John Deere 3029, 4039, 4045, 6059, 6068 Repair Manual

3029 4039, 4045 6059, 6068

Engines (Saran)

( -499999CD)

COMPONENT

TECHNICAL

MANUAL

John Deere Usine de Saran

CTM3274 (01JUL99)

European Version

Printed in Germany

ANGLAIS

3029, 4039, 4045, 6059, 6068

Engines (Saran)

( -499999CD)

CTM3274 (01JUL99)

FOREWORD

Introduction

This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use.

Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.

This is the safety-alert symbol. When you see

this symbol on the machine or in this manual, be alert to the potential for personal injury.

Use this component technical manual in conjunction with the machine technical manual. An application listing in the introduction identifies product-model/component type-model relationship. See the machine technical manual for information on component removal and installation, and gaining access to the components.

This manual is divided in two parts: repair and operation and tests. Repair sections contain

necessary instructions to repair the component. Operation and tests sections help you identify the majority of routine failures quickly.

Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values.

Component Technical Manuals are concise service guides for specific components. Component technical manuals are written as stand-alone manuals covering multiple machine applications.

Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.

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ENGINE IDENTIFICATION VIEWS

Introduction

CD30699 -UN-23FEB99

3029D 3029T

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4039D 4039T

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Introduction

ENGINE IDENTIFICATION VIEWS (CONT’D)

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6068D 6068H

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Engine application chart

This Component Technical Manual contains service information on the 3029, 4039, 4045, 6059 and 6068 engines produced by JOHN DEERE Saran (FRANCE)

NOTE: Information on how to remove and reinstall

the engine in the vehicle is contained in the relevant Technical Manual.

for the applications listed in the application chart.

3000-SERIES TRACTORS ENGINE MODEL SERIAL NUMBER

3100 . . . . . . . . . . . . . . . . . . . . . . . . CD3029DRT65 (189846 - )

3110 . . . . . . . . . . . . . . . . . . . . . . . . CD3029DRT65

3200/3200X . . . . . . . . . . . . . . . . . . . . CD4039DRT35 (181345 - )

3210/3210X . . . . . . . . . . . . . . . . . . . . CD4039DRT35

3300/3300X . . . . . . . . . . . . . . . . . . . . CD4045DRT35 (182145 - )

3310/3310X . . . . . . . . . . . . . . . . . . . . CD4045DRT35

3400/3400X . . . . . . . . . . . . . . . . . . . . CD4039TRT35 (181775 - )

3410/3410X . . . . . . . . . . . . . . . . . . . . CD4039TRT35

4000-SERIES TELESCOPIC ENGINE MODEL SERIAL NUMBER HANDLERS

4400 . . . . . . . . . . . . . . . . . . . . . . . . CD4039TF005 (237697 - )

4500 . . . . . . . . . . . . . . . . . . . . . . . . CD4039TF005

5000-SERIES TRACTORS ENGINE MODEL SERIAL NUMBER (Agritalia-built)

5300/5300N . . . . . . . . . . . . . . . . . . . . CD3029DAT01 (315424 - )

5400/5400N . . . . . . . . . . . . . . . . . . . . CD3029TAT02 (289398 - )

5500/5500N . . . . . . . . . . . . . . . . . . . . CD4039TAT01 (346168 - )

5000-SERIES TRACTORS ENGINE MODEL SERIAL NUMBER (Augusta-built)

5400N . . . . . . . . . . . . . . . . . . . . . . . CD3029TLV01

5500N . . . . . . . . . . . . . . . . . . . . . . . CD4039TLV01 (201353 - )

5000-SERIES TRACTORS ENGINE MODEL SERIAL NUMBER (For India)

5300 . . . . . . . . . . . . . . . . . . . . . . . . CD3029DPY01 (383283 - )

(Continued on next page)

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Engine application chart

ENGINE APPLICATION CHART (CONT’)

6000-SERIES TRACTORS ENGINE MODEL SERIAL NUMBER

6100 (Direct fan drive) . . . . . . . . . . . . CD4045DL001 (101582 - )

6100 (Viscous fan drive) . . . . . . . . . . . CD4045DL002 (101582 - )

6200 (Direct fan drive) . . . . . . . . . . . . CD4039TL001 (101625 - )

6200 (Viscous fan drive) . . . . . . . . . . . CD4039TL004 (101625 - )

6300 (Direct fan drive) . . . . . . . . . . . . CD4039TL003 (101649 - )

6300 (Viscous fan drive) . . . . . . . . . . . CD4039TL006 (101649 - )

6400 (Direct fan drive) . . . . . . . . . . . . CD4045TL001 (101682 - )

6400 (Viscous fan drive) . . . . . . . . . . . CD4045TL003 (101682 - )

6506 (Viscous fan drive) . . . . . . . . . . . CD6068DL001 (214852 - )

6600 (Viscous fan drive) . . . . . . . . . . . CD6059TL001 (128886 - )

6800 (Viscous fan drive) . . . . . . . . . . . CD6068TL001 (124505 - )

6900 (Viscous fan drive) . . . . . . . . . . . CD6068TL002 (186326 - )

WATERLOO TRACTORS ENGINE MODEL SERIAL NUMBER

7600 . . . . . . . . . . . . . . . . . . . . . . . . T06068TRW01

ZWEIBRÜCKEN COMBINES ENGINE MODEL SERIAL NUMBER

2054 . . . . . . . . . . . . . . . . . . . . . . . . 6068HZ001 (116452 - )

2254 . . . . . . . . . . . . . . . . . . . . . . . . 6068HZ001

ENGINES FOR CHINESE COMBINES SERIAL NUMBER

CD6059TYC01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . (367019 - )

CD6059TYC02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . (363170 - )

ENGINES FOR GOLDONI TRACTORS SERIAL NUMBER

CD3029DFG21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . (287123 - )

CD3029DFG22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . (287325 - )

CD3029TFG21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . (287526 - )

(Continued on next page)

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Engine application chart

ENGINE APPLICATION CHART (CONT’)

SARAN OEM ENGINES SERIAL NUMBER SARAN OEM ENGINES SERIAL NUMBER

CD3029DF CD3029TF CD3029DF001 CD3029TF001 CD3029DF005 (162670 - ) CD3029TF002 (170797 - ) CD3029DF031 CD3029TF031 CD3029DF032 CD3029TF032 (176015 - ) CD3029DF033 (177875 - ) CD3029TF033 (177880 - ) CD3029DF034 CD3029TF120 CD3029DF120 CD3029TF121 CD3029DF121 CD3029TF123 (354029 - ) CD3029DF122 (263024 - ) CD3029TF160 CD3029DF123 (312932 - ) CD3029TF161 (288419 - ) CD3029DF124 (340207 - ) CD3029TF162 CD3029DF128 CD3029TF163 (342829 - ) CD3029DF160 CD3029DF161 (288417 - ) CD3029DF162 CD3029DF163 CD3029DF164 CD3029DF165

CD4039DF CD4039TF CD4039DF001 CD4039TF001 CD4039DF002 CD4039TF002 CD4039DF004 (152613 - ) CD4039TF003 (169516 - ) CD4039DF005 (165009 - ) CD4039TF004 (152616 - ) CD4039DF006 (340212 - ) CD4039TF005 CD4039DF007 (378895 - ) CD4039TF006 (339780 - ) CD4039DF008 CD4039TF007 (379066 - ) CD4039DF031 CD4039TF008 CD4039DF032 CD4039TF031

CD4039TF032 (166826 - )

CD4045DF001 CD4045TF001 CD4045DF031 CD4045TF002 (170081 - )

CD4045TF003 (342250 - ) CD4045TF008 CD4045TF031

(Continued on next page)

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Engine application chart

ENGINE APPLICATION CHART (CONT’)

SARAN OEM ENGINES SERIAL NUMBER SARAN OEM ENGINES SERIAL NUMBER

CD6059DF CD6059TF CD6059DF001 CD6059TF001 CD6059DF002 CD6059TF002 (158390 - ) CD6059DF003 CD6059TF003 (158394 - )

CD6059TF004 CD6059TF005 (166159 - ) CD6059TF006 (166960 - ) CD6059TF008 (341217 - )

CD6068DF001 CD6068TF001

CD6068TF002 (187378 - ) CD6068TF003 CD6068TF004 (344260 - ) CD6068TF008 CD6068TF009

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HANDLE FLUIDS SAFELY—AVOID FIRES

Group 00

Safety

When you work around fuel, do not smoke or work near heaters or other fire hazards.

Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers.

Make sure machine is clean of trash, grease, and debris. Do not store oily rags; they can ignite and burn

spontaneously.

PREVENT BATTERY EXPLOSIONS

Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode.

00 1

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Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer.

Do not charge a frozen battery; it may explode. Warm battery to 16˚C (60˚F).

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.

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PREVENT ACID BURNS

Sulfuric acid in battery electrolyte is poisonous. It is

strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.

Avoid the hazard by:

1. Filling batteries in a well-ventilated area.

2. Wearing eye protection and rubber gloves.

3. Avoiding breathing fumes when electrolyte is added.

4. Avoiding spilling or dripping electrolyte.

5. Use proper jump start procedure. If you spill acid on yourself:

1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize the acid.

3. Flush your eyes with water for 15—30 minutes. Get medical attention immediately.

If acid is swallowed:

1. Do not induce vomiting.

2. Drink large amounts of water or milk, but do not exceed 2 L (2 quarts).

3. Get medical attention immediately.

Safety

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AVOID HIGH-PRESSURE FLUIDS

Safety

Escaping fluid under pressure can penetrate the skin causing serious injury.

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids.

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 & Company Medical Department in Moline, Illinois, U.S.A.

00 3

X9811 -UN-23AUG88

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.

Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine.

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SERVICE MACHINES SAFELY

Tie long hair behind your head. Do not wear a necktie,

scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result.

Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.

WORK IN VENTILATED AREA

Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension.

If you do not have an exhaust pipe extension, open the doors and get outside air into the area.

Safety

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WORK IN CLEAN AREA

Before starting a job:

• Clean work area and machine.

• Make sure you have all necessary tools to do your job.

• Have the right parts on hand.

• Read all instructions thoroughly; do not attempt shortcuts.

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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. Do all work outside or in a well ventilated area. Dispose

of paint and solvent properly.

00 5

Remove paint before welding or heating:

• If you sand or grind paint, avoid breathing the dust. Wear an approved respirator.

• If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

AVOID HEATING NEAR PRESSURIZED FLUID LINES

Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area.

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ILLUMINATE WORK AREA SAFELY

Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.

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USE PROPER LIFTING EQUIPMENT

Lifting heavy components incorrectly can cause severe

injury or machine damage. Follow recommended procedure for removal and

installation of components in the manual.

PRACTICE SAFE MAINTENANCE

Understand service procedure before doing work. Keep area clean and dry.

Never lubricate, service, or adjust machine while it is moving. Keep hands, feet , and clothing from power-driven parts. Disengage all power and operate controls to relieve pressure. Lower equipment to the ground. Stop the engine. Remove the key. Allow machine to cool.

Safety

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Securely support any machine elements that must be raised for service work.

Keep all parts in good condition and properly installed. Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or debris.

On self-propelled equipment, disconnect battery ground cable (-) before making adjustments on electrical systems or welding on machine.

On towed implements, disconnect wiring harnesses from tractor before servicing electrical system components or welding on machine.

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USE PROPER TOOLS

Safety

Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards.

Use power tools only to loosen threaded parts and fasteners.

For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches.

Use only service parts meeting John Deere specifications.

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.

00 7

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Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

Do not pour waste onto the ground, down a drain, or into any water source.

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.

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LIVE WITH SAFETY

Before returning machine to customer, make sure

machine is functioning properly, especially the safety systems. Install all guards and shields.

Safety

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ENGINE IDENTIFICATION

The engine can be identified from the serial plate (A) located on the right-hand side of the engine. Some applications also have an additional serial plate located on top of the flywheel housing. Refer to the engine type to identify repair information in the Component Technical Manual.

ENGINE PLATE INFORMATION (EARLIER DESIGN)

Three types of plates are used on engines and give the following information:

Group 01

General information

01 1

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First line (all plates)

CD . . . . . . . . . . . . . Manufacturing factory

(CD = Saran, T0 = Dubuque)

4045 . . . . . . . . . . Engine model designation

4 = Number of cylinders 045 = Total displacement (045 = 4.5 liters)

D . . . . . . . . . Aspiration code

D = Naturally Aspirated H = air-to-air aftercooled T = Turbocharged

000000 . . . . Sequential serial number

Second line (all plates)

4045D . . . . . . . . . . . See above

L . . . . . . . . . . User code

F = OEM application L = Mannheim RW = Waterloo Tractor Z = Zweibrücken

001 . . . . . . . . Application number

Third line (OEM plates only)

First field . . . . . . . . . Not used

Second field . . . . . . . Absorption coefficient of smoke

emissions (shown on certain OEM engines)

CD30230 -UN-07MAR95CD30224 -UN-07MAR95CD30225 -UN-07MAR95

A—Plate used on John Deere equipment B—Plate used on OEM engines C—Generic plate used on certain OEM engines

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General information/Repower engine plate

ENGINE PLATE INFORMATION (LATER DESIGN)

A new engine plate design as shown, is now affixed to the engine.

Information on this new plate is the same as previously.

REPOWER ENGINE PLATE

A specific plate is fixed on repower engines for proper identification. This plate gives the following information:

First line

First field . . . . . . . . . . . Engine type

Second field . . . . . . . . . Sequential serial number

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Second line

DD————— . . . . . . . Repower engine part number

The third line contains a bar code information for factory use.

NOTE: The serial number plate from original engine

must be fixed on the repower plate as shown.

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General information/Engine references

OEM ENGINE OPTION CODE LABEL

An option code label is secured to the top of the valve cover and identifies the factory installed options on each OEM engine to ensure correct parts acquisition.

Always provide option code information and engine base code when ordering repair parts. A listing of option codes is given in Parts Catalogs and Operator’s Manual.

NOTE: Before “hot tank” cleaning, ensure that option

codes are recorded elsewhere.

01 3

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ENGINE REFERENCES

Direction of engine rotation:

Clockwise rotation when viewed from water pump end.

Engine front reference:

The water pump end is the “front” of the engine. Cylinder number 1 is at the front of engine.

Engine side references:

“Right-hand” and “left-hand” sides are determined by facing the flywheel end (rear) of the engine. Right-hand side is the camshaft side while left-hand side is the fuel injection pump side.

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General information/Basic engine specifications (3029 - 4039 & 6059)

BASIC ENGINE SPECIFICATIONS (3029 - 4039 & 6059)

UNIT of

GENERAL

Measure 3029D 3029T 4039D 4039T 6059D 6059T

Number of Cylinders --- 3 3 4 4 6 6

Bore mm 106.5 106.5 106.5 106.5 106.5 106.5

(in.) (4.19) (4.19) (4.19) (4.19) (4.19) (4.19)

Stroke mm 110 110 110 110 110 110

(in.) (4.33) (4.33) (4.33) (4.33) (4.33) (4.33)

Displacement L 2.9 2.9 3.9 3.9 5.9 5.9

(in.3) (179) (179) (239) (239) (359) (359)

Compression Ratio --- 17.8:1 17.8:1 17.8:1 17.8:1 17.8:1 17.8:1

Firing Order --- 1-2-3 1-2-3 1-3-4-2 1-3-4-2 1-5-3-6-2-4 1-5-3-6-2-4

Injection System --- Direct Direct Direct Direct Direct Direct

Aspiration --- Natural Turbocharged Natural Turbocharged Natural Turbocharged

Rated Speed

Power

Weight (dry) kg 323 330 422 458 518 525

*Vary by application; refer to the machine technical or operator’s manual for specific engine speeds and powers.

**Without fan.

@ Rated Speed (hp) (58) (79) (80) (110) (120) (165)

@ 1800 rpm (hp) (47) (66) (102) (165)

@ 1500 rpm (hp) (42) (54) (85) (140)

rpm 2500 2500 2500 2500 2500 2500

kW 43 59 60 82 89 123

kW 35 49 76 123

kW 31 40 63 104

(lbs) (712) (728) (931) (1010) (1143) (1158)

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General information/Basic engine specifications (4045 & 6068)

BASIC ENGINE SPECIFICATIONS (4045 & 6068)

UNIT of Measure 4045D 4045T 6068D 6068T 6068H

GENERAL

Number of Cylinders --- 4 4 6 6 6 Bore mm 106.5 106.5 106.5 106.5 106.5

(in.) (4.19) (4.19) (4.19) (4.19) (4.19)

Stroke mm 127 127 127 127 127

(in.) (5.00) (5.00) (5.00) (5.00) (5.00)

