PowerTech CD4045HF120, CD4045DF120, CD4045TF120, CD4045TF220, CD6068TF120 Operator's Manual

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PowerTech

4.5 L and 6.8 L

Non-Certified and

Tier 1 Certified

OEM Diesel Engines

OPERATOR’S MANUAL

PowerTech 4.5 L and 6.8 L

Non-Certified and Tier 1 Certified

OEM Diesel Engines

OMRG25204 Issue 02Nov06 (ENGLISH)

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.

If this product contains a gasoline engine:

WARNING

The engine exhaust from this product contains chemicals

known to the State of California to cause cancer, birth

defects or other reproductive harm.

The State of California requires the above two warnings.

John Deere Power Systems

LITHO IN U.S.A.

Foreword

Introduction

This manual contains information to operate and service the following 4.5 L & 6.8 L non-certified and Tier 11emission certified OEM engines built at Dubuque Iowa (T0), Saran France (CD) and Torreon Mexico (PE) from 1996 on. These engines have mechanically-controlled fuel systems.

SARAN BUILT NON-CERTIFIED ENGINES

• CD4045DF120

• CD4045TF120

• CD4045TF220

• CD4045HF120

• CD6068TF120

• CD6068TF220

• CD6068HF120

TORREON BUILT NON-CERTIFIED ENGINES

• PE4045TF120

• PE4045TF220

• PE4045HF120

• PE6068TF120

• PE6068TF220

• PE6068HF120

DUBUQUE BUILT NON-CERTIFIED ENGINES

• T04045DF120

• T04045TF120

• T04045TF220

• T04045HF120

SARAN BUILT TIER 1 CERTIFIED ENGINES

• CD4045DF150

• CD4045DF151

• CD4045DF152

• CD4045DF153

• CD4045DF154

• CD4045DF157

• CD4045DF158

• CD4045TF150

• CD4045TF152

• CD4045TF154

• CD4045TF155

• CD4045TF157

• CD4045TF158

• CD4045TF161

• CD4045TF162

• CD4045TF250

• CD4045TF251

• CD4045TF252

• CD4045TF253

• CD4045TF257

• CD4045TF258

• CD4045HF150

• CD4045HF152

• CD4045HF157

• CD4045HF158

• CD4045HF252

• CD6068DF150

• CD6068TF150

• CD6068TF151

• CD6068TF152

• CD6068TF157

• CD6068TF158

• CD6068TF159

• CD6068TF250

• CD6068TF251

• CD6068TF257

• CD6068TF258

• CD6068HF150

• CD6068HF157

• CD6068HF158

• CD6068HF250

• CD6068HF252

• CD6068HF254

• CD6068HF258

TORREON BUILT TIER 1 CERTIFIED ENGINES

• PE4045DF150

• PE4045TF150

Emission certified for United States as EPA Tier 1 and European

Union as Stage 1.

OURGP11,0000004 –19–27OCT06–1/2

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Introduction

• PE4045TF151

• PE4045HF150

• PE4045HF252

• PE6068DF150

• PE6068TF150

• PE6068TF151

• PE6068TF250

• PE6068HF150

• PE6068HF250

DUBUQUE BUILT TIER 1 CERTIFIED ENGINES

• T04045DF150

• T04045DF151

• T04045DF152

• T04045DF153

• T04045TF150

• T04045TF151

• T04045TF152

• T04045TF250

• T04045TF251

• T04045HF120

• T04045HF150

• T06068DF150

• T06068TF150

• T06068TF151

• T06068TF250

• T06068HF150

• T06068HF250

NOTE: Before 2005, all Non-certified and Tier 1

Certified Saran built engines used the following serial number sequences:

•

(CDxxxxD500000) - (CDxxxxD799999)

•

(CDxxxxT500000) - (CDxxxxT799999)

•

(CDxxxxH500000) - (CDxxxxH799999)

Since 2005, non-certified engines have the seventh digit of the serial number as “B” while Tier 1 certified engines have the seventh digit as “C”.

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 both metric and customary U.S. unit equivalents. Use only correct replacement parts and fasteners. Metric and inch fasteners may require a specific metric or inch wrench.

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.

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.

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

CERTAIN ENGINE ACCESSORIES such as radiator, air cleaner, and instruments are optional equipment on John Deere OEM Engines. These accessories may be provided by the equipment manufacturer instead of John Deere. This operator’s manual applies only to the engine and those options available through the John Deere distribution network.

NOTE: This operators manual covers only engines

provided to OEM (Outside Equipment Manufacturers). For engines in Deere machines, refer to the machine operators manual.

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Engine Owner

Introduction

John Deere Engine Owner:

Don’t wait until you need warranty or other service to meet your local John Deere Engine Distributor or Service Dealer. To register your engine for warranty via the Internet, use the following URL: http://www.johndeere.com/enginewarranty

Learn who your dealer is and where he is. At your first convenience, go meet him. He’ll want to get to know you and to learn what your needs might be.

Aux Utilisateurs De Moteurs John Deere:

N’attendez pas d’eˆtre oblige´d’avoir recours a`votre concessionnaire John Deere ou au point de service le plus proche pour vous adresser a`lui. Pour enregistrer votre moteur pour la garantie via Internet, utilisez l’adresse suivante: http://www.johndeere.com/enginewarranty

Renseignez-vous de`s que possible pour l’identifier et le localiser. A la premie`re occasion, prenez contact avec lui et faites-vous connaıˆtre. Il sera lui aussi heureux de faire votre connaissance et de vous proposer ses services le moment venu.

An Den Besitzer Des John Deere Motors:

Warten Sie nicht auf einen evt. Reparaturfall, um den na¨chstgelegenen John Deere Ha¨ndler kennen zu lernen. Zur Registrierung Ihres Motors fu¨r die Garantie dient folgende Internet-Adresse: http://www.johndeere.com/enginewarranty

distributore dei motori John Deere o del concessionario che fornisce l’assistenza tecnica. Per registrare via Internet la garanzia del suo motore, si collegi al seguente sito URL: http://www.johndeere.com/enginewarranty

Lo identifichi e si informi sulla sua ubicazione. Alla prima occasione utile lo contatti. Egli desidera fare la sua conoscenza e capire quali potrebbero essere le sue necessita`.

Propietario De Equipo John Deere:

No espere hasta necesitar servicio de garantı´aode otro tipo para conocer a su Distribuidor de Motores John Deere o al Concesionario de Servicio. Registre su motor para la garantı´a en la siguiente direccio´nde internet: http://www.johndeere.com/enginewarranty

Ente´rese de quie´nes,ydo´nde esta´situado. Cuando tenga un momento, vaya a visitarlo. A e´l le gustara

´ conocerlo, y saber cua´les podrı´an ser sus necesidades.

Till a¨gare av John Deere motorer:

Ta reda pa˚vem din a˚terfo¨rsa¨ljare a¨r och beso¨k honom sa˚snart tillfa¨lle ges. Va¨nta inte tills det a¨r dags fo¨r service eller eventuellt garantiarbete. Din motor garantiregistrerar Du via Internet pa

http://www.johndeere.com/enginewarranty Din a˚terfo¨rsa¨ljare vill mycket ga¨rna tra¨ffa dig fo¨r att la¨ra

ka¨nna dina behov och hur ba¨st han kan hja¨lpa dig.

Machen Sie sich bei ihm bekannt und nutzen Sie sein “Service Angebot”.

Proprietario del motore John Deere:

Non aspetti fino al momento di far valere la garanzia o di chiedere assistenza per fare la conoscenza del

OURGP11,0000251 –19–11OCT06–1/1

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Introduction

POWERTECH4.5 L Engines With Mechanical Controls (Tier 1 Emission Certified)

4045D Engine

4045T Engine

4045D Engine

RG7998 –UN–19JUN00

RG7999 –UN–19JUN00

RG7997 –UN–19JUN00

4045T Engine

RG7996 –UN–19JUN00

OWERTECH

is a trademark of Deere & Company

RG,RG34710,5501 –19–04JAN02–1/1

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Introduction

POWERTECH6.8 L Engines With Mechanical Controls (Tier 1 Emission Certified)

6068D Engine

6068T Engine

RG8003 –UN–19JUN00

RG8001 –UN–19JUN00

6068D Engine

RG8002 –UN–19JUN00

RG8000 –UN–19JUN00

6068T Engine

OWERTECH

is a trademark of Deere & Company

RG,RG34710,5503 –19–04JAN02–1/1

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Contents

Page Page

Record Keeping

PowerTech Medallion.....................01-1

Engine Serial Number Plate ................01-1

Record Engine Serial Number ..............01-2

Engine Option Codes .....................01-3

Record Fuel Injection Pump Model Number ....01-5

Safety ................................05-1

Fuels, Lubricants, and Coolant

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

Lubricity of Diesel Fuel....................10-1

Handling and Storing Diesel Fuel ............10-2

Testing Diesel Fuel.......................10-2

Bio-Diesel Fuel..........................10-3

Aviation (Jet) Fuels.......................10-4

Burner Fuels............................10-4

Minimizing the Effect of Cold Weather on

Diesel Engines ........................10-5

Diesel Engine Break-In Oil .................10-6

Diesel Engine Oil ........................10-7

Extended Diesel Engine Oil Service Intervals. . . 10-8

Mixing of Lubricants ......................10-8

OILSCANand COOLSCAN ..............10-9

Alternative and Synthetic Lubricants..........10-9

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

Oil Filters .............................10-10

Grease...............................10-11

Diesel Engine Coolant ...................10-12

Drain Intervals for Diesel Engine Coolant ....10-13

Additional Information About Diesel

Engine Coolants and Supplemental Coolant

Additives............................10-14

Supplemental Coolant Additives............10-15

Additional Information About Diesel

Engine Coolants and Supplemental Coolant

Additives............................10-16

Testing Diesel Engine Coolant .............10-17

Operating in Warm Temperature Climates ....10-18

Disposing of Coolant ....................10-18

Engine Operating Guidelines

Instrument (Gauge) Panels.................15-1

Instrument (Gauge) Panel (North America).....15-2

VDO Instrument (Gauge) Panel (Except

North America) ........................15-4

Engine Break-In Service...................15-6

Auxiliary Gear Drive Limitations .............15-9

Generator Set (Standby) Applications.........15-9

Starting the Engine......................15-10

Warming Engine........................15-12

Normal Engine Operation.................15-13

Cold Weather Operation..................15-14

Changing Engine Speed..................15-15

Avoid Excessive Engine Idling .............15-15

Stopping the Engine.....................15-16

Using a Booster Battery or Charger .........15-17

Lubrication and Maintenance

Observe Service Intervals..................20-1

Use Correct Fuels, Lubricants, and Coolant ....20-1

Lubrication and Maintenance Service

Interval Chart—Standard Industrial Engines . . 20-2 Lubrication and Maintenance Service

Interval Chart—Generator (Standby)

Applications ..........................20-4

Lubrication & Maintenance/Daily

Daily Prestarting Checks ..................25-1

Lubrication & Maintenance/250 Hour/6 Month

Servicing Fire Extinguisher.................30-1

Changing Engine Oil and Replacing Filter .....30-2

Checking Engine Mounts ..................30-4

Servicing Battery ........................30-5

Manual Belt Tensioner Adjustment...........30-7

Manual Belt Tensioner Adjustment Using

Belt Tension Tool (Alternate Method

For Engines Without Auxiliary Drive)........30-8

Lubrication & Maintenance/500 Hour/12 Month

Cleaning Crankcase Vent Tube .............35-1

Checking Air Intake System ................35-2

Replacing Fuel Filter Element (Single Filter)....35-3

Continued on next page

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

DEERE & COMPANY

Moline, Illinois

A John Deere ILLUSTRUCTIONManual

Previous Editions

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Contents

Page Page

Replacing Fuel Filter Elements (Dual Filters) . . . 35-5 Specifications

General OEM Engine Specifications—4.5 LChecking Belt Tensioner Spring Tension

and Belt Wear (Automatic Tensioner) .......35-6 Engines..............................60-1

General OEM Engine Specifications—6.8 LChecking Engine Speeds ..................35-9

Checking Engine Electrical Ground Engines..............................60-2

Engine Power Ratings And Fuel InjectionConnections ..........................35-9

