POWER Units for
Gensets (Saran)
2.9L/4039/4.5/6.8L
(128/008/158/258)
OPERATOR'S
MANUAL
John Deere Usine de Saran
OMCD16564 (03JAN00)
Printed in Germany
ENGLISH
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Contents
Page
Page
Identification Views
Identification views . . . . . . . . . . . . . . . . . . . . . . . 01-1
Diesel Engine Coolant . . . . . . . . . . . . . . . . . . . . 10-4
Operating in Warm Temperature Climates . . . . . 10-5
Maintenance Records
Operating the Engine
Using maintenance records . . . . . . . . . . . . . . . . 02-1
100 Hours of operation. . . . . . . . . . . . . . . . . . . . 02-1
500 Hours of operation. . . . . . . . . . . . . . . . . . . . 02-2
1000 Hours of operation. . . . . . . . . . . . . . . . . . . 02-2
1500 Hours of operation. . . . . . . . . . . . . . . . . . . 02-3
2000 Hours of operation. . . . . . . . . . . . . . . . . . . 02-3
2500 Hours of operation. . . . . . . . . . . . . . . . . . . 02-4
3000 Hours of operation. . . . . . . . . . . . . . . . . . . 02-4
3500 Hours of operation. . . . . . . . . . . . . . . . . . . 02-5
4000 Hours of operation. . . . . . . . . . . . . . . . . . . 02-5
4500 Hours of operation. . . . . . . . . . . . . . . . . . . 02-6
5000 Hours of operation. . . . . . . . . . . . . . . . . . . 02-6
5500 Hours of operation. . . . . . . . . . . . . . . . . . . 02-7
6000 Hours of operation. . . . . . . . . . . . . . . . . . . 02-7
6500 Hours of operation. . . . . . . . . . . . . . . . . . . 02-8
7000 Hours of operation. . . . . . . . . . . . . . . . . . . 02-8
7500 Hours of operation. . . . . . . . . . . . . . . . . . . 02-9
8000 Hours of operation. . . . . . . . . . . . . . . . . . . 02-9
8500 Hours of operation. . . . . . . . . . . . . . . . . . 02-10
9000 Hours of operation. . . . . . . . . . . . . . . . . . 02-10
9500 Hours of operation. . . . . . . . . . . . . . . . . . 02-11
10000 Hours of operation. . . . . . . . . . . . . . . . . 02-11
Break-in period. . . . . . . . . . . . . . . . . . . . . . . . . . 15-1
Starting the engine . . . . . . . . . . . . . . . . . . . . . . . 15-1
Cold weather operation . . . . . . . . . . . . . . . . . . . 15-1
Using a booster battery or charger . . . . . . . . . . . 15-3
Engine operation . . . . . . . . . . . . . . . . . . . . . . . . 15-4
Standby power units. . . . . . . . . . . . . . . . . . . . . . 15-4
Stopping the engine . . . . . . . . . . . . . . . . . . . . . . 15-5
Maintenance
Observe service intervals . . . . . . . . . . . . . . . . . . 20-1
Use correct fuels, lubricants and coolant . . . . . . 20-1
Maintenance interval chart . . . . . . . . . . . . . . . . . 20-2
Maintenance/Daily or every 10 hours
Daily prestarting checks . . . . . . . . . . . . . . . . . . . 25-1
Maintenance/500 hours
Changing engine oil and filter . . . . . . . . . . . . . . 30-1
Replacing fuel filter element . . . . . . . . . . . . . . . 30-3
Checking belt (300-SERIES ENGINES) . . . . . . . 30-4
Checking belt (POWERTech ENGINES with
manual tensioner) . . . . . . . . . . . . . . . . . . . . . . 30-5
Record Keeping
POWERTech medallion . . . . . . . . . . . . . . . . . . 03-1
Engine serial number plate. . . . . . . . . . . . . . . . . 03-1
Record engine serial number . . . . . . . . . . . . . . . 03-2
Engine option codes. . . . . . . . . . . . . . . . . . . . . . 03-3
Record fuel injection pump model number . . . . . 03-5
Maintenance/1000 hours/1 year
Cleaning crankcase vent tube . . . . . . . . . . . . . . 35-1
Checking air intake system . . . . . . . . . . . . . . . . 35-1
Checking automatic belt tensioner
(POWERTech ENGINES) . . . . . . . . . . . . . . . 35-2
Check and adjust engine valve clearance
(300-SERIES ENGINES) . . . . . . . . . . . . . . . . 35-3
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-1
Fuels, Lubricants and Coolant
Maintenance/2000 hours/2 years
Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Handling and Storing Diesel Fuel . . . . . . . . . . . 10-1
Engine Break-In Oil . . . . . . . . . . . . . . . . . . . . . . 10-2
Diesel Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Lubricant Storage . . . . . . . . . . . . . . . . . . . . . . . 10-3
Mixing of Lubricants . . . . . . . . . . . . . . . . . . . . . 10-4
Check and adjust engine valve clearance
(POWERTech ENGINE) . . . . . . . . . . . . . . . . . 40-1
Checking engine speed . . . . . . . . . . . . . . . . . . . 40-3
Adjust speed droop governor . . . . . . . . . . . . . . . 40-3
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 re-
served to make changes at any time without notice.
COPYRIGHT 1999
DEERE & COMPANY
European Office Mannheim
All rights reserved
A John Deere ILLUSTRUCTION Manual
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Contents
Page
Checking crankshaft vibration damper
(6-CYLINDER ENGINE ONLY) . . . . . . . . . . . 40-4
Maintenance/2500 hours/3 years
Drain and flush cooling system . . . . . . . . . . . . . 45-1
Maintenance/As required
Additional service information. . . . . . . . . . . . . . . 50-1
Do not modify fuel system . . . . . . . . . . . . . . . . . 50-1
Clean or replace air filter (one-piece) . . . . . . . . 50-2
Clean or replace air filter element . . . . . . . . . . . 50-3
Replacing fan and alternator belt
(POWERTech ENGINES) . . . . . . . . . . . . . . . 50-4
Checking fuel filter . . . . . . . . . . . . . . . . . . . . . . . 50-5
Bleeding the fuel system . . . . . . . . . . . . . . . . . . 50-6
Troubleshooting
Engine troubleshooting. . . . . . . . . . . . . . . . . . . . 55-1
Electrical troubleshooting . . . . . . . . . . . . . . . . . . 55-6
Storage
Engine storage guidelines . . . . . . . . . . . . . . . . . 60-1
Use AR41785 engine storage kit . . . . . . . . . . . . 60-1
Preparing engine for long term storage . . . . . . . 60-2
Removing engine from long term storage. . . . . . 60-3
Specifications
General engine specifications. . . . . . . . . . . . . . . 65-1
Unified Inch Bolt and Cap Screw Torque
Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65-4
Metric Bolt and Cap Screw Torque Values . . . . 65-5
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Identification Views
IDENTIFICATION VIEWS
4045HF158
Continued on next page
DPSG,CD03523,3 –19–05JUL99–1/2
01-1
112699
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Identification Views
6068HF158
DPSG,CD03523,3 –19–05JUL99–2/2
01-2
112699
PN=6
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Maintenance Records
USING MAINTENANCE RECORDS
To obtain the best performance, economy and service
life from your engine, ensure service is carried out
according to this present manual and recorded in the
following pages. It is recommended that your engine
Distributor or your Dealer carry out this service work
and stamp the appropriate case.
John Deere oils and coolants have been formulated to
give maximum protection and performance to your
engine. We recommend only genuine John Deere
service products and replacement parts.
To protect your rights under the warranty ensure all
scheduled services are carried out and recorded. If
your engine is covered by extended warranty, it is
important to maintain this record for the duration of the
warranty.
Keeping an accurate account of all service performed
on your engine will give more value to the machine
when you resell it.
DPSG,CD03523,6 –19–05JUL99–1/1
100 HOURS OF OPERATION
❒ Engine oil, replace
❒ Engine oil filter, replace
❒ Hose connections, check
Number of hours:
Date:
Comments:
Dealer or distributor stamp
Job done by:
DPSG,CD03523,7 –19–05JUL99–1/1
02-1
112699
PN=7
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Maintenance Records
500 HOURS OF OPERATION
❒ Engine oil, replace
❒ Engine oil filter, replace
❒ Fuel filter, replace
❒ Belt, check tension and wear (300-Series and POWERTech with
manual tensioner)
❒ Valve clearance, adjust (300-Series)
Number of hours:
Date:
Comments:
Dealer or distributor stamp
Job done by:
DPSG,CD03523,8 –19–05JUL99–1/1
1000 HOURS OF OPERATION
❒ Engine oil, replace
❒ Air intake system, check
❒ Engine oil filter, replace
❒ Fuel filter, replace
❒ Check belt and tensioning system
❒ Crankcase vent tube, clean
Number of hours:
Date:
Comments:
Dealer or distributor stamp
Job done by:
DPSG,CD03523,9 –19–05JUL99–1/1
112699
02-2
PN=8
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Maintenance Records
1500 HOURS OF OPERATION
❒ Engine oil, replace
❒ Engine oil filter, replace
❒ Fuel filter, replace
❒ Belt, check tension and wear (300-Series and POWERTech with
manual tensioner)
❒ Valve clearance, adjust (300-Series)
Number of hours:
Date:
Comments:
Dealer or distributor stamp
Job done by:
DPSG,CD03523,10 –19–05JUL99–1/1
2000 HOURS OF OPERATION
❒ Engine oil, replace
❒ Cooling system, drain and flush (if COOL-GARD is not used)
❒ Valve clearance, adjust (POWERTech)
❒ Air intake system, check
❒ Engine oil filter, replace
❒ Fuel filter, replace
❒ Check belt and tensioning system
❒ Crankcase vent tube, clean
❒ Vibration damper, check
Number of hours:
Date:
Comments:
Dealer or distributor stamp
Job done by:
DPSG,CD03523,59 –19–16AUG99–1/1
112699
02-3
PN=9
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Maintenance Records
2500 HOURS OF OPERATION
❒ Engine oil, replace
❒ Engine oil filter, replace
❒ Fuel filter, replace
❒ Cooling system, drain and flush (if COOL-GARD is used)
❒ Belt, check tension and wear (300-Series and POWERTech with
manual tensioner)
❒ Valve clearance, adjust (300-Series)
Number of hours:
Date:
Comments:
Dealer or distributor stamp
Job done by:
DPSG,CD03523,60 –19–16AUG99–1/1
3000 HOURS OF OPERATION
❒ Engine oil, replace
❒ Air intake system, check
❒ Engine oil filter, replace
❒ Fuel filter, replace
❒ Check belt and tensioning system
❒ Crankcase vent tube, clean
Number of hours:
Date:
Comments:
Dealer or distributor stamp
Job done by:
DPSG,CD03523,61 –19–16AUG99–1/1
112699
02-4
PN=10
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Maintenance Records
3500 HOURS OF OPERATION
❒ Engine oil, replace
❒ Engine oil filter, replace
❒ Fuel filter, replace
❒ Belt, check tension and wear (300-Series and POWERTech with
manual tensioner)
❒ Valve clearance, adjust (300-Series)
Number of hours:
Date:
Comments:
Dealer or distributor stamp
Job done by:
DPSG,CD03523,62 –19–16AUG99–1/1
4000 HOURS OF OPERATION
❒ Engine oil, replace
❒ Cooling system, drain and flush (if COOL-GARD is not used)
❒ Valve clearance, adjust (POWERTech)
❒ Air intake system, check
❒ Engine oil filter, replace
❒ Fuel filter, replace
❒ Check belt and tensioning system
❒ Crankcase vent tube, clean
❒ Vibration damper, check
Number of hours:
Date:
Comments:
Dealer or distributor stamp
Job done by:
DPSG,CD03523,63 –19–16AUG99–1/1
112699
02-5
PN=11
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Maintenance Records
4500 HOURS OF OPERATION
❒ Engine oil, replace
❒ Engine oil filter, replace
❒ Fuel filter, replace
❒ Vibration damper, replace (6 cyl.)