Displacement L 4.5 4.5 6.8 6.8 6.8

(cu.in.) (276) (276) (414) (414) (414) Compression Ratio --- 17.8:1 17.2:1 17.8:1 17.2:1 17.2:1 Firing Order --- 1-3-4-2 1-3-4-2 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4

01 5

Injection System --- Direct Direct Direct Direct Direct Aspiration --- Natural Turbo- Natural Turbo- Air-to-air

charged charged aftercooler

Rated Speed

Power

rpm 2400 2400 2400 2400 2200

kW 63 86 97 130 140

at Rated Speed (hp) (85) (115) (130) (175) (190)

Power

kW 84

at 1800 rpm (hp) (113)

Power

kW 70 116

at 1500 rpm (hp) (95) (155)

Weight (dry) kg 474 487 588 602

(lbs) (1046) (1074) (1297) (1328)

*Vary by application; refer to the machine technical or operator’s manual for specific engine speeds and powers.

**Without fan.

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DIESEL FUEL

General information/Fuel specifications

Consult your local fuel distributor for properties of the diesel fuel available in your area.

In general, diesel fuels are blended to satisfy the low

temperature requirements of the geographical area in

which they are marketed. Diesel fuels specified to EN 590 or ASTM D975 are

recommended. In all cases, the fuel shall meet the following

properties:

• Cetane number of 40 minimum.

Cetane number greater than 50 is preferred, especially for temperatures below -20˚C (-4˚F) or elevations above 1500 m (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% — 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 -19-12FEB99

CTM3274 (01JUL99) 01-6 Saran Liter Engines

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General information/Oil specifications

DIESEL ENGINE OIL

Use oil viscosity based on the expected air temperature range during the period between oil changes.

The following oil is preferred.

• John Deere PLUS-50

The following oil is also recommended:

• John Deere 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%.

Extended service intervals may apply when John Deere preferred engine oils are used. Consult your John Deere dealer for more information.

01 7

TS1661 -UN-10OCT97

DX,ENOIL -19-10OCT97

CTM3274 (01JUL99) 01-7 Saran Liter Engines

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DIESEL ENGINE COOLANT

General information/Coolant specifications

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 refill with new coolant after the first 3 years or 3000 hours of operation. Subsequent drain intervals are determined by the coolant used for service. At each interval, drain the coolant, flush the cooling system, and refill with new coolant.

When John Deere COOL-GARD is used, the coolant drain interval is 3 years or 3000 hours operation.

If COOL-GARD is not used, the drain interval is reduced to 2 years or 2000 hours of operation.

DX,COOL8 -19-12FEB99

CTM3274 (01JUL99) 01-8 Saran Liter Engines

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General information/Metric cap screw torque values

METRIC BOLT AND CAP SCREW TORQUE VALUES

Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9

01 9

TS1163 -19-04MAR91

Size Lubricated

N·m lb-ft N·m lb-ft N·m lb-ft N·m lb-ft N·m lb-ft N·m lb-ft N·m lb-ft N·m lb-ft

M6 4.8 3.5 6 4.5 9 6.5 11 8.5 13 9.5 17 12 15 11.5 19 14.5 M8 12 8.5 15 11 22 16 28 20 32 24 40 30 37 28 47 35

M10 23 17 29 21 43 32 55 40 63 47 80 60 75 55 95 70

M12 40 29 50 37 75 55 95 70 110 80 140 105 130 95 165 120 M14 63 47 80 60 120 88 150 110 175 130 225 165 205 150 260 190 M16 100 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

Dry

Lubricated

Dry

Lubricated

Dry

Lubricated

Dry

Make sure fasteners threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening.

only. Check tightness of fasteners periodically.

Tighten plastic insert or crimped steel-type lock nuts Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical property class.

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. 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.

“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.

DX,TORQ2 -19-20JUL94

CTM3274 (01JUL99) 01-9 Saran Liter Engines

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General information/Inch cap screw torque values

UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUES

01 10

TS1162 -19-04MAR91

Grade 1 Grade 2

Size Lubricated

N·m lb-ft N·m lb-ft N·m lb-ft N·m lb-ft N·m lb-ft N·m lb-ft N·m lb-ft N·m lb-ft

1/4 3.7 2.8 4.7 3.5 6 4.5 7.5 5.5 9.5 7 12 9 13.5 10 17 12.5

5/16 7.7 5.5 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 1250 2150 1550 2700 2000 3400 2550 1-1/2 1000 725 1250 925 990 725 1250 930 2250 1650 2850 2100 3600 2650 4550 3350

Dry

Lubricated

DO NOT use these values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only. Check tightness of fasteners periodically.

Dry

Grade 5, 5.1, or 5.2 Grade 8 or 8.2

Lubricated

Dry

Lubricated

Fasteners should be replaced with the same or higher grade. If higher grade fasteners are used, these should only be tightened to the strength of the original.

Dry

Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade.

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.

“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.

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.

Tighten toothed or serrated-type lock nuts to the full torque value.

DX,TORQ1 -19-20JUL94

CTM3274 (01JUL99) 01-10 Saran Liter Engines

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ENGINE REPAIR STAND

To facilitate engine repair, the D01003AA repair stand can be used in conjunction with D05225ST adapter for 300 series engines.

Group 02

Engine mounting

02 1

R26420N -UN-22MAY95

D01003AA repair stand

D05225ST adapter

D05225ST -UN-22MAY95

CD,3274,G02,1 -19-24FEB92

CTM3274 (01JUL99) 02-1 Saran Liter Engines

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SAFETY PRECAUTIONS

Engine mounting/Engine lifting procedure

This repair stand should be used only by qualified service technicians familiar with this equipment.

To maintain shear strength specifications, alloy steel SAE Grade 8 or higher cap screws must be used to mount adapters or engine.

For full thread engagement, be certain that tapped

holes in adapters and engine blocks are clean and not damaged. A thread length engagement equal to 1-1/2 screw diameters minimum is required to maintain strength requirements.

To avoid structural damage or personal injury, do not exceed the maximum weight capacity. When engine weight is more than 450 kg (992 lb), it is recommended to use additional support. Approximate engine weights are listed below:

— 3 cyl. engines = 330 kg (728 lb) — 4 cyl. engines = 450 kg (992 lb) — 6 cyl. engines = 580 kg (1279 lb)

To prevent possible personal injury due to engine slippage, recheck to make sure engine is solidly mounted before releasing support from engine lifting device.

Never permit any part of the body to be positioned under a load being lifted or suspended. Accidental slippage may result in personal injury.

CD,3274,G02,2 -19-24FEB92

ENGINE LIFTING PROCEDURE

Attach JDG23 engine lifting sling (A), or other suitable sling, to JD-244 engine lifting eyes (B) and hoist the engine using a lifting device.

NOTE: Use of an engine lifting sling (as shown) is the

preferred method for lifting engines. However, if a sling is not on hand, engine can be lifted by chain(s) attached to lifting eyes and lifting device.

IMPORTANT: If a turbocharged engine with

low-profile design is to be lifted, remove the turbocharger before attaching engine to repair stand.

RG4738 -UN-18MAY90

CD,3274,G02,3 -19-01FEB94

CTM3274 (01JUL99) 02-2 Saran Liter Engines

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Engine mounting/Disconnect turbocharger oil line

CLEAN ENGINE

1. Cap or plug all openings on engine. If electrical components (starting motor, alternator, etc...) are not removed prior to cleaning, cover with plastic and tape securely to prevent moisture from entering.

2. Steam-clean engine thoroughly.

IMPORTANT: Never steam-clean or pour cold water

on an injection pump while it is still warm. To do so may cause seizure of pump parts.

DISCONNECT TURBOCHARGER OIL INLET LINE

Drain all engine oil and coolant, if not previously done.

IMPORTANT: When servicing turbocharged engines

on a rollover stand, disconnect turbo oil inlet line from turbocharger (A) or oil filter housing before rolling engine over. Failure to do so may cause a hydraulic lock upon starting engine. Hydraulic lock may cause severe engine damage.

02 3

CD,3274,G02,4 -19-24FEB92

RG5642 -UN-02APR90

Hydraulic lock occurs when trapped oil in the oil filter housing drains through the turbocharger, the exhaust and intake manifolds, and then into the cylinder head. After starting the engine, the trapped oil in the manifold and head is released into the cylinders filling them with oil causing hydraulic lock and severe engine damage.

CD,3274,G02,5 -19-24FEB92

CTM3274 (01JUL99) 02-3 Saran Liter Engines

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