John Deere CD4039DF008 OPERATOR’S MANUAL

Download

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

DPSG,CD03523,1 –19–01JUL99–1/1

112699

PN=2

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

PN=1

112699

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

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

112699

PN=2

IDENTIFICATION VIEWS

Identification Views

4045HF158

Continued on next page

01-1

CD30744 –UN–23AUG99

DPSG,CD03523,3 –19–05JUL99–1/2

112699

PN=5

Identification Views

6068HF158

CD30745 –UN–23AUG99

DPSG,CD03523,3 –19–05JUL99–2/2

01-2

112699

PN=6

Maintenance Records

USING MAINTENANCE RECORDS

To obtain the best performance, economy and service life from your engine, ensure service is carried out according to this present manual and recorded in the following pages. It is recommended that your engine Distributor or your Dealer carry out this service work and stamp the appropriate case.

Keeping an accurate account of all service performed on your engine will give more value to the machine when you resell it.

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.

DPSG,CD03523,6 –19–05JUL99–1/1

❒ 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:

02-2

DPSG,CD03523,9 –19–05JUL99–1/1

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:

02-3

DPSG,CD03523,59 –19–16AUG99–1/1

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:

02-4

DPSG,CD03523,61 –19–16AUG99–1/1

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:

02-5

DPSG,CD03523,63 –19–16AUG99–1/1

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:

02-6

DPSG,CD03523,65 –19–16AUG99–1/1

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:

02-7

DPSG,CD03523,67 –19–16AUG99–1/1

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:

02-8

DPSG,CD03523,69 –19–16AUG99–1/1

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:

02-9

DPSG,CD03523,71 –19–16AUG99–1/1

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:

02-10

DPSG,CD03523,73 –19–16AUG99–1/1

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:

02-11

DPSG,CD03523,75 –19–16AUG99–1/1

112699

PN=17

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.

DPSG,CD03523,12 –19–05JUL99–1/1

03-1

112699

PN=18

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

DPSG,CD03523,13 –19–05JUL99–1/1

CD30747 –UN–23AUG99

03-2

112699

PN=19

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.

DPSG,CD03523,14 –19–05JUL99–1/2

112699

PN=20

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

DPSG,CD03523,14 –19–05JUL99–2/2

112699

PN=21

Record Keeping

RECORD FUEL INJECTION PUMP MODEL NUMBER

Record the fuel injection pump model and serial information found on the serial number plate (A).

Model No. _____________________ RPM _______ Manufacturer’s No. __________________________ Serial No. _________________________________

CD30749 –UN–24SEP99

DPSG,CD03523,15 –19–07JUL99–1/1

03-5

112699

PN=22

Safety

RECOGNIZE SAFETY INFORMATION

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

Follow recommended precautions and safe operating 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

05-1

112699

PN=23

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

DPSG,CD03523,95 –19–06OCT99–1/1

112699

PN=24

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

05-3

112699

PN=25

Safety

HANDLE FUEL SAFELY—AVOID FIRES

Handle fuel with care: it is highly flammable. Do not refuel the machine while smoking or when near open flame or sparks.

Always stop engine before refueling machine. Fill fuel tank 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

112699

PN=26

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.

PROTECT AGAINST NOISE

Safety

TS206 –UN–23AUG88

DX,WEAR –19–10SEP90–1/1

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.

DX,NOISE –19–03MAR93–1/1

TS207 –UN–23AUG88

05-5

112699

PN=27

Safety

HANDLE CHEMICAL PRODUCTS SAFELY

Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere equipment include such items as lubricants, coolants, paints, and adhesives.

A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques.

Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and recommended equipment.

(See your John Deere dealer for MSDS’s on chemical products used with John Deere equipment.)

STAY CLEAR OF ROTATING DRIVELINES

Entanglement in rotating driveline can cause serious injury or death.

Keep master shield and driveline shields in place at all times. Make sure rotating shields turn freely.

TS1132 –UN–26NOV90

DX,MSDS,NA –19–03MAR93–1/1

Wear close fitting clothing. Stop the engine and be sure the PTO driveline is stopped before making adjustments or performing any type service on the engine or PTO-driven equipment.

05-6

TS1644 –UN–22AUG95

CD,PTO –19–12SEP95–1/1

112699

PN=28

Safety

PRACTICE SAFE MAINTENANCE

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

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

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

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

On self-propelled equipment, disconnect 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.

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

TS218 –UN–23AUG88

DX,SERV –19–17FEB99–1/1

TS220 –UN–23AUG88

DX,AIR –19–17FEB99–1/1

05-7

112699

PN=29

Safety

AVOID HIGH-PRESSURE FLUIDS

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

Avoid the hazard 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.

X9811 –UN–23AUG88

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.

DX,FLUID –19–03MAR93–1/1

TS953 –UN–15MAY90

DX,TORCH –19–03MAR93–1/1

05-8

112699

PN=30

Safety

REMOVE PAINT BEFORE WELDING OR HEATING

Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated

by welding, soldering, or using a torch. Do all work outside or in a well ventilated area. Dispose of

paint and solvent properly. 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.

SERVICE COOLING SYSTEM SAFELY

Explosive release of fluids from pressurized cooling system can cause serious burns.

Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

TS220 –UN–23AUG88

DX,PAINT –19–03MAR93–1/1

05-9

DX,RCAP –19–04JUN90–1/1

TS281 –UN–23AUG88

112699

PN=31

Safety

AVOID HARMFUL ASBESTOS DUST

Avoid breathing dust that may be generated when handling components containing asbestos fibers. Inhaled asbestos fibers may cause lung cancer.

Components in products that may contain asbestos fibers are brake pads, brake band and lining assemblies, clutch plates, and some gaskets. The asbestos used in these components is usually found in a resin or sealed in some way. Normal handling is not hazardous as long as airborne dust containing asbestos is not generated.

Avoid creating dust. Never use compressed air for cleaning. Avoid brushing or grinding material containing asbestos. When servicing, wear an approved respirator. A special vacuum cleaner is recommended to clean asbestos. If not available, apply a mist of oil or water on the material containing asbestos.

Keep bystanders away from the area.

TS220 –UN–23AUG88

DISPOSE OF WASTE PROPERLY

Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with John Deere equipment include such items as oil, fuel, coolant, brake fluid, filters, and batteries.

Use leakproof containers when draining fluids. Do not use food 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.

DX,DUST –19–15MAR91–1/1

TS1133 –UN–26NOV90

05-10

DX,DRAIN –19–03MAR93–1/1

112699

PN=32

DIESEL FUEL

Fuels, Lubricants and Coolant

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.

HANDLING AND STORING DIESEL FUEL

CAUTION: Handle fuel carefully. Do not fill the fuel tank when engine is running.

DO NOT smoke while you fill the fuel tank or service the fuel system.

Fill the fuel tank at the end of each day’s operation to prevent condensation and freezing during cold weather.

DX,FUEL1 –19–17FEB99–1/1

IMPORTANT: The fuel tank is vented through the

filler cap. If a new filler cap is required, always replace it with an original vented cap.

When fuel is stored for an extended period or if there is a slow turnover of fuel, add a fuel conditioner to stabilize the fuel and prevent water condensation. Contact your fuel supplier for recommendations.

DX,FUEL4 –19–18MAR96–1/1

10-1

112699

PN=33

ENGINE BREAK-IN OIL

Fuels, Lubricants and Coolant

New engines are filled at the factory with John Deere ENGINE BREAK-IN OIL. During the break-in period, add John Deere ENGINE BREAK-IN OIL as needed to maintain the specified oil level.

Change the oil and filter after the first 100 hours of operation of a new or rebuilt engine.

After engine overhaul, fill the engine with John Deere ENGINE BREAK-IN OIL.

If John Deere ENGINE BREAK-IN OIL is not available, use a diesel engine oil meeting one of the following during the first 100 hours of operation:

• API Service Classification CE

PLUS-50 is a registered trademark of Deere & Company.

• ACEA Specification E1

After the break-in period, use John Deere PLUS-50 other diesel engine oil as recommended in this manual.

IMPORTANT: Do not use PLUS-50 oil or engine

oils meeting API CG4, API CF4, ACEA E3, or ACEA E2 performance levels during the first 100 hours of operation of a new or rebuilt engine. These oils will not allow the engine to break-in properly.

DX,ENOIL4 –19–10OCT97–1/1



10-2

112699

PN=34

Fuels, Lubricants and Coolant

DIESEL ENGINE OIL

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

The following oil is preferred:

• John Deere PLUS-50



The following oil is also recommended:

• John Deere TORQ-GARD SUPREME TORQ-GARD SUPREME



Other oils may be used if they meet one or more of the following:

• API Service Classification CG-4

• API Service Classification CF-4

• ACEA Specification E3

• ACEA Specification E2

Multi-viscosity diesel engine oils are preferred.

If diesel fuel with sulfur content greater than 0.5% is used, reduce the service interval by 50%.

TS1661 –UN–10OCT97

PLUS-50 is a registered trademark of Deere & Company.

TORQ-GARD SUPREME is a trademark of Deere & Company

LUBRICANT STORAGE

Your equipment can operate at top efficiency only when clean lubricants are used.

Use clean containers to handle all lubricants. Whenever possible, store lubricants and containers in

an area protected from dust, moisture, and other contamination. Store containers on their side to avoid water and dirt accumulation.

CD,ENOIL –19–10OCT97–1/1

Make certain that all containers are properly marked to identify their contents.

Properly dispose of all old containers and any residual lubricant they may contain.

DX,LUBST –19–18MAR96–1/1

10-3

112699

PN=35

MIXING OF LUBRICANTS

Fuels, Lubricants and Coolant

In general, avoid mixing different brands or types of oil. Oil manufacturers blend additives in their oils to meet certain specifications and performance requirements.

Mixing different oils can interfere with the proper functioning of these additives and degrade lubricant performance.

DIESEL ENGINE COOLANT

The engine cooling system is filled to provide year-round protection against corrosion and cylinder liner pitting, and winter freeze protection to -37°C (-34°F).

John Deere COOL-GARD is preferred for service.

If John Deere COOL-GARD is not available, use a low silicate ethylene glycol base coolant concentrate in a 50% mixture of concentrate with quality water.

The coolant concentrate shall be of a quality that provides cavitation protection to cast iron and aluminum parts in the cooling system. John Deere COOL-GARD meets this requirement.

Consult your John Deere dealer to obtain specific information and recommendations.

DX,LUBMIX –19–18MAR96–1/1

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.

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

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

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

DX,COOL8 –19–12FEB99–1/1

10-4

112699

PN=36

Fuels, Lubricants and Coolant

OPERATING IN WARM TEMPERATURE CLIMATES

John Deere engines are designed to operate using glycol base engine coolants.

Always use a recommended glycol base engine coolant, even when operating in geographical areas where freeze protection is not required.

IMPORTANT: Water may be used as coolant

emergency situations only.

Foaming, hot surface aluminum and iron corrosion, scaling, and cavitation will occur when water is used as the coolant, even when coolant conditioners are added.

Drain cooling system and refill with recommended glycol base engine coolant as soon as possible.

DX,COOL6 –19–18MAR96–1/1

10-5

112699

PN=37

BREAK-IN PERIOD

Operating the Engine

Within first 100 hours of operation

During the first 100 hours of operation, avoid overloading, excessive idling and no-load operation.

See ENGINE BREAK-IN OIL for eventual addition of oil.

NOTE: During the break-in period a higher-than-usual

oil consumption should be considered as normal.

After first 100 hours of operation

After the first 100 hours, drain the crankcase and

STARTING THE ENGINE

CAUTION: Before starting engine in a confined building, install proper outlet exhaust ventilation equipment. Always use safety approved fuel storage and piping.

change the oil filter (see CHANGING ENGINE OIL AND FILTER). Fill crankcase with seasonal viscosity grade oil (see DIESEL ENGINE OIL).

Check tension of alternator belt. Check connections of air intake hoses. Check for proper tightening of cap screws all around

the engine.

DPSG,CD03523,17 –19–09JUL99–1/1

2. Open the fuel supply shut-off valve, if equipped.

3. Activate the starter motor switch to crank the engine and release it as soon as engine starts.

NOTE: If temperature is below 0°C (32°F), it may be

necessary to use cold weather starting aids (See COLD WEATHER OPERATION).

1. Perform all prestarting checks outlined in Maintenance/Daily Section.

COLD WEATHER OPERATION

Depending on equipment, various cold weather starting aids are available to assist in starting the engine at temperatures below 0°C (32°F).

NOTE: Do not operate the starter motor more than

20 seconds at a time.

DPSG,CD03523,18 –19–09JUL99–1/1

Continued on next page

15-1

DPSG,CD03523,19 –19–09JUL99–1/4

112699

PN=38

Operating the Engine

Air intake heater

Air intake heater is either a grid-type (A) for POWERTech engines or a glow plug-type (B) for 300-Series engines installed in the air intake channel.

CAUTION: NEVER use Ether Starting Fluid when air intake heater is used to start the engine.

Activate the heating element (preheater position) for 30 seconds maximum then start the engine.

CD30750 –UN–03SEP99

DPSG,CD03523,19 –19–09JUL99–2/4

Coolant heater

Connect plug of coolant heater (A) to a power source (110 or 220 V).

At an ambient temperature of -15°C(5°F), the heating process takes approximatively 2 hours. Extend heating period if ambient temperature is lower.

Fuel preheater

Fuel preheater (A) switches ON and OFF automatically in relation to the ambient temperature.

LX1017768 –UN–24OCT97

DPSG,CD03523,19 –19–09JUL99–3/4

15-2

LX1017708 –UN–09OCT97

DPSG,CD03523,19 –19–09JUL99–4/4

112699

PN=39

Operating the Engine

USING A BOOSTER BATTERY OR CHARGER

A 12-volt booster battery can be connected in parallel with battery(ies) on the unit to aid in cold weather starting. ALWAYS use heavy duty jumper cables.

CAUTION: Gas given off by batteries is explosive. Keep sparks and flames away from batteries. Before connecting or disconnecting a battery charger, turn charger off. Make last connection and first disconnection at a point away from battery. Always connect NEGATIVE (–) cable last and disconnect this cable first.

IMPORTANT: Be sure polarity is correct before

making connections. Reversed polarity will damage electrical system. Always connect positive to positive and negative to ground. Always use 12-volt booster battery for 12-volt electrical systems and 24-volt booster battery/ batteries for 24-volt electrical systems.

1. Connect booster battery or batteries to produce the required system voltage for your engine application.

TS204 –UN–23AUG88RG4678 –UN–14DEC88

12-Volt System

NOTE: To avoid sparks, DO NOT allow the free ends of

jumper cables to touch the engine.

2. Connect one end of jumper cable to the POSITIVE (+) post of the booster battery.

3. Connect the other end of the jumper cable to the POSITIVE (+) post of battery connected to starter.

4. Connect one end of the other jumper cable to the NEGATIVE (–) post of the booster battery.

5. ALWAYS complete the hookup by making the last connection of the NEGATIVE (–) cable to a good ground on the engine frame and away from the battery(ies).

6. Start the engine. Disconnect jumper cables immediately after engine starts. Disconnect NEGATIVE (–) cable first.

24-Volts System

RG4698 –UN–14DEC88

A—12-Volt Machine battery/batteries B—12-Volt Booster battery/batteries C—Booster cable D—Cable to starter motor

15-3

DPSG,CD03523,20 –19–09JUL99–1/1

112699

PN=40

ENGINE OPERATION

Operating the Engine

Warming engine

Operate engine at high idle for 1 to 2 minutes before applying the load.

NOTE: This procedure does not apply to standby

generator sets where the engine is loaded immediately upon reaching rated speed.

Normal engine operation

Compare engine coolant temperature and engine oil pressure with specifications below:

Minimum oil pressure at full load rated speed1—Specification

Pressure 275 kPa (2.75 bar; 40 psi).....................................................

Coolant temperature range—Specification

Temperature 82°—94°C (180°—202°F)...............................................

Stop engine immediately if coolant temperature is above or oil pressure below specifications or if there are any signs of part failure. Symptoms that may be early signs of engine problems could be:

• Sudden loss of power

• Unusual noise or vibration

• Excessive black exhaust fumes

• Excessive fuel consumption

• Excessive oil consumption

• Fluid leaks

Recommendation for turbocharger engines

Should the engine stall when operating under load, IMMEDIATELY restart it to prevent overheating of turbocharger components.

Idling engine

Avoid excessive engine idling. Prolonged idling may cause the engine coolant temperature to fall below its normal range. This, in turn, causes crankcase oil dilution, due to incomplete fuel combustion, and permits formation of gummy deposits on valves, pistons and piston rings. It also promotes rapid accumulation of engine sludge and unburned fuel in the exhaust system. If an engine will be idling for more than 5 minutes, stop and restart later.

NOTE: Generator set applications have the governor

locked at a specified speed and do not have a slow idle function. These engines idle at no load governed speed (fast idle).

Oil at normal operating temperature of 115°C (240°F).

STANDBY POWER UNITS

To assure that your engine will deliver efficient standby operation when needed, start engine and run at rated speed (with 50%—70% load) for 30 minutes every

DPSG,CD03523,21 –19–09JUL99–1/1

2 weeks. DO NOT allow engine to run an extended period of time with no load.

DPSG,CD03523,22 –19–09JUL99–1/1

15-4

112699

PN=41

Operating the Engine

STOPPING THE ENGINE

1. Before stopping, run engine for at least 2 minutes at fast idle and no load.

2. Stop the engine.

DPSG,CD03523,23 –19–09JUL99–1/1

15-5

112699

PN=42

OBSERVE SERVICE INTERVALS

Maintenance

Using hour meter as a guide, perform all services at the hourly intervals indicated on following pages. At each scheduled maintenance interval, perform all previous maintenance operations in addition to the ones specified. Keep a record of hourly intervals and services performed using charts provided in Maintenance Records Section.

USE CORRECT FUELS, LUBRICANTS AND COOLANT

IMPORTANT: Use only fuels, lubricants, and coolants

meeting specifications outlined in Fuels, Lubricants, and Coolant Section when servicing your John Deere Engine.

Consult your John Deere engine distributor, servicing dealer or your nearest John Deere Parts Network for recommended fuels, lubricants, and coolant. Also available are necessary additives for use when operating engines in tropical, arctic, or any other adverse conditions.

IMPORTANT: Recommended service intervals are

for normal operating conditions. Service MORE OFTEN if engine is operated under adverse conditions. Neglecting maintenance can result in failures or permanent damage to the engine.

DPSG,CD03523,24 –19–09JUL99–1/1

TS100 –UN–23AUG88

20-1

DPSG,CD03523,25 –19–09JUL99–1/1

112699

PN=43

MAINTENANCE INTERVAL CHART

Maintenance

Item 10 H / 500 H 1000 H / 2000 H / 2500 H / As

daily 1 year 2 years 3 years required

Check engine oil and coolant level • Check air filter restriction indicator Change engine oil and filter

•

Replace fuel filter element • Check belt tension and automatic tensioner Check and adjust valve clearance

••

Clean crankcase vent tube • Check air intake hoses, connections and system • Check vibration damper (6 cyl.)

•

Check engine speed and speed droop governor • Drain and flush cooling system

••

Drain water and sediment from fuel filter • Clean filter element (see note a) • Test thermostat and injection nozzles (see your dealer)

Clean air filter element when restriction indicator is red. Replace filter element after 6 cleanings or once a year.

Change oil and filter after the first 100 hours of operation, then every 500 hours thereafter. Change oil and filter at least once a year.

Check belt tension every 500 hours on 300-Series engines and on POWERTech engines with manual tensioner. Check automatic belt

•

tensioner every 1000 hours/1 year on POWERTech engines when equipped.

Have your authorized servicing dealer or engine distributor adjust valve clearance as follows. After the first 500 hours of operation then every

1000 hours thereafter on 300-Series engines. Every 2000 hours on POWERTech engines.

Have your authorized dealer or engine distributor replace the vibration damper every 4500 hours/5 years.

Drain and flush cooling system every 2500 hours/3 years when John Deere COOL-GARD coolant is used. Otherwise every 2000

hours/2 years.

Contact your dealer when thermostat or injection nozzles are suspected to be defective. Replace injection nozzles every 5000 hours and

thermostat every 10000 hours.

20-2

DPSG,CD03523,26 –19–09JUL99–1/1

112699

PN=44

Maintenance/Daily or every 10 hours

DAILY PRESTARTING CHECKS

POWERTech engine

Do the following BEFORE STARTING THE ENGINE for the first time each day:

IMPORTANT: DO NOT top up with fresh oil until

the oil level is BELOW the add mark.

1. Check engine oil level on dipstick (A). Add as required, using seasonal viscosity grade oil. (See

CD30753 –UN–26AUG99

300-Series engine

CD30755 –UN–24SEP99

DIESEL ENGINE OIL). Add oil at rocker arm cover filler cap (B).

IMPORTANT: DO NOT fill above the crosshatch

area. Oil levels anywhere within crosshatch are considered in the acceptable operating range.

CD30754 –UN–26AUG99

FD000047 –UN–13MAR96

Continued on next page

25-1

DPSG,CD03523,27 –19–12JUL99–1/3

112699

PN=45

Maintenance/Daily or every 10 hours

2. CAUTION: Explosive release of fluids from

pressurized cooling system can cause serious burns.

Only remove filler cap when engine is cold or when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

3. If air filter has a dust unloading valve (C), squeeze valve tip to release any trapped dirt particles.

4. Check air intake restriction indicator (D). When indicator is red, air filter needs to be cleaned.

IMPORTANT: Maximum air intake restriction is

6.25 kPa (0.06 bar; 1.0 psi) (25 in. H A clogged air cleaner element will cause excessive intake restriction and a reduced air supply to the engine.

5. Make a thorough inspection of the engine compartment.

TS281 –UN–23AUG88

O).

CD30756 –UN–26AUG99

Remove radiator cap (E) and check coolant level which should be at bottom of filler neck. Fill radiator with proper coolant solution if level is low. (See DIESEL ENGINE COOLANT). Check overall cooling system for leaks.

DPSG,CD03523,27 –19–12JUL99–2/3

RG4687 –UN–20DEC88CD30757 –UN–26AUG99

NOTE: Wipe all fittings, caps and plugs before performing

any maintenance to reduce the chance of system contamination.

25-2

DPSG,CD03523,27 –19–12JUL99–3/3

112699

PN=46

Maintenance/500 hours

CHANGING ENGINE OIL AND FILTER

NOTE: Change engine oil and filter for the first time after

100 hours maximum of operation, then every 500 hours thereafter. Change oil and filter at least once a year.

1. Run engine approximately 5 minutes to warm up oil. Shut engine off.

2. Open oil pan drain valve (A).

3. Drain crankcase oil from engine while warm.

4. Remove and discard oil filter element (B) using a suitable filter wrench.

5. Remove oil filter packing and clean filter mounting pad.

IMPORTANT: Filtration of oils is critical to proper

lubrication. Always change filter regularly. Use filters meeting John Deere performance specifications.

CD30758 –UN–26AUG99CD30759 –UN–26AUG99

6. Oil the new packing and install a new filter element. Hand tighten element according to values printed on filter element. If values are not provided, tighten element approximately 3/4 — 1-1/4 turn after packing contacts filter housing. DO NOT overtighten filter element.

7. Close oil pan drain valve.

Continued on next page

POWERTEch engine

CD30760 –UN–26AUG99

300-Series engine

DPSG,CD03523,29 –19–12JUL99–1/2

30-1

112699

PN=47

Maintenance/500 hours

8. Fill engine crankcase with correct John Deere engine oil through rocker arm cover opening (C); see DIESEL ENGINE OIL.

To determine the correct oil fill quantity for your engine, see “Engine Oil Quantities” in Specifications Section.

NOTE: Crankcase oil capacity may vary slightly.

ALWAYS fill crankcase to full mark or within crosshatch on dipstick, whichever is present. DO NOT overfill.

IMPORTANT: Immediately after completing any oil

change, crank engine for 30 seconds without permitting engine to start. This will help insure adequate lubrication to engine components before engine starts.

9. Start engine and run to check for possible leaks.

10. Stop engine and check oil level after 10 minutes. If

necessary, top up.

CD30761 –UN–24SEP99

DPSG,CD03523,29 –19–12JUL99–2/2

FD000047 –UN–13MAR96

30-2

112699

PN=48

REPLACING FUEL FILTER ELEMENT

Maintenance/500 hours

X9811 –UN–23AUG88

A—Retaining ring B—Filter element C—Drain plug D—Bleed plug

CAUTION: CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting fuel or other lines. Tighten all connections before applying pressure. Keep hands and body away from pinholes and nozzles which eject fluids under high pressure. Use a piece of cardboard or paper to search for leaks. Do not use your hand.

If any fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result. Doctors unfamiliar with this type of injury may call the Deere & Company Medical Department in Moline, Illinois, or other knowledgeable medical source.

1. Thoroughly clean fuel filter assembly and surrounding area.

2. Loosen drain plug (C) and drain fuel into a suitable container.

IMPORTANT: Do not dump the old fuel into the

new filter element. This could cause fuel injection problem.

A plug is provided with the new element for plugging the used element.

4. Inspect filter mounting base for cleanliness. Clean as required.

NOTE: Raised locators on fuel filter canister must be

indexed properly with slots in mounting base for correct installation.