❒ Belt, check tension and wear (300-Series and POWERTech with
manual tensioner)
❒ Valve clearance, adjust (300-Series)
Number of hours:
Date:
Comments:
Dealer or distributor stamp
Job done by:
DPSG,CD03523,64 –19–16AUG99–1/1
5000 HOURS OF OPERATION
❒ Engine oil, replace
❒ Injection nozzles, replace
❒ Air intake system, check
❒ Engine oil filter, replace
❒ Fuel filter, replace
❒ Cooling system, drain and flush (if COOL-GARD is used)
❒ Check belt and tensioning system
❒ Crankcase vent tube, clean
Number of hours:
Date:
Comments:
Dealer or distributor stamp
Job done by:
DPSG,CD03523,65 –19–16AUG99–1/1
112699
02-6
PN=12
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Maintenance Records
5500 HOURS OF OPERATION
❒ Engine oil, replace
❒ Engine oil filter, replace
❒ Fuel filter, replace
❒ Belt, check tension and wear (300-Series and POWERTech with
manual tensioner)
❒ Valve clearance, adjust (300-Series)
Number of hours:
Date:
Comments:
Dealer or distributor stamp
Job done by:
DPSG,CD03523,66 –19–16AUG99–1/1
6000 HOURS OF OPERATION
❒ Engine oil, replace
❒ Cooling system, drain and flush (if COOL-GARD is not used)
❒ Valve clearance, adjust (POWERTech)
❒ Air intake system, check
❒ Engine oil filter, replace
❒ Fuel filter, replace
❒ Check belt and tensioning system
❒ Crankcase vent tube, clean
❒ Vibration damper, check
Number of hours:
Date:
Comments:
Dealer or distributor stamp
Job done by:
DPSG,CD03523,67 –19–16AUG99–1/1
112699
02-7
PN=13
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Maintenance Records
6500 HOURS OF OPERATION
❒ Engine oil, replace
❒ Engine oil filter, replace
❒ Fuel filter, replace
❒ Belt, check tension and wear (300-Series and POWERTech with
manual tensioner)
❒ Valve clearance, adjust (300-Series)
Number of hours:
Date:
Comments:
Dealer or distributor stamp
Job done by:
DPSG,CD03523,68 –19–16AUG99–1/1
7000 HOURS OF OPERATION
❒ Engine oil, replace
❒ Air intake system, check
❒ Engine oil filter, replace
❒ Fuel filter, replace
❒ Check belt and tensioning system
❒ Crankcase vent tube, clean
Number of hours:
Date:
Comments:
Dealer or distributor stamp
Job done by:
DPSG,CD03523,69 –19–16AUG99–1/1
112699
02-8
PN=14
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Maintenance Records
7500 HOURS OF OPERATION
❒ Engine oil, replace
❒ Engine oil filter, replace
❒ Fuel filter, replace
❒ Cooling system, drain and flush (if COOL-GARD is used)
❒ Belt, check tension and wear (300-Series and POWERTech with
manual tensioner)
❒ Valve clearance, adjust (300-Series)
Number of hours:
Date:
Comments:
Dealer or distributor stamp
Job done by:
DPSG,CD03523,70 –19–16AUG99–1/1
8000 HOURS OF OPERATION
❒ Engine oil, replace
❒ Cooling system, drain and flush (if COOL-GARD is not used)
❒ Valve clearance, adjust (POWERTech)
❒ Air intake system, check
❒ Engine oil filter, replace
❒ Fuel filter, replace
❒ Check belt and tensioning system
❒ Crankcase vent tube, clean
❒ Vibration damper, check
Number of hours:
Date:
Comments:
Dealer or distributor stamp
Job done by:
DPSG,CD03523,71 –19–16AUG99–1/1
112699
02-9
PN=15
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Maintenance Records
8500 HOURS OF OPERATION
❒ Engine oil, replace
❒ Engine oil filter, replace
❒ Fuel filter, replace
❒ Belt, check tension and wear (300-Series and POWERTech with
manual tensioner)
❒ Valve clearance, adjust (300-Series)
Number of hours:
Date:
Comments:
Dealer or distributor stamp
Job done by:
DPSG,CD03523,72 –19–16AUG99–1/1
9000 HOURS OF OPERATION
❒ Engine oil, replace
❒ Air intake system, check
❒ Vibration damper, replace (6 cyl.)
❒ Engine oil filter, replace
❒ Fuel filter, replace
❒ Check belt and tensioning system
❒ Crankcase vent tube, clean
Number of hours:
Date:
Comments:
Dealer or distributor stamp
Job done by:
DPSG,CD03523,73 –19–16AUG99–1/1
112699
02-10
PN=16
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Maintenance Records
9500 HOURS OF OPERATION
❒ Engine oil, replace
❒ Engine oil filter, replace
❒ Fuel filter, replace
❒ Belt, check tension and wear (300-Series and POWERTech with
manual tensioner)
❒ Valve clearance, adjust (300-Series)
Number of hours:
Date:
Comments:
Dealer or distributor stamp
Job done by:
DPSG,CD03523,74 –19–16AUG99–1/1
10000 HOURS OF OPERATION
❒ Engine oil, replace
❒ Cooling system, drain and flush
❒ Engine oil filter, replace
❒ Fuel filter, replace
❒ Valve clearance, adjust (POWERTech)
❒ Thermostat, replace
❒ Check belt and tensioning system
❒ Crankcase vent tube, clean
❒ Air intake system, check
❒ Vibration damper, check
❒ Injection nozzles, replace
Number of hours:
Date:
Comments:
Dealer or distributor stamp
Job done by:
DPSG,CD03523,75 –19–16AUG99–1/1
112699
02-11
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Record Keeping
POWERTECH MEDALLION
A medallion is located on the rocker arm cover which
identifies each engine as a John Deere POWERTECH
engine.
POWERTECH is a trademark of Deere & Company
DPSG,CD03523,11 –19–05JUL99–1/1
ENGINE SERIAL NUMBER PLATE
POWERTech engine
300-Series engine
Each engine has a 13–digit John Deere serial number.
The first two digits identify the factory that produced
the engine:
Your engine’s serial number plate (A) is located on the
right-hand side of cylinder block behind the fuel filter
for POWERTech engines and near the fuel supply
pump on 300–Series engines.
“CD” indicates the engines was built in Saran, France.
DPSG,CD03523,12 –19–05JUL99–1/1
03-1
112699
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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)
___________________
300-Series engine plate
Engine Model Number (C)
___________________
Coefficient of Absorption Value (D)
___________________
POWERTech engine plate
DPSG,CD03523,13 –19–05JUL99–1/1
03-2
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Record Keeping
ENGINE OPTION CODES
Engine option code label
In addition to the serial number plate, OEM engines
have an engine option code label affixed to the rocker
arm cover. These codes indicate which of the engine
options were installed on your engine at the factory.
When in need of parts or service, furnish your
authorized servicing dealer or engine distributor with
these numbers.
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.
An additional sticker may be also delivered (in a plastic
bag attached to the engine or inserted in the machine
documentation). It is recommended to stick this option
code list sticker either:
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.
• On this page of your Operator’s manual below this
section.
or
• On the “Engine Owner’s Warranty” booklet under the
title OPTION CODES (Engine manufacturing
configuration).
NOTE: The Machine Manufacturer may have already
stuck it at a specific accessible place (inside
the enclosure or close to a maintenance area).
NOTE: Your engine option code label may not contain
all option codes if an option has been added
after the engine left the producing factory.
The engine option code label includes an engine base
code (A). This base code must also be recorded along
with the option codes. At times it will be necessary to
furnish this base code to differentiate two identical
option codes for the same engine model.
If option code label is lost or destroyed,
consult your servicing dealer or engine
distributor selling the engine for a replacement.
Continued on next page
DPSG,CD03523,14 –19–05JUL99–1/2
112699
03-3
PN=20
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Record Keeping
Option
Codes
Description
Option
Codes
Description
Engine Base Code:________
Rocker Arm Cover
11____
12____
13____
14____
15____
16____
17____
18____
19____
20____
21____
22____
23____
24____
25____
26____
27____
28____
29____
30____
31____
32____
35____
36____
37____
39____
40____
41____
43____
44____
45____
46____
47____
48____
49____
50____
51____
52____
54____
55____
56____
57____
59____
60____
62____
64____
65____
66____
67____
68____
69____
74____
75____
76____
86____
87____
88____
91____
97____
98____
Balancer Shaft
Oil Filler Neck
Crankshaft Pulley
Flywheel Housing
Flywheel
Fuel Injection Pump
Air inlet
Air cleaner
Oil pan
Coolant pump
Thermostat Cover
Thermostat
Cylinder Block With Liners and Camshaft
Crankshaft and Bearings
Connecting Rods and Pistons
Valve Actuating Mechanisms
Oil Pump
Cylinder Head With Valves
Auxiliary Gear Drive
Oil heater
Shipping stand
Paint Option
Coolant Inlet
Oil Cooler
Fan Drive
Fan Belt
Fan
Add-on Auxiliary Drive Pulley
Alternator Mounting
Exhaust Elbow
Engine Coolant Heater
Radiator
Exhaust Manifold
Ventilator System
Starting Motor
Alternator
Instrument Panel
Fuel Filter
Front Plate
Fuel Transfer Pump
Thermostat Housing
Oil Dipstick
Belt Driven Front Auxiliary Drive
Starting Aid
Turbocharger
Temperature Switch
Electronic Tachometer Sensor
Damper
Engine Serial Number Plate
Air Conditioning System Compressor Mounting
Air Restriction Indicator
Oil Pressure Switch
Fan Pulley
Automatic Belt Tensioner
Oil Filter
Special Equipment (Factory Installed)
Special Equipment (Field Installed)
Shipping
Timing Gear Cover with Gears
DPSG,CD03523,14 –19–05JUL99–2/2
03-4
112699
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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. _________________________________
DPSG,CD03523,15 –19–07JUL99–1/1
03-5
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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.
DX,ALERT –19–29SEP98–1/1
UNDERSTAND SIGNAL WORDS
A signal word—DANGER, WARNING, or CAUTION—is
used with the safety-alert symbol. DANGER identifies the
most serious hazards.
DANGER or WARNING safety signs are located near
specific hazards. General precautions are listed on
CAUTION safety signs. CAUTION also calls attention to
safety messages in this manual.
DX,SIGNAL –19–03MAR93–1/1
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Safety
ENGINE LIFTING PROCEDURE
CAUTION: The only recommended method for
lifting the engine is with JDG23 Engine Lifting
Sling (A) and safety approved lifting straps (B)
that come with engine. Use extreme caution
when lifting and NEVER permit any part of the
body to be positioned under an engine being
lifted or suspended.
Lift engine with longitudinal loading on lifting
sling and lifting straps only. Angular loading
greatly reduces lifting capacity of sling and
straps.
NOTE: If engine does not have lifting straps, universal
straps can be procured through service parts
under part numbers JD-244-1 and JD-244-2.
1. If not equipped, install lifting straps and torque to
200 N•m (145 lb-ft).
2. Attach JDG23 Engine Lifting Sling (A) to engine lifting
straps (B) and overhead hoist.
IMPORTANT: Lifting straps are designed to lift the
engine and accessories such as
radiator, air filter and other small
components. If larger components,
such as power take-off, transmission,
generator air compressor... etc, are
attached to engine, the lifting straps
provided with engine or through parts
channel are not intended for this
purpose. Technician is responsible for
providing adequate lifting devices under
these situations. See machine manuals
for additional information on removing
engine from machine.
3. Carefully move engine to desired location.
DPSG,CD03523,95 –19–06OCT99–1/1
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Safety
FOLLOW SAFETY INSTRUCTIONS
Carefully read all safety messages in this manual and on
your machine safety signs. Keep safety signs in good
condition. Replace missing or damaged safety signs. Be
sure new equipment components and repair parts include
the current safety signs. Replacement safety signs are
available from your John Deere dealer.
Learn how to operate the machine and how to use
controls properly. Do not let anyone operate without
instruction.
Keep your machine in proper working condition.
Unauthorized modifications to the machine may impair the
function and/or safety and affect machine life.
If you do not understand any part of this manual and need
assistance, contact your John Deere dealer.
DX,READ –19–03MAR93–1/1
PREVENT MACHINE RUNAWAY
Avoid possible injury or death from machinery runaway.
Do not start engine by shorting across starter terminals.
Machine will start in gear if normal circuitry is bypassed.
NEVER start engine while standing on ground. Start
engine only from operator’s seat, with transmission in
neutral or park.
DX,BYPAS1 –19–29SEP98–1/1
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Safety
HANDLE FUEL SAFELY—AVOID FIRES
Handle fuel with care: it is highly flammable. Do not refuel
the machine while smoking or when near open flame or
sparks.
Always stop engine before refueling machine. Fill fuel tank
outdoors.
Prevent fires by keeping machine clean of accumulated
trash, grease, and debris. Always clean up spilled fuel.
DX,FIRE1 –19–03MAR93–1/1
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.
DX,FIRE2 –19–03MAR93–1/1
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,FIRE3 –19–16APR92–1/1
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Safety
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,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.
DX,NOISE –19–03MAR93–1/1
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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.)
DX,MSDS,NA –19–03MAR93–1/1
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.
Wear close fitting clothing. Stop the engine and be sure
the PTO driveline is stopped before making adjustments
or performing any type service on the engine or
PTO-driven equipment.
CD,PTO –19–12SEP95–1/1
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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.
DX,SERV –19–17FEB99–1/1
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
DX,AIR –19–17FEB99–1/1
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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.
DX,FLUID –19–03MAR93–1/1
AVOID HEATING NEAR PRESSURIZED FLUID
LINES
Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to
yourself and bystanders. Do not heat by welding,
soldering, or using a torch near pressurized fluid lines or
other flammable materials. Pressurized lines can be
accidentally cut when heat goes beyond the immediate
flame area.
DX,TORCH –19–03MAR93–1/1
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Safety
REMOVE PAINT BEFORE WELDING OR
HEATING
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated
by welding, soldering, or using a torch.
Do all work outside or in a well ventilated area. Dispose of
paint and solvent properly.
Remove paint before welding or heating:
• If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
• If you use solvent or paint stripper, remove stripper with
soap and water before welding. Remove solvent or
paint stripper containers and other flammable material
from area. Allow fumes to disperse at least 15 minutes
before welding or heating.
DX,PAINT –19–03MAR93–1/1
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.
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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.
DX,DUST –19–15MAR91–1/1
DISPOSE OF WASTE PROPERLY
Improperly disposing of waste can threaten the
environment and ecology. Potentially harmful waste used
with John Deere equipment include such items as oil, fuel,
coolant, brake fluid, filters, and batteries.
Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.
Do not pour waste onto the ground, down a drain, or into
any water source.
Air conditioning refrigerants escaping into the air can
damage the Earth’s atmosphere. Government regulations
may require a certified air conditioning service center to
recover and recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of waste
from your local environmental or recycling center, or from
your John Deere dealer.
DX,DRAIN –19–03MAR93–1/1
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Fuels, Lubricants and Coolant
DIESEL FUEL
Consult your local fuel distributor for properties of the
diesel fuel available in your area.
Fuel lubricity should pass a minimum of 3100 gram
load level as measured by the BOCLE scuffing test.
In general, diesel fuels are blended to satisfy the low
temperature requirements of the geographical area in
which they are marketed.
Sulfur content:
• Sulfur content should not exceed 0.5%. Sulfur
content less than 0.05% is preferred.
• If diesel fuel with sulfur content greater than 0.5%
sulfur content is used, reduce the service interval for
engine oil and filter by 50%.
Diesel fuels specified to EN 590 or ASTM D975 are
recommended.
In all cases, the fuel shall meet the following
properties:
• DO NOT use diesel fuel with sulfur content greater
than 1.0%.
Cetane number of 40 minimum. Cetane number
greater than 50 is preferred, especially for
temperatures below -20°C (-4°F) or elevations above
1500 m (5,000 ft).
Bio-diesel fuels may be used ONLY if the fuel
properties meet DIN 51606 or equivalent specification.
DO NOT mix used engine oil or any other type of
lubricant with diesel fuel.
Cold Filter Plugging Point (CFPP) below the
expected low temperature OR Cloud Point at least
5°C (9°F) below the expected low temperature.
DX,FUEL1 –19–17FEB99–1/1
HANDLING AND STORING DIESEL FUEL
IMPORTANT: The fuel tank is vented through the
filler cap. If a new filler cap is
CAUTION: Handle fuel carefully. Do not fill
the fuel tank when engine is running.
required, always replace it with an
original vented cap.
DO NOT smoke while you fill the fuel tank or
service the fuel system.
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.
Fill the fuel tank at the end of each day’s operation to
prevent condensation and freezing during cold
weather.
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Fuels, Lubricants and Coolant
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.
• ACEA Specification E1
After the break-in period, use John Deere PLUS-50 or
other diesel engine oil as recommended in this
manual.
Change the oil and filter after the first 100 hours of
operation of a new or rebuilt engine.
IMPORTANT: Do not use PLUS-50 oil or engine
oils meeting API CG4, API CF4,
After engine overhaul, fill the engine with John Deere
ENGINE BREAK-IN OIL.
ACEA E3, or ACEA E2 performance
levels during the first 100 hours of
operation of a new or rebuilt engine.
These oils will not allow the engine
to break-in properly.
If John Deere ENGINE BREAK-IN OIL is not available,
use a diesel engine oil meeting one of the following
during the first 100 hours of operation:
• API Service Classification CE
PLUS-50 is a registered trademark of Deere & Company.
DX,ENOIL4 –19–10OCT97–1/1
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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.
The following oil is preferred:
• John Deere PLUS-50
The following oil is also recommended:
• John Deere TORQ-GARD SUPREME TORQ-GARD
SUPREME
Other oils may be used if they meet one or more of the
following:
• API Service Classification CG-4
• API Service Classification CF-4
• ACEA Specification E3
• ACEA Specification E2
Multi-viscosity diesel engine oils are preferred.
If diesel fuel with sulfur content greater than 0.5% is used,
reduce the service interval by 50%.
PLUS-50 is a registered trademark of Deere & Company.
TORQ-GARD SUPREME is a trademark of Deere & Company
CD,ENOIL –19–10OCT97–1/1
LUBRICANT STORAGE
Your equipment can operate at top efficiency only
when clean lubricants are used.
Make certain that all containers are properly marked to
identify their contents.
Use clean containers to handle all lubricants.
Properly dispose of all old containers and any residual
lubricant they may contain.
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.
DX,LUBST –19–18MAR96–1/1
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Fuels, Lubricants and Coolant
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.
Consult your John Deere dealer to obtain specific
information and recommendations.
Mixing different oils can interfere with the proper
functioning of these additives and degrade lubricant
performance.
DX,LUBMIX –19–18MAR96–1/1
DIESEL ENGINE COOLANT
The engine cooling system is filled to provide
year-round protection against corrosion and cylinder
liner pitting, and winter freeze protection to -37°C
(-34°F).
water is recommended for mixing with ethylene glycol
base engine coolant concentrate.
IMPORTANT: Do not use cooling system sealing
additives or antifreeze that contains
sealing additives.
John Deere COOL-GARD is preferred for service.
If John Deere COOL-GARD is not available, use a low
silicate ethylene glycol base coolant concentrate in a
50% mixture of concentrate with quality water.
COOLANT DRAIN INTERVALS
Drain the factory fill engine coolant, flush the cooling
system, and refill with new coolant after the first 3
years or 3000 hours of operation. Subsequent drain
intervals are determined by the coolant used for
service. At each interval, drain the coolant, flush the
cooling system, and refill with new coolant.
The coolant concentrate shall be of a quality that
provides cavitation protection to cast iron and
aluminum parts in the cooling system. John Deere
COOL-GARD meets this requirement.
A 50% mixture of ethylene glycol engine coolant in
water provides freeze protection to -37°C (-34°F). If
protection at lower temperatures is required, consult
your John Deere dealer for recommendations.
When John Deere COOL-GARD is used, the coolant
drain interval is 3 years or 3000 hours of operation.
If COOL-GARD is not used, the drain interval is
reduced to 2 years or 2000 hours of operation.
Water quality is important to the performance of the
cooling system. Distilled, deionized, or demineralized
DX,COOL8 –19–12FEB99–1/1
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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 in
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.
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Operating the Engine
BREAK-IN PERIOD
Within first 100 hours of operation
During the first 100 hours of operation, avoid
overloading, excessive idling and no-load operation.
change the oil filter (see CHANGING ENGINE OIL
AND FILTER). Fill crankcase with seasonal viscosity
grade oil (see DIESEL ENGINE OIL).
See ENGINE BREAK-IN OIL for eventual addition of
oil.
Check tension of alternator belt.
Check connections of air intake hoses.
NOTE: During the break-in period a higher-than-usual
oil consumption should be considered as
normal.
Check for proper tightening of cap screws all around
the engine.
After first 100 hours of operation
After the first 100 hours, drain the crankcase and
DPSG,CD03523,17 –19–09JUL99–1/1
STARTING THE ENGINE
2. Open the fuel supply shut-off valve, if equipped.
CAUTION: Before starting engine in a
confined building, install proper outlet
exhaust ventilation equipment. Always use
safety approved fuel storage and piping.
3. Activate the starter motor switch to crank the
engine and release it as soon as engine starts.
NOTE: Do not operate the starter motor more than
20 seconds at a time.
NOTE: If temperature is below 0°C (32°F), it may be
necessary to use cold weather starting aids
(See COLD WEATHER OPERATION).
1. Perform all prestarting checks outlined in
Maintenance/Daily Section.
DPSG,CD03523,18 –19–09JUL99–1/1
COLD WEATHER OPERATION
Depending on equipment, various cold weather starting
aids are available to assist in starting the engine at
temperatures below 0°C (32°F).
Continued on next page
DPSG,CD03523,19 –19–09JUL99–1/4
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Operating the Engine
Air intake heater
Air intake heater is either a grid-type (A) for POWERTech
engines or a glow plug-type (B) for 300-Series engines
installed in the air intake channel.
CAUTION: NEVER use Ether Starting Fluid
when air intake heater is used to start the
engine.
Activate the heating element (preheater position) for
30 seconds maximum then start the engine.
DPSG,CD03523,19 –19–09JUL99–2/4
DPSG,CD03523,19 –19–09JUL99–3/4
DPSG,CD03523,19 –19–09JUL99–4/4
Coolant heater
Connect plug of coolant heater (A) to a power source (110
or 220 V).
At an ambient temperature of -15°C (5°F), the heating
process takes approximatively 2 hours. Extend heating
period if ambient temperature is lower.
Fuel preheater
Fuel preheater (A) switches ON and OFF automatically in
relation to the ambient temperature.
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Operating the Engine
USING A BOOSTER BATTERY OR CHARGER
A 12-volt booster battery can be connected in parallel with
battery(ies) on the unit to aid in cold weather starting.
ALWAYS use heavy duty jumper cables.
CAUTION: Gas given off by batteries is
explosive. Keep sparks and flames away from
batteries. Before connecting or disconnecting a
battery charger, turn charger off. Make last
connection and first disconnection at a point
away from battery. Always connect NEGATIVE
(–) cable last and disconnect this cable first.
IMPORTANT: Be sure polarity is correct before
making connections. Reversed polarity
will damage electrical system. Always
connect positive to positive and
negative to ground. Always use 12-volt
booster battery for 12-volt electrical
systems and 24-volt booster battery/
batteries for 24-volt electrical systems.
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.
24-Volts System
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).
A—12-Volt Machine battery/batteries
B—12-Volt Booster battery/batteries
C—Booster cable
D—Cable to starter motor
6. Start the engine. Disconnect jumper cables
immediately after engine starts. Disconnect NEGATIVE
(–) cable first.
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Operating the Engine
ENGINE OPERATION
Warming engine
Operate engine at high idle for 1 to 2 minutes before
applying the load.
• Unusual noise or vibration
• Excessive black exhaust fumes
• Excessive fuel consumption
• Excessive oil consumption
• Fluid leaks
NOTE: This procedure does not apply to standby
generator sets where the engine is loaded
immediately upon reaching rated speed.
Recommendation for turbocharger engines
Should the engine stall when operating under load,
IMMEDIATELY restart it to prevent overheating of
turbocharger components.
Normal engine operation
Compare engine coolant temperature and engine oil
pressure with specifications below:
Idling engine
Minimum oil pressure at full load rated speed1—Specification
Avoid excessive engine idling. Prolonged idling may
cause the engine coolant temperature to fall below its
normal range. This, in turn, causes crankcase oil
dilution, due to incomplete fuel combustion, and
permits formation of gummy deposits on valves,
pistons and piston rings. It also promotes rapid
accumulation of engine sludge and unburned fuel in
the exhaust system. If an engine will be idling for more
than 5 minutes, stop and restart later.
Pressure..................................................... 275 kPa (2.75 bar; 40 psi)
Coolant temperature range—Specification
Temperature ............................................... 82°—94°C (180°—202°F)
Stop engine immediately if coolant temperature is
above or oil pressure below specifications or if there
are any signs of part failure. Symptoms that may be
early signs of engine problems could be:
NOTE: Generator set applications have the governor
locked at a specified speed and do not have a
slow idle function. These engines idle at no
load governed speed (fast idle).
• Sudden loss of power
1Oil at normal operating temperature of 115°C (240°F).
DPSG,CD03523,21 –19–09JUL99–1/1
STANDBY POWER UNITS
To assure that your engine will deliver efficient standby
operation when needed, start engine and run at rated
speed (with 50%—70% load) for 30 minutes every
2 weeks. DO NOT allow engine to run an extended
period of time with no load.
DPSG,CD03523,22 –19–09JUL99–1/1
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Operating the Engine
STOPPING THE ENGINE
1. Before stopping, run engine for at least 2 minutes at
fast idle and no load.
2. Stop the engine.
DPSG,CD03523,23 –19–09JUL99–1/1
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Maintenance
OBSERVE SERVICE INTERVALS
Using hour meter as a guide, perform all services at
the hourly intervals indicated on following pages. At
each scheduled maintenance interval, perform all
previous maintenance operations in addition to the
ones specified. Keep a record of hourly intervals and
services performed using charts provided in
Maintenance Records Section.
IMPORTANT: Recommended service intervals are
for normal operating conditions.
Service MORE OFTEN if engine is
operated under adverse conditions.
Neglecting maintenance can result in
failures or permanent damage to the
engine.
DPSG,CD03523,24 –19–09JUL99–1/1
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.
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Maintenance
MAINTENANCE INTERVAL CHART
Item
10 H /
daily
500 H
1000 H /
1 year
2000 H /
2 years
2500 H /
3 years
As
required
Check engine oil and coolant level
Check air filter restriction indicatora
Change engine oil and filterb
•
•
•
•
•
Replace fuel filter element
Check belt tension and automatic tensionerc
Check and adjust valve clearanced
Clean crankcase vent tube
•
•
•
•
•
Check air intake hoses, connections and system
Check vibration damper (6 cyl.)e
•
•
•
Check engine speed and speed droop governor
Drain and flush cooling systemf
•
Drain water and sediment from fuel filter
Clean filter element (see note a)
•
•
•
Test thermostat and injection nozzles (see your dealer)g
aClean air filter element when restriction indicator is red. Replace filter element after 6 cleanings or once a year.
bChange oil and filter after the first 100 hours of operation, then every 500 hours thereafter. Change oil and filter at least once a year.
cCheck belt tension every 500 hours on 300-Series engines and on POWERTech engines with manual tensioner. Check automatic belt
tensioner every 1000 hours/1 year on POWERTech engines when equipped.
dHave your authorized servicing dealer or engine distributor adjust valve clearance as follows. After the first 500 hours of operation then every
1000 hours thereafter on 300-Series engines. Every 2000 hours on POWERTech engines.
eHave your authorized dealer or engine distributor replace the vibration damper every 4500 hours/5 years.
fDrain and flush cooling system every 2500 hours/3 years when John Deere COOL-GARD coolant is used. Otherwise every 2000
hours/2 years.
gContact your dealer when thermostat or injection nozzles are suspected to be defective. Replace injection nozzles every 5000 hours and
thermostat every 10000 hours.
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Maintenance/Daily or every 10 hours
DAILY PRESTARTING CHECKS
POWERTech engine
300-Series engine
Do the following BEFORE STARTING THE ENGINE
for the first time each day:
DIESEL ENGINE OIL). Add oil at rocker arm cover
filler cap (B).
IMPORTANT: DO NOT top up with fresh oil until
the oil level is BELOW the add mark.
IMPORTANT: DO NOT fill above the crosshatch
area. Oil levels anywhere within
crosshatch are considered in the
acceptable operating range.
1. Check engine oil level on dipstick (A). Add as
required, using seasonal viscosity grade oil. (See
Continued on next page
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Maintenance/Daily or every 10 hours
Remove radiator cap (E) and check coolant level
2.
CAUTION: Explosive release of fluids from
pressurized cooling system can cause
serious burns.
which should be at bottom of filler neck. Fill radiator
with proper coolant solution if level is low. (See
DIESEL ENGINE COOLANT). Check overall cooling
system for leaks.
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.
DPSG,CD03523,27 –19–12JUL99–2/3
3. If air filter has a dust unloading valve (C), squeeze
valve tip to release any trapped dirt particles.
4. Check air intake restriction indicator (D). When
indicator is red, air filter needs to be cleaned.
IMPORTANT: Maximum air intake restriction is
6.25 kPa (0.06 bar; 1.0 psi) (25 in. H2O).
A clogged air cleaner element will
cause excessive intake restriction and a
reduced air supply to the engine.
5. Make a thorough inspection of the engine
compartment.
NOTE: Wipe all fittings, caps and plugs before performing
any maintenance to reduce the chance of system
contamination.
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Maintenance/500 hours
CHANGING ENGINE OIL AND FILTER
NOTE: Change engine oil and filter for the first time after
100 hours maximum of operation, then every 500
hours thereafter. Change oil and filter at least
once a year.
1. Run engine approximately 5 minutes to warm up oil.
Shut engine off.
2. Open oil pan drain valve (A).
3. Drain crankcase oil from engine while warm.
4. Remove and discard oil filter element (B) using a
suitable filter wrench.
5. Remove oil filter packing and clean filter mounting pad.
IMPORTANT: Filtration of oils is critical to proper
lubrication. Always change filter
regularly. Use filters meeting John
Deere performance specifications.
6. Oil the new packing and install a new filter element.
Hand tighten element according to values printed on
filter element. If values are not provided, tighten
element approximately 3/4 — 1-1/4 turn after packing
contacts filter housing. DO NOT overtighten filter
element.
POWERTEch engine
7. Close oil pan drain valve.
300-Series engine
Continued on next page
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Maintenance/500 hours
8. Fill engine crankcase with correct John Deere engine
oil through rocker arm cover opening (C); see DIESEL
ENGINE OIL.
To determine the correct oil fill quantity for your engine,
see “Engine Oil Quantities” in Specifications Section.
NOTE: Crankcase oil capacity may vary slightly.
ALWAYS fill crankcase to full mark or within
crosshatch on dipstick, whichever is present. DO
NOT overfill.
IMPORTANT: Immediately after completing any oil
change, crank engine for 30 seconds
without permitting engine to start. This
will help insure adequate lubrication to
engine components before engine
starts.
9. Start engine and run to check for possible leaks.
10. Stop engine and check oil level after 10 minutes. If
necessary, top up.
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Maintenance/500 hours
REPLACING FUEL FILTER ELEMENT
A—Retaining ring
B—Filter element
C—Drain plug
D—Bleed plug
IMPORTANT: Do not dump the old fuel into the
new filter element. This could cause
fuel injection problem.
CAUTION: CAUTION: Escaping fluid under
pressure can penetrate the skin causing
serious injury. Relieve pressure before
disconnecting fuel or other lines. Tighten all
connections before applying pressure. Keep
hands and body away from pinholes and
nozzles which eject fluids under high
A plug is provided with the new
element for plugging the used
element.
pressure. Use a piece of cardboard or paper
to search for leaks. Do not use your hand.
4. Inspect filter mounting base for cleanliness. Clean
as required.
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.
NOTE: Raised locators on fuel filter canister must be
indexed properly with slots in mounting base
for correct installation.
5. Install new filter element dry onto mounting base.
Be sure element is properly indexed and firmly
seated on base. It may be necessary to rotate filter
for correct alignment.
1. Thoroughly clean fuel filter assembly and
surrounding area.
6. Install retaining ring onto mounting base making
certain dust seal is in place on filter base. Hand
tighten ring (about 1/3 turn) until it “snaps” into the
detent. DO NOT overtighten retaining ring.
2. Loosen drain plug (C) and drain fuel into a suitable
container.
NOTE: The proper installation is indicated when a
"click" is heard and a release of the retaining
ring is felt.
NOTE: Lifting up on retaining ring as it is rotated helps
to get it past raised locators.
3. Firmly grasp the retaining ring (A) and rotate it
clockwise 1/4 turn. Remove ring with filter element
(B).
7. Bleed the fuel system.
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Maintenance/500 hours
CHECKING BELT (300-SERIES ENGINES)
1. Inspect belt for cracks, fraying, or stretched out areas.
Replace as necessary.
2. Check belt tension using one of following methods:
a) Use of JDG529 Tension Gauge (A)
Belt tension—Specification
New belt.................................................. 578—622 N (130—140 lb-force)
Used belt .................................................... 378—423 N (85—94 lb-force)
NOTE: Belt is considered used after 10 minutes of
operation.
b) Use of tension tester (B) and straight edge (C)
A 89 N (20 lb) force applied halfway between pulleys
should deflect belt by 19 mm (0.75 in.).
3. If adjustment is necessary, loosen alternator nuts (D)
and (E). Pull alternator frame outward until belt is
correctly tensioned.
IMPORTANT: Do not pry against the alternator rear
frame. Do not tighten or loosen belts
while they are hot.
4. Tighten alternator bracket nuts firmly.
5. Run engine for 10 minutes then recheck belt tension.
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Maintenance/500 hours
CHECKING BELT (POWERTECH ENGINES
WITH MANUAL TENSIONER)
Inspect belt for cracks, fraying, or stretched out areas.
Replace if necessary.
NOTE: Belt adjustment is measured using a gauge
stamped on the top edge of the alternator bracket.
1. Loosen cap screws (B) and (C).
2. Slide alternator in slot by hand to remove all excess
slack in belt.
A—Belt gauge
B—Cap screw
C—Cap screw
IMPORTANT: Do not pry against alternator rear frame.
3. Using the gauge (A) on the alternator bracket, stretch
belt by prying outward on alternator front frame.
Stretch the belt 1 gauge unit for a used belt and 1.5
gauge units for a new belt.
4. Tighten cap screws (B) and (C).
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Maintenance/1000 hours/1 year
CLEANING CRANKCASE VENT TUBE
If you operate the engine in dusty conditions, clean the
tube at shorter intervals.
1. Remove and clean crankcase vent tube (A).
2. Install the vent tube. Be sure the O-ring fits correctly in
the rocker arm cover bore for elbow adapter. Tighten
hose clamp securely.
DPSG,CD03523,32 –19–12JUL99–1/1
CHECKING AIR INTAKE SYSTEM
IMPORTANT: The air intake system must not leak.
Any leak, no matter how small, may
result in engine failure due to
2. Check clamps on piping (A) which connect the air
filter, engine and, if present, turbocharger and
air-to-air radiator. Tighten clamps as necessary.
abrasive dirt and dust entering the
intake system.
3. Test air restriction indicator (B) for proper operation.
Replace indicator as necessary.
1. Inspect all intake hoses (piping) for cracks. Replace
as necessary.
Continued on next page
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Maintenance/1000 hours/1 year
4. If engine has a rubber dust unloading valve (C),
inspect the valve on bottom of air filter for cracks or
plugging. Replace as necessary.
5. Service air filter as necessary.
DPSG,CD03523,33 –19–12JUL99–2/2
CHECKING AUTOMATIC BELT TENSIONER
(POWERTECH ENGINES)
Belt drive systems equipped with automatic (spring) belt
tensioners cannot be adjusted or repaired. The automatic
belt tensioner is designed to maintain proper belt tension
over the life of the belt. If tensioner spring tension is not
within specification, replace tensioner assembly.
• Checking belt wear
The belt tensioner is designed to operate within the limit
of arm movement provided by the cast stops (A) and
(B) when correct belt length and geometry is used. If
the tensioner stop on swing arm (A) is hitting the fixed
stop (B), check mounting brackets (alternator, belt
tensioner, idler pulley, etc.) and the belt length. Replace
belt as needed (see REPLACING FAN AND
ALTERNATOR BELTS).
Continued on next page
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Maintenance/1000 hours/1 year
• Checking tensioner spring tension
A belt tension gauge will not give an accurate measure
of the belt tension when automatic spring tensioner is
used. Measure tensioner spring tension using a torque
wrench and procedure outlined below:
a. Release tension on belt using a breaker bar and
socket on tension arm. Remove belt from pulleys.
b. Release tension on tension arm and remove breaker
bar.
c. Put a mark (A) on swing arm of tensioner as shown.
d. Measure 21 mm (0.83 in.) from (A) and put a mark
(B) on tensioner mounting base.
e. Rotate the swing arm using a torque wrench until
marks (A) and (B) are aligned.
f. Record torque wrench measurement and compare
with specification below. Replace tensioner assembly
as required.
Spring—Specification
Force................................................................. 18—22 N•m (13—16 lb-ft)
DPSG,CD03523,34 –19–13JUL99–2/2
CHECK AND ADJUST ENGINE VALVE
CLEARANCE (300-SERIES ENGINES)
NOTE: Valve clearance must be adjusted after the first
500 hours of operation, then every 1000 hours
thereafter.
Adjust engine valve clearance as follows or have your
authorized servicing dealer or engine distributor adjust the
engine valve clearance.
1. Remove rocker arm cover and crankcase vent tube.
2. Using JDE83 or JDG820 Flywheel Turning Tool (A),
rotate engine flywheel in running direction (clockwise
viewed from water pump) until No.1 piston (front) has
reached top dead center (TDC) on compression stroke.
Insert timing pin JDE81-4 (B) into flywheel bore.
Continued on next page
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Maintenance/1000 hours/1 year
3. Check and adjust valve clearance to specifications
according to following procedures.
Valve clearance (engine cold)—Specification
Intake.......................................................................... 0.35 mm (0.014 in.)
Exhaust....................................................................... 0.45 mm (0.018 in.)
NOTE: If rocker arm is equipped with adjusting screw and
lock nut (A), tighten lock nut to 27 N•m (20 lb-ft)
after adjusting valve clearance.
4. Reinstall rocker arm cover and crankcase vent tube.
DPSG,CD03523,35 –19–13JUL99–2/4
• 3-Cylinder Engine:
NOTE: Firing order is 1-2-3.
a. Lock No. 1 piston at TDC compression stroke (D).
b. Adjust valve clearance on No. 1 and 2 exhaust
valves and No.1 and 3 intake valves.
c. Rotate flywheel 360°. Lock No. 1 piston at TDC
exhaust stroke (E).
d. Adjust valve clearance on No. 3 exhaust valve and
No. 2 intake valve.
A—Front of engine
B—Exhaust valve
C—Intake valve
D—No.1 Piston at TDC compression stroke
E—No.1 Piston at TDC exhaust stroke
Continued on next page
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Maintenance/1000 hours/1 year
• 4-Cylinder Engine:
NOTE: Firing order is 1-3-4-2.
a. Lock No. 1 piston at TDC compression stroke (B).
b. Adjust valve clearance on No. 1 and 3 exhaust
valves and No.1 and 2 intake valves.
c. Rotate flywheel 360°. Lock No. 4 piston at TDC
compression stroke (C).
d. Adjust valve clearance on No. 2 and 4 exhaust
valves and No. 3 and 4 intake valves.
A—Front of engine
B—No.1 Piston at TDC compression stroke
C—No.4 Piston at TDC compression stroke
E—Exhaust valve
I—Intake valve
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Maintenance/2000 hours/2 years
CHECK AND ADJUST ENGINE VALVE
CLEARANCE (POWERTECH ENGINE)
Adjust engine valve clearance as follows or have your
authorized servicing dealer or engine distributor adjust the
engine valve clearance.
1. Remove rocker arm cover and crankcase vent tube.
2. Using JDE83 or JDG820 Flywheel Turning Tool (A),
rotate engine flywheel in running direction (clockwise
viewed from water pump) until No.1 piston (front) has
reached top dead center (TDC) on compression stroke.
Insert timing pin JDE81-4 (B) into flywheel bore.
DPSG,CD03523,36 –19–13JUL99–1/4
3. Check and adjust valve clearance to specifications
according to following procedures.
Valve clearance (engine cold)—Specification
Intake.......................................................................... 0.35 mm (0.014 in.)
Exhaust....................................................................... 0.45 mm (0.018 in.)
4. If valves need adjusting, loosen the lock nut on rocker
arm adjusting screw. Turn adjusting screw until feeler
gauge slips with a slight drag. Hold the adjusting screw
from turning with screwdriver and tighten lock nut to
27 N•m (20 lb-ft). Recheck clearance again after
tightening lock nut. Readjust clearance as necessary
5. Reinstall rocker arm cover and crankcase vent tube.
Continued on next page
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Maintenance/2000 hours/2 years
• 4-Cylinder Engine:
NOTE: Firing order is 1-3-4-2.
a. Lock No. 1 piston at TDC compression stroke (B).
b. Adjust valve clearance on No. 1 and 3 exhaust
valves and No.1 and 2 intake valves.
c. Rotate flywheel 360°. Lock No. 4 piston at TDC
compression stroke (C).
d. Adjust valve clearance on No. 2 and 4 exhaust
valves and No. 3 and 4 intake valves.
A—Front of engine
B—No.1 Piston at TDC compression stroke
C—No.4 Piston at TDC compression stroke
E—Exhaust valve
I—Intake valve
DPSG,CD03523,36 –19–13JUL99–3/4
• 6-Cylinder Engine:
NOTE: Firing order is 1-5-3-6-2-4.
a. Lock No. 1 piston at TDC compression stroke (B).
b. Adjust valve clearance on No. 1, 3, and 5 exhaust
valves and No. 1, 2, and 4 intake valves.
c. Rotate flywheel 360°. Lock No. 6 piston at TDC
compression stroke (C).
d. Adjust valve clearance on No. 2, 4, and 6 exhaust
valves and No. 3, 5, and 6 intake valves.
A—Front of engine
B—No.1 Piston at TDC compression stroke
C—No.6 Piston at TDC compression stroke
E—Exhaust valve
I—Intake valve
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Maintenance/2000 hours/2 years
CHECKING ENGINE SPEED
NOTE: Most engines for generator set application
(1500 rpm for 50 Hz or 1800 rpm for 60 Hz) run
only at fast idle and therefore they do not have
slow idle.
Fast idle—Specification
50 Hz Generator set........................................................ 1550—1580 rpm
60 Hz Generator set........................................................ 1865—1890 rpm
NOTE: Fast idle is settled by the factory then the idle
adjusting screw (A) is sealed to prevent from
tampering. Fast idle adjustment can only be done
by an authorized fuel system agent.
DPSG,CD03523,38 –19–13JUL99–1/1
ADJUST SPEED DROOP GOVERNOR
1. Warm engine to normal operating temperature.
2. Run engine at fast idle.
3. Apply full load.
4. If specified power cannot be obtained, turn screw (B)
to adjust droop until the requested power is reached.
NOTE: If surging exists upon removing the load, turn
screw (B) clockwise to eliminate.
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Maintenance/2000 hours/2 years
CHECKING CRANKSHAFT VIBRATION
DAMPER (6-CYLINDER ENGINE ONLY)
1. Remove belts (shown removed).
2. Grasp vibration damper with both hands and attempt to
turn it in both directions. If rotation is felt, damper is
defective and should be replaced.
IMPORTANT: The vibration damper assembly is not
repairable and should be replaced every
4500 hours or 5 years, whichever
occurs first.
3. Check vibration damper radial runout by positioning a
dial indicator so probe contacts damper outer
circumference.
4. With engine at operating temperature, rotate crankshaft
using JDG820 or JDE83 Flywheel Turning Tool.
5. Note dial indicator reading. If runout exceeds
specifications given below, replace vibration damper.
Damper—Specification
Maximum radial runout............................................... 1.50 mm (0.060 in.)
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Maintenance/2500 hours/3 years
DRAIN AND FLUSH COOLING SYSTEM
NOTE: Drain and flush cooling system every
2500 hours/3 years when John Deere
COOL-GARD coolant is used. Otherwise every
2000 hours/2 years.
CAUTION: Explosive release of fluids from
pressurized cooling system can cause serious
burns.
Shut off engine. Only remove filler cap when
cool enough to touch with bare hands. Slowly
loosen cap to first stop to relieve pressure
before removing completely.
1. Slowly open the radiator cap.
2. Remove engine block drain plug (A).
3. On POWERTech engines, remove oil cooler housing
drain plug (B).
4. Open radiator drain valve (C). Drain all coolant from
radiator.
5. Close all drain orifices after coolant has drained.
6. Fill the cooling system with clean water. Run engine
until water passes through the thermostat to stir up
possible rust or sediment.
7. Stop engine and immediately drain the water from
system before rust and sediment settle.
8. After draining water, close all drain orifices and fill the
cooling system with clean water and TY15979 John
Deere Heavy Duty Cooling System Cleaner or
equivalent cleaner. Follow manufacturer’s directions on
label.
9. After cleaning the cooling system, drain cleaner and fill
with water to flush the system. Run engine until water
passes through the thermostat, then drain out flushing
water.
Continued on next page
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Maintenance/2500 hours/3 years
10. Check cooling system hoses for proper condition.
Replace as necessary.
11. Close all drain orifices and fill the cooling system with
specified coolant (see DIESEL ENGINE COOLANT).
Cooling system capacity—Specification
CD3029DF128................................................................... 14.5 L (15.5 qt)
CD4039DF008................................................................... 16.5 L (17.5 qt)
CD4039TF008 ................................................................... 16.5 L (17.5 qt)
CD4045DF158......................................................................... 20 L (21 qt)
CD4045HF158...................................................................... 25 L (26.5 qt)
CD4045TF158 ...................................................................... 25 L (26.5 qt)
CD4045TF258 ...................................................................... 25 L (26.5 qt)
CD6068HF158...................................................................... 29 L (30.5 qt)
CD6068TF158 ...................................................................... 26 L (27.5 qt)
CD6068TF258 ...................................................................... 26 L (27.5 qt)
DPSG,CD03523,41 –19–13JUL99–2/3
12. When refilling cooling system, loosen temperature
sensor (B) or plug at the rear of cylinder head to
allow air to escape.
13. Run engine until it reaches operating temperature
then check coolant level and entire cooling system for
leaks.
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Maintenance/As required
ADDITIONAL SERVICE INFORMATION
This manual does not allow a complete repair of your
engine. If you want want more detailled service
information the following publications are available from
your regular parts channel.
• PC2451 — Parts Catalog
• CTM3274 — Component Technical Manual for
300-Series engines (English)
• CTM104 — Component Technical Manual for
POWERTech engines (English)
• CTM67 — Component Technical Manual for OEM
Engine accessories (English only)
• CTM77 — Component Technical Manual for Alternators
and Starter Motors (English only)
DPSG,CD03523,42 –19–15JUL99–1/1
DO NOT MODIFY FUEL SYSTEM
IMPORTANT: Modification or alteration of the
injection pump, the injection pump
timing, or the fuel injectors in ways not
recommended by the manufacturer will
terminate the warranty obligation to the
purchaser.
Do not attempt to service injection
pump or fuel injectors yourself. Special
training and special tools are required
(see your authorized servicing dealer or
engine distributor).
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Maintenance/As required
CLEAN OR REPLACE AIR FILTER
(ONE-PIECE)
Clean air filter when restriction indicator (A) is red. Air
filter can be cleaned up to six times. Thereafter, or at
least once a year, it must be replaced.
Proceed as follows:
1. Thoroughly clean all dirt around air filter area.
2. Loosen clamp (B) then remove air filter.
IMPORTANT: Never reinstall an air filter which shows
evidence of bad condition (punched,
dented...) allowing no filtered air to
enter the engine.
3. Clean air filter with compressed air working from
“clean” to “dirty” side.
NOTE: Compressed air must not exceed 600 kPa (6 bar;
88 psi).
4. Mark air filter to keep track of each cleaning operation.
5. Fully depress air restriction indicator reset button and
release to reset indicator.
6. Check air system entirely for proper condition (see
CHECKING AIR INTAKE SYSTEM).
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Maintenance/As required
CLEAN OR REPLACE AIR FILTER ELEMENT
A—Primary element
B—Secondary (safety)
element
C—Air restriction indicator
D—Wing nut
Clean air filter when restriction indicator (C) is red.
Replace both primary (A) and secondary (B) filter
elements every 6 primary element cleaning or at least
once a year.
dented...), replace both the primary
and the secondary elements.
4. Clean primary element with compressed air working
from “clean” to “dirty” side.
Proceed as follows:
NOTE: Compressed air must not exceed 600 kPa
(6 bar; 88 psi).
1. Thoroughly clean all dirt around air filter area.
2. Remove wing nut (D) and remove primary element
(A) from canister.
5. Mark air filter to keep track of each cleaning
operation.
IMPORTANT: Do not attempt to clean the
secondary (safety) element (B). It
must be only replaced as
6. Fully depress air restriction indicator reset button
and release to reset indicator.
recommended.
7. Check air system entirely for proper condition (see
CHECKING AIR INTAKE SYSTEM).
3. Thoroughly clean all dirt from inside canister.
IMPORTANT: If primary element shows evidence
of bad condition (punched,
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Maintenance/As required
REPLACING FAN AND ALTERNATOR BELT
(POWERTECH ENGINES)
NOTE: Refer to CHECKING BELT TENSIONER SPRING
TENSION AND BELT WEAR for additional
information on the belt tensioner.
1. Inspect belts for cracks, fraying, or stretched out areas.
Replace if necessary.
2. On engines with automatic belt tensioner, release
tension on belt using a breaker bar and socket on
tension arm.
Installation on 4 cyl. engines
On engines with manual tensioner, loosen cap screws
holding the alternator.
3. Remove poly-vee belt from pulleys and discard belt.
4. Install new belt, making sure belt is correctly seated in
all pulley grooves. Refer to belt routing at right for your
application.
5. Apply tension to belt (see CHECKING BELT).
6. Start engine and check belt alignment.
Installation on 6 cyl. engines
ALT—Alternator
CP—Crankshaft Pulley
FD—Fan Drive
I—Idler Pulley
T—Tensioner
WP—Water Pump
DPSG,CD03523,45 –19–15JUL99–1/1
50-4
112699
PN=66
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Maintenance/As required
CHECKING FUEL FILTER
Periodically the fuel filter should be checked for water or
debris.
IMPORTANT: Drain water into a suitable container
and dispose of properly.
1. Loosen drain plug (B) at bottom of fuel filter two or
three turns.
2. Loosen air bleed plug two full turns (A) on fuel filter
base and drain water from bottom until fuel starts to
drain out.
3. When fuel starts to drain out, tighten drain plug
securely.
4. After draining water from the fuel filter, the filter must
be primed by bleeding all air from the fuel system.
Operate primer lever of the fuel supply pump (C) until
fuel flow is free from air bubbles.
5. Tighten bleed plug securely, continue operating hand
primer until pumping action is not felt. Push hand
primer inward (toward engine) as far as it will go.
If the fuel system needs further bleeding of air, see
BLEEDING THE FUEL SYSTEM.
DPSG,CD03523,28 –19–12JUL99–1/1
50-5
112699
PN=67
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Maintenance/As required
BLEEDING THE FUEL SYSTEM
CAUTION: Escaping fluid under pressure can
penetrate the skin causing serious injury.
Relieve pressure before disconnecting fuel or
other lines. Tighten all connections before
applying pressure. Keep hands and body away
from pinholes and nozzles which eject fluids
under high pressure. Use a piece of cardboard
or paper to search for leaks. Do not use your
hand.
If ANY fluid is injected into the skin, it must be
surgically removed within a few hours by a
doctor familiar with this type injury or gangrene
may result. Doctors unfamiliar with this type of
injury may call the Deere & Company Medical
Department in Moline, Illinois, or other
knowledgeable medical source.
Whenever the fuel system has been opened up for
service (lines disconnected or filters removed), it will be
necessary to bleed air from the system.
1. Loosen the air bleed screw (A) two full turns by hand
on fuel filter base.
2. Operate supply pump primer lever (B) until fuel flow is
free from air bubbles.
3. Tighten bleed plug securely, continue operating hand
primer until pumping action is not felt. Push hand
primer inward (toward engine) as far as it will go.
4. Start engine and check for leaks.
If engine will not start, it may be necessary to bleed air
from fuel system at fuel injection pump or injection
nozzles as explained next.
Continued on next page
DPSG,CD03523,46 –19–10AUG99–1/2
50-6
112699
PN=68
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Maintenance/As required
• At Fuel Injection Pump:
a. Slightly loosen fuel return line connector (C) at fuel
injection pump.
b. Operate fuel supply pump primer lever until fuel,
without air bubbles, flows from fuel return line
connection.
c. Tighten return line connector to 16 N•m (12 lb-ft).
d. Leave hand primer in the inward position toward
cylinder block.
• At Fuel Injection Nozzles:
a. Using two open-end wrenches, loosen fuel line
connection at injection nozzle.
b. Crank engine over with starting motor (but do not
start engine), until fuel free from bubbles flows out of
loosened connection. Retighten connection to
27 N•m (20 lb-ft).
c. Repeat procedure for remaining injection nozzles (if
necessary) until all air has been removed from fuel
system.
If engine still will not start, see your authorized servicing
dealer or engine distributor.
DPSG,CD03523,46 –19–10AUG99–2/2
50-7
112699
PN=69
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Troubleshooting
ENGINE TROUBLESHOOTING
Symptom
Problem
Solution
Engine cranks but will not start
Incorrect starting procedure.
No fuel.
Verify correct starting procedure.
Check fuel in tank and manual
shut-off valve.
Exhaust restricted.
Check and correct exhaust
restriction.
Fuel filter plugged or full of water.
Replace fuel filter or drain water
from filter.
Injection pump not getting fuel or air
in fuel system.
Check fuel flow at supply pump or
bleed fuel system.
Faulty injection pump or nozzles.
Engine starting under load.
Consult authorized diesel repair
station for repair or replacement.
Engine hard to start or will not
start
Remove load.
Improper starting procedure.
No fuel.
Review starting procedure.
Check fuel tank.
Air in fuel line.
Bleed fuel line.
Cold weather.
Use cold weather starting aids.
See “Starter Cranks Slowly”.
Use oil of correct viscosity.
Slow starter speed.
Crankcase oil too heavy.
Improper type of fuel.
Consult fuel supplier; use proper
type fuel for operating conditions.
Water, dirt or air in fuel system.
Clogged fuel filter.
Drain, flush, fill and bleed system.
Replace filter element.
Dirty or faulty injection nozzles.
Have authorized servicing dealer or
engine distributor check injectors.
Continued on next page
DPSG,CD03523,49 –19–10AUG99–1/5
55-1
112699
PN=70
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Troubleshooting
Symptom
Problem
Solution
Injection pump shut-off not reset.
Turn key switch to “OFF” then to
“ON”.
Engine knocks
Low engine oil level.
Add oil to engine crankcase.
Injection pump out of time.
See your authorized servicing dealer
or engine distributor.
Low coolant temperature.
Engine overheating.
Remove and check thermostat.
See “Engine Overheats”.
Engine runs irregularly or stalls
frequently
Low coolant temperature.
Remove and check thermostat.
Clogged fuel filter.
Replace fuel filter element.
Water, dirt or air in fuel system.
Dirty or faulty injection nozzles.
Drain, flush, fill and bleed system.
Have authorized servicing dealer or
engine distributor check injectors.
Below normal engine
temperature
Defective thermostat.
Remove and check thermostat.
Defective temperature gauge or
sender.
Check gauge, sender and
connections.
Lack of power
Engine overloaded.
Reduce load.
Intake air restriction.
Service air cleaner.
Replace filter element.
Use proper fuel.
Clogged fuel filter.
Improper type of fuel.
Overheated engine.
See “Engine Overheats”.
Remove and check thermostat.
Below normal engine temperature.
Improper valve clearance.
See your authorized servicing dealer
or engine distributor.
Dirty or faulty injection nozzles.
Have authorized servicing dealer or
engine distributor check injectors.
Continued on next page
DPSG,CD03523,49 –19–10AUG99–2/5
55-2
112699
PN=71
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Troubleshooting
Symptom
Problem
Solution
Injection pump out of time.
See your authorized servicing dealer
or engine distributor.
Turbocharger not functioning.
Leaking exhaust manifold gasket.
Defective aneroid control line.
See your authorized servicing dealer
or engine distributor.
See your authorized servicing dealer
or engine distributor.
See your authorized servicing dealer
or engine distributor.
Restricted fuel hose.
Low fast idle speed.
Clean or replace fuel hose.
See your authorized servicing dealer
or engine distributor.
Low oil pressure
Low oil level.
Add oil.
Improper type of oil.
Drain and fill crankcase with oil of
proper viscosity and quality.
High oil consumption
Crankcase oil too light.
Oil leaks.
Use oil of correct viscosity.
Check for leaks in lines, gaskets,
and drain plug.
Restricted crankcase vent tube.
Defective turbocharger.
Clean vent tube.
See your authorized servicing dealer
or engine distributor.
Engine emits white smoke
Improper type of fuel.
Use proper fuel.
Low engine temperature.
Warm up engine to normal operating
temperature.
Defective thermostat.
Remove and check thermostat.
Defective injection nozzles.
See your authorized servicing dealer
or engine distributor.
Engine out of time.
See your authorized servicing dealer
or engine distributor.
Continued on next page
DPSG,CD03523,49 –19–10AUG99–3/5
55-3
112699
PN=72
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Troubleshooting
Symptom
Problem
Solution
Engine emits black or grey
exhaust smoke
Improper type of fuel.
Use proper fuel.
Clogged or dirty air cleaner.
Engine overloaded.
Service air cleaner.
Reduce load.
Injection nozzles dirty.
See your authorized servicing dealer
or engine distributor.
Engine out of time.
See your authorized servicing dealer
or engine distributor.
Turbocharger not functioning.
See your authorized servicing dealer
or engine distributor.
Engine overheats
Engine overloaded.
Low coolant level.
Reduce load.
Fill radiator to proper level, check
radiator and hoses for loose
connections or leaks.
Faulty radiator cap.
Have serviceman check.
Stretched poly-vee belt or defective
belt tensioner.
Check automatic belt tensioner and
check belts for stretching. Replace
as required.
Low engine oil level.
Check oil level. Add oil as required.
Flush cooling system.
Cooling system needs flushing.
Defective thermostat.
Remove and check thermostat.
Defective temperature gauge or
sender.
Check coolant temperature with
thermometer and replace, if
necessary.
Incorrect grade of fuel.
Improper type of fuel.
Use correct grade of fuel.
Use proper type of fuel.
Service air cleaner.
High fuel consumption
Clogged or dirty air cleaner.
Continued on next page
DPSG,CD03523,49 –19–10AUG99–4/5
55-4
112699
PN=73
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Troubleshooting
Symptom
Problem
Solution
Engine overloaded.
Reduce load.
Improper valve clearance.
See your authorized servicing dealer
or engine distributor.
Injection nozzles dirty.
Engine out of time.
See your authorized servicing dealer
or engine distributor.
See your authorized servicing dealer
or engine distributor.
Defective turbocharger.
Low engine temperature.
See your authorized servicing dealer
or engine distributor.
Check thermostat.
DPSG,CD03523,49 –19–10AUG99–5/5
55-5
112699
PN=74
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Troubleshooting
ELECTRICAL TROUBLESHOOTING
Symptom
Problem
Solution
Undercharged system
Excessive electrical load from added Remove accessories or install higher
accessories.
output alternator.
Excessive engine idling.
Increase engine rpm when heavy
electrical load is used.
Poor electrical connections on
battery, ground strap, starter or
alternator.
Inspect and clean as necessary.
Defective battery.
Test battery.
Defective alternator.
Cracked battery case.
Test charging system.
Battery uses too much water
Check for moisture and replace as
necessary.
Defective battery.
Test battery.
Battery charging rate too high.
Loose or corroded connections.
Sulfated or worn-out battery.
Test charging system.
Clean and tighten connections.
Battery will not charge
See your authorized servicing dealer
or engine distributor.
Stretched poly-vee belt or defective
belt tensioner.
Adjust belt tension or replace belts.
Starter will not crank
Engine under load
Remove load
Loose or corroded connections.
Low battery output voltage.
Clean and tighten loose connections.
See your authorized servicing dealer
or engine distributor.
Faulty start circuit relay.
Blown fuse.
See your authorized servicing dealer
or engine distributor.
Replace fuse.
Continued on next page
DPSG,CD03523,50 –19–10AUG99–1/2
55-6
112699
PN=75
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Troubleshooting
Symptom
Problem
Solution
Starter cranks slowly
Low battery output.
See your authorized servicing dealer
or engine distributor.
Crankcase oil too heavy.
Use proper viscosity oil.
Loose or corroded connections.
Faulty battery connection.
Sulfated or worn-out battery.
Clean and tighten loose connections.
Clean and tighten connections.
Entire electrical system
See your authorized servicing dealer
or engine distributor.
Blown fuse.
Replace fuse.
DPSG,CD03523,50 –19–10AUG99–2/2
55-7
112699
PN=76
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Storage
ENGINE STORAGE GUIDELINES
1. John Deere engines can be stored outside for up to
three (3) months with no long term preparation IF
COVERED BY WATERPROOF COVERING.
MUST BE taken. (See PREPARING ENGINE FOR
LONG TERM STORAGE).
5. For John Deere engines not yet installed in
machines, run a line from a container of AR41937
Nucle Oil (from AR41785 Engine Storage Kit) to the
fuel transfer pump intake, and another line from the
fuel return manifold to the tank, so that Nucle Oil is
circulated through the injection system during
cranking.
2. John Deere engines can be stored in a standard
overseas shipping container for up to three (3)
months with no long term preparation.
3. John Deere engines can be stored inside,
warehoused, for up to six (6) months with no long
term preparation.
4. John Deere engines expected to be stored more
than six (6) months, long term storage preparation
DPSG,CD03523,51 –19–10AUG99–1/1
USE AR41785 ENGINE STORAGE KIT
See your John Deere servicing dealer or engine distributor
for an AR41785 Engine Storage Kit. Closely follow
instructions provided with this kit.
IMPORTANT: Inhibitors can easily change to gas.
Seal or tape each opening immediately
after adding inhibitor.
DPSG,CD03523,52 –19–10AUG99–1/1
60-1
112699
PN=77
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Storage
PREPARING ENGINE FOR LONG TERM STORAGE
The following storage preparations are good for long
term engine storage up to one year. After that, the
engine should be started, warmed up, and retreated
for an extended storage period.
5. Add 30 ml (1 oz) of inhibitor to the engine
crankcase for each 0.95 L (1 qt) of crankcase oil.
6. Disconnect air intake piping from the manifold. Pour
90 ml (3 oz) of inhibitor into intake system and
reconnect the piping.
IMPORTANT: Any time your engine will not be
used for over six (6) months, the
following recommendations for
storing it and removing it from
storage will help to minimize
7. Crank the engine several revolutions with starter
(do not allow the engine to start).
corrosion and deterioration. Use the
AR41785 Engine Storage Kit. Follow
recommended service procedure
included with storage kit.
8. Remove fan/alternator belt, if desired.
9. Remove and clean battery. Store them in a cool,
dry place and keep them fully charged.
1. Change engine oil and replace filter. Used oil will
not give adequate protection. (See CHANGING
ENGINE OIL AND FILTER).
10. Clean the exterior of the engine with salt-free
water and touchup any scratched or chipped
painted surfaces with a good quality paint.
2. Service air cleaner. (See CLEAN OR REPLACE
AIR FILTER).
11. Coat all exposed (machined) metal surfaces with
grease or corrosion inhibitor if not feasible to paint.
3. Draining and flushing of cooling system is not
necessary if engine is to be stored only for several
months. However, for extended storage periods of a
year or longer, it is recommended that the cooling
system be drained, flushed, and refilled. Refill with
appropriate coolant. (See DIESEL ENGINE
COOLANT).
12. Seal all openings on engine with plastic bags and
tape supplied in storage kit. Follow instructions
supplied in kit.
13. Store the engine in a dry protected place. If
engine must be stored outside, cover it with a
waterproof canvas or other suitable protective
material and use a strong waterproof tape.
4. Drain fuel tank and add 30 ml (1 oz) of inhibitor to
the fuel tank for each 15 L (4 U.S. gal) of tank
capacity. Completely drain fuel filter and close fuel
valve, if equipped.
DPSG,CD03523,53 –19–10AUG99–1/1
60-2
112699
PN=78
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Storage
REMOVING ENGINE FROM LONG TERM STORAGE
Refer to the appropriate section for detailed services
listed below or have your authorized servicing dealer
or engine distributor perform services that you may not
be familiar with.
IMPORTANT: DO NOT operate starter more than
30 seconds at a time. Wait at least 2
minutes for starter to cool before
trying again.
1. Remove all protective coverings from engine.
Unseal all openings in engine and remove covering
from electrical systems.
6. Crank engine for 20 seconds with starter (do not
allow the engine to start). Wait 2 minutes and crank
engine an additional 20 seconds to assure bearing
surfaces are adequately lubricated.
2. Remove the battery from storage. Install battery
(fully charged) and connect the terminals.
7. Start engine and run at no load for several minutes.
Warm up carefully and check all gauges before
placing engine under load.
3. Install fan/alternator belt if removed.
4. Fill fuel tank.
8. On the first day of operation after storage, check
overall engine for leaks and check all gauges for
correct operation.
5. Perform all appropriate prestarting checks. (See
DAILY PRESTARTING CHECKS).
DPSG,CD03523,54 –19–10AUG99–1/1
60-3
112699
PN=79
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Specifications
GENERAL ENGINE SPECIFICATIONS
ITEM
UNIT OF MEASURE 3029DF128
4039DF008
4039TF008
Number of Cylinders
Fuel
3
4
4
Diesel
Diesel
Diesel
Bore
mm
mm
L
106.5
110
106.5
110
106.5
110
Stroke
Displacement
Compression Ratio
2.9
3.9
3.9
17.8:1
26 (35)
17.8:1
35 (48)
17.8:1
55 (75)
POWERa @
1500 rpm (Prime)
kW (hp)
kW (hp)
kW (hp)
kW (hp)
POWERa @
1500 rpm (Standby)
30 (41)
30 (41)
34 (46)
38 (52)
41 (56)
47 (64)
61 (83)
67 (91)
73 (99)
POWERa @
1800 rpm (Prime)
POWERa @
1800 rpm (Standby)
Width (overall)
Length (overall)
Height (overall)
Weight (dry)b
mm
mm
mm
kg
582
888
931
345
6
588
1016
960
410
12
588
1016
979
455
12
Engine oil quantity
L
Engine coolant
quantity
L
14.5
16.5
16.5
aWith Fan
bApproximate
Continued on next page
DPSG,CD03523,55 –19–10AUG99–1/3
65-1
112699
PN=80
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Specifications
ITEM
UNIT OF MEASURE 4045HF158
4045TF158
4045TF258
4045DF158
4
Number of Cylinders
Fuel
4
4
4
Diesel
Diesel
106.5
127
Diesel
Diesel
106.5
127
Bore
mm
mm
L
106.5
127
106.5
127
Stroke
Displacement
Compression Ratio
4.5
4.5
4.5
4.5
17.0:1
88 (120)
17.0:1
61 (83)
17.0:1
72 (98)
17.6:1
41 (56)
POWERa @
1500 rpm (Prime)
kW (hp)
kW (hp)
kW (hp)
kW (hp)
POWERa @
1500 rpm (Standby)
96 (131)
108 (147)
120 (163)
68 (92)
72 (98)
79 (107)
80 (109)
80 (109)
88 (120)
42 (57)
48 (65)
51 (69)
POWERa @
1800 rpm (Prime)
POWERa @
1800 rpm (Standby)
Width (overall)
Length (overall)
Height (overall)
Weight (dry)b
mm
mm
mm
kg
798
1356
1136
446
12
668
1219
1010
436
12
668
1219
1010
436
12
668
1219
1010
391
8
Engine oil quantity
L
Engine coolant
quantity
L
25
25
25
20
aWith Fan
bApproximate
Continued on next page
DPSG,CD03523,55 –19–10AUG99–2/3
65-2
112699
PN=81
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Specifications
ITEM
UNIT OF
6068HF158
6068TF158
6068TF258
MEASURE
Number of Cylinders
Fuel
6
6
6
Diesel
Diesel
106.5
127
Diesel
Bore
mm
106.5
127
106.5
127
Stroke
mm
L
Displacement
Compression Ratio
6.8
6.8
6.8
17.0:1
134 (182)
17.0:1
92 (125)
17.0:1
105 (143)
POWERa @ 1500 rpm
(Prime)
kW (hp)
kW (hp)
kW (hp)
kW (hp)
POWERa @ 1500 rpm
(Standby)
148 (201)
164 (223)
187 (254)
101 (137)
108 (147)
119 (162)
116 (158)
124 (169)
137 (186)
POWERa @ 1800 rpm
(Prime)
POWERa @1800 rpm
(Standby)
Width (overall)
Length (overall)
Height (overall)
Weight (dry)b
mm
mm
mm
kg
798
1476
1136
613
668
1383
1032
593
668
1383
1032
593
Engine oil quantity
L
19.5
29
19.5
26
19.5
26
Engine coolant
quantity
L
aWith Fan
bApproximate
DPSG,CD03523,55 –19–10AUG99–3/3
65-3
112699
PN=82
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Specifications
UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUES
DX,TORQ1 –19–20JUL94–1/1
112699
65-4
PN=83
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Specifications
METRIC BOLT AND CAP SCREW TORQUE VALUES
DX,TORQ2 –19–20JUL94–1/1
112699
65-5
PN=84
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Index
Page
Page
A
Fuel system
Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-6
Fuel
Air filter
Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Handling and storing. . . . . . . . . . . . . . . . . . . . 10-1
Clean or replace (one-piece). . . . . . . . . . . . . . 50-2
Clean or replace element . . . . . . . . . . . . . . . . 50-3
Air intake system
Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-1
I
B
Identification views, . . . . . . . . . . . . . . . . . . . . . . 01-1
Inch torque values . . . . . . . . . . . . . . . . . . . . . . . 65-4
Belt
Check automatic tensioner . . . . . . . . . . . . . . . 35-2
Check tension. . . . . . . . . . . . . . . . . . . . . . . . . 30-4
Replace (POWERTech) . . . . . . . . . . . . . . . . . 50-4
Break-in engine oil . . . . . . . . . . . . . . . . . . . . . . . 10-2
L
Lubricant
Mixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
C
Coolant
Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Drain and flush cooling system . . . . . . . . . . . . 45-1
Warm temperature climates . . . . . . . . