . . . . . . . . . . . . . 30-3 Checking belt (300-SERIES ENGINES) . . . . . . . 30-4 Checking belt (POWERTech ENGINES with

manual tensioner) . . . . . . . . . . . . . . . . . . . . . . 30-5

Maintenance/1000 hours/1 year

Cleaning crankcase vent tube . . . . . . . . . . . . . . 35-1 Checking air intake system . . . . . . . . . . . . . . . . 35-1 Checking automatic belt tensioner

(POWERTech ENGINES) . . . . . . . . . . . . . . . 35-2 Check and adjust engine valve clearance

(300-SERIES ENGINES) . . . . . . . . . . . . . . . . 35-3

Maintenance/2000 hours/2 years

Check and adjust engine valve clearance (POWERTech ENGINE) . . . . . . . . . . . . . . . . . 40-1

Checking engine speed . . . . . . . . . . . . . . . . . . . 40-3 Adjust speed droop governor . . . . . . . . . . . . . . . 40-3

Continued on next page

All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice.

COPYRIGHT 1999

DEERE & COMPANY

European Office Mannheim

All rights reserved

A John Deere ILLUSTRUCTION Manual

i

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Contents

Page

Checking crankshaft vibration damper

(6-CYLINDER ENGINE ONLY) . . . . . . . . . . . 40-4

Maintenance/2500 hours/3 years

Drain and flush cooling system . . . . . . . . . . . . . 45-1

Maintenance/As required

Additional service information . . . . . . . . . . . . . . . 50-1 Do not modify fuel system . . . . . . . . . . . . . . . . . 50-1 Clean or replace air filter (one-piece) . . . . . . . . 50-2 Clean or replace air filter element . . . . . . . . . . . 50-3 Replacing fan and alternator belt

(POWERTech ENGINES) . . . . . . . . . . . . . . . 50-4 Checking fuel filter . . . . . . . . . . . . . . . . . . . . . . . 50-5 Bleeding the fuel system . . . . . . . . . . . . . . . . . . 50-6

Troubleshooting

Engine troubleshooting . . . . . . . . . . . . . . . . . . . . 55-1

Electrical troubleshooting . . . . . . . . . . . . . . . . . . 55-6

Storage

Engine storage guidelines . . . . . . . . . . . . . . . . . 60-1

Use AR41785 engine storage kit . . . . . . . . . . . . 60-1

Preparing engine for long term storage . . . . . . . 60-2

Removing engine from long term storage . . . . . . 60-3

Specifications

General engine specifications. . . . . . . . . . . . . . . 65-1

Unified Inch Bolt and Cap Screw Torque

Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65-4

Metric Bolt and Cap Screw Torque Values . . . . 65-5

ii

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John Deere CD4039DF008 OPERATOR’S MANUAL

Identification Views

IDENTIFICATION VIEWS

CD30744 –UN–23AUG99

4045HF158

Continued on next page

DPSG,CD03523,3 –19–05JUL99–1/2

01-1

112699

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Identification Views

CD30745 –UN–23AUG99

6068HF158

DPSG,CD03523,3 –19–05JUL99–2/2

01-2

112699

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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 engine 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

Engine oil, replace

Engine oil filter, replace

Hose connections, check

Number of hours:

Comments:

Dealer or distributor stamp

Date:

Job done by:

DPSG,CD03523,7 –19–05JUL99–1/1

02-1

112699

PN=7

Maintenance Records

500 HOURS OF OPERATION

Engine oil, replace

Engine oil filter, replace

Fuel filter, replace

Belt, check tension and wear (300-Series and POWERTech with manual tensioner)

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

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Engine oil, replace

 

 

Air intake system, check

 

 

 

Engine oil filter, replace

 

 

 

 

 

 

 

Fuel filter, replace

 

 

 

 

 

 

 

Check belt and tensioning system

 

 

 

 

 

 

 

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

Engine oil, replace

Engine oil filter, replace

Fuel filter, replace

Belt, check tension and wear (300-Series and POWERTech with manual tensioner)

Valve clearance, adjust (300-Series)

Number of hours:

Comments:

Dealer or distributor stamp

Date:

Job done by:

DPSG,CD03523,10 –19–05JUL99–1/1

 

2000 HOURS OF OPERATION

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Engine oil, replace

 

 

Cooling system, drain and flush (if COOL-GARD is not used)

 

 

Engine oil filter, replace

 

 

Valve clearance, adjust (POWERTech)

 

 

 

Fuel filter, replace

 

 

Air intake system, check

 

 

 

Check belt and tensioning system

 

 

Vibration damper, check

 

 

 

Crankcase vent tube, clean

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Number of hours:

Comments:

 

 

Dealer or distributor stamp

 

 

 

Date:

 

 

 

 

 

 

 

Job done by:

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

DPSG,CD03523,59

–19–16AUG99–1/1

 

 

 

 

 

 

 

 

 

 

 

 

 

02-3

 

112699

PN=9

Maintenance Records

2500 HOURS OF OPERATION

Engine oil, replace

Cooling system, drain and flush (if COOL-GARD is used)

Engine oil filter, replace

Fuel filter, replace

Belt, check tension and wear (300-Series and POWERTech with manual tensioner)

Valve clearance, adjust (300-Series)

Number of hours:

Comments:

Dealer or distributor stamp

Date:

Job done by:

DPSG,CD03523,60 –19–16AUG99–1/1

 

3000 HOURS OF OPERATION

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Engine oil, replace

 

 

Air intake system, check

 

 

 

Engine oil filter, replace

 

 

 

 

 

 

 

Fuel filter, replace

 

 

 

 

 

 

 

Check belt and tensioning system

 

 

 

 

 

 

 

Crankcase vent tube, clean

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Number of hours:

Comments:

 

 

Dealer or distributor stamp

 

 

 

Date:

 

 

 

 

 

 

 

Job done by:

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

DPSG,CD03523,61

–19–16AUG99–1/1

 

 

 

 

 

 

 

 

 

 

 

 

 

02-4

 

112699

PN=10

Maintenance Records

3500 HOURS OF OPERATION

Engine oil, replace

Engine oil filter, replace

Fuel filter, replace

Belt, check tension and wear (300-Series and POWERTech with manual tensioner)

Valve clearance, adjust (300-Series)

Number of hours:

Comments:

Dealer or distributor stamp

Date:

Job done by:

DPSG,CD03523,62 –19–16AUG99–1/1

 

4000 HOURS OF OPERATION

 

 

 

 

 

 

 

 

 

 

 

 

Engine oil, replace

 

Cooling system, drain and flush (if COOL-GARD is not used)

 

 

Engine oil filter, replace

 

Valve clearance, adjust (POWERTech)

 

 

 

Fuel filter, replace

 

Air intake system, check

 

 

 

Check belt and tensioning system

 

Vibration damper, check

 

 

 

Crankcase vent tube, clean

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Number of hours:

Comments:

 

Dealer or distributor stamp

 

 

 

Date:

 

 

 

 

 

 

Job done by:

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

DPSG,CD03523,63

–19–16AUG99–1/1

 

 

 

02-5

 

112699

PN=11

Maintenance Records

4500 HOURS OF OPERATION

Engine oil, replace

Vibration damper, replace (6 cyl.)

Engine oil filter, replace

Fuel filter, replace

Belt, check tension and wear (300-Series and POWERTech with manual tensioner)

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

 

 

 

 

 

 

 

 

 

 

 

 

 

Engine oil, replace

 

Injection nozzles, replace

 

 

 

Engine oil filter, replace

 

Air intake system, check

 

 

 

Fuel filter, replace

 

Cooling system, drain and flush (if COOL-GARD is used)

 

 

Check belt and tensioning system

 

 

 

 

 

 

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

Engine oil, replace

Engine oil filter, replace

Fuel filter, replace

Belt, check tension and wear (300-Series and POWERTech with manual tensioner)

Valve clearance, adjust (300-Series)

Number of hours:

Comments:

Dealer or distributor stamp

Date:

Job done by:

DPSG,CD03523,66 –19–16AUG99–1/1

 

6000 HOURS OF OPERATION

 

 

 

 

 

 

 

 

 

 

 

 

Engine oil, replace

 

Cooling system, drain and flush (if COOL-GARD is not used)

 

 

Engine oil filter, replace

 

Valve clearance, adjust (POWERTech)

 

 

 

Fuel filter, replace

 

Air intake system, check

 

 

 

Check belt and tensioning system

 

Vibration damper, check

 

 

 

Crankcase vent tube, clean

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Number of hours:

Comments:

 

Dealer or distributor stamp

 

 

 

Date:

 

 

 

 

 

 

Job done by:

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

DPSG,CD03523,67

–19–16AUG99–1/1

 

 

 

02-7

 

112699

PN=13

Maintenance Records

6500 HOURS OF OPERATION

Engine oil, replace

Engine oil filter, replace

Fuel filter, replace

Belt, check tension and wear (300-Series and POWERTech with manual tensioner)

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

 

 

 

 

 

 

 

 

 

 

 

 

 

Engine oil, replace

 

Air intake system, check

 

 

 

Engine oil filter, replace

 

 

 

 

 

 

Fuel filter, replace

 

 

 

 

 

 

Check belt and tensioning system

 

 

 

 

 

 

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

Engine oil, replace

Cooling system, drain and flush (if COOL-GARD is used)

Engine oil filter, replace

Fuel filter, replace

Belt, check tension and wear (300-Series and POWERTech with manual tensioner)

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

 

 

 

 

 

 

 

 

 

 

 

 

Engine oil, replace

 

Cooling system, drain and flush (if COOL-GARD is not used)

 

 

Engine oil filter, replace

 

Valve clearance, adjust (POWERTech)

 

 

 

Fuel filter, replace

 

Air intake system, check

 

 

 

Check belt and tensioning system

 

Vibration damper, check

 

 

 

Crankcase vent tube, clean

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Number of hours:

Comments:

 

Dealer or distributor stamp

 

 

 

Date:

 

 

 

 

 

 

Job done by:

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

DPSG,CD03523,71

–19–16AUG99–1/1

 

 

 

02-9

 

112699

PN=15

Maintenance Records

8500 HOURS OF OPERATION

Engine oil, replace

Engine oil filter, replace

Fuel filter, replace

Belt, check tension and wear (300-Series and POWERTech with manual tensioner)

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

 

 

 

 

 

 

 

 

 

 

 

 

 

Engine oil, replace

 

Air intake system, check

 

 

 

Engine oil filter, replace

 

Vibration damper, replace (6 cyl.)

 

 

 

Fuel filter, replace

 

 

 

 

 

 

Check belt and tensioning system

 

 

 

 

 

 

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

Engine oil, replace

Engine oil filter, replace

Fuel filter, replace

Belt, check tension and wear (300-Series and POWERTech with manual tensioner)

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

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Engine oil, replace

 

Cooling system, drain and flush

 

 

 

Engine oil filter, replace

 

Valve clearance, adjust (POWERTech)

 

 

 

Fuel filter, replace

 

Thermostat, replace

 

 

 

Check belt and tensioning system

 

Vibration damper, check

 

 

 

Crankcase vent tube, clean

 

Injection nozzles, replace

 

 

 

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 & Company

ENGINE SERIAL NUMBER PLATE

RG8007 –UN–15JAN99

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.

–UN–15JAN99 RG8041 DPSG,CD03523,11 –19–05JUL99–1/1

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

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Record Keeping

RECORD ENGINE SERIAL NUMBER

Record all of the numbers and letters found on your engine serial number plate in the spaces provided below.

This information is very important for repair parts or warranty information.

Engine Serial Number (B)

___________________

CD30705B –UN–24AUG99

Engine Model Number (C)

300-Series engine plate

___________________

Coefficient of Absorption Value (D)

___________________

POWERTech engine plate

CD30747 –UN–23AUG99

DPSG,CD03523,13 –19–05JUL99–1/1

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Record Keeping

ENGINE OPTION CODES

CD30748A –UN–26AUG99

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:

On this page of your Operator’s manual below this section.

or

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 codes if an option has been added after the engine left the producing factory.

If option code label is lost or destroyed, consult your servicing dealer or engine distributor selling the engine for a replacement.

Continued on next page

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Record Keeping

Option

Description

Option

Description

Codes

 

Codes

 

Engine Base Code:________

 

 

11____

Rocker Arm Cover

45____

Balancer Shaft

12____

Oil Filler Neck

46____

Cylinder Block With Liners and Camshaft

13____

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

51____

Cylinder Head With Valves

18____

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

28____

Exhaust Manifold

66____

Temperature Switch

29____

Ventilator System

67____

Electronic Tachometer Sensor

30____

Starting Motor

68____

Damper

31____

Alternator

69____

Engine Serial Number Plate

32____

Instrument Panel

74____

Air Conditioning System Compressor Mounting

35____

Fuel Filter

75____

Air Restriction Indicator

36____

Front Plate

76____

Oil Pressure Switch

37____

Fuel Transfer Pump

86____

Fan Pulley

39____

Thermostat Housing

87____

Automatic Belt Tensioner

40____

Oil Dipstick

88____

Oil Filter

41____

Belt Driven Front Auxiliary Drive

91____

Special Equipment (Factory Installed)

43____

Starting Aid

97____

Special Equipment (Field Installed)

44____

Timing Gear Cover with Gears

98____

Shipping

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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. _________________________________

CD30749 –UN–24SEP99

DPSG,CD03523,15 –19–07JUL99–1/1

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Safety

RECOGNIZE SAFETY INFORMATION

This is a safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury.

Follow recommended precautions and safe operating practices.

UNDERSTAND SIGNAL WORDS

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 specific hazards. General precautions are listed on CAUTION safety signs. CAUTION also calls attention to safety messages in this manual.

–UN–07DEC88 T81389 DX,ALERT –19–29SEP98–1/1

TS187 –19–30SEP88

DX,SIGNAL –19–03MAR93–1/1

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Safety

ENGINE LIFTING PROCEDURE

CAUTION: The only recommended method for lifting the engine is with JDG23 Engine Lifting Sling (A) and safety approved lifting straps (B) that come with engine. Use extreme caution when lifting and NEVER permit any part of the body to be positioned under an engine being lifted or suspended.

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 N•m (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.

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RG7784 –UN–11NOV97

DPSG,CD03523,95 –19–06OCT99–1/1

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Safety

FOLLOW SAFETY INSTRUCTIONS

Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in good condition. Replace missing or damaged safety signs. Be sure new equipment components and repair parts include the current safety signs. Replacement safety signs are available from your John Deere dealer.

Learn how to operate the machine and how to use controls properly. Do not let anyone operate without instruction.

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.

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.

05-3

TS201 –UN–23AUG88

DX,READ –19–03MAR93–1/1

TS177 –UN–11JAN89

DX,BYPAS1 –19–29SEP98–1/1

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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 outdoors.

Prevent fires by keeping machine clean of accumulated trash, grease, and debris. Always clean up spilled fuel.

PREPARE FOR EMERGENCIES

Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.

HANDLE STARTING FLUID SAFELY

Starting fluid is highly flammable.

Keep all sparks and flame away when using it. Keep starting fluid away from batteries and cables.

To prevent accidental discharge when storing the pressurized can, keep the cap on the container, and store in a cool, protected location.

Do not incinerate or puncture a starting fluid container.

05-4

TS202 –UN–23AUG88

DX,FIRE1 –19–03MAR93–1/1

–UN–23AUG88 TS291 DX,FIRE2 –19–03MAR93–1/1

TS1356 –UN–18MAR92

DX,FIRE3 –19–16APR92–1/1

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