5. Install new filter element dry onto mounting base. Be sure element is properly indexed and firmly seated on base. It may be necessary to rotate filter for correct alignment.

6. Install retaining ring onto mounting base making certain dust seal is in place on filter base. Hand tighten ring (about 1/3 turn) until it “snaps” into the detent. DO NOT overtighten retaining ring.

RG7721 –UN–15JAN99

NOTE: Lifting up on retaining ring as it is rotated helps

to get it past raised locators.

3. Firmly grasp the retaining ring (A) and rotate it clockwise 1/4 turn. Remove ring with filter element (B).

NOTE: The proper installation is indicated when a

"click" is heard and a release of the retaining ring is felt.

7. Bleed the fuel system.

DPSG,CD03523,30 –19–12JUL99–1/1

30-3

112699

PN=49

Maintenance/500 hours

CHECKING BELT (300-SERIES ENGINES)

1. Inspect belt for cracks, fraying, or stretched out areas. Replace as necessary.

2. Check belt tension using one of following methods:

a) Use of JDG529 Tension Gauge (A)

Belt tension—Specification

New belt 578—622 N (130—140 lb-force)..................................................

Used belt 378—423 N (85—94 lb-force)....................................................

NOTE: Belt is considered used after 10 minutes of

operation.

b) Use of tension tester (B) and straight edge (C)

A 89 N (20 lb) force applied halfway between pulleys should deflect belt by 19 mm (0.75 in.).

3. If adjustment is necessary, loosen alternator nuts (D) and (E). Pull alternator frame outward until belt is correctly tensioned.

IMPORTANT: Do not pry against the alternator rear

frame. Do not tighten or loosen belts while they are hot.

4. Tighten alternator bracket nuts firmly.

5. Run engine for 10 minutes then recheck belt tension.

CD30644 –UN–04MAY98

CD30645 –UN–04MAY98CD30646 –UN–04MAY98

30-4

DPSG,CD03523,31 –19–12JUL99–1/1

112699

PN=50

Maintenance/500 hours

CHECKING BELT (POWERTECH ENGINES WITH MANUAL TENSIONER)

Inspect belt for cracks, fraying, or stretched out areas. Replace if necessary.

NOTE: Belt adjustment is measured using a gauge

stamped on the top edge of the alternator bracket.

1. Loosen cap screws (B) and (C).

2. Slide alternator in slot by hand to remove all excess slack in belt.

IMPORTANT: Do not pry against alternator rear frame.

3. Using the gauge (A) on the alternator bracket, stretch belt by prying outward on alternator front frame. Stretch the belt 1 gauge unit for a used belt and 1.5 gauge units for a new belt.

4. Tighten cap screws (B) and (C).

RG9132 –UN–04OCT99

A—Belt gauge B—Cap screw C—Cap screw

DPSG,CD03523,57 –19–16AUG99–1/1

30-5

112699

PN=51

Maintenance/1000 hours/1 year

CLEANING CRANKCASE VENT TUBE

If you operate the engine in dusty conditions, clean the tube at shorter intervals.

1. Remove and clean crankcase vent tube (A).

2. Install the vent tube. Be sure the O-ring fits correctly in the rocker arm cover bore for elbow adapter. Tighten hose clamp securely.

CHECKING AIR INTAKE SYSTEM

CD30773 –UN–27AUG99

DPSG,CD03523,32 –19–12JUL99–1/1

IMPORTANT: The air intake system must not leak.

Any leak, no matter how small, may result in engine failure due to abrasive dirt and dust entering the intake system.

1. Inspect all intake hoses (piping) for cracks. Replace as necessary.

CD30762 –UN–27AUG99

2. Check clamps on piping (A) which connect the air filter, engine and, if present, turbocharger and air-to-air radiator. Tighten clamps as necessary.

3. Test air restriction indicator (B) for proper operation. Replace indicator as necessary.

Continued on next page

DPSG,CD03523,33 –19–12JUL99–1/2

35-1

112699

PN=52

Maintenance/1000 hours/1 year

4. If engine has a rubber dust unloading valve (C), inspect the valve on bottom of air filter for cracks or plugging. Replace as necessary.

5. Service air filter as necessary.

CHECKING AUTOMATIC BELT TENSIONER (POWERTECH ENGINES)

Belt drive systems equipped with automatic (spring) belt tensioners cannot be adjusted or repaired. The automatic belt tensioner is designed to maintain proper belt tension over the life of the belt. If tensioner spring tension is not within specification, replace tensioner assembly.

• Checking belt wear

The belt tensioner is designed to operate within the limit of arm movement provided by the cast stops (A) and (B) when correct belt length and geometry is used. If the tensioner stop on swing arm (A) is hitting the fixed stop (B), check mounting brackets (alternator, belt tensioner, idler pulley, etc.) and the belt length. Replace belt as needed (see REPLACING FAN AND ALTERNATOR BELTS).

DPSG,CD03523,33 –19–12JUL99–2/2

RG4687 –UN–20DEC88

RG8098 –UN–18NOV97

Continued on next page

35-2

DPSG,CD03523,34 –19–13JUL99–1/2

112699

PN=53

Maintenance/1000 hours/1 year

• Checking tensioner spring tension

A belt tension gauge will not give an accurate measure of the belt tension when automatic spring tensioner is used. Measure tensioner spring tension using a torque wrench and procedure outlined below: a. Release tension on belt using a breaker bar and

socket on tension arm. Remove belt from pulleys.

b. Release tension on tension arm and remove breaker

bar. c. Put a mark (A) on swing arm of tensioner as shown. d. Measure 21 mm (0.83 in.) from (A) and put a mark

(B) on tensioner mounting base. e. Rotate the swing arm using a torque wrench until

marks (A) and (B) are aligned. f. Record torque wrench measurement and compare

with specification below. Replace tensioner assembly as required.

Spring—Specification

Force 18—22 N•m (13—16 lb-ft).................................................................

RG7977 –UN–14NOV97

CHECK AND ADJUST ENGINE VALVE CLEARANCE (300-SERIES ENGINES)

NOTE: Valve clearance must be adjusted after the first

500 hours of operation, then every 1000 hours thereafter.

Adjust engine valve clearance as follows or have your authorized servicing dealer or engine distributor adjust the engine valve clearance.

1. Remove rocker arm cover and crankcase vent tube.

2. Using JDE83 or JDG820 Flywheel Turning Tool (A), rotate engine flywheel in running direction (clockwise viewed from water pump) until No.1 piston (front) has reached top dead center (TDC) on compression stroke. Insert timing pin JDE81-4 (B) into flywheel bore.

DPSG,CD03523,34 –19–13JUL99–2/2

CD30544 –UN–19MAY98

Continued on next page

35-3

DPSG,CD03523,35 –19–13JUL99–1/4

112699

PN=54

Maintenance/1000 hours/1 year

3. Check and adjust valve clearance to specifications according to following procedures.

Valve clearance (engine cold)—Specification

Intake 0.35 mm (0.014 in.)..........................................................................

Exhaust 0.45 mm (0.018 in.).......................................................................

NOTE: If rocker arm is equipped with adjusting screw and

lock nut (A), tighten lock nut to 27 N

•

m (20 lb-ft)

after adjusting valve clearance.

4. Reinstall rocker arm cover and crankcase vent tube.

• 3-Cylinder Engine:

NOTE: Firing order is 1-2-3.

a. Lock No. 1 piston at TDC compression stroke (D). b. Adjust valve clearance on No. 1 and 2 exhaust

valves and No.1 and 3 intake valves.

c. Rotate flywheel 360°. Lock No. 1 piston at TDC

exhaust stroke (E).

d. Adjust valve clearance on No. 3 exhaust valve and

No. 2 intake valve.

CD30545 –UN–19MAY98

RG6307 –UN–03AUG92

DPSG,CD03523,35 –19–13JUL99–2/4

Continued on next page

35-4

CD30549 –UN–16JUN98

A—Front of engine B—Exhaust valve C—Intake valve D—No.1 Piston at TDC compression stroke E—No.1 Piston at TDC exhaust stroke

DPSG,CD03523,35 –19–13JUL99–3/4

112699

PN=55

Maintenance/1000 hours/1 year

• 4-Cylinder Engine:

NOTE: Firing order is 1-3-4-2.

a. Lock No. 1 piston at TDC compression stroke (B). b. Adjust valve clearance on No. 1 and 3 exhaust

valves and No.1 and 2 intake valves.

c. Rotate flywheel 360°. Lock No. 4 piston at TDC

compression stroke (C).

d. Adjust valve clearance on No. 2 and 4 exhaust

valves and No. 3 and 4 intake valves.

RG4776 –UN–31OCT97

A—Front of engine B—No.1 Piston at TDC compression stroke C—No.4 Piston at TDC compression stroke E—Exhaust valve I—Intake valve

DPSG,CD03523,35 –19–13JUL99–4/4

35-5

112699

PN=56

Maintenance/2000 hours/2 years

CHECK AND ADJUST ENGINE VALVE CLEARANCE (POWERTECH ENGINE)

Adjust engine valve clearance as follows or have your authorized servicing dealer or engine distributor adjust the engine valve clearance.

1. Remove rocker arm cover and crankcase vent tube.

CD30544 –UN–19MAY98

DPSG,CD03523,36 –19–13JUL99–1/4

3. Check and adjust valve clearance to specifications according to following procedures.

Valve clearance (engine cold)—Specification

Intake 0.35 mm (0.014 in.)..........................................................................

Exhaust 0.45 mm (0.018 in.).......................................................................

4. If valves need adjusting, loosen the lock nut on rocker arm adjusting screw. Turn adjusting screw until feeler gauge slips with a slight drag. Hold the adjusting screw from turning with screwdriver and tighten lock nut to 27 N•m (20 lb-ft). Recheck clearance again after tightening lock nut. Readjust clearance as necessary

5. Reinstall rocker arm cover and crankcase vent tube.

Continued on next page

RG7409 –UN–06AUG96

DPSG,CD03523,36 –19–13JUL99–2/4

40-1

112699

PN=57

Maintenance/2000 hours/2 years

• 4-Cylinder Engine:

NOTE: Firing order is 1-3-4-2.

a. Lock No. 1 piston at TDC compression stroke (B). b. Adjust valve clearance on No. 1 and 3 exhaust

valves and No.1 and 2 intake valves.

c. Rotate flywheel 360°. Lock No. 4 piston at TDC

compression stroke (C).

d. Adjust valve clearance on No. 2 and 4 exhaust

valves and No. 3 and 4 intake valves.

RG4776 –UN–31OCT97

A—Front of engine B—No.1 Piston at TDC compression stroke C—No.4 Piston at TDC compression stroke E—Exhaust valve I—Intake valve

• 6-Cylinder Engine:

NOTE: Firing order is 1-5-3-6-2-4.

a. Lock No. 1 piston at TDC compression stroke (B). b. Adjust valve clearance on No. 1, 3, and 5 exhaust

valves and No. 1, 2, and 4 intake valves.

c. Rotate flywheel 360°. Lock No. 6 piston at TDC

compression stroke (C).

d. Adjust valve clearance on No. 2, 4, and 6 exhaust

valves and No. 3, 5, and 6 intake valves.

DPSG,CD03523,36 –19–13JUL99–3/4

RG4777 –UN–31OCT97

A—Front of engine B—No.1 Piston at TDC compression stroke C—No.6 Piston at TDC compression stroke E—Exhaust valve I—Intake valve

40-2

DPSG,CD03523,36 –19–13JUL99–4/4

112699

PN=58

Maintenance/2000 hours/2 years

CHECKING ENGINE SPEED

NOTE: Most engines for generator set application

(1500 rpm for 50 Hz or 1800 rpm for 60 Hz) run only at fast idle and therefore they do not have slow idle.

Fast idle—Specification

50 Hz Generator set 1550—1580 rpm........................................................

60 Hz Generator set 1865—1890 rpm........................................................

NOTE: Fast idle is settled by the factory then the idle

adjusting screw (A) is sealed to prevent from tampering. Fast idle adjustment can only be done by an authorized fuel system agent.

ADJUST SPEED DROOP GOVERNOR

1. Warm engine to normal operating temperature.

2. Run engine at fast idle.

3. Apply full load.

4. If specified power cannot be obtained, turn screw (B) to adjust droop until the requested power is reached.

NOTE: If surging exists upon removing the load, turn

screw (B) clockwise to eliminate.

CD30763 –UN–24SEP99

DPSG,CD03523,38 –19–13JUL99–1/1

CD30764 –UN–24SEP99

40-3

DPSG,CD03523,39 –19–13JUL99–1/1

112699

PN=59

Maintenance/2000 hours/2 years

CHECKING CRANKSHAFT VIBRATION DAMPER (6-CYLINDER ENGINE ONLY)

1. Remove belts (shown removed).

2. Grasp vibration damper with both hands and attempt to turn it in both directions. If rotation is felt, damper is defective and should be replaced.

IMPORTANT: The vibration damper assembly is not

repairable and should be replaced every 4500 hours or 5 years, whichever occurs first.

3. Check vibration damper radial runout by positioning a dial indicator so probe contacts damper outer circumference.

4. With engine at operating temperature, rotate crankshaft using JDG820 or JDE83 Flywheel Turning Tool.

5. Note dial indicator reading. If runout exceeds specifications given below, replace vibration damper.

RG8018 –UN–15JAN99RG7508 –UN–23NOV97

Damper—Specification

Maximum radial runout 1.50 mm (0.060 in.)...............................................

DPSG,CD03523,40 –19–13JUL99–1/1

40-4

112699

PN=60

Maintenance/2500 hours/3 years

DRAIN AND FLUSH COOLING SYSTEM

NOTE: Drain and flush cooling system every

2500 hours/3 years when John Deere COOL-GARD coolant is used. Otherwise every 2000 hours/2 years.

CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns.

Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

1. Slowly open the radiator cap.

2. Remove engine block drain plug (A).

3. On POWERTech engines, remove oil cooler housing drain plug (B).

4. Open radiator drain valve (C). Drain all coolant from radiator.

5. Close all drain orifices after coolant has drained.

6. Fill the cooling system with clean water. Run engine until water passes through the thermostat to stir up possible rust or sediment.

7. Stop engine and immediately drain the water from system before rust and sediment settle.

TS281 –UN–23AUG88RG4894 –UN–14DEC88

8. After draining water, close all drain orifices and fill the cooling system with clean water and TY15979 John Deere Heavy Duty Cooling System Cleaner or equivalent cleaner. Follow manufacturer’s directions on label.

9. After cleaning the cooling system, drain cleaner and fill with water to flush the system. Run engine until water passes through the thermostat, then drain out flushing water.

45-1

Continued on next page

ZX016192 –UN–11JAN99

CD30765 –UN–27AUG99

DPSG,CD03523,41 –19–13JUL99–1/3

112699

PN=61

Maintenance/2500 hours/3 years

10. Check cooling system hoses for proper condition.

Replace as necessary.

11. Close all drain orifices and fill the cooling system with

specified coolant (see DIESEL ENGINE COOLANT).

Cooling system capacity—Specification

CD3029DF128 14.5 L (15.5 qt)...................................................................

CD4039DF008 16.5 L (17.5 qt)...................................................................

CD4039TF008 16.5 L (17.5 qt)...................................................................

CD4045DF158 20 L (21 qt).........................................................................

CD4045HF158 25 L (26.5 qt)......................................................................

CD4045TF158 25 L (26.5 qt)......................................................................

CD4045TF258 25 L (26.5 qt)......................................................................

CD6068HF158 29 L (30.5 qt)......................................................................

CD6068TF158 26 L (27.5 qt)......................................................................

CD6068TF258 26 L (27.5 qt)......................................................................

12. When refilling cooling system, loosen temperature

sensor (B) or plug at the rear of cylinder head to allow air to escape.

13. Run engine until it reaches operating temperature

then check coolant level and entire cooling system for leaks.

DPSG,CD03523,41 –19–13JUL99–2/3

CD30643 –UN–04MAY98

DPSG,CD03523,41 –19–13JUL99–3/3

45-2

112699

PN=62

Maintenance/As required

ADDITIONAL SERVICE INFORMATION

This manual does not allow a complete repair of your engine. If you want want more detailled service information the following publications are available from your regular parts channel.

• PC2451 — Parts Catalog

• CTM3274 — Component Technical Manual for

300-Series engines (English)

• CTM104 — Component Technical Manual for

POWERTech engines (English)

• CTM67 — Component Technical Manual for OEM

Engine accessories (English only)

• CTM77 — Component Technical Manual for Alternators

and Starter Motors (English only)

RG4624 –UN–15DEC88

DO NOT MODIFY FUEL SYSTEM

IMPORTANT: Modification or alteration of the

injection pump, the injection pump timing, or the fuel injectors in ways not recommended by the manufacturer will terminate the warranty obligation to the purchaser.

Do not attempt to service injection pump or fuel injectors yourself. Special training and special tools are required (see your authorized servicing dealer or engine distributor).

DPSG,CD03523,42 –19–15JUL99–1/1

CD30768 –UN–24SEP99

DPSG,CD03523,43 –19–15JUL99–1/1

50-1

112699

PN=63

Maintenance/As required

CLEAN OR REPLACE AIR FILTER (ONE-PIECE)

Clean air filter when restriction indicator (A) is red. Air filter can be cleaned up to six times. Thereafter, or at least once a year, it must be replaced.

Proceed as follows:

1. Thoroughly clean all dirt around air filter area.

2. Loosen clamp (B) then remove air filter.

IMPORTANT: Never reinstall an air filter which shows

evidence of bad condition (punched, dented...) allowing no filtered air to enter the engine.

3. Clean air filter with compressed air working from “clean” to “dirty” side.

NOTE: Compressed air must not exceed 600 kPa (6 bar;

88 psi).

4. Mark air filter to keep track of each cleaning operation.

5. Fully depress air restriction indicator reset button and release to reset indicator.

6. Check air system entirely for proper condition (see CHECKING AIR INTAKE SYSTEM).

CD30766 –UN–06SEP99

RG9912 –UN–25FEB99

50-2

DPSG,CD03523,44 –19–15JUL99–1/1

112699

PN=64

Maintenance/As required

CLEAN OR REPLACE AIR FILTER ELEMENT

A—Primary element C—Air restriction indicator B—Secondary (safety) D—Wing nut

element

Clean air filter when restriction indicator (C) is red. Replace both primary (A) and secondary (B) filter elements every 6 primary element cleaning or at least once a year.

Proceed as follows:

1. Thoroughly clean all dirt around air filter area.

2. Remove wing nut (D) and remove primary element (A) from canister.

IMPORTANT: Do not attempt to clean the

secondary (safety) element (B). It must be only replaced as recommended.

3. Thoroughly clean all dirt from inside canister.

CD30772 –UN–27AUG99

dented...), replace both the primary and the secondary elements.

4. Clean primary element with compressed air working from “clean” to “dirty” side.

NOTE: Compressed air must not exceed 600 kPa

(6 bar; 88 psi).

5. Mark air filter to keep track of each cleaning operation.

6. Fully depress air restriction indicator reset button and release to reset indicator.

7. Check air system entirely for proper condition (see CHECKING AIR INTAKE SYSTEM).

IMPORTANT: If primary element shows evidence

of bad condition (punched,

50-3

DPSG,CD03523,58 –19–16AUG99–1/1

112699

PN=65

Maintenance/As required

REPLACING FAN AND ALTERNATOR BELT (POWERTECH ENGINES)

NOTE: Refer to CHECKING BELT TENSIONER SPRING

TENSION AND BELT WEAR for additional information on the belt tensioner.

1. Inspect belts for cracks, fraying, or stretched out areas. Replace if necessary.

2. On engines with automatic belt tensioner, release tension on belt using a breaker bar and socket on tension arm.

On engines with manual tensioner, loosen cap screws holding the alternator.

3. Remove poly-vee belt from pulleys and discard belt.

4. Install new belt, making sure belt is correctly seated in all pulley grooves. Refer to belt routing at right for your application.

Installation on 4 cyl. engines

CD30769 –UN–01SEP99

5. Apply tension to belt (see CHECKING BELT).

6. Start engine and check belt alignment.

Installation on 6 cyl. engines

CD30770 –UN–01SEP99

ALT—Alternator CP—Crankshaft Pulley FD—Fan Drive I—Idler Pulley T—Tensioner WP—Water Pump

DPSG,CD03523,45 –19–15JUL99–1/1

50-4

112699

PN=66

Maintenance/As required

CHECKING FUEL FILTER

Periodically the fuel filter should be checked for water or debris.

IMPORTANT: Drain water into a suitable container

and dispose of properly.

1. Loosen drain plug (B) at bottom of fuel filter two or three turns.

2. Loosen air bleed plug two full turns (A) on fuel filter base and drain water from bottom until fuel starts to drain out.

3. When fuel starts to drain out, tighten drain plug securely.

4. After draining water from the fuel filter, the filter must be primed by bleeding all air from the fuel system. Operate primer lever of the fuel supply pump (C) until fuel flow is free from air bubbles.

5. Tighten bleed plug securely, continue operating hand primer until pumping action is not felt. Push hand primer inward (toward engine) as far as it will go.

If the fuel system needs further bleeding of air, see BLEEDING THE FUEL SYSTEM.

RG9868 –UN–15JAN99RG8013B –UN–15JAN99

50-5

DPSG,CD03523,28 –19–12JUL99–1/1

112699

PN=67

Maintenance/As required

BLEEDING THE FUEL SYSTEM

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting fuel or other lines. Tighten all connections before applying pressure. Keep hands and body away from pinholes and nozzles which eject fluids under high pressure. Use a piece of cardboard or paper to search for leaks. Do not use your hand.

If ANY fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result. Doctors unfamiliar with this type of injury may call the Deere & Company Medical Department in Moline, Illinois, or other knowledgeable medical source.

Whenever the fuel system has been opened up for service (lines disconnected or filters removed), it will be necessary to bleed air from the system.

1. Loosen the air bleed screw (A) two full turns by hand on fuel filter base.

X9811 –UN–23AUG88

RG7947 –UN–13NOV97RG8013A –UN–15JAN99

2. Operate supply pump primer lever (B) until fuel flow is free from air bubbles.

3. Tighten bleed plug securely, continue operating hand primer until pumping action is not felt. Push hand primer inward (toward engine) as far as it will go.

4. Start engine and check for leaks.

If engine will not start, it may be necessary to bleed air from fuel system at fuel injection pump or injection nozzles as explained next.

Continued on next page

DPSG,CD03523,46 –19–10AUG99–1/2

50-6

112699

PN=68

Maintenance/As required

• At Fuel Injection Pump:

a. Slightly loosen fuel return line connector (C) at fuel

injection pump.

b. Operate fuel supply pump primer lever until fuel,

without air bubbles, flows from fuel return line

connection. c. Tighten return line connector to 16 N•m (12 lb-ft). d. Leave hand primer in the inward position toward

cylinder block.

• At Fuel Injection Nozzles:

a. Using two open-end wrenches, loosen fuel line

connection at injection nozzle. b. Crank engine over with starting motor (but do not

start engine), until fuel free from bubbles flows out of

loosened connection. Retighten connection to

27 N•m (20 lb-ft). c. Repeat procedure for remaining injection nozzles (if

necessary) until all air has been removed from fuel

system. If engine still will not start, see your authorized servicing

dealer or engine distributor.

CD30771 –UN–24SEP99

RG7725 –UN–08JAN97

DPSG,CD03523,46 –19–10AUG99–2/2

50-7

112699

PN=69

ENGINE TROUBLESHOOTING

Troubleshooting

Symptom Problem

Solution

Engine cranks but will not start Incorrect starting procedure. Verify correct starting procedure.

No fuel. Check fuel in tank and manual

shut-off valve.

Exhaust restricted. Check and correct exhaust

restriction.

Fuel filter plugged or full of water. Replace fuel filter or drain water

from filter.

Injection pump not getting fuel or air Check fuel flow at supply pump or in fuel system. bleed fuel system.

Faulty injection pump or nozzles. Consult authorized diesel repair

station for repair or replacement.

Engine hard to start or will not Engine starting under load. Remove load. start

Improper starting procedure. Review starting procedure. No fuel. Check fuel tank. Air in fuel line. Bleed fuel line. Cold weather. Use cold weather starting aids. Slow starter speed. See “Starter Cranks Slowly”. Crankcase oil too heavy. Use oil of correct viscosity. Improper type of fuel. Consult fuel supplier; use proper

type fuel for operating conditions. Water, dirt or air in fuel system. Drain, flush, fill and bleed system. Clogged fuel filter. Replace filter element. Dirty or faulty injection nozzles. Have authorized servicing dealer or

engine distributor check injectors.

Continued on next page

55-1

DPSG,CD03523,49 –19–10AUG99–1/5

112699

PN=70

Troubleshooting

Symptom Problem

Solution

Injection pump shut-off not reset. Turn key switch to “OFF” then to

“ON”.

Engine knocks Low engine oil level. Add oil to engine crankcase.

Injection pump out of time. See your authorized servicing dealer

or engine distributor. Low coolant temperature. Remove and check thermostat. Engine overheating. See “Engine Overheats”.

Engine runs irregularly or stalls Low coolant temperature. Remove and check thermostat. frequently

Clogged fuel filter. Replace fuel filter element. Water, dirt or air in fuel system. Drain, flush, fill and bleed system. Dirty or faulty injection nozzles. Have authorized servicing dealer or

engine distributor check injectors.

Below normal engine Defective thermostat. Remove and check thermostat. temperature

Defective temperature gauge or Check gauge, sender and sender. connections.

Lack of power Engine overloaded. Reduce load.

Intake air restriction. Service air cleaner. Clogged fuel filter. Replace filter element. Improper type of fuel. Use proper fuel. Overheated engine. See “Engine Overheats”. Below normal engine temperature. Remove and check thermostat. Improper valve clearance. See your authorized servicing dealer

or engine distributor. Dirty or faulty injection nozzles. Have authorized servicing dealer or

engine distributor check injectors.

Continued on next page

55-2

DPSG,CD03523,49 –19–10AUG99–2/5

112699

PN=71

Troubleshooting

Symptom Problem

Solution

Injection pump out of time. See your authorized servicing dealer

or engine distributor. Turbocharger not functioning. See your authorized servicing dealer

or engine distributor. Leaking exhaust manifold gasket. See your authorized servicing dealer

or engine distributor. Defective aneroid control line. See your authorized servicing dealer

or engine distributor. Restricted fuel hose. Clean or replace fuel hose. Low fast idle speed. See your authorized servicing dealer

or engine distributor.

Low oil pressure Low oil level. Add oil.

Improper type of oil. Drain and fill crankcase with oil of

proper viscosity and quality.

High oil consumption Crankcase oil too light. Use oil of correct viscosity.

Oil leaks. Check for leaks in lines, gaskets,

and drain plug. Restricted crankcase vent tube. Clean vent tube. Defective turbocharger. See your authorized servicing dealer

or engine distributor.

Engine emits white smoke Improper type of fuel. Use proper fuel.

Low engine temperature. Warm up engine to normal operating

temperature. Defective thermostat. Remove and check thermostat. Defective injection nozzles. See your authorized servicing dealer

or engine distributor. Engine out of time. See your authorized servicing dealer

or engine distributor.

Continued on next page

55-3

DPSG,CD03523,49 –19–10AUG99–3/5

112699

PN=72

Troubleshooting

Symptom Problem

Solution

Engine emits black or grey Improper type of fuel. Use proper fuel. exhaust smoke

Clogged or dirty air cleaner. Service air cleaner. Engine overloaded. Reduce load. Injection nozzles dirty. See your authorized servicing dealer

or engine distributor. Engine out of time. See your authorized servicing dealer

or engine distributor. Turbocharger not functioning. See your authorized servicing dealer

or engine distributor.

Engine overheats Engine overloaded. Reduce load.

Low coolant level. Fill radiator to proper level, check

radiator and hoses for loose

connections or leaks. Faulty radiator cap. Have serviceman check. Stretched poly-vee belt or defective Check automatic belt tensioner and

belt tensioner. check belts for stretching. Replace

as required. Low engine oil level. Check oil level. Add oil as required. Cooling system needs flushing. Flush cooling system. Defective thermostat. Remove and check thermostat. Defective temperature gauge or Check coolant temperature with

sender. thermometer and replace, if

necessary. Incorrect grade of fuel. Use correct grade of fuel.

High fuel consumption Improper type of fuel. Use proper type of fuel.

Clogged or dirty air cleaner. Service air cleaner.

Continued on next page

55-4

DPSG,CD03523,49 –19–10AUG99–4/5

112699

PN=73

Troubleshooting

Symptom Problem

Engine overloaded. Reduce load. Improper valve clearance. See your authorized servicing dealer

Injection nozzles dirty. See your authorized servicing dealer

Engine out of time. See your authorized servicing dealer

Defective turbocharger. See your authorized servicing dealer

Low engine temperature. Check thermostat.

Solution

or engine distributor.

DPSG,CD03523,49 –19–10AUG99–5/5

55-5

112699

PN=74

ELECTRICAL TROUBLESHOOTING

Troubleshooting

Symptom Problem

Solution

Undercharged system Excessive electrical load from added Remove accessories or install higher

accessories. output alternator. Excessive engine idling. Increase engine rpm when heavy

electrical load is used. Poor electrical connections on Inspect and clean as necessary.

battery, ground strap, starter or alternator.

Defective battery. Test battery. Defective alternator. Test charging system.

Battery uses too much water Cracked battery case. Check for moisture and replace as

necessary. Defective battery. Test battery. Battery charging rate too high. Test charging system.

Battery will not charge Loose or corroded connections. Clean and tighten connections.

Sulfated or worn-out battery. See your authorized servicing dealer

or engine distributor. Stretched poly-vee belt or defective Adjust belt tension or replace belts.

belt tensioner.

Starter will not crank Engine under load Remove load

Loose or corroded connections. Clean and tighten loose connections. Low battery output voltage. See your authorized servicing dealer

or engine distributor. Faulty start circuit relay. See your authorized servicing dealer

or engine distributor. Blown fuse. Replace fuse.

Continued on next page

55-6

DPSG,CD03523,50 –19–10AUG99–1/2

112699

PN=75

Troubleshooting

Symptom Problem

Solution

Starter cranks slowly Low battery output. See your authorized servicing dealer

or engine distributor. Crankcase oil too heavy. Use proper viscosity oil. Loose or corroded connections. Clean and tighten loose connections.

Entire electrical system Faulty battery connection. Clean and tighten connections.

Sulfated or worn-out battery. See your authorized servicing dealer

or engine distributor. Blown fuse. Replace fuse.

DPSG,CD03523,50 –19–10AUG99–2/2

55-7

112699

PN=76

ENGINE STORAGE GUIDELINES

Storage

1. John Deere engines can be stored outside for up to three (3) months with no long term preparation IF COVERED BY WATERPROOF COVERING.

2. John Deere engines can be stored in a standard overseas shipping container for up to three (3) months with no long term preparation.

3. John Deere engines can be stored inside, warehoused, for up to six (6) months with no long term preparation.

4. John Deere engines expected to be stored more than six (6) months, long term storage preparation

USE AR41785 ENGINE STORAGE KIT

See your John Deere servicing dealer or engine distributor for an AR41785 Engine Storage Kit. Closely follow instructions provided with this kit.

MUST BE taken. (See PREPARING ENGINE FOR LONG TERM STORAGE).

5. For John Deere engines not yet installed in machines, run a line from a container of AR41937 Nucle Oil (from AR41785 Engine Storage Kit) to the fuel transfer pump intake, and another line from the fuel return manifold to the tank, so that Nucle Oil is circulated through the injection system during cranking.

DPSG,CD03523,51 –19–10AUG99–1/1

IMPORTANT: Inhibitors can easily change to gas.

Seal or tape each opening immediately after adding inhibitor.

T85452 –UN–06DEC88

DPSG,CD03523,52 –19–10AUG99–1/1

60-1

112699

PN=77

Storage

PREPARING ENGINE FOR LONG TERM STORAGE

The following storage preparations are good for long term engine storage up to one year. After that, the engine should be started, warmed up, and retreated for an extended storage period.

IMPORTANT: Any time your engine will not be

used for over six (6) months, the following recommendations for storing it and removing it from storage will help to minimize corrosion and deterioration. Use the AR41785 Engine Storage Kit. Follow recommended service procedure included with storage kit.

1. Change engine oil and replace filter. Used oil will not give adequate protection. (See CHANGING ENGINE OIL AND FILTER).

2. Service air cleaner. (See CLEAN OR REPLACE AIR FILTER).

3. Draining and flushing of cooling system is not necessary if engine is to be stored only for several months. However, for extended storage periods of a year or longer, it is recommended that the cooling system be drained, flushed, and refilled. Refill with appropriate coolant. (See DIESEL ENGINE COOLANT).

4. Drain fuel tank and add 30 ml (1 oz) of inhibitor to the fuel tank for each 15 L (4 U.S. gal) of tank capacity. Completely drain fuel filter and close fuel valve, if equipped.

5. Add 30 ml (1 oz) of inhibitor to the engine crankcase for each 0.95 L (1 qt) of crankcase oil.

6. Disconnect air intake piping from the manifold. Pour 90 ml (3 oz) of inhibitor into intake system and reconnect the piping.

7. Crank the engine several revolutions with starter (do not allow the engine to start).

8. Remove fan/alternator belt, if desired.

9. Remove and clean battery. Store them in a cool, dry place and keep them fully charged.

10. Clean the exterior of the engine with salt-free

water and touchup any scratched or chipped painted surfaces with a good quality paint.

11. Coat all exposed (machined) metal surfaces with

grease or corrosion inhibitor if not feasible to paint.

12. Seal all openings on engine with plastic bags and

tape supplied in storage kit. Follow instructions supplied in kit.

13. Store the engine in a dry protected place. If

engine must be stored outside, cover it with a waterproof canvas or other suitable protective material and use a strong waterproof tape.

60-2

DPSG,CD03523,53 –19–10AUG99–1/1

112699

PN=78

Storage

REMOVING ENGINE FROM LONG TERM STORAGE

Refer to the appropriate section for detailed services listed below or have your authorized servicing dealer or engine distributor perform services that you may not be familiar with.

1. Remove all protective coverings from engine. Unseal all openings in engine and remove covering from electrical systems.

2. Remove the battery from storage. Install battery (fully charged) and connect the terminals.

3. Install fan/alternator belt if removed.

4. Fill fuel tank.

5. Perform all appropriate prestarting checks. (See DAILY PRESTARTING CHECKS).

IMPORTANT: DO NOT operate starter more than

30 seconds at a time. Wait at least 2 minutes for starter to cool before trying again.

6. Crank engine for 20 seconds with starter (do not allow the engine to start). Wait 2 minutes and crank engine an additional 20 seconds to assure bearing surfaces are adequately lubricated.

7. Start engine and run at no load for several minutes. Warm up carefully and check all gauges before placing engine under load.

8. On the first day of operation after storage, check overall engine for leaks and check all gauges for correct operation.

DPSG,CD03523,54 –19–10AUG99–1/1

60-3

112699

PN=79

Specifications

GENERAL ENGINE SPECIFICATIONS

ITEM UNIT OF MEASURE 3029DF128 4039DF008 4039TF008

Number of Cylinders 3 4 4

Fuel Diesel Diesel Diesel

Bore mm 106.5 106.5 106.5

Stroke mm 110 110 110

Displacement L 2.9 3.9 3.9

Compression Ratio 17.8:1 17.8:1 17.8:1

POWER

@ kW (hp) 26 (35) 35 (48) 55 (75)

1500 rpm (Prime)

POWER

@ kW (hp) 30 (41) 38 (52) 61 (83)

1500 rpm (Standby)

POWER

@ kW (hp) 30 (41) 41 (56) 67 (91)

1800 rpm (Prime)

POWER

@ kW (hp) 34 (46) 47 (64) 73 (99)

1800 rpm (Standby)

Width (overall) mm 582 588 588

Length (overall) mm 888 1016 1016

Height (overall) mm 931 960 979

Weight (dry)

kg 345 410 455

Engine oil quantity L 6 12 12

Engine coolant L 14.5 16.5 16.5 quantity

With Fan

Approximate

Continued on next page

65-1

DPSG,CD03523,55 –19–10AUG99–1/3

112699

PN=80

Specifications

ITEM UNIT OF MEASURE 4045HF158 4045TF158 4045TF258 4045DF158

Number of Cylinders 4 4 4 4

Fuel Diesel Diesel Diesel Diesel

Bore mm 106.5 106.5 106.5 106.5

Stroke mm 127 127 127 127

Displacement L 4.5 4.5 4.5 4.5

Compression Ratio 17.0:1 17.0:1 17.0:1 17.6:1

POWER 1500 rpm (Prime)

@ kW (hp) 88 (120) 61 (83) 72 (98) 41 (56)

POWER

@ kW (hp) 96 (131) 68 (92) 80 (109) 42 (57)

1500 rpm (Standby)

POWER

@ kW (hp) 108 (147) 72 (98) 80 (109) 48 (65)

1800 rpm (Prime)

POWER

@ kW (hp) 120 (163) 79 (107) 88 (120) 51 (69)

1800 rpm (Standby)

Width (overall) mm 798 668 668 668

Length (overall) mm 1356 1219 1219 1219

Height (overall) mm 1136 1010 1010 1010

Weight (dry)

kg 446 436 436 391

Engine oil quantity L 12 12 12 8

Engine coolant L 25 25 25 20 quantity

With Fan

Approximate

Continued on next page

65-2

DPSG,CD03523,55 –19–10AUG99–2/3

112699

PN=81

Specifications

ITEM UNIT OF 6068HF158 6068TF158 6068TF258

MEASURE

Number of Cylinders 6 6 6

Fuel Diesel Diesel Diesel

Bore mm 106.5 106.5 106.5

Stroke mm 127 127 127

Displacement L 6.8 6.8 6.8

Compression Ratio 17.0:1 17.0:1 17.0:1

POWER

@ 1500 rpm kW (hp) 134 (182) 92 (125) 105 (143)

(Prime)

POWER

@ 1500 rpm kW (hp) 148 (201) 101 (137) 116 (158)

(Standby)

POWER

@ 1800 rpm kW (hp) 164 (223) 108 (147) 124 (169)

(Prime)

POWER

@1800 rpm kW (hp) 187 (254) 119 (162) 137 (186)

(Standby)

Width (overall) mm 798 668 668

Length (overall) mm 1476 1383 1383

Height (overall) mm 1136 1032 1032

Weight (dry)

kg 613 593 593

Engine oil quantity L 19.5 19.5 19.5

Engine coolant L 29 26 26 quantity

With Fan

Approximate

DPSG,CD03523,55 –19–10AUG99–3/3

65-3

112699

PN=82

Specifications

UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUES

65-4

DX,TORQ1 –19–20JUL94–1/1

112699

PN=83

TS1656 –19–02APR97

Specifications

METRIC BOLT AND CAP SCREW TORQUE VALUES

65-5

DX,TORQ2 –19–20JUL94–1/1

112699

PN=84

TS1657 –19–02APR97

Index

Page Page

Air filter

Clean or replace (one-piece). . . ...........50-2

Clean or replace element ................50-3

Air intake system

Checking.............................35-1

Fuel system

Bleeding .............................50-6

Fuel

Diesel ...............................10-1

Handling and storing....................10-1

Belt

Check automatic tensioner . . .............35-2

Check tension.........................30-4

Replace (POWERTech) .................50-4

Break-in engine oil . . .....................10-2

Coolant

Diesel engine .........................10-4

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

Warm temperature climates . .............10-5

Crankcase vent tube

Cleaning .........................03-1, 35-1

Damper . . .............................40-4

Diesel engine oil.........................10-3

Diesel fuel .............................10-1

Engine oil

Break-In .............................10-2

Diesel . . .............................10-3

Draining .............................30-1

Engine speed ...........................40-3

Replacement..........................30-3 Do not modify fuel system ..............50-1

Identification views, ......................01-1

Inch torque values .......................65-4

Lubricant

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

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

Maintenance records .....................02-1

Maintenance

1000 hours/1 year

Check and adjust valve clearance

(300-Series).......................35-3

Checking air intake system .............35-1

Checking automatic belt tensioner

(POWERTech).....................35-2

Cleaning crankcase vent tube . . .....03-1, 35-1

2000 hours/2 years

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

Adjust valve clearance (POWERTech) ....40-1

Check engine speed . . . ...............40-3

Damper check.......................40-4

2500 hours/3 years

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

50 hours/2 weeks

Checking fuel filter. ...................50-5

500 hours

Changing engine oil and filter ...........30-1

Checking belt........................30-4

Replace fuel filter.....................30-3

As required

Additional service information ...........50-1

Clean or replace air filter (one-piece)......50-2

Clean or replace air filter element ........50-3Fuel filter

Index-1

112699

PN=1

Index

Page Page

Replace fan and alternator belts

(POWERTech).....................50-4

Daily or every 10 hours..................25-1 Valve clearance

Adjust (300-Series) .....................35-3Observe service intervals ................20-1

Use correct fuel, lubricant and coolant . .....20-1 Adjust (POWERTech) . . .................40-1

Metric torque values. . . ...................65-5

Mixing lubricants.........................10-4

Operating the engine

Break-in period . .......................15-1

Engine operation.......................15-4

Standby power units ....................15-4

Starting the engine .....................15-1

Stopping the engine ....................15-5

Using a booster battery or charger .........15-3

Record keeping

Engine option codes ....................03-3

Engine serial number plate . . .............03-1

POWERTech medallion .................03-1

Record engine serial number .............03-2

Record fuel injection pump model number . . . 03-5

Specifications

Engine ..............................65-1

Storage

Engine ..............................60-1

Storing fuel.............................10-1

Storing lubricants . .......................10-3

Torque values

Inch.................................65-4

Metric ...............................65-5

Troubleshooting

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

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

Index-2

112699

PN=2

John Deere CD4039DF008 OPERATOR’S MANUAL

Specifications and Main Features

Frequently Asked Questions

User Manual