John Deere CD4039DF008 OPERATOR’S MANUAL

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

POWERTECH



CD4039DF008 CD4039TF008 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.

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.

SETTING FUEL DELIVERY beyond published factory specifications or otherwise overpowering will result in loss of warranty protection for this engine.

POWERTECH is a trademark of Deere & Company

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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

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

Fuels, Lubricants and Coolant Maintenance/2000 hours/2 years

Check and adjust engine valve clearanceDiesel Fuel ............................10-1

Handling and Storing Diesel Fuel ...........10-1 (POWERTech ENGINE) .................40-1

Checking engine speed . . .................40-3Engine Break-In Oil . . . ...................10-2

Diesel Engine Oil . .......................10-3 Adjust speed droop governor ...............40-3

Lubricant Storage . . .....................10-3

Mixing of Lubricants .....................10-4

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.

DEERE & COMPANY

European Office Mannheim

A John Deere ILLUSTRUCTIONManual

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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

Contents

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

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IDENTIFICATION VIEWS

Identification Views

4045HF158

Continued on next page

01-1

CD30744 –UN–23AUG99

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Identification Views

6068HF158

CD30745 –UN–23AUG99

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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.

100 HOURS OF OPERATION

❒ Engine oil, replace

❒ Engine oil filter, replace

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.

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❒ Hose connections, check

Number of hours: Comments: Dealer or distributor stamp

Date:

Job done by:

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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:

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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:

02-2

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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:

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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:

02-3

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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:

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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:

02-4

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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:

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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:

02-5

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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:

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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:

02-6

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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:

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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:

02-7

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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:

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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:

02-8

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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:

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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:

02-9

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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:

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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:

02-10

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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:

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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:

02-11

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POWERTECHMEDALLION

Record Keeping

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



RG8041 –UN–15JAN99

DPSG,CD03523,11 –19–05JUL99–1/1

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.

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.

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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) ___________________ Engine Model Number (C) ___________________ Coefficient of Absorption Value (D) ___________________

300-Series engine plate

CD30705B –UN–24AUG99

POWERTech engine plate

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CD30747 –UN–23AUG99

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ENGINE OPTION CODES

Record Keeping

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.

• 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).

CD30748A –UN–26AUG99

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.

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.

Continued on next page

03-3

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

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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

03-4

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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

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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.

DX,ALERT –19–29SEP98–1/1

T81389 –UN–07DEC88

TS187 –19–30SEP88

DX,SIGNAL –19–03MAR93–1/1

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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.

Safety

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.

RG7784 –UN–11NOV97

3. Carefully move engine to desired location.

05-2

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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.

TS201 –UN–23AUG88

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.

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

TS202 –UN–23AUG88

DX,FIRE1 –19–03MAR93–1/1

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.

DX,FIRE2 –19–03MAR93–1/1

TS291 –UN–23AUG88

TS1356 –UN–18MAR92

05-4

DX,FIRE3 –19–16APR92–1/1

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