Checking Cooling System.................35-10 Pump Specifications ....................60-3

Engine Crankcase Oil Fill Quantities ........60-11Replenishing Supplemental Coolant

Additives (SCAs) Between Coolant Unified Inch Bolt and Screw Torque Values . . . 60-15

Metric Bolt and Screw Torque Values........60-16Changes ............................35-11

Testing Diesel Engine Coolant .............35-12

Pressure Testing Cooling System...........35-13 Lubrication and Maintenance Records

Using Lubrication and Maintenance Records . . . 65-1

Lubrication & Maint./2000 Hour/24 Month

Adjusting Variable Speed (Droop) on

Generator Set Engines ..................40-1

Checking Crankshaft Vibration Damper

(6-Cylinder Engine Only).................40-3

Daily (Prestarting) Service .................65-1

250 Hour/6 Month Service .................65-2

500 Hour/12 Month Service ................65-3

2000 Hour/24 Month Service ...............65-4

Service as Required......................65-5

Flushing and Refilling Cooling System ........40-4

Testing Thermostats Opening Temperature ....40-7

Check and Adjust Valve Clearance .........40-10

Emission System Warranty

U.S. EPA Emissions Control Warranty

Statement ............................70-1

Service as Required

Emissions Control System Certification Label. . . 70-1

Additional Service Information ..............45-1

Do Not Modify Fuel System ................45-1

Adding Coolant..........................45-2

Replacing Single Stage Air Cleaner ..........45-3

Replacing Axial Seal Air Cleaner Filter

Element .............................45-4

Replacing Radial Seal Air Cleaner Filter

Element .............................45-6

Replacing Fan and Alternator Belts ..........45-8

Checking Fuses In Instrument Panels ........45-9

Checking Air Compressors................45-10

Bleeding the Fuel System.................45-11

Troubleshooting

General Troubleshooting Information .........50-1

Engine Wiring Diagram Legend

(Standard Instrument Panel For North

America) .............................50-3

Wiring Diagram (Standard Instrument

Panel For North America) ................50-4

Engine Wiring Diagram—VDO

Instrument Panel (Except North America) ....50-5

Engine Wiring Diagram Legend—VDO

Instrument Panel (Except North America) ....50-6

Engine Troubleshooting ...................50-7

Storage

Engine Storage Guidelines.................55-1

Preparing Engine for Long Term Storage......55-2

Removing Engine from Long Term Storage ....55-3

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POWERTECHMedallion

Record Keeping

A medallion is located on the rocker arm cover which identifies each engine as a John Deere P

OWERTECH

engine.



RG11608 –UN–17OCT01RG11609 –UN–17OCT01

OWERTECH

is a trademark of Deere & Company.

Engine Serial Number Plate

Each engine has a 13-digit John Deere engine serial number. The first two digits identify the factory that produced the engine:

• “T0” indicates the engine was built in Dubuque, Iowa

• “CD” indicates the engine was built in Saran, France

• “PE” indicates the engine was built in Torreon, Mexico

• “J0” indicates the engine was built in Rosario, Argentina

Your engine’s serial number plate (A) is located on the right-hand side of cylinder block behind the fuel filter.

01-1

RG,RG34710,5505 –19–04JAN02–1/1

RG8007 –UN–15JAN99

13-Digit Engine Serial Number Plate

RG,RG34710,5506 –19–04JAN02–1/1

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Record Keeping

Record Engine Serial Number

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

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

Engine Serial Number (B)

Engine Model Number (C)

Coefficient of Absorption Value (D)

(Saran Engines Only)

Dubuque Engine Serial Number Plate

RG7936 –UN–13NOV97

Saran Engine Serial Number Plate

Torreon Engine Serial Number Plate

RG,RG34710,5507 –19–04JAN02–1/1

RG7935 –UN–13NOV97

RG9062 –UN–16MAR98

01-2

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Engine Option Codes

Record Keeping

Engine Option Codes

A—Engine Base Code

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.

The engine option code label includes an engine base code (A). This base code must also be recorded along with the option codes.

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.

RG10603A –UN–15JUN00

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.

Continued on next page

01-3

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Record Keeping

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.

An additional option code label may also be delivered with the engine. Place this sticker or tag, for reference, either on this page or in the engine owner’s warranty booklet under

If option code label is lost or destroyed,

OPTION CODES title. consult your servicing dealer or engine distributor selling the engine for a replacement.

Option Codes Description Option Codes Description

11 Rocker Arm Cover 45 Balancer Shafts 12 Oil Fill Inlet 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 Mechanism 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 55 Shipping Stand 20 Coolant Pump 56 Paint Option 21 Thermostat Cover 57 Coolant Pump Inlet 22 Thermostat 59 Oil Cooler 23 Fan Drive 60 Add-on Auxiliary Drive Pulley 24 Fan Belt 62 Alternator Mounting Bracket 25 Fan 64 Exhaust Elbow 26 Engine Coolant Heater 65 Turbocharger 27 Radiator 66 Coolant Temperature Switch 28 Exhaust Manifold 67 Electronic Tachometer Sensor 29 Crankcase Ventilator System 68 Crankshaft Rear Damper 30 Starter Motor 69 Engine Serial Number Plate 31 Alternator 74 Air Conditioning (Freon) Compressor 32 Instrument Panel 75 Air Restriction Indicator 33 Tachometer 76 Oil Pressure Switch 35 Fuel Filters 78 Air Compressor 36 Front Plate 81 Water Separator 37 Fuel Transfer Pump 86 Fan Pulley 39 Thermostat Housing 87 Belt Tensioner 40 Oil Dipstick 88 Oil Filter 41 Belt-Driven Front Auxiliary Drive 95 Special Equipment (Factory Installed) 43 Starting Aid 97 Special Equipment (Field Installed) 44 Timing Gear Cover With Gears 98 Shipping

99 Service Only Items

01-4

Engine Base Code (See “A” on previous page.)

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Record Keeping

Record Fuel Injection Pump Model Number

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

Model No. RPM

Manufacturer’s No.

Serial No.

A—Serial Number Plate

Record Injection Pump Serial Number

RG8008A –UN–13JUN00

RG,RG34710,5511 –19–20MAY96–1/1

01-5

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Safety

Recognize Safety Information

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

Follow recommended precautions and safe operating practices.

Understand Signal Words

A signal word—DANGER, WARNING, or CAUTION—is used with the safety-alert symbol. DANGER identifies the most serious hazards.

DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs. CAUTION also calls attention to safety messages in this manual.

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.

DX,ALERT –19–29SEP98–1/1

T81389 –UN–07DEC88

TS187 –19–30SEP88

DX,SIGNAL –19–03MAR93–1/1

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.

05-1

TS201 –UN–23AUG88

DX,READ –19–03MAR93–1/1

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Replace Safety Signs

Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement.

Safety

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.

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.

DX,SIGNS1 –19–04JUN90–1/1

TS201 –UN–23AUG88

TS177 –UN–11JAN89

DX,BYPAS1 –19–29SEP98–1/1

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

05-2

TS202 –UN–23AUG88

DX,FIRE1 –19–03MAR93–1/1

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Safety

Prepare for Emergencies

Be prepared if a fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance service,

hospital, and fire department near your telephone.

Handle Starting Fluid Safely

Starting fluid is highly flammable. Keep all sparks and flame away when using it. Keep

starting fluid away from batteries and cables. To prevent accidental discharge when storing the

pressurized can, keep the cap on the container, and store in a cool, protected location.

Do not incinerate or puncture a starting fluid container.

DX,FIRE2 –19–03MAR93–1/1

TS291 –UN–23AUG88

TS1356 –UN–18MAR92

DX,FIRE3 –19–16APR92–1/1

Handle Fluids Safely—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.

05-3

TS227 –UN–23AUG88

DX,FLAME –19–29SEP98–1/1

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Safety

Service Machines Safely

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

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

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.

DX,LOOSE –19–04JUN90–1/1

TS228 –UN–23AUG88

TS206 –UN–23AUG88

DX,WEAR –19–10SEP90–1/1

Protect Against Noise

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.

05-4

DX,NOISE –19–03MAR93–1/1

TS207 –UN–23AUG88

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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 PTO driveline is stopped before making adjustments, connections, or performing any type of service on the engine or PTO-driven equipment.

05-5

Rotating Drivelines

TS1644 –UN–22AUG95

OUO1004,0000BD8 –19–11OCT06–1/1

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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

05-6

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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 accidentally burst when heat goes beyond the immediate flame area.

DX,FLUID –19–03MAR93–1/1

TS953 –UN–15MAY90

DX,TORCH –19–10DEC04–1/1

05-7

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Safety

Remove Paint Before Welding or Heating

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

by welding, soldering, or using a torch. 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.

TS220 –UN–23AUG88

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

Dispose of paint and solvent properly.

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.

DX,PAINT –19–24JUL02–1/1

TS281 –UN–23AUG88

DX,RCAP –19–04JUN90–1/1

05-8

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Safety

Install Fan Guards

Rotating cooling system fans can cause serious injury. Keep fan guards in place at all times during engine

operation. Wear close fitting clothes. Stop the engine and be sure fan is stopped before making adjustments or connections, or cleaning near the front of the engine.

Avoid Hot Parts

Avoid skin contact with exhaust manifolds, turbochargers and mufflers. Keep flammable materials clear of the turbocharger.

External dry exhaust parts become very hot during operation. Turbochargers may reach temperatures as high as 500°C (932°F) under full load, and naturally aspired exhaust manifolds may reach 600°C (1112°F) under full load. This may ignite paper, cloth or wooden materials. Parts on engines that have been at full load and reduced to no load idle will maintain approximately 150°C (302°F).

Rotating Fan

TS677 –UN–21SEP89

OUOD006,000009D –19–11OCT06–1/1

TS271 –UN–23AUG88

Hot Surface

05-9

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PN=22

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

Prevent Battery Explosions

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

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

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

DX,DUST –19–15MAR91–1/1

TS204 –UN–23AUG88

DX,SPARKS –19–03MAR93–1/1

05-10

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Handling Batteries Safely

CAUTION: 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.

Safety

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

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

Avoid the hazard by:

1. Filling batteries in a well-ventilated area.

2. Wearing eye protection and rubber gloves.

3. Avoiding breathing fumes when electrolyte is added.

4. Avoiding spilling or dripping electrolyte.

5. Using proper jump start procedure.

If you spill acid on yourself:

1. Flush your skin with water.

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

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

Explosion

TS204 –UN–23AUG88

If acid is swallowed:

1. Do not induce vomiting.

2. Drink large amounts of water or milk, but do not exceed2L(2qt.).

3. Get medical attention immediately.

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.

05-11

Acid

TS203 –UN–23AUG88

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PN=24

Safety

Protect Against High Pressure Spray

Spray from high pressure nozzles can penetrate the skin and cause serious injury. Keep spray from contacting hands or body.

If an accident occurs, see a doctor immediately. Any high pressure spray 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.

Use Proper Lifting Equipment

TS1343 –UN–18MAR92

DX,SPRAY –19–16APR92–1/1

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

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

Use 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.

DX,LIFT –19–04JUN90–1/1

TS226 –UN–23AUG88

TS779 –UN–08NOV89

Use only service parts meeting John Deere specifications.

05-12

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Safety

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.

TS1133 –UN–26NOV90

DX,DRAIN –19–03MAR93–1/1

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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.

Required fuel properties

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

Cetane number of 45 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 OR Cloud Point at least 5°C(9°F) below the expected low temperature.

Fuel lubricity should pass a minimum level of 3100 grams as measured by ASTM D6078 or maximum

scar diameter of 0.45 mm as measured by ASTM D6079 or ISO 12156-1.

Sulfur content:

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

• Use of diesel fuel with sulfur content less than

0.10% (1000 ppm) is STRONGLY recommended.

• Use of diesel fuel with sulfur content 0.10% (1000 ppm to 0.50% (5000 ppm) may result in REDUCED oil and filter change intervals.

• BEFORE using diesel fuel with sulfur content greater than 0.50% (5000 ppm), contact your John Deere dealer.

• DO NOT use diesel fuel with sulfur content greater than 1.0%.

IMPORTANT: Do not mix used diesel engine oil or

any other type of lubricating oil with diesel fuel.

IMPORTANT: Improper fuel additive usage may

cause damage on fuel injection equipment of diesel engines.

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.

DX,FUEL1 –19–17NOV05–1/1

Fuel lubricity should pass a minimum load level of 3100 grams as measured by ASTM D6078 or 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.

DX,FUEL5 –19–27OCT05–1/1

10-1

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PN=27

Handling and Storing Diesel Fuel

Fuels, Lubricants, and Coolant

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 water condensation and freezing during cold weather.

Keep all storage tanks as full as practicable to minimize condensation.

Ensure that all fuel tank caps and covers are installed properly to prevent moisture from entering.

Monitor water content of the fuel regularly.

When using bio-diesel fuel, the fuel filter may require more frequent replacement due to premature plugging.

Check engine oil level daily prior to starting engine. A rising oil level may indicate fuel dilution of the engine oil.

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 –19–19DEC03–1/1

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.

DIESELSCAN is a trademark of Deere & Company

DX,FUEL6 –19–14NOV05–1/1

10-2

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Bio-Diesel Fuel

Fuels, Lubricants, and Coolant

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

Bio-diesel fuels may be used ONLY if the bio-diesel fuel properties meet the latest edition of ASTM D6751, EN 14214, or equivalent specification.

It is recommended to purchase bio-diesel fuel blended with B100 from a BQ-9000 Accredited Producer or a BQ-9000 Certified Marketer as recommended by the National Bio-diesel Board.

The maximum allowable bio-diesel concentration is a 5% blend (also known as B5) in petroleum diesel fuel. It has been found that bio-diesel fuels may improve lubricity in concentrations up to this 5% blend.

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

IMPORTANT: Raw pressed vegetable oils are NOT

acceptable for use as fuel in any concentration in John Deere engines.

leaving deposits on injectors and in the combustion chamber.

A major environmental benefit of bio-diesel fuel is its ability to biodegrade. This makes proper storage and handling of bio-diesel fuel especially important. Areas of concern include:

• Quality of new 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 and/or blocked injector nozzles, resulting in

engine misfire

• Filter plugging

• Lacquering and/or seizure of internal components

• Sludge and sediments

• Reduced service life of engine components

These oils do not burn completely, and will cause engine failure by

Consult your fuel supplier for additives to improve storage and performance of bio-diesel fuels.

DX,FUEL7 –19–14NOV05–1/1

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Fuels, Lubricants, and Coolant

Aviation (Jet) Fuels

Aviation (jet) fuels may be used with the following restrictions.

Type Comments

Jet A Lower viscosity and density than base No. 2-D diesel

Jet A-1 Lower viscosity and density than base No. 2-D diesel

Jet B Not Recommended.Lower density and extremely

JP-4 Not Recommended.Lower density and extremely

JP-5 Lower viscosity and density than base No. 2-D diesel

JP-7 Lower viscosity and density than base No. 2-D diesel

JP-8 Lower viscosity and density than base No. 2-D diesel

fuel. Power loss up to 10% can be expected.

low viscosity compared to base No. 2-D diesel fuel. Power loss up to 14% can be expected.

low viscosity compared to base No. 2-D diesel fuel. Power loss up to 12% can be expected.

fuel. Power loss up to 9% can be expected.

fuel. Power loss up to 10% can be expected.

Burner Fuels

Burner fuels, like kerosene, may be used with the following restrictions.

Type Comments

No.2 Higher density and specific gravity than base No. 2-D

diesel fuel. Power increase up to 3% can be expected.

No.1 Lower viscosity than base No. 2-D diesel fuel. Power

loss up to 2% can be expected.

10-4

OURGP12,000003F –19–07JUL04–1/1

OURGP12,0000040 –19–07JUL04–1/1

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Fuels, Lubricants, and Coolant

Minimizing the Effect of Cold Weather on Diesel Engines

John Deere diesel engines are designed to operate effectively in cold weather.

However, for effective starting and cold weather operation, a little extra care is necessary. The information below outlines steps that can minimize the effect that cold weather may have on starting and operation of your engine. See your John Deere dealer for additional information and local availability of cold weather aids

Use Winter Grade Fuel

When temperatures fall below 5°C (40°F), winter grade fuel (Grade No. 1-D fuel in North America) is best suited for cold weather operation. Winter grade fuel has a lower cloud point and a lower pour point.

Cloud point is the temperature at which wax will begin to form in the fuel and this wax causes fuel filters to plug. Pour point is the temperature at which fuel begins to thicken and becomes more resistant to flow through fuel pumps and lines.

NOTE: On an average, winter grade fuel has a lower

BTU (heat content) rating. Using winter grade fuel may reduce power and fuel efficiency, but should not cause any other engine performance effects. Check the grade of fuel being used before troubleshooting for low power complaints in cold weather operation.

CAUTION: Do not use any starting fluid with an engine equipped with glow plugs

Coolant Heater

An engine block heater (coolant heater) is an available option to aid cold weather starting.

Seasonal Viscosity Oil and Proper Coolant Concentration

Use seasonal grade viscosity engine oil based ion the expected air temperature range between oil changes and proper concentration of low silicate antifreeze as recommended. (See DIESEL ENGINE OIL and ENGINE COOLANT requirements this section.)

Diesel Fuel Flow Additive

Use John Deere Premium Diesel Fuel Conditioner (Winter) or equivalent to treat fuel during the cold weather season. This winter formulation is a combination diesel fuel conditioner and anti-gel additive.

IMPORTANT: Treat fuel when outside temperature

drops below 0°C (32°F). For best results, use with untreated fuel. Follow all recommended instructions on label.

Air Intake Heater

An air intake heater is an available option to aid cold weather starting.

CAUTION: Do not use any starting fluid with an air intake heater.

Starting Fluid

A starting fluid port on the intake is available to aid cold weather starting.

Winterfronts

Use of fabric, cardboard , or solid winterfronts is not recommended with any John Deere engine. Their use can result in excessive engine coolant, oil, and charge air temperatures. This can lead to reduced engine life, loss of power and poor fuel economy. Winterfronts may also put abnormal stress on fan and fan drive components potentially causing premature failures.

Continued on next page

DX,FUEL10 –19–16DEC05–1/2

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If winterfronts are used, they should never totally close off the grill frontal area. Approximately 25% area in the center of the grill should remain open at all times. At no time should the air blockage device be applied directly to the radiator core.

Radiator Shutters

If equipped with a thermostatically controlled radiator shutter system, this system should be regulated in such a way that the shutters are completely open by

Diesel Engine Break-In Oil

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

• API Service Classification CD

• API Service Classification CC

• ACEA Oil Sequence E2

• ACEA Oil Sequence E1

the time the coolant reaches 93°C (200°F) to prevent excessive intake manifold temperatures. Manually controlled systems are not recommended.

If air-to-air aftercooling is used, the shutters must be completely open by the time the intake manifold air temperature reaches the maximum allowable temperature out of the charge air cooler.

For more information, see your John Deere dealer.

DX,FUEL10 –19–16DEC05–2/2

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

IMPORTANT: Do not use PLUS-50 oil or engine

oils meeting any of the following during the first 100 hours of operation of a new or rebuilt engine:

API CJ-4 ACEA E7 API CI-4 PLUS ACEA E6 API CI-4 ACEA E5 API CH-4 ACEA E4 API CG-4 ACEA E3 API CF-4 API CF-2 API CF

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

PLUS-50 is a trademark of Deere & Company.

10-6

DX,ENOIL4 –19–13SEP06–1/1

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Fuels, Lubricants, and Coolant

Diesel Engine Oil

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

John Deere PLUS-50 oil is preferred.

Oils meeting one of the following specifications are also recommended:

• ACEA Oil Sequence E7

• ACEA Oil Sequence E6

• ACEA Oil Sequence E5

• ACEA Oil Sequence E4

Extended service intervals may apply when John Deere PLUS-50, ACEA E7, ACEA E6, ACEA E5, or ACEA E4 engine oils are used. Consult your John Deere dealer for more information.

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 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%.

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 ppm) is used, reduce the service interval by 50%.

Oil Viscosities for Air Temperature Ranges

TS1681 –UN–09OCT06

PLUS-50 is a trademark of Deere & Company TORQ-GARD SUPREME is a trademark of Deere & Company

Continued on next page

10-7

DX,ENOIL –19–13SEP06–1/2

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Fuels, Lubricants, and Coolant

DO NOT use diesel fuel with sulfur content greater than

1.00% (10 000 ppm).

Extended Diesel Engine Oil Service Intervals

DX,ENOIL –19–13SEP06–2/2

When 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 maxium of 500 hours.

When 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, ACEA E7, ACEA E6, ACEA E5, or ACEA E4 oils are used with other than the

PLUS-50 is a trademark of Deere & Company TORQ-GARD SUPREME is a trademark of Deere & Company

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.

DX,ENOIL6 –19–13SEP06–1/1

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.

DX,LUBMIX –19–18MAR96–1/1

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Fuels, Lubricants, and Coolant

OILSCANand COOLSCAN

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.

T6828AB –UN–15JUN89T6829AB –UN–18OCT88

OILSCAN is a registered trademark of Deere & Company. COOLSCAN is a trademark of Deere & Company.

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.

Consult your John Deere dealer to obtain information and recommendations.

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.

DX,OILSCAN –19–02DEC02–1/1

10-9

DX,ALTER –19–15JUN00–1/1

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PN=35

Lubricant Storage

Fuels, Lubricants, and Coolant

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.

Oil Filters

Filtration of oils is critical to proper operation and lubrication.

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

Always change filters regularly as specified in this manual. Use filters meeting John Deere performance

specifications.

DX,FILT –19–18MAR96–1/1

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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

TS1673 –UN–31OCT03

GREASE-GARD is a trademark of Deere & Company

DX,GREA1 –19–07NOV03–1/1

10-11

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Diesel Engine Coolant

Fuels, Lubricants, and 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 Prediluted Coolant is preferred for service.

John Deere COOL-GARD Prediluted Coolant is available in a concentration of either 50% ethylene glycol or 55% propylene glycol.

Additional recommended coolants

The following engine coolant is also recommended:

• John Deere COOL-GARD Coolant Concentrate in a 40% to 60% mixture of concentrate with quality water.

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

Other fully formulated coolants

Other fully formulated low silicate ethylene or propylene glycol base coolants for heavy-duty engines may be used if they meet one of the following specifications:

Other low silicate ethylene glycol base coolants for heavy-duty engines may also be used if they meet one of the following specifications:

• ASTM D4985 ethylene glycol base prediluted (50%) coolant

• ASTM D4985 ethylene glycol base coolant concentrate in a 40% to 60% mixture of concentrate with quality water

Coolants meeting ASTM D4985 require an initial charge of supplemental coolant additives, formulated for protection of heavy duty diesel engines against corrosion and cylinder liner erosion and pitting. They also require periodic replenishment of additives during the drain interval.

Other coolants

It is possible that neither John Deere COOL-GARD nor coolants meeting one of the coolant standards listed above is available in the geographical area where service is performed. If these coolants are unavailable, use a coolant concentrate or prediluted coolant with a quality additive package that provides cylinder liner cavitation protection and 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:

• ASTM D6210 prediluted (50%) coolant

• ASTM D6210 coolant concentrate in a 40% to 60%

mixture of concentrate with quality water

Coolants meeting ASTM D6210 do not require use of supplemental coolant additives, except for periodic replenishment of additives during the drain interval.

Coolants requiring supplemental coolant additives

COOL-GARD is a trademark of Deere & Company

• ethylene glycol or propylene glycol base prediluted (40% to 60%) coolant

• ethylene glycol or propylene glycol base coolant concentrate in a 40% to 60% mixture of concentrate with quality water

Water quality

Continued on next page

DX,COOL3 –19–27OCT05–1/2

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IMPORTANT: Do not use cooling system sealing

additives or antifreeze that contains sealing additives.

Drain Intervals for Diesel Engine Coolant

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.

IMPORTANT: Do not mix ethylene glycol and

propylene glycol base coolants.

DX,COOL3 –19–27OCT05–2/2

When John Deere COOL-GARD is used, the drain interval may be extended to 5 years or 5000 hours of operation, provided that the coolant is tested annually AND additives are replenished, as needed, by adding a supplemental coolant additive.

If John Deere COOL-GARD is used but the coolant is not tested OR additives are not replenished by adding a supplemental coolant additive, the 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.

COOL-GARD is a trademark of Deere & Company

DX,COOL11 –19–19DEC03–1/1

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Additional Information About Diesel Engine Coolants and Supplemental Coolant Additives

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

Coolant specifications

Some products, including 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.

Coolants meeting ASTM D6210 do not require an initial charge of supplemental coolant additives.

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

Coolants meeting ASTM D4985 require an initial charge of supplemental coolant additives.

Replenish coolant additives

simple mixture of ethylene glycol or propylene 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). 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.

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. All water used in the cooling system should meet the following minimum specifications for quality:

The concentration of coolant additives is gradually depleted during engine operation. Periodic replenishment of inhibitors is required, even when John Deere COOL-GARD or another fully formulated coolant 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

COOL-GARD is a trademark of Deere & Company

Chlorides <40 mg/L Sulfates <100 mg/L Total dissolved solids <340 mg/L Total hardness <170 mg/L pH 5.5 to 9.0

Freeze protection

The relative concentrations of glycol and water in the engine coolant determine its freeze protection limit.

Continued on next page

DX,COOL7 –19–19DEC03–1/2

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Fuels, Lubricants, and Coolant

Ethylene Glycol Freeze Protection Limit

40% -24°C (-12°F) 50% -37°C (-34°F) 60% -52°C (-62°F)

Propylene Glycol Freeze Protection Limit

40% -21°C (-6°F) 50% -33°C (-27°F) 60% -49°C (-56°F)

Supplemental Coolant Additives

The concentration of coolant additives is gradually depleted during engine operation. For all recommended coolants, replenish additives between drain intervals by adding a supplemental coolant additive every 12 months or as determined necessary by coolant testing.

John Deere COOLANT CONDITIONER is recommended as a supplemental coolant additive in John Deere engines.

IMPORTANT: Do not add a supplemental coolant

additive when the cooling system is drained and refilled with John DeereCOOL-GARD.

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

DX,COOL7 –19–19DEC03–2/2

If other coolants are used, consult the coolant supplier and follow the manufacturer’s recommendation for use of supplemental coolant additives.

The use of non-recommended supplemental coolant additives may result in additive drop-out and gelation of the coolant.

Add the manufacturer’s recommended concentration of supplemental coolant additive. DO NOT add more than the recommended amount.

COOL-GARD is a trademark of Deere & Company

10-15

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PN=41

Fuels, Lubricants, and Coolant

Additional Information About Diesel Engine Coolants and Supplemental Coolant Additives

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

Coolant specifications

Coolants meeting ASTM D6210 do not require an initial charge of supplemental coolant additives.

Coolants meeting ASTM D4985 require an initial charge of supplemental coolant additives.

Replenish coolant additives

simple mixture of ethylene glycol or propylene glycol and water will not give adequate protection.

Avoid automotive-type coolants

Water quality

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

COOL-GARD is a trademark of Deere & Company

Chlorides <40 mg/L Sulfates <100 mg/L Total dissolved solids <340 mg/L Total hardness <170 mg/L pH 5.5 to 9.0

Freeze protection

The relative concentrations of glycol and water in the engine coolant determine its freeze protection limit.

Continued on next page

DX,COOL7 –19–19DEC03–1/2

10-16

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Fuels, Lubricants, and Coolant

Ethylene Glycol Freeze Protection Limit

40% -24°C (-12°F) 50% -37°C (-34°F) 60% -52°C (-62°F)

Propylene Glycol Freeze Protection Limit

40% -21°C (-6°F) 50% -33°C (-27°F) 60% -49°C (-56°F)

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.

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

DX,COOL7 –19–19DEC03–2/2

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 and COOLSCAN PLUS

Coolant test strips

Coolant test strips are available from your John Deere dealer. These test strips provide a simple, effective

COOLSCAN is a trademark of Deere & Company COOLSCAN PLUS is a trademark of Deere & Company

For a more thorough evaluation of your coolant, perform a COOLSCAN or COOLSCAN PLUS analysis, where available. See your John Deere dealer for information.

DX,COOL9 –19–19DEC03–1/1

10-17

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PN=43

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.

Disposing of Coolant

Improperly disposing of engine coolant can threaten the environment and ecology.

DX,COOL6 –19–18MAR96–1/1

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.

Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your John Deere engine distributor or servicing dealer.

10-18

Recycle Waste

TS1133 –UN–26NOV90

RG,RG34710,7543 –19–11OCT06–1/1

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PN=44

Engine Operating Guidelines

Instrument (Gauge) Panels

All controls and gauges are optional equipment for John Deere OEM Engines. They may be provided by the equipment manufacturer instead of John Deere. The following information applies only to those controls and gauges provided by John Deere.

IMPORTANT: Any time an electric gauge or meter

does not register correctly, replace it with a new one. Do not attempt to repair it.

Two types of instrument panels are offered on 4.5 L and

6.8 L engines, as shown on this page. See following for complete information on each type of instrument panel.

North American Instrument Panel

VDO Instrument Panel (Except North America)

DPSG,RG34710,107 –19–10JAN02–1/1

RG11299 –UN–12SEP00

RG10606A –UN–19JUN00

15-1

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PN=45

Engine Operating Guidelines

Instrument (Gauge) Panel (North America)

IMPORTANT: Any time an electric gauge or meter

does not register correctly, replace it with a new one. Do not attempt to repair it.

Following is a brief description of the components on the instrument (gauge) panel:

A—Oil Pressure Gauge - This gauge indicates oil pressure. It also has an adjustable electrical contact which activates the safety switch when oil pressure goes below the pressure set point. This will automatically stop the engine.

North American Instrument Panel

RG11299B –UN–17AUG00

B—Coolant Temperature Gauge - This gauge indicates coolant temperature. It also has an electrical contact which activates the safety switch when coolant temperature goes above the temperature set point. This will automatically stop the engine.

C—Key Switch - The key switch is used to start and stop the engine. A key is required to operate the switch so as to prevent unauthorized operation of the engine.

D—Tachometer - The tachometer indicates engine speed in hundreds of revolutions per minute (rpm).

E—Safety Switch (Reset Button) - The safety switch de-energizes the fuel shut-off solenoid or injection rack puller to stop the engine, if one or more conditions are met:

• Low or no oil pressure

• High coolant temperature

• Low crankcase oil level (if equipped with engine oil level

switch)

• High crankcase oil level (if equipped with engine oil level switch)

Hour Meter And Tachometer Codes

RG10607 –UN–19OCT99

A—Oil Pressure Gauge B—Coolant Temperature Gauge C—Key Switch D—Tachometer E—Reset (Safety) Switch F—Fuse Holder (14 Amp Fuse) G—Ammeter H—Hourmeter I—Hand Throttle J—Tachometer Binary Code

Continued on next page

15-2

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Engine Operating Guidelines

The reset button has to be held in when starting the engine. The button allows the safety switch to override the shut-down circuits until safe engine oil pressure is maintained. Once engine oil pressure is within specifications, the safety switch will latch and the reset button can be released.

F—Fuse Holder - Contains 14 amp fuse. G—Ammeter - The ammeter indicates the rate of charge

(+) or discharge (—) of the battery. When the engine is first started, the ammeter will usually indicate a charge rate of approximately 30 amps. After a short period of operation, the ammeter needle will point slightly to the right of “0”, indicating the charging system is operating normally. A problem with the charging system is indicated if the ammeter needle points to the left of “0” during engine operation.

H—Hour Meter - The hour meter operates when the engine is operating, or when the reset button is manually held in while the key switch is in the ON position. The accumulated hours are displayed in hours and tenths of hours. On some panels, the hourmeter may be separate from the tachometer.

I—Hand Throttle - The hand throttle is used to manually control engine speed. If the hand throttle is electronic (as shown), turn the knob clockwise or counterclockwise to change engine speed. If the hand throttle is mechanical (not shown), turning the handle, either clockwise or counterclockwise, will lock the throttle position. Turn the handle half way between the two lock positions to unlock the throttle.

J—Tachometer Binary Code - The tachometer is calibrated to the number of flywheel gear teeth read. The dip switch to set the binary code is located in back of tachometer and must be set at “10110011” to operate at 30 pulses per revolution.

DPSG,RG34710,108 –19–08JAN02–2/2

15-3

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Engine Operating Guidelines

VDO Instrument (Gauge) Panel (Except North America)

IMPORTANT: Any time an electric gauge or meter

does not register correctly, replace it with a new one. Do not attempt to repair it.

VDO Instrument Panel

RG10606B –UN–20OCT99

Following is a brief description of the components on the instrument (gauge) panel:

A—Oil Pressure Gauge - The oil pressure gauge indicates engine oil pressure.

B—Coolant Temperature Gauge - The coolant temperature gauge indicates coolant temperature.

C—Tachometer - The tachometer indicates engine speed in hundreds of revolutions per minute (rpm).

The engine control system consists of the following: D—Engine Control Light - The engine control light

illuminates after the engine has started and oil pressure is up to specification. The light indicates that the engine protection circuitry is activated.

E—Preheater Light - The preheater light illuminates when the key is turned to the bulb test position (position I). It should go off after approximately five seconds. When the key switch is held in position II, the engine preheater is energized and the preheater light illuminates.

A—Oil Pressure Gauge B—Coolant Temperature Gauge C—Tachometer D—Engine Control Light E—Preheater Light F—Fuel Level Light G—Battery Light H—Oil Pressure Light I—Coolant Temperature Light J—Key/Start Switch K—Hour Meter

F—Fuel Level Light - The fuel level light illuminates

when the key is turned to the bulb test position (position I). It should go off after approximately five seconds. After the engine is running, if the engine runs out of fuel, the light will illuminate and protection circuitry will stop the engine. The fuel level light will remain on indicating the engine was stopped due to the fuel tank being empty.

Continued on next page

15-4

DPSG,RG34710,109 –19–08JAN02–1/2

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Engine Operating Guidelines

G—Battery Light - The battery light illuminates when the key is turned to the bulb test position (position I). It should go off after approximately five seconds. After the engine is running, if the alternator stops charging, the light will illuminate and protection circuitry will stop the engine. The battery light will remain on indicating the engine was stopped due to the alternator not charging.

H—Oil Pressure Light - The oil pressure light illuminates when the key switch is turned to the bulb test position (position I). The light will remain on until the engine is started and the specified oil pressure is reached. If oil pressure is lost during engine operation, the light will illuminate and protection circuitry will stop the engine. The oil pressure light will remain on, indicating that the engine was stopped due to a low oil pressure condition.

I—Coolant Temperature Light - The coolant temperature light illuminates when the key is turned to the bulb test position (position I). It should go off after approximately five seconds. After the engine is running, if the engine overheats, the light will illuminate and protection circuitry will stop the engine. The coolant temperature light will remain on indicating the engine was stopped due to the engine overheating.

Other components on the instrument panel: J—Key/Start Switch - The four-position key start switch

controls the electrical system. K—Hour Meter - The hour meter is an integral part of the

tachometer. It shows the accumulated hours of engine service. The hour meter operates when the engine is running and accumulated hours are displayed in hours and tenths of hours.

DPSG,RG34710,109 –19–08JAN02–2/2

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Engine Operating Guidelines

Engine Break-In Service

The engine is ready for normal operation. However, extra care during the first 250 hours of operation will result in more satisfactory long-term engine performance and life. DO NOT exceed 250 hours of operation with break-in oil.

1. This engine is factory-filled with John Deere ENGINE

BREAK-IN OIL. Operate the engine at heavy loads with minimal idling during the break-in period.

2. If the engine has significant operating time at idle,

constant speeds, and/or light load usage, or makeup oil is required in the first 250 hour period, a longer break-in period may be required. In these situations, an additional 250 hour break-in period is recommended using a new change of John Deere ENGINE BREAK-IN OIL and a new John Deere oil filter.

Continued on next page

Check Engine Oil

RG8009 –UN–06JAN99

OURGP12,0000076 –19–09SEP04–1/4

15-6

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PN=50

Engine Operating Guidelines

IMPORTANT: DO NOT add makeup oil until the oil

level is BELOW the ADD mark on dipstick. John Deere ENGINE BREAK-IN OIL (TY22041) should be used to make up any oil consumed during the break-in period.

3. Check engine oil level more frequently during engine

break-in period. If oil must be added during this period, John Deere ENGINE BREAK-IN OIL is preferred. See ENGINE BREAK-IN OIL, in Fuels, Lubricants, and Coolant Section.

IMPORTANT: DO NOT use PLUS-50Engine Oil

during the break-in period of a new engine or engine that has had a major overhaul. PLUS-50oil will not allow a new or overhauled engine to properly wear during this break-in period.

DO NOT fill above the crosshatch pattern (A) or the FULL mark, whichever is present. Oil levels anywhere within the crosshatch are considered in the acceptable operating range.

RG8028A –UN–15JAN99

Crosshatch Pattern On Oil Dipstick

A—Crosshatch Pattern On Oil Dipstick

Engine1—Oil Pressure at Full Load Rated Speed 345 ± 103 kPa (3.45 ± 1.03 bar)

Minimum Oil Pressure at Rated

Speed 275 (2.75 bar) (40 psi).....................................................................

Minimum Oil Pressure at 850 rpm 105 kPa (1.05 bar) (15 psi).................

Coolant Temperature Range 82°–94°C (180°–202°F)................................

PLUS-50 is a trademark of Deere & Company.

At normal operating temperature of 115°C (240°F) sump.

.................................

Specification

(50 ± 15 psi)

Continued on next page

OURGP12,0000076 –19–09SEP04–2/4

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Engine Operating Guidelines

4. During the first 20 hours, avoid prolonged periods of

engine idling or sustained maximum load operation. If engine will idle longer than 5 minutes, stop engine.

5. Before the first 250 hours (maximum), change engine

oil and replace engine oil filter. (See CHANGING ENGINE OIL AND REPLACING OIL FILTER in Lubrication and Maintenance/250 Hour/6 Month Section.) Fill crankcase with the normal seasonal viscosity grade oil. (See DIESEL ENGINE OIL, in Fuels, Lubricants, and Coolant Section.)

NOTE: Some increase in oil consumption may be

expected when low viscosity oils are used. Check oil levels more frequently.

If air temperature is below -10°C (14°F), use an engine block heater.

Changing Oil And Oil Filter Before First 250 Hours

RG7961B –UN–22JAN99

6. Watch coolant temperature gauge (A) closely. If

coolant temperature rises above 112°C (234°F), reduce load on engine. Unless temperature drops quickly, stop the engine and determine the cause before resuming operation.

NOTE: When the coolant temperature gauge reads

approximately 115°C (239°F), the engine will shutdown automatically, if equipped with safety controls.

7. Check poly-vee belt for proper alignment and seating

in pulley grooves.

A—Coolant Temperature Gauge

OURGP12,0000076 –19–09SEP04–3/4

RG11299F –UN–17AUG00

North American (1999— ) Instrument Panel Shown

15-8

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110306

PN=52

Engine Operating Guidelines

Auxiliary Gear Drive Limitations

IMPORTANT: When attaching an air compressor,

hydraulic pump, or other accessory to be driven by the auxiliary gear drive (A) (engine timing gear train at front of engine), power requirements of the accessory must be limited to values listed below:

• 30 kW (40 hp) Continuous Operation at 2500 rpm

• 37 kW (50 hp) Intermittent Operation at 2500 rpm

A—Auxiliary Gear Drive

Generator Set (Standby) Applications

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

Auxiliary Gear Drive

RG7634A –UN–22JAN99

RG,RG34710,5555 –19–27JUL06–1/1

RG,RG34710,5556 –19–27JUL06–1/1

15-9

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PN=53

Engine Operating Guidelines

Starting the Engine

The following instructions apply to the optional controls and instruments available through the John Deere Parts Distribution Network. The controls and instruments for your engine may be different from those shown here; always follow manufacturer’s instructions.

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

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

necessary to use cold weather starting aids (See COLD WEATHER OPERATION, later in this section).

1. Perform all prestarting checks outlined in Lubrication &

Maintenance/Daily Section later in this manual.

Use Proper Ventilation

TS220 –UN–23AUG88

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

3. Disengage clutch (if equipped) controlling any engine

drivelines.

Continued on next page

RG,RG34710,5557 –19–07JAN02–1/2

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Engine Operating Guidelines

NOTE: Electronically controlled governor applications may

be equipped with a rotary speed potentiometer on the throttle (A) on the instrument panel.

4. On mechanical governor (7-10% regulation) engines,

pull hand throttle (A) 1/3 of the way out. Turn the handle in either direction to lock it in place.

5. If equipped, depress and hold reset button (B) while

starting.

IMPORTANT: Do not operate the starter for more than

30 seconds at a time. To do so may overheat the starter. If the engine does not start the first time, wait at least 2 minutes before trying again. If engine does not start after four attempts, see Troubleshooting Section.

6. Turn the key switch (C) clockwise to crank the engine.

When the engine starts, release the key so that it returns to the "ON" position.

North American Standard Instrument Panel (1999— ) Shown

RG11299X –UN–18OCT01

IMPORTANT: If the key switch is released before the

engine starts, wait until the starter and the engine stop turning before trying again. This will prevent possible damage to the starter and/or flywheel.

7. After the engine starts, continue to hold the reset button

in until the oil pressure gauge (D) reads at least 105 kPa (1.05 bar) (15 psi). The safety controls will not allow the engine to run at a lower oil pressure unless the reset button is held in.

IMPORTANT: Should the engine die when operating

under load, immediately disengage PTO clutch and restart the engine. Overheating of turbocharger parts may occur when oil flow is stopped.

8. Check all gauges for normal engine operation. If

operation is not normal, stop the engine and determine the cause.

VDO Standard Instrument Panel (Except North America)

RG11610 –UN–17OCT01

A—Hand Throttle B—Reset Button C—Key Start Switch D—Oil Pressure Gauge

15-11

RG,RG34710,5557 –19–07JAN02–2/2

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PN=55

Engine Operating Guidelines

Warming Engine

IMPORTANT: To assure proper lubrication, operate

engine at or below 1200 rpm with no load for 1–2 minutes. Extend this period 2–4 minutes when operating at temperatures below freezing.

Engines used in generator set applications where the governor is locked at a specified speed may not have a slow idle function. Operate these engines at high idle for 1 to 2 minutes before applying the load. This procedure does not apply to standby generator sets where the engine is loaded immediately upon reaching rated speed.

1. Check oil pressure gauge (A) as soon as engine starts.

If gauge needle does not rise above minimum oil pressure specification of 105 kPa (1.05 bar) (15.0 psi) within 5 seconds, stop the engine and determine the cause. Normal engine oil pressure is 345 kPa (3.45 bar) (50 psi) at rated full load speed (1800–2500 rpm) with oil at normal operating temperature of 115°C (240°F).

Standard North American Instrument Panel

RG11612 –UN–17OCT01

RG10613 –UN–21OCT99

Standard VDO Instrument Panel (Except North America)

NOTE: On certain engines, the oil pressure and coolant

temperature gauges are replaced by indicator warning lights. The lights must be "OFF" when engine is running.

2. Watch coolant temperature gauge (B). Do not place

engine under full load until it is properly warmed up. The normal engine coolant temperature range is 82°— 94°C (180°—202°F).

NOTE: It is a good practice to operate the engine under a

lighter load and at lower speeds than normal for the first few minutes after start-up.

A—Oil Pressure Gauge B—Coolant Temperature Gauge

RG,RG34710,5560 –19–08JAN02–1/1

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Normal Engine Operation

Engine Operating Guidelines

Observe engine coolant temperature and engine oil pressure. Temperatures and pressures will vary between engines and with changing operating conditions, temperatures, and loads.

Normal engine coolant operating temperature range is 82°—94°C (180°—202°F). If coolant temperature rises above 112°C (234°F), reduce load on engine. Unless temperature drops quickly, stop engine and determine cause before resuming operation.

Operate the engine under a lighter load and at slower than normal speed for first 15 minutes after start-up. DO NOT run engine at slow idle.

IMPORTANT: Should the engine die while

operating under load, immediately

remove load and restart the engine. Overheating of the turbocharger parts may occur when oil flow is stopped.

Stop engine immediately if there are any signs of part failure. Symptoms that may be early signs of engine problems are:

• Sudden drop in oil pressure

• Abnormal coolant temperatures

• Unusual noise or vibration

• Sudden loss of power

• Excessive black exhaust

• Excessive fuel consumption

• Excessive oil consumption

• Fluid leaks

RG,RG34710,5552 –19–20MAY96–1/1

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Cold Weather Operation

CAUTION: Ether injector starting fluid is highly flammable. DO NOT use starting fluid on engines equipped with air intake heaters.

DO NOT use starting fluid near fire, sparks, or flames. DO NOT incinerate or puncture a starting fluid container.

Engine Operating Guidelines

Engines may be equipped with intake air heaters, coolant heaters, or ether injectors as a cold weather starting aid.

Starting aids are required below 32°F(0°C). They will enhance starting performance above these temperatures and may be needed to start applications that have high parasitic loads during cranking and/or start acceleration to idle.

Using correct grade of oil (per engine and machine operator’s manual) is critical to achieving adequate cold weather cranking speed.

Other cold weather starting aids are required at temperatures below -22°F (-30°C) or at altitudes above 1500 m (5000 ft).

1. Follow steps 1—4 as listed under , then proceed as

follows according to the instrument (gauge) panel on your engine.

2. Switch on the air intake heater for 30 seconds or

activate ether injector by following suppliers instructions.

Handle Starting Fluid with Care

TS1356 –UN–18MAR92

RG11521 –19–10JAN01

Cold Weather Starting Guidelines

3. Follow remaining steps 5—8 as listed under earlier in

this section. Additional information on cold weather operation is

available from your authorized servicing dealer.

15-14

RG,RG34710,5050 –19–08JAN02–1/1

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PN=58

Engine Operating Guidelines

Changing Engine Speed

To increase engine speed, turn throttle handle (A), if equipped, to the horizontal position and pull out until desired engine speed is obtained. Turn the handle in either direction to lock throttle position. The handle is pushed inward to decrease engine speed.

NOTE: On engines without handle, use throttle lever to

control engine speed.

A—Throttle Handle

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.

Once an engine is warmed to normal operating temperatures, engine should be idled at slow idle

North American Standard Instrument Panel Shown

RG11299I –UN–11SEP00

RG,RG34710,5561 –19–07JAN02–1/1

speed. Slow idle speed for this engine is 850 rpm at factory. If an engine will be idling for more than 5 minutes, stop and restart later.

NOTE: Generator set applications where the governor

is locked at a specified speed may not have a slow idle function. These engines will idle at no load governed speed (high idle).

15-15

RG,RG34710,5562 –19–27JUL06–1/1

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PN=59

Engine Operating Guidelines

Stopping the Engine

1. Disengage clutch (if equipped) controlling engine

drivelines.

2. Move the throttle (A) to slow idle on standard

(mechanical) governor engines.

IMPORTANT: Before stopping an engine that has

been operating at working load, idle engine at least 2 minutes at 1000–1200 rpm to cool hot engine parts.

For engines in generator set applications, where the governor is locked at a specified speed and no slow idle function is available, run engine for at least 2 minutes at fast idle and no load.

3. Turn key switch (B) to "OFF" position to stop the

engine. Remove ignition key.

North American Standard Instrument Panel Shown

RG11299J –UN–11SEP00

IMPORTANT: Make sure that exhaust stack cap (rain

cap) is installed when engine is not running. This will prevent water and dirt from entering engine.

A—Throttle B—Key Switch

Exhaust Stack Rain Cap

RG10616 –UN–16JUN00

RG,RG34710,5563 –19–07JAN02–1/1

15-16

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PN=60

Engine Operating Guidelines

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 battery is explosive. Keep sparks and flames away from battery. 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.

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.

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 (ies) for 24-volt electrical systems.

Exploding Battery

TS204 –UN–23AUG88

RG4678 –UN–14DEC88

12-Volt System

1. Connect booster battery or batteries to produce the

required system voltage for your engine application.

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).

24-Volt System

RG4698 –UN–14DEC88

A—12-Volt Machine Battery (ies) B—12-Volt Booster Battery (ies) C—Booster Cable D—Cable to Starting Motor

Continued on next page

15-17

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Engine Operating Guidelines

6. Start the engine. Disconnect jumper cables

immediately after engine starts. Disconnect NEGATIVE (–) cable first.

RG,RG34710,5564 –19–27JUL06–2/2

15-18

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Lubrication and Maintenance

Observe Service Intervals

Using hour meter (A) as 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 Lubrication and Maintenance Records Section.

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.

A—Hour Meter

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.

North American Instrument Panel Hour Meter Shown

RG11299A –UN–17AUG00

DPSG,OUOE003,20 –19–07JAN02–1/1

TS100 –UN–23AUG88

20-1

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Lubrication and Maintenance

Lubrication and Maintenance Service Interval Chart—Standard Industrial Engines

NOTE: The service intervals below are for standard

industrial engines. See details in Sections which follow these charts.

Lubrication and Maintenance Service Intervals

Item Daily 6 Month 12 Month 24 Month As Required

Check Engine Oil and Coolant Level • Check Fuel Filter(s)/Water Separator Bowl • Check Air Cleaner Dust Unloader Valve & Indicator

•

Perform Visual Walkaround Inspection • Service Fire Extinguisher • Change Engine Oil And Replace Oil Filter

Check Engine Mounts • Service Battery • Check Manual Belt Tensioner and Belt Wear • Clean Crankcase Vent Tube • Check Air Intake Hoses, Connections, & System • Replace Single or Dual Fuel Filter Elements • Check Automatic Belt Tensioner and Belt Wear • Check Engine Speeds • Check Engine Electrical Ground Connection • Check Cooling System • Coolant Solution Analysis-Add SCAs as required • Pressure Test Cooling System • Check Crankshaft Vibration Damper Flush Cooling System

(6.8 L Engines)

Test Thermostats • Check and Adjust Engine Valve Clearance • Add Coolant • Replace Air Cleaner Elements • Replace Poly-Vee Belt • Check Fuses •

Replace primary air cleaner element when restriction indicator shows a vacuum of 625 mm (25 in.) H2O.

Change the oil for the first time after 100 hours maximum of break-in operation. For subsequent oil and filter intervals, see recommendations

in section 10.

Replace crankshaft damper every 4500 hours or 60 months, whichever occurs first.

If John Deere COOL-GARD is used, the flushing interval may be extended to 3000 hours or 36 months. If John Deere COOL-GARD is used and the coolant is tested annually AND additives are replenished as needed by adding a supplemental coolant additive, the flushing interval may be extended to 5000 hours or 60 months, whichever occurs first.

250 Hour/ 500 Hour/ 2000 Hour/

•

Continued on next page

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Lubrication and Maintenance

Lubrication and Maintenance Service Intervals

Item Daily 6 Month 12 Month 24 Month As Required

Check Air Compressor (If Equipped) • Bleed Fuel System •

250 Hour/ 500 Hour/ 2000 Hour/

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Lubrication and Maintenance

Lubrication and Maintenance Service Interval Chart—Generator (Standby) Applications

NOTE: Use service intervals listed below for generator

(standby) applications. Match service items below to titles in Lubrication and Maintenance Sections for procedures.

Lubrication and Maintenance Service Intervals

Item Weeks 12 Months 12 Months or 24 Months As Required

Operate Engine at Rated Speed and 50%–70% Load a • Minimum of 30 Minutes

Check Engine Oil and Coolant Level • Check Fuel Filter(s)/Water Separator Bowl • Check Air Cleaner Dust Unloader Valve & Indicator

Perform Visual Walkaround Inspection • Service Fire Extinguisher • Change Engine Oil and Replace Oil Filter

Check Engine Mounts • Service Battery • Clean Crankcase Vent Tube • Check Air Intake Hoses, Connections, & System • Replace Single or Dual Fuel Filter Elements • Check Belt Tensioner and Belt Wear • Check Engine Speeds • Check Engine Electrical Ground Connection • Check Cooling System • Coolant Solution Analysis-Add SCAs as required • Pressure Test Cooling System • Check Variable Speed (Droop) (Gen-Sets) • Check Crankshaft Vibration Damper Flush Cooling System

(6.8 L Engines)

Test Thermostats • Check and Adjust Engine Valve Clearance • Add Coolant • Replace Air Cleaner Elements •

Replace primary air cleaner element when restriction indicator shows a vacuum of 625 mm (25 in.) H2O.

Change the oil for the first time after 100 hours maximum of break-in operation. For subsequent oil and filter intervals, see recommendations in section 10.

Replace crankshaft damper every 4500 hours or 60 months, whichever occurs first.

Every 2 250 Hours or 500 Hours or 2000 Hours

•

Continued on next page

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Lubrication and Maintenance

Lubrication and Maintenance Service Intervals

Item Weeks 12 Months 12 Months or 24 Months As Required

Replace Poly-Vee Belt • Check Fuses • Check Air Compressor (If Equipped) • Bleed Fuel System •

Every 2 250 Hours or 500 Hours or 2000 Hours

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Daily Prestarting Checks

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

IMPORTANT: DO NOT add makeup oil until the oil

level is BELOW the add mark.

1. Check engine oil level on dipstick. Add as required, using seasonal viscosity grade oil. (See DIESEL ENGINE OIL in Fuels, Lubricants, and Coolant Section for oil specifications.)

Depending on application, oil may be added at left (A) or right (B) side oil filler cap and rocker arm cover filler cap (C) locations.

IMPORTANT: DO NOT fill above the top mark on the

dipstick. Oil levels anywhere within crosshatch (D) are considered in the acceptable operating range.

Left Side Oil Filler Cap

RG8009A –UN–16JUN00

A—Left Side Oil Filler Cap B—Right Side Oil Filler Cap C—Cover Oil Filler Cap D—Crosshatch On Dipstick

Right Side Oil Filler Cap

RG8028B –UN–15JAN99

Rocker Arm Cover Filler Cap

Crosshatch on Dipstick

RG8054A –UN–16JUN00

RG8025B –UN–16JUN00

Continued on next page

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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.

2. Check the coolant level when engine is cold. Coolant level should be at bottom of filler neck. Fill radiator (A) with proper coolant solution if level is low. (See ADDING COOLANT in Service As Required Section.) Check overall cooling system for leaks.

NOTE: Refer to your vehicle’s operator’s manual for

recommendations for non-John Deere supplied accessories.

A—Fill Radiator

High-Pressure Fluids

TS281 –UN–23AUG88

Continued on next page

25-2

Fill Radiator

RG4675 –UN–14DEC88

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3. Check the single or dual fuel filters for water or debris. If filter is fitted with a see-through water separator bowl, drain as needed based on a daily visual inspection.

IMPORTANT: Drain water into a suitable container

and dispose of properly.

a. Loosen drain plugs (B) at bottom of each fuel filter

or bowl, if equipped, two or three turns.

b. Loosen air bleed plugs (A) two full turns on fuel

filter mountings and drain water from bottom until fuel starts to drain out.

c. When fuel starts to drain out, tighten drain plugs

securely.

After draining water from the fuel filter, the filter must be primed by bleeding all air from the fuel system.

a. Operate primer lever of the fuel supply pump (C)

until fuel flow is free from air bubbles.

b. Tighten bleed plugs securely, and continue

operating hand primer until pumping action is not felt. Primer lever is spring-loaded, and will return to normal position.

If the fuel system needs further bleeding of air, see BLEEDING FUEL SYSTEM in Service As Required Section, later in this manual.

Drain Fuel Filters (Dual Filters Shown)

RG13542 –UN–20JUL04

RG7317A –UN–16JUN00

Priming At Fuel Supply Pump

A—Air Bleed Plugs B—Drain Plugs C—Fuel Supply Pump Primer Lever

Continued on next page

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4. If the air cleaner has an automatic dust unloader valve (A), squeeze the unloader valve on air cleaner assembly to clear away any dust buildup.

If equipped with air intake restriction indicator gauge (B), check gauge to determine if air cleaner needs to be serviced.

IMPORTANT: Maximum air intake restriction is 6.25

kPa (0.06 bar) (1.0 psi) (25 in. H2O). A clogged air cleaner element will cause excessive intake restriction and a reduced air supply to the engine.

Dust Unloader Valve and Indicator Gauge

RG7332A –UN–22JAN99

5. Make a thorough inspection of the engine compartment. Look for oil or coolant leaks, worn fan and accessory drive belts, loose connections and trash build-up. Remove trash buildup and have repairs made as needed if leaks are found.

NOTE: Wipe all fittings, caps, and plugs before

performing any maintenance to reduce the chance of system contamination.

Inspect:

• Radiator for leaks and trash build-up.

• Air intake system hoses and connections for cracks

and loose clamps.

• Fan, alternator, and accessory drive belts for cracks,

breaks or other damage.

• Water pump for coolant leaks.

NOTE: It is normal for a small amount of leakage to occur

as the engine cools down and parts contract. Excessive coolant leakage may indicate the need to replace the water pump seal. Contact your engine distributor or servicing dealer for repairs.

A—Dust Unloader Valve B—Air Restriction Indicator

25-4

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Servicing Fire Extinguisher

A fire extinguisher (A) is available from your authorized servicing dealer or engine distributor.

Read and follow the instructions which are packaged with it. The extinguisher should be inspected at least every 250 hours of engine operation or once a month. Once extinguisher is operated, no matter how long, it must be recharged. Keep record of inspections on the tag which comes with the extinguisher instruction booklet.

A—Fire Extinguisher

Fire Extinguisher

RG,RG34710,5567 –19–20MAY96–1/1

RW4918 –UN–15DEC88

30-1

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Changing Engine Oil and Replacing Filter

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

after 100 hours maximum of operation, then every 250 hours thereafter.

If John Deere PLUS-50or ACEA E4 or E5 engine oil and a John Deere oil filter are used, the oil and filter change interval may be extended by 50 percent.

OILSCANor OILSCAN PLUSis a John Deere sampling program to help you monitor machine performance and identify potential problems before they cause serious damage. OILSCANand OILSCAN PLUSkits are available from your John Deere engine distributor or servicing dealer. Oil samples should be taken prior to the oil change. Refer to instructions provided with kit.

To change engine oil and oil filter:

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

2. Remove oil pan drain plug (arrow).

3. Drain crankcase oil from engine while warm.

NOTE: Drain plug location may vary, depending on the

application.

Oil Filter

RG11616 –UN–24OCT01

RG4881 –UN–29NOV88

Oil Pan Drain Plug

A—Oil Filter Element

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

Continued on next page

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4. Turn filter element (A) counterclockwise using a suitable filter wrench to remove. Discard oil filter element.

NOTE: Depending on engine application, oil filter may be

located on either side of the engine.

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

IMPORTANT: Filtration of oils is critical to proper

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

Removing Oil Filter Element

RG7961A –UN–22JAN99

6. Oil new packing and install 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. Install oil pan drain plug with O-ring or copper washer. If copper washer is used, install with raised center against plug. If O-ring or washer is damaged, replace it.

8. Tighten drain plug to specifications.

Specification

Oil Pan Drain Plug With Copper

Washer—Torque 70 N•m (52 lb ft).............................................................

Oil Pan Drain Plug With O-Ring—

Torque 50 N•m (37 lb ft).............................................................................

A—Oil Filter Element

Continued on next page

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9. Fill engine crankcase with correct John Deere engine oil through rocker arm cover opening (B) or either side oil filler (C) depending on engine application. (See DIESEL ENGINE OIL in Fuels, Lubricants, and Coolant Section for determining correct engine oil.)

To determine the correct oil fill quantity for your engine, see ENGINE CRANKCASE OIL FILL QUANTITIES in the Specifications Section of this manual.

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.

NOTE: Crankcase oil capacity may vary slightly.

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

Rocker Arm Cover Oil Filler

RG8025A –UN–19JUN00

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

11. Stop engine and check oil level after 10 minutes. Oil

level reading should be within crosshatch of dipstick.

Checking Engine Mounts

Engine mounting is the responsibility of the vehicle or generator manufacturer. Follow manufacturer’s guidelines for mounting specifications.

IMPORTANT: Use only Grade SAE 8 or higher grade

of hardware for engine mounting.

1. Check the engine mounting bracket, vibration isolators, and mounting bolts on support frame and engine block for tightness. Tighten as necessary.

Side Oil Filler

RG8054B –UN–19JUN00

B—Rocker Arm Cover Oil Filler C—Side Oil Filler

OURGP12,0000078 –19–31OCT06–3/3

2. Inspect overall condition of vibration isolators, if equipped. Replace isolators if rubber has deteriorated or mounts have collapsed, as necessary.

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Servicing Battery

CAUTION: 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.

Lubrication & Maintenance/250 Hour/6 Month

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

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.

1. On regular batteries, check electrolyte level. Fill each cell to bottom of filler neck with distilled water.

NOTE: Low-maintenance or maintenance-free batteries

should require little additional service. However, electrolyte level can be checked by cutting the center section of decal on dash-line, and removing cell plugs. If necessary, add clean, soft water to bring level to bottom of filler neck.

2. Keep batteries clean by wiping them with a damp cloth. Keep all connections clean and tight. Remove any corrosion, and wash terminals with a solution of 1 part baking soda and 4 parts water. Tighten all connections securely.

NOTE: Coat battery terminals and connectors with a

mixture of petroleum jelly and baking soda to retard corrosion.

Exploding Battery

TS204 –UN–23AUG88

3. Keep battery fully charged, especially during cold weather. If a battery charger is used, turn charger off before connecting charger to battery(ies). Attach POSITIVE (+) battery charger lead to POSITIVE (+) battery post. Then attach NEGATIVE (–) battery charger lead to a good ground.

Continued on next page

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

Avoid the hazard by:

1. Filling batteries in a well-ventilated area.

2. Wearing eye protection and rubber gloves.

3. Avoiding breathing fumes when electrolyte is added.

4. Avoiding spilling or dripping electrolyte.

5. Use proper jump start procedure.

If you spill acid on yourself:

1. Flush your skin with water.

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

3. Flush your eyes with water for 10–15 minutes. Get medical attention immediately.

If acid is swallowed:

1. Drink large amounts of water or milk.

2. Then drink milk of magnesia, beaten eggs, or vegetable oil.

3. Get medical attention immediately.

In freezing weather, run engine at least 30 minutes to assure thorough mixing after adding water to battery.

If necessary to replace battery(ies), replacements must meet or exceed the following recommended capacities at

-18°C(0°F):

Specification

12 Volt Standard Duty Starter—

Cold Cranking Amps 640............................................................................

12 Volt Heavy Duty Starter—Cold

Cranking Amps 800.....................................................................................

24 Volt Standard Duty Starter—

Cold Cranking Amps 570............................................................................

Sulfuric Acid

TS203 –UN–23AUG88

30-6

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Manual Belt Tensioner Adjustment

NOTE: Two types of manual tensioners shown. NOTE: Inspect belts for cracks, fraying, or stretched-out

areas. Replace if necessary. As a reference check, twist belt in the middle of a

254—305 mm (10—12 in.) span with two fingers. A properly tensioned belt will turn 75—85 degrees. If belt turns more, it needs to be tightened. If belt turns less, it needs to be loosened.

NOTE: If timing gear cover or alternator bracket interfere

with installation/centering of belt tension gauge (A), install gauge with face toward engine.

1. Install JDG1341 Belt Tension Gauge (A) on belt, halfway between pulleys as shown. (JDG1341 Belt Tension Gauge available from local John Deere Dealer or Distributor.)

Check Belt Tension

RG10556 –UN–21DEC99

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

3. Slide alternator or tensioner bracket (D) in slot by hand to remove all excess slack in belt.

IMPORTANT: Do not pry against alternator rear frame.

4. Stretch belt by prying outward on alternator front frame or tensioner bracket. Observing tension gauge, stretch the belt until specified tension is achieved.

Specification

New Belt—Tension 470—650 N (105—145 lb-force).................................

Used Belt—Tension 400—580 N (90—130 lb-force)..................................

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

NOTE: After ten minutes run-in, new belts are considered

used. Belt tension must then be rechecked per used belt specifications.

6. Run engine for ten minutes and immediately re-check belt tension per used belt specification above.

7. Reset belt tension as necessary.

Adjust Belt Tension

RG10557 –UN–21DEC99

A—Belt Tension Gauge B—Cap Screw C—Cap Screw D—Tensioner Bracket

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Manual Belt Tensioner Adjustment Using Belt Tension Tool (Alternate Method For Engines Without Auxiliary Drive)

NOTE: The JDG1520 Belt Tension Tool may not be

compatible with all alternators. In that case, use the preceding method for belt tensioning.

NOTE: Inspect belts for cracks, fraying, or stretched-out

areas. Replace if necessary. As a reference check, twist belt in the middle of a

254—305 mm (10—12 in.) span with two fingers. A properly tensioned belt will turn 75—85 degrees. If belt turns more, it needs to be tightened. If belt turns less, it needs to be loosened.

1. Loosen upper (A) and lower (B) alternator bracket cap screws. Lower cap screw must remain tight enough to prevent excessive alternator play but allow alternator to pivot by hand.

2. Insert JDG1520 Belt Tension Tool (C) behind belt (D) and over alternator mounting screw.

Alternator Bracket and Cap Screws

Belt Tension Tool

A—Upper Alternator Bracket Cap Screw B—Lower Alternator Bracket Cap Screw C—JDG1520 Belt Tension Tool D—Belt

Continued on next page

RG11812 –UN–31OCT01

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3. Place torque wrench (C) on belt tensioning tool (B) at 90° to tool. Pivot alternator (A) until desired torque is achieved according to specification using the following table.

New Belt—Tension 470—650 N (105—145 lb-force).................................

Specification

Used Belt—Tension 400—580 N (90—130 lb-force)..................................

JDG1520 Belt Tensioning Tool Torque Table

Desired Belt Tension Applied Torque On Tool

N (lb-force) N•m (lb-ft)

445 (100) 108 (90) 489 (110) 115 (85) 534 (120) 122 (90) 623 (140) 135 (100)

4. While holding tension with torque wrench (B), scribe a reference mark (D) on alternator in line with notch (E) on upper alternator bracket.

5. Continue to hold tension with torque wrench and tighten upper alternator bracket cap screw.

6. Check position of reference mark to see if alternator moved while tightening. If alternator moved, loosen upper alternator bracket cap screw and repeat the tension adjustment procedure.

Belt Tension Tool and Torque Wrench

RG11814 –UN–31OCT01

7. Remove belt tension tool and tighten lower alternator bracket cap screw.

A—Alternator B—Belt Tensioning Tool C—Torque Wrench D—Reference Mark E—Alternator Upper Bracket Notch

Scribe Reference Mark

RG11815 –UN–31OCT01

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Lubrication & Maintenance/500 Hour/12 Month

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 for elbow adapter. Tighten hose clamp securely.

A—Crankcase Vent Tube

Crankcase Vent Tube

RG8017A –UN–19JUN00

RG,RG34710,5574 –19–08JAN02–1/1

35-1

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Checking Air Intake System

IMPORTANT: The air intake system must not leak.

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

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

2. Check clamps (A) on piping which connect the air cleaner, engine and, if present, turbocharger. Tighten clamps as necessary. This will help prevent dirt from entering the air intake system through loose connections causing internal engine damage.

3. If engine has a rubber dust unloader valve (B), inspect the valve on bottom of air cleaner for cracks or plugging. Replace as necessary.

IMPORTANT: ALWAYS REPLACE primary air cleaner

element when air restriction indicator shows a vacuum of 625 mm (25 in.) H2O, is torn, or visibly dirty.

4. Test air restriction indicator (C) for proper operation. Replace indicator as necessary.

IMPORTANT: If not equipped with air restriction

indicator, replace air cleaner elements at 500 Hours or 12 Months, whichever occurs first.

Check Clamps

RG4689 –UN–20DEC88

RG7332B –UN–22JAN99

Unloader Valve and Air Restriction Indicator

A—Clamps B—Dust Unloader Valve C—Air Restriction Indicator

35-2

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Lubrication & Maintenance/500 Hour/12 Month

Replacing Fuel Filter Element (Single Filter)

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. Close fuel shut-off valve, if equipped.

High-Pressure Fluids

X9811 –UN–23AUG88

2. Thoroughly clean fuel filter assembly and surrounding area.

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

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

get it past raised locators.

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

5. 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.

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

Fuel Filter

RG7721 –UN–15JAN99

A—Retaining Ring B—Filter Element C—Drain Plug D—Bleed Plug

Continued on next page

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7. Align keys on filter element with slots in filter base.

8. 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.

NOTE: The proper installation is indicated when a "click"

is heard and a release of the retaining ring is felt. A plug is provided with the new element for

plugging the used element.

9. Open fuel shut-off valve and bleed the fuel system. (See BLEEDING FUEL SYSTEM in Service As Required Section.) Tighten bleed plug (D).

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Replacing Fuel Filter Elements (Dual Filters)

1. Close fuel shut-off valve, if equipped.

High-Pressure Fluids

X9811 –UN–23AUG88

2. Thoroughly clean fuel filter assemblies and surrounding area.

NOTE: Perform the following steps on each fuel filter.

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

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

get it past raised locators.

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

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

6. On primary filter with water separator, remove filter element from water separator bowl. Drain and clean separator bowl. Dry with compressed air. Install water separator bowl onto new element. Tighten securely.

Dual Fuel Filters (Final Filter at Left, Primary Filter with Bowl at

RG13543 –UN–21JUL04

Right)

A—Retaining Ring B—Filter Element C—Drain Plug D—Bleed Plug

Continued on next page

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NOTE: Raised locators on fuel filter canister must be

indexed properly with slots in mounting base for correct installation.

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

8. Align keys on filter element with slots in filter base.

9. 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.

NOTE: The proper installation is indicated when a "click"

is heard and a release of the retaining ring is felt. A plug is provided with the new element for

plugging the used element.

10. Open fuel shut-off valve and bleed the fuel system.

(See BLEEDING FUEL SYSTEM in Service As Required Section.) Tighten bleed plug (D).

Checking Belt Tensioner Spring Tension and Belt Wear (Automatic Tensioner)

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.

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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.

Visually inspect cast stops (A and B) on belt tensioner assembly.

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 in Service As Required Section).

Cast Stops

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A—Cast Stops B—Cast Stop

Continued on next page

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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:

NOTE: Later engines have a 12.7 mm (1/2 in.) square

drive hole in tensioner, so no socket drive is required.

1. Release tension on belt using a breaker bar and socket (if required) on tension arm. Remove belt from pulleys.

2. Release tension on tension arm and remove breaker bar.

3. Put a mark (A) on swing arm of tensioner as shown.

4. Measure 21 mm (0.83 in.) from (A) and put a mark (B) on tensioner mounting base.

5. Install torque wrench (C) so that it is aligned with center of pulley and tensioner. Rotate the swing arm with the torque wrench until marks (A and B) are aligned.

6. Record torque wrench measurement and compare with specification below. Replace tensioner assembly as required.

Specification

Spring Tension—Torque 18-22 N•m (13-16 lb-ft).......................................

NOTE: Threads on earlier belt tensioner roller cap screw

are LEFT-HAND threads.

Marks on Tensioner

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RG12054 –UN–08JAN02

Align Marks

35-8

Align Torque Wrench With Pulley And Tensioner

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A—Mark On Swing Arm B—Mark On Tensioner Mounting Base C—Torque Wrench

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Checking Engine Speeds

Observe tachometer (A) reading on the instrument panel to verify engine speeds while running engine. (Refer to Specifications section later in this manual for engine speed specifications.) If engine speeds need adjustment, contact your engine dealer or distributor.

A—Tachometer

Checking Engine Electrical Ground Connections

Keep all engine ground connections clean and tight to prevent electrical arcing which can damage electronic components.

Check Engine Speed On Tachometer

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Checking Cooling System

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.

Lubrication & Maintenance/500 Hour/12 Month

IMPORTANT: Air must be expelled from cooling

system when system is refilled. Loosen temperature sending unit fitting at rear of cylinder head or plug in thermostat housing to allow air to escape when filling system. Retighten fitting or plug when all the air has been expelled.

