John Deere POWERTECH 8.1 L Technical Manual

PowerTech 8.1L

Diesel Engines

Mechanical Fuel

Systems

COMPONENT TECHNICAL MANUAL

Diesel models 6081

CTM243 18 FEB 05 (ENGLISH)

For complete service information also see:

PowerTech 8.1 L Diesel Engines Base Engine

Alternators and Starting Motors CTM77

OEM Engine Accessories CTM67

CTM106819 - Application List CTM106819

CTM86

John Deere Power Systems

CTM243-COMPONENT TECHNICAL MANUAL

FORWARD Section 01 - GENERAL

Group 000 - Safety Group 001 - Engine Identiﬁcation Group 002 - Fuels, Lubricants and Coolant

Section 02 - REPAIR AND ADJUSTMENT

Group 090 - Mechanical Fuel System Repair and Adjustments

Section 03 - THEORY OF OPERATION

Group 130 - Mechanical Fuel Systems Operation

Section 04 - DIAGNOSTICS

Group 150 - Observable Diagnostics and Tests

Section 05 - TOOLS

Group 170 - Repair Tools Group 180 - Diagnostic Service Tools

Section 6 - SPECIFICATIONS

Group 200 - Repair and General OEM Speciﬁcations

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GENERAL

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Forward

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

This manual (CTM243) covers only the mechanical fuel system. It is one of ﬁve volumes on the 8.1L engine. The following four companion manuals cover the base engine and electronic fuel system repair, operation and diagnostics:

CTM68—Electronic Fuel Injection Systems CTM86—Base Engine CTM134—John Deere Level 3 Electronic Fuel Systems with Bosch In-Line Pump. CTM255—John Deere Level 9 Electronic Fuel Systems with Denso In-Line Pump.

This new CTM covers information formerly in Group 35 of CTM86 dated 06JUL99 and Group 115 of CTM134 dated 22FEB99.

Other manuals will be added in the future to provide additional information on electronic fuel systems as needed.

A complete set of all manuals covering the 8.1L engines, excluding CTM68, can be procured by ordering CTM450 Binder Set.

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

CAUTION:

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

Use this component technical manual in conjunction with the machine technical manual. An application listing in Section 01, Group 001 identiﬁes product-model/component type-model relationship. See the machine technical manual for information on component removal and installation, and gaining access to the components.

Information is organized in sections and groups for the various components requiring service instruction.

Before beginning repair on an engine, clean the engine.

This manual contains SI Metric units of measure followed immediately by the U.S. customary units of measure. Most hardware on these engines is metric sized.

Some components of this engine may be serviced without removing the engine from the machine. Refer to the speciﬁc machine technical manual for information on components that can be serviced without removing the engine from the machine and for engine removal and installation procedures.

Read each block of material completely before performing service to check for diﬀerences in procedures or speciﬁcations. Follow only the procedures that apply to the engine model number you are working on. If only one procedure is given, that procedure applies to all the engines in the manual.

California Proposition 65 Warning

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.

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Section 01 page 1

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL

Table of contents

Group 000 - Safety 1 ...................................................................................................................................

Handle Fluids Safely—Avoid Fires 1 .........................................................................................................

Handle Starting Fluid Safely 1 .................................................................................................................

Handling Batteries Safely 1 .....................................................................................................................

Prepare for Emergencies 4 ......................................................................................................................

Avoid High-Pressure Fluids 4 ...................................................................................................................

Wear Protective Clothing 5 ......................................................................................................................

Service Machines Safely 5 .......................................................................................................................

Work In Ventilated Area 6 ........................................................................................................................

Work in Clean Area 6 ...............................................................................................................................

Remove Paint Before Welding or Heating 6 .............................................................................................

Avoid Heating Near Pressurized Fluid Lines 8 ..........................................................................................

Illuminate Work Area Safely 8 .................................................................................................................

Use Proper Lifting Equipment 8 ...............................................................................................................

Construct Dealer-Made Tools Safely 9 .....................................................................................................

Practice Safe Maintenance 10 .................................................................................................................

Use Proper Tools 10 .................................................................................................................................

Dispose of Waste Properly 11 ..................................................................................................................

Live With Safety 11 .................................................................................................................................

Group 001 - Engine Identiﬁcation 13 .......................................................................................................

Engine Model Designation 13 ..................................................................................................................

Engine Serial Number Plate Information 13 .............................................................................................

Engine Option Code Label 14 ..................................................................................................................

Group 002 - Fuels, Lubricants and Coolant 15 .......................................................................................

Diesel Fuel 15 ..........................................................................................................................................

Bio-Diesel Fuel 16 ....................................................................................................................................

Lubricity of Diesel Fuel 17 .......................................................................................................................

Testing Diesel Fuel 17 .............................................................................................................................

Diesel Engine Break-In Oil 18 ..................................................................................................................

Diesel Engine Oil 19 ................................................................................................................................

Extended Diesel Engine Oil Service Intervals 20 .....................................................................................

Alternative and Synthetic Lubricants 20 ..................................................................................................

Mixing of Lubricants 20 ...........................................................................................................................

OILSCAN OILSCAN is a registered trademark of Deere & Company. and CoolScan CoolScan is a

registered trademark of Deere & Company. 20 ................................................................................

Grease 21 ................................................................................................................................................

Heavy Duty Diesel Engine Coolant 22 .....................................................................................................

Diesel Engine Coolants, Supplemental Additive Information 24 ..............................................................

Testing Diesel Engine Coolant 25 ............................................................................................................

Replenishing Supplemental Coolant Additives (SCAs) Between Coolant Changes 26 .............................

Operating in Warm Temperature Climates 27 .........................................................................................

Flush and Service Cooling System 27 ......................................................................................................

Disposing of Coolant 29 ...........................................................................................................................

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Section 01 - GENERAL Group 000: Safety

Group 000 - Safety

Handle Fluids Safely—Avoid Fires

Avoid Fires

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

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

Make sure machine is clean of trash, grease, and debris.

Do not store oily rags; they can ignite and burn spontaneously.

Handle Starting Fluid Safely

Store 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.

Handling Batteries Safely

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Section 01 page 1

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL Group 000: Safety

CAUTION:

Explosion

Battery gas can explode. Keep sparks and ﬂames away from batteries. Use a ﬂashlight to check battery electrolyte level.

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

Always remove grounded (-) battery clamp ﬁrst and replace it last.

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

CAUTION:

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Section 01 page 2

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL Group 000: Safety

Acid

Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.

Avoid the hazard by:

Filling batteries in a well-ventilated area.1. Wearing eye protection and rubber gloves.2. Avoiding breathing fumes when electrolyte is added.3. Avoiding spilling or dripping electrolyte.4. Use proper jump start procedure.5.

If you spill acid on yourself:

Flush your skin with water.1. Apply baking soda or lime to help neutralize the acid.2. Flush your eyes with water for 15—30 minutes. Get medical attention immediately.3.

If acid is swallowed:

Do not induce vomiting.1. Drink large amounts of water or milk, but do not exceed 2 L (2 quarts).2. Get medical attention immediately.3.

WARNING: Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm.Wash hands after handling.

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Section 01 page 3

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL Group 000: Safety

Prepare for Emergencies

First Aid Kit

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.

Avoid High-Pressure Fluids

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 in English from Deere & Company Medical Department in Moline, Illinois, U.S.A., by calling 1-800-822-8262 or +1 309-748-5636.

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Section 01 page 4

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL Group 000: Safety

Wear Protective Clothing

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.

Service Machines Safely

Moving Parts

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Section 01 page 5

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL Group 000: Safety

Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result.

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

Work In Ventilated Area

Engine exhaust fumes

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.

Work in Clean Area

Clean Work Area

Before starting a job:

Clean work area and machine. Make sure you have all necessary tools to do your job. Have the right parts on hand. Read all instructions thoroughly; do not attempt shortcuts.

Remove Paint Before Welding or Heating

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Section 01 page 6

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL Group 000: Safety

Toxic Fumes

Avoid potentially toxic fumes and dust.

Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch.

Remove paint before heating:

Remove paint a minimum of 100 mm (4 in.) from area to be aﬀected by heating. If paint cannot be removed, wear an approved respirator before heating or welding. 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.

Do not use a chlorinated solvent in areas where welding will take place.

Do all work in an area that is well ventilated to carry toxic fumes and dust away.

Dispose of paint and solvent properly.

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Section 01 page 7

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL Group 000: Safety

Avoid Heating Near Pressurized Fluid Lines

Flammable Spray

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 accidentally burst when heat goes beyond the immediate ﬂame area.

Illuminate Work Area Safely

Work Area Safely

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

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Section 01 page 8

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL Group 000: Safety

Use Proper Lifting Equipment

Proper Lifting Equipment

Lifting heavy components incorrectly can cause severe injury or machine damage.

Follow recommended procedure for removal and installation of components in the manual.

Construct Dealer-Made Tools Safely

Faulty or broken tools can result in serious injury. When constructing tools, use proper, quality materials and good workmanship.

Do not weld tools unless you have the proper equipment and experience to perform the job.

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Section 01 page 9

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL Group 000: Safety

Practice Safe Maintenance

Keep Area Clean

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.

Use Proper Tools

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Section 01 page 10

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL Group 000: Safety

Proper Tools

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

Use power tools only to loosen threaded parts and fasteners.

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

Use only service parts meeting John Deere speciﬁcations.

Dispose of Waste Properly

Recycle Waste

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.

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Section 01 page 11

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL Group 001: Engine Identiﬁcation

Live With Safety

Safety Systems

Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields.

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Section 01 page 12

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL Group 001: Engine Identiﬁcation

Group 001 - Engine Identification

Engine Model Designation

JOHN DEERE ENGINE MODEL—6081

John Deere engine model designation includes number of cylinders, displacement in liters, aspiration, user code, and application code. For example:

Engine Model Designation

6081 HRW01 Engine

6 .......... Number of cylinders

8.1 .......... Liter designation

H .......... Aspiration code

RW .......... User code

01 .......... Application Code

Aspiration Code

T .......... Turbocharged, not aftercooled

A .......... Turbocharged and water-to-air aftercooled

H .......... Turbocharged and air-to-air aftercooled

User Code

CQ .......... S.L.C. Horizontina (Brazil)

DW .......... Davenport

F .......... OEM

FF .......... Kernersville Deere-Hitachi (North Carolina)

H .......... Harvester

N .......... Des Moines

RW .......... Waterloo (Tractors)

T .......... Dubuque

TJ .......... Ontario (Canada)

Bessemer (Alabama)

Z .......... Zweibrucken

Application Code

001, etc. .......... See Application Manual, CTM106819.

Engine Serial Number Plate Information

Engine Serial Number Plate

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Section 01 page 13

LEGEND:

A Engine Serial Number B Engine Application Data

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL Group 002: Fuels, Lubricants and Coolant

IMPORTANT:

The engine serial number plate can be easily destroyed. Remove the plate or record the information elsewhere, before “hot tank” cleaning the block.

Engine Serial Number (A)

Each engine has a 13-digit John Deere engine serial number identifying the producing factory, engine model designation, and a 6-digit sequential number. The following is an example:

Engine Serial Numbers

RG6081H000000

RG .......... Factory code producing engine

6081H .......... Engine model designation

000000 .......... Sequential serial number

Factory Code

RG .......... Waterloo Engine Works

Engine Model Designation

6801H .......... (See ENGINE MODEL DESIGNATION.)

Sequential Number

000000 .......... 6-digit sequential number

The engine serial number plate is located either on the right-hand side of engine between the oil ﬁlter base and fuel injection pump (viewed from ﬂywheel end) or on the left-hand side of the engine directly above the starter motor.

Engine Application Data (B)

The second line of information on the engine serial number plate identiﬁes the engine/Deere machine or OEM relationship. See Application Manual, CTM106819.

Engine Option Code Label

Option Code Label

In addition to the serial number plate, later 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.

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Section 01 page 14

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL Group 002: Fuels, Lubricants and Coolant

Group 002 - Fuels, Lubricants and Coolant

Diesel Fuel

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

In general, diesel fuels are blended to satisfy the low temperature requirements of the geographical area in which they are marketed.

Diesel fuels speciﬁed to EN 590 or ASTM D975 are recommended.

In all cases, the fuel shall meet the following properties:

Cetane number of 40 minimum. Cetane number greater than 50 is preferred, especially for temperatures below -20°C (-4°F) or elevations above 1500 m (5000 ft).

Cold Filter Plugging Point (CFPP) below the expected low temperature ORCloud 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%.

DO NOT mix used engine oil or any other type of lubricant with diesel fuel.

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Section 01 page 15

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL Group 002: Fuels, Lubricants and Coolant

Bio-Diesel Fuel

Bio-diesel fuels may be used ONLY if the fuel properties meet DIN 51606 or equivalent speciﬁcation. It has been shown that bio-diesel fuels have been found to improve lubricity in concentrations up to 5% blend in petroleum diesel fuel.

When using a blend of bio-diesel fuel with fuel pumps, the oil level MUST be checked daily when the air temperature is -10° C (14° F) or lower. If oil becomes diluted with fuel, oil change intervals must be shortened accordingly.

IMPORTANT:

Raw pressed vegetable oils are NOT acceptable for use for fuel in any concentration in John Deere engines. These oils do not burn completely, and will cause engine failure by leaving deposits on injectors and in the combustion chamber.

Users of bio-diesel fuel should always remember that a major selling merit is its ability to biodegrade, so the storage and handling of this fuel is very important. This importance can be seen in the following areas of concern:

The quality of the fresh fuel, Water content of the fuel, Problems due to aging of the fuel.

Potential problems resulting from deﬁciencies in the above areas when using bio-diesel fuel in concentrations above 5% may lead to the following symptoms:

Power loss and deterioration of performance, Fuel leakage, Corrosion of fuel injection equipment, Coked/blocked injector nozzles, leading to poor atomization of fuel, Filter plugging, Lacquering/seizure of internal components, Sludge and sediments, Reduced service life.

DIN 51606 Speciﬁcation

Bio-Diesel Property List for DIN 51606

Property Unit DIN 51606 Sept 1997

Density at 15° C (59° F)

Viscosity at 40° C (104° F)

Flash Point °C (°F) Min. 110 (230)

Cold Filter Plugging Point—Summer °C (°F) Max. 0 (32)

Cold Filter Plugging Point—Winter °C (°F) Max. -20 (-4)

Total Sulfur % Mass 0.01

Conradson (CCR) at 100% % Mass Max. 0.05

Cetane Number — Min. 49

Ash Content % Mass Max. 0.03

Water Content % Mass Max. 0.03

Total Contamination % Mass Max. 0.002

Copper Corrosion (3 hours, 50° C) (3 hours, 122° F) Degree of Corrosion 1

Neutralization Value mg KOH/g Max. 0.5

Methanol Content % Mass Max. 0.3

Monoglycerides % Mass Max. 0.8

Diglycerides % Mass Max. 0.4

Trigycerides % Mass Max. 0.4

Free Glycerine % Mass Max. 0.02

g/cm 3 (lb/ft 3 )

mm 2 /s (cST)

0.875—0.900 (55—56)

3.5—5.0

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Section 01 page 16

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL Group 002: Fuels, Lubricants and Coolant

Bio-Diesel Property List for DIN 51606

Property Unit DIN 51606 Sept 1997

Total Glycerine % Mass Max. 0.25

Iodine Number — Max. 115

Phosphorus % Mass Max. 0.001

Alkali Content (Na + K) % Mass Max. 0.0005

Lubricity of Diesel Fuel

Most diesel fuels manufactured in the United States, Canada, and the European Union have adequate lubricity to ensure proper operation and durability of fuel injection system components. However, diesel fuels manufactured in some areas of the world may lack the necessary lubricity.

IMPORTANT:

Make sure the diesel fuel used in your machine demonstrates good lubricity characteristics.

Fuel lubricity should pass a maximum scar diameter of 0.45 mm as measured by ASTM D6079 or ISO 12156-1.

If fuel of low or unknown lubricity is used, add John Deere PREMIUM DIESEL FUEL CONDITIONER (or equivalent) at the speciﬁed concentration.

Lubricity of Biodiesel Fuel

Signiﬁcant improvement in lubricity can occur with biodiesel blends up to B20. The gain in lubricity above a 20% blend is limited.

Testing Diesel Fuel

DIESELSCAN ™ is a John Deere fuel analysis program that can be used to monitor the quality of your fuel. The DIESELSCAN analysis veriﬁes fuel type, cleanliness, water content, suitability for cold weather operation, and whether the fuel meets speciﬁcations.

Check with your John Deere dealer for availability of DIESELSCAN kits.

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Section 01 page 17

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL Group 002: Fuels, Lubricants and Coolant

Diesel Engine Break-In Oil

New engines are ﬁlled at the factory with either John Deere Break-In ™ or Break-In™ Plus Engine Oil. During the break-in period, add John Deere Break-In™ or Break-In™ Plus Engine Oil, respectively, as needed to maintain the speciﬁed oil level.

Operate the engine under various conditions, particularly heavy loads with minimal idling, to help seat engine components properly.

Change the oil and ﬁlter at 100 hours maximum for Break-In™ Oil or 500 hours maximum for Break-In™ Plus Oil during the initial operation of a new or rebuilt engine.

After engine overhaul, ﬁll the engine with either John Deere Break-In™ or Break-In™ Plus Engine Oil.

If John Deere Break-In™ or Break-In™ Plus Engine Oil is not available, use a 10W-30 diesel engine oil meeting one of the following during the ﬁrst 100 hours of operation:

API Service Classiﬁcation CE API Service Classiﬁcation CD API Service Classiﬁcation CC ACEA Oil Sequence E2 ACEA Oil Sequence E1

IMPORTANT:

Do not use Plus-50™ II, Plus-50 or engine oils meeting any of the following for the initial break-in of a new or rebuilt engine:

Oils

API CJ-4 ACEA E9

API CI-4 PLUS ACEA E7

API CI-4 ACEA E6

API CH-4 ACEA E5

API CG-4 ACEA E4

API CF-4 ACEA E3

API CF-2

API CF

These oils will not allow the engine to break in properly.

John Deere Break-In™ Plus Engine Oil can be used for all John Deere diesel engines at all emission certiﬁcation levels.

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

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Section 01 page 18

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL Group 002: Fuels, Lubricants and Coolant

Diesel Engine Oil

Oil Viscosities for Air Temperature Ranges

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

John Deere Plus-50 ™ II oil is preferred.

John Deere Plus-50™ is also recommended.

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

John Deere Torq-Gard Supreme ™ API Service Category CJ-4 API Service Category CI-4 PLUS API Service Category CI-4 API Service Category CH-4 API Service Category CG-4 API Service Category CF-4 ACEA Oil Sequence E9 ACEA Oil Sequence E7 ACEA Oil Sequence E6 ACEA Oil Sequence E5 ACEA Oil Sequence E4 ACEA Oil Sequence E3 ACEA Oil Sequence E2

If oils meeting API CG-4, API CF-4, or ACEA E2 are used, reduce the service interval by 50%.

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Section 01 page 19

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL Group 002: Fuels, Lubricants and Coolant

Multi-viscosity diesel engine oils are preferred.

Diesel fuel quality and fuel sulfur content must comply with all existing emissions regulations for the area in which the engine operates.

If diesel fuel with sulfur content greater than 0.50% (5000 mg/kg) is used, reduce the service interval by 50%.

DO NOT use diesel fuel with sulfur content greater than 1.00% (10 000 mg/kg).

Extended Diesel Engine Oil Service Intervals

When John Deere Plus-50 ™ II or John Deere Plus-50™ oil is used with the speciﬁed John Deere ﬁlter, the service interval for engine oil and ﬁlter changes may be increased by 50% but not to exceed a maximum of 500 hours.

When ACEA E9, ACEA E7, ACEA E6, ACEA E5, or ACEA E4 oils are used with speciﬁed John Deere ﬁlter, use engine oil analysis to determine if the service interval for engine oil and ﬁlter changes may be increased by a maximum of 50% but not to exceed 500 hours.

If John Deere Plus-50™ II or John Deere Plus-50™, ACEA E9, ACEA E7, ACEA E6, ACEA E5, or ACEA E4 oils are used with other than the speciﬁed John Deere ﬁlter, change the engine oil and ﬁlter at the normal service interval.

If John Deere Torq-Gard Supreme ™ , API CJ-4, API CI-4 PLUS, API CI-4, API CH-4, or ACEA E3 oils are used, change the engine oil and ﬁlter at the normal service interval.

If API CG-4, API CF-4, or ACEA E2 oils are used, change the engine oil and ﬁlter at 50% of the normal service interval.

IMPORTANT:

When using biodiesel blends greater than B20, reduce the oil and ﬁlter service interval by 50% or monitor engine oil based on test results from Oilscan.

Alternative and Synthetic Lubricants

Conditions in certain geographical areas may require lubricant recommendations diﬀerent from those printed in this manual.

Some John Deere brand coolants and lubricants may not be available in your location.

Synthetic lubricants may be used if they meet the performance requirements as shown in this manual.

The temperature limits and service intervals shown in this manual apply to both conventional and synthetic oils.

Re-reﬁned base stock products may be used if the ﬁnished lubricant meets the performance requirements.

Avoid mixing diﬀerent brands or types of oils. Oil manufacturers blend base stock and additives to create their oils and to meet certain speciﬁcations and performance requirements. Mixing diﬀerent oils can interfere with proper functioning of these formulations and degrade lubricant performance.

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

Mixing of Lubricants

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.

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

OILSCAN ™ and CoolScan ™

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Section 01 - GENERAL Group 002: Fuels, Lubricants and Coolant

Sampling Programs

Recommended Change Interval

OILSCAN ™ and CoolScan ™ are John Deere sampling programs to help you monitor machine performance and identify potential problems before they cause serious damage.

Oil and coolant samples should be taken from each system prior to its recommended change interval.

Check with your John Deere dealer for the availability of OILSCAN ™ and CoolScan ™ kits.

Grease

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Section 01 - GENERAL Group 002: Fuels, Lubricants and Coolant

Grease

Use grease based on NLGI consistency numbers and the expected air temperature range during the service interval.

John Deere SD POLYUREA GREASE is preferred.

The following greases are also recommended

John Deere HD LITHIUM COMPLEX GREASE John Deere HD WATER RESISTANT GREASE John Deere GREASE-GARD ™

Other greases may be used if they meet the following:

NLGI Performance Classiﬁcation GC-LB

IMPORTANT:

Some types of grease thickeners are not compatible with others. Consult your grease supplier before mixing diﬀerent types of grease.

Heavy Duty 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). If protection at lower temperatures is required, consult your John Deere dealer for recommendations.

John Deere COOL-GARD ™ II Premix Coolant is preferred.

John Deere COOL-GARD II Premix is available in a concentration of 50% ethylene glycol.

Additional Recommended Coolants

The following engine coolants are also recommended:

John Deere COOL-GARD II Concentrate in a 40% to 60% mixture of concentrate with quality water. John Deere COOL-GARD Premix (available in a concentration of 50% ethylene glycol). John Deere COOL-GARD Concentrate in a 40% to 60% mixture of concentrate with quality water. John Deere COOL-GARD PG Premix (available in a concentration of 55% propylene glycol).

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Section 01 - GENERAL Group 002: Fuels, Lubricants and Coolant

John Deere COOL-GARD II Premix and COOL-GARD II Concentrate coolants do not require use of supplemental coolant additives.

John Deere COOL-GARD Premix, COOL-GARD Concentrate, and COOL-GARD PG Premix do not require use of supplemental coolant additives, except for periodic replenishment of additives during the drain interval.

Use John Deere COOL-GARD PG Premix when a non-toxic coolant formulation is required.

Other Coolants

It is possible that John Deere COOL-GARD II, COOL-GARD, and COOL-GARD PG coolants are unavailable in the geographical area where service is performed.

If these coolants are unavailable, use a coolant concentrate or prediluted coolant intended for use with heavy duty diesel engines and with a minimum of the following chemical and physical properties:

Is formulated with a quality nitrite-free additive package. Provides cylinder liner cavitation protection according to either the John Deere Cavitation Test Method or a ﬂeet study run at or above 60% load capacity. Protects the cooling system metals (cast iron, aluminum alloys, and copper alloys such as brass) from corrosion.

The additive package must be part of one of the following coolant mixtures:

ethylene glycol or propylene glycol base prediluted (40% to 60%) heavy duty coolant ethylene glycol or propylene glycol base heavy duty coolant concentrate in a 40% to 60% mixture of concentrate with quality water

Water Quality

Water quality is important to the performance of the cooling system. Distilled, deionized, or demineralized water is recommended for mixing with ethylene glycol and propylene glycol base engine coolant concentrate.

IMPORTANT:

Do not use cooling system sealing additives or antifreeze that contains sealing additives.

Do not mix ethylene glycol and propylene glycol base coolants.

Do not use coolants that contain nitrites.

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Section 01 - GENERAL Group 002: Fuels, Lubricants and Coolant

Diesel Engine Coolants, Supplemental Additive Information

Engine coolants are a combination of three chemical components: ethylene glycol (antifreeze), inhibiting coolant additives, and quality water.

Coolant Speciﬁcations

Some products, including John Deere John Deere COOL-GARD Prediluted Coolant, are fully formulated coolants that contain all three components in their correct concentrations. Do not add an initial charge of supplemental coolant additives to these fully formulated products.

Some coolant concentrates, including John Deere COOL-GARD Coolant Concentrate, contain both ethylene glycol antifreeze and inhibiting coolant additives. Mix these products and quality water, but do not add an initial charge of supplemental coolant additives.

Coolants meeting ASTM D5345 (prediluted coolant) or ASTM D4985 (coolant concentrate) require an initial charge of supplemental coolant additives.

Replenish Coolant Additives

The concentration of coolant additives is gradually depleted during engine operation. Periodic replenishment of inhibitors is required, even when John Deere COOL-GARD is used. Follow the recommendations in this manual for the use of supplemental coolant additives.

Why Use Supplemental Coolant Additives?

Operating without proper coolant additives will result in increased corrosion, cylinder liner erosion and pitting, and other damage to the engine and cooling system. A simple mixture of ethylene glycol and water will not give adequate protection.

Use of supplemental coolant additives reduces corrosion, erosion, and pitting. These chemicals reduce the number of vapor bubbles in the coolant and help form a protective ﬁlm on cylinder liner surfaces. This ﬁlm acts as a barrier against the harmful eﬀects of collapsing vapor bubbles.

Avoid Automotive-Type Coolants

Never use automotive-type coolants (such as those meeting ASTM D3306 or ASTM D4656). These coolants do not contain the correct additives to protect heavy-duty diesel engines. They often contain a high concentration of silicates and may damage the engine or cooling system.

Non-Aqueous Propylene Glycol

Non-aqueous propylene glycol should not be used with John Deere diesel engines. This coolant works best with coolant temperatures above the acceptable engine operating range. This could decrease engine life due to lower engine oil viscosity. In addition, electronically controlled engines could experience premature power de-rate due to high coolant temperature.

Water Quality

Water quality is important to the performance of the cooling system. Distilled, deionized, or demineralized water is recommended for mixing with ethylene glycol base engine coolant concentrate. All water used in the cooling system should meet the following minimum speciﬁcations for quality:

Water Quality

Chlorides 40 mg/L or less

Sulfates 100 mg/L or less

Total Dissolved Solids 340 mg/L or less

Total Hardness 170 mg/L or less

pH Level 5.5 to 9.0

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Section 01 - GENERAL Group 002: Fuels, Lubricants and Coolant

Freeze Protection

The relative concentrations of ethylene glycol and water in the engine coolant determine its freeze protection limit. Refer to the chart on the following page.

Freeze Protection

Ethylene Glycol Freeze Protection Limit

40% -24°C (-12°F)

50% -37°C (-34°F)

60% -52°C (-62°F)

DO NOT use a coolant-water mixture greater than 60% ethylene glycol.

Testing Diesel Engine Coolant

Maintaining adequate concentrations of glycol and inhibiting additives in the coolant is critical to protect the engine and cooling system against freezing, corrosion, and cylinder liner erosion and pitting.

Test the coolant solution at intervals of 12 months or less and whenever excessive coolant is lost through leaks or overheating.

Coolant Test Strips

Coolant test strips are available from your John Deere dealer. These test strips provide a simple, eﬀective method to check the freeze point and additive levels of your engine coolant.

Compare the results to the supplemental coolant additive (SCA) chart to determine the amount of inhibiting additives in your coolant and whether more John Deere COOLANT CONDITIONER should be added.

CoolScan

For a more thorough evaluation of your coolant, perform a CoolScan analysis. See your John Deere dealer for information about CoolScan.

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