1. Visually check entire cooling system for leaks. Tighten all clamps securely.

2. Thoroughly inspect all cooling system hoses for hard, flimsy, or cracked condition. Replace hoses if any of the above conditions are found.

High-Pressure Fluids

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Replenishing Supplemental Coolant Additives (SCAs) Between Coolant Changes

Radiator Coolant Check

IMPORTANT: Do not add supplemental coolant

additives when the cooling system is drained and refilled with John Deere COOL-GARD



NOTE: If system is to be filled with coolant that does

not contain SCAs, the coolant must be precharged. Determine the total system capacity and premix with 3% John Deere Coolant Conditioner.

Through time and use, 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. The cooling system must be recharged with additional supplemental coolant additives available in the form of liquid coolant conditioner.

Maintaining the correct coolant conditioner concentration (SCAs) and freeze point is essential in

RG6261 –UN–08DEC97

JT07298 Coolant/Battery Tester

your cooling system to protect against rust, liner pitting and corrosion, and freeze-ups due to incorrect coolant dilution.

John Deere LIQUID COOLANT CONDITIONER is recommended as a supplemental coolant additive in John Deere engines.

DO NOT mix one brand of SCA with a different brand.

Test the coolant solution every 500 hours or 12 months of operation using either John Deere coolant test strips or a COOLSCANanalysis. If a COOLSCANanalysis is not available, recharge the system per instructions printed on label of John Deere Liquid Coolant Conditioner.

RG6262 –UN–05DEC97

COOL-GARD is a registered trademark of Deere & Company COOLSCAN is a registered trademark of Deere & Company

Continued on next page

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Lubrication & Maintenance/500 Hour/12 Month

IMPORTANT: ALWAYS maintain coolant at correct

level and concentration. DO NOT operate engine without coolant even for a few minutes.

If frequent coolant makeup is required, the glycol concentration should be checked with JTO7298 Coolant/Battery Tester to ensure that the desired freeze point is maintained. Follow manufacturer’s instructions provided with Coolant/Battery Tester.

Add the manufacturer’s recommended concentration of supplemental coolant additive. DO NOT add more than the recommended amount.

The use of non-recommended supplemental coolant additives may result in additive drop-out and gelation of the coolant.

If other coolants are used, consult the coolant supplier and follow the manufacturer’s recommendation for use of supplemental coolant additives.

See DIESEL ENGINE COOLANTS AND SUPPLEMENTAL ADDITIVE INFORMATION for proper mixing of coolant ingredients before adding to the cooling system.

Testing Diesel Engine Coolant

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

DPSG,OUOD002,1921 –19–07JAN02–2/2

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 and COOLSCAN PLUS

For a more thorough evaluation of your coolant, perform a COOLSCAN or COOLSCAN PLUS analysis, where available. See your John Deere dealer for information.

COOLSCAN is a trademark of Deere & Company COOLSCAN PLUS is a trademark of Deere & Company

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Pressure Testing Cooling System

Test Radiator Cap

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.

Test Radiator Cap

1. Remove radiator cap and attach to D05104ST Tester as shown.

2. Pressurize cap to specification listed. Gauge should hold pressure for 10 seconds within the normal range if cap is acceptable.

If gauge does not hold pressure, replace radiator cap.

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RG6558 –UN–20JAN93

Test Cooling System

1. Allow engine to cool, then carefully remove radiator cap.

2. Fill radiator with coolant to the normal operating level.

IMPORTANT: DO NOT apply excessive pressure to

cooling system, doing so may damage radiator and hoses.

3. Connect gauge and adapter to radiator filler neck. Pressurize cooling system to specification listed for radiator cap.

4. With pressure applied, check all cooling system hose connections, radiator, and overall engine for leaks.

If leakage is detected, correct as necessary and pressure test system again.

Radiator Cap Holding Pressure (Not Opening For 10 Seconds)—Pressure 70 kPa (0.7 bar) (10 psi)

Specification

....................................

minimum

3. Remove the cap from gauge, turn it 180°, and retest cap. This will verify that the first measurement was accurate.

Test Cooling System

NOTE: Engine should be warmed up to test overall

cooling system.

35-13

If no leakage is detected, but the gauge indicated a drop in pressure, coolant may be leaking internally within the system or at the block-to-head gasket. Have your engine distributor or servicing dealer correct this problem immediately.

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Adjusting Variable Speed (Droop) on Generator Set Engines

Stanadyne Mechanical Injection Pumps Only

1. Warm engine to normal operating temperature.

2. When necessary, disconnect throttle linkage or cable.

3. Adjust slow idle (C) and adjust fast idle (B) speed when necessary.

4. Run engine at fast idle, then apply load until reaching rated speed.

5. Check power. Adjust with the screw (A) if needed.

6. Remove load from engine.

7. Again check and adjust fast idle if screw (A) has been turned.

8. Repeat procedure until both the engine power and the fast idle speed are correct.

9. Reinstall throttle linkage if previously removed.

A—Adjustment Screw B—Fast Idle Adjustment C—Slow Idle Adjustment

Continued on next page

Droop Adjustment Screw

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DENSO In-Line Injection Pumps Only

1. Check for specified no-load (frequency). If governor regulation is within 5–7% range, no adjustment is necessary.

2. If governor regulation is above 7% or below 5%, stop engine and remove cap nuts from adjusting screws before making adjustments.

3. Remove droop adjusting screw access plug (B, shown removed) from top of governor housing.

4. Back out slow idle (adjusting) screw (D) and bumper screw. Pull back on throttle lever (F, toward rear of governor housing) by hand until the droop adjusting screw (C) inside housing can be adjusted through the access plug hole.

5. Screw the droop screw in (clockwise), counting the turns until screw bottoms out. Then, return screw to original setting.

NOTE: A noticeable click will occur at each 1/4 turn of

droop adjusting screw. One click clockwise will increase no-load speed approximately 10 rpm, counterclockwise will reduce speed by 10 rpm.

6. Screw in the droop screw (clockwise) no more than 1/2 turn (two clicks) at a time to reduce governor droop. Turn counterclockwise no more than two clicks at a time to increase governor droop (to reduce governor sensitivity).

7. Replace access plug in top of governor housing. Start engine, apply full (100%) load, and readjust high idle adjusting screw until 1500 rpm is obtained at the specified power.

8. Screw in idle (bumper) spring until engine speed increases 5–10 rpm.

9. Repeat steps 4 through 7 until governor regulation is within the 5–7% range.

10. Replace all cap nuts onto adjusting screws and

tighten lock nuts securely.

DENSO In-Line Injection Pump

RG5752 –UN–03NOV97

A—Fast Idle (Stop) Screw B—Droop Adjusting Screw Access Plug Location C—Droop Adjusting Screw D—Slow Idle (Adjusting) Screw E—Idle (Bumper) Spring F—Throttle Lever G—Mechanical Shutoff Lever

Continued on next page

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Delphi (Lucas) Injection Pumps Only

See your authorized Delphi (Lucas) Repair Station for speed droop adjustment. This service requires that an internal pump adjustment be made.

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.

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IMPORTANT: The vibration damper assembly is not

repairable and should be replaced every 4500 hours or 60 months, whichever occurs first.

3. Check vibration damper radial runout by positioning a dial indicator (A) so probe contacts damper outer diameter.

4. With engine at operating temperature, rotate crankshaft using either JDE83 or JD81-1 Flywheel Turning Tool.

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

Specification

Vibration Damper—Maximum

Radial Runout 1.50 mm (0.060 in.).............................................................

Grasp Vibration Damper

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Check Runout

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Flushing and Refilling Cooling System

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.

NOTE: When John Deere COOL-GARD is used, the drain

interval is 3000 hours or 36 months. The drain interval may be extended to 5000 hours or 60 months of operation, provided that the coolant

is tested annually AND additives are replenished, as needed, by adding a supplemental coolant additive (SCA).

If COOL-GARD is not used, the flushing interval is 2000 hours or 24 months of operation.

Drain old coolant, flush the entire cooling system, test thermostats, and fill with recommended clean coolant per the following procedure.

1. Pressure test entire cooling system and pressure cap if not previously done. (See PRESSURE TESTING COOLING SYSTEM, in the Lubrication and Maintenance/500 Hour/12 Month Section.)

2. Slowly open the engine cooling system filler cap or radiator cap (A) to relieve pressure and allow coolant to drain faster.

High-Pressure Fluids

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Radiator Cap

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3. Open engine block drain valve (A) on left side of engine. Drain all coolant from engine block.

NOTE: These engines use several different oil filter

adapters. Use either drain plug (B) or (C) to drain coolant, whichever is more accessible for the oil filter adapter on your engine.

4. Open radiator drain valve. Drain all coolant from radiator.

5. Remove thermostats at this time, if not previously done. Install cover (without thermostats) using old gasket and tighten cap screws to 47 N•m (35 lb-ft).

6. Test thermostat opening temperature. (See Inspecting Thermostats And Testing Opening Temperature in Service As Required Section.)

7. Close all drain valves after coolant has drained.

CAUTION: Do not run engine longer than 10 minutes. Doing so may cause engine to overheat which may cause burns when radiator water is draining.

8. Fill the cooling system with clean water. Run the engine about 10 minutes to stir up possible rust or sediment.

9. Stop engine, pull off lower radiator hose and remove radiator cap. Immediately drain the water from system before rust and sediment settle.

10. After draining water, close drain valves. Reinstall

radiator cap and radiator hose and clamp. Fill the cooling system with clean water and a heavy duty cooling system cleaner such as Fleetguard



RESTORE and RESTORE PLUS. Follow manufacturer’s directions on label.

Engine Block Drain Valve

RG8019A –UN–19JUN00

A—Engine Block Drain Valve B—Engine Block Drain Plug C—Engine Block Drain Plug

Fleetguard is a trademark of Cummins Engine Company, Inc. RESTORE is a trademark of Fleetguard. RESTORE PLUS is a trademark of Fleetguard.

Continued on next page

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11. After cleaning the cooling system, drain cleaner and

fill with water to flush the system. Run the engine about 10 minutes, remove radiator cap and pull off lower radiator hose to drain out flushing water.

12. Close all drain valves on engine and radiator.

Reinstall radiator hose and tighten clamps securely. Install thermostats using a new gasket. (See TESTING THERMOSTATS OPENING TEMPERATURE later in this section.)

IMPORTANT: Air must be expelled from cooling

NOTE: Coolant capacity may vary depending on

application.

13. Add coolant to radiator until coolant touches bottom of

filler neck. (See specification for capacity.) Install radiator cap.

4.5 L Engine— Coolant Capacity 8.5 L (9 qt).............................................

6.8 L Engine—Coolant Capacity 11.3 L (12 qt)..........................................

Specification

14. Run engine until it reaches operating temperature.

This mixes the solution uniformly and circulates it through the entire system. The normal engine coolant temperature range is 82°—94°C (180° — 202°F).

15. After running engine, check coolant level and entire

cooling system for leaks.

16. Inspect the fan belt for wear and check belt tension.

(See Checking Belt Tensioner Spring Tension and Belt Wear in Lubrication and Maintenance 500 Hour/12 Month section.

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Testing Thermostats Opening Temperature

To Remove Thermostat(s)

NOTE: On some engines, the coolant manifold/thermostat

housing is an integral part of the cylinder head.

CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. DO NOT drain coolant until it has cooled below operating temperature. Always loosen radiator pressure cap or drain valve slowly to relieve pressure.

1. Visually inspect area around thermostat housing for leaks.

2. Remove radiator pressure cap and partially drain cooling system.

3. Remove thermostat cover-to-water pump tube (A) and seal.

High Pressure Fluids

TS281 –UN–23AUG88

A—Cover-To-Coolant Pump Tube

4. Remove thermostat cover (B) with gasket.

5. Remove thermostat(s)

6. Remove and discard all gasket material. Clean gasket surfaces.

7. Clean and check cover for cracks or damage.

B—Thermostat Cover

Thermostat Cover-to-Water Pump Tube

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RG7921A –UN–13NOV97

Thermostat Cover

Continued on next page

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PowerTech CD4045HF120, CD4045DF120, CD4045TF120, CD4045TF220, CD6068TF120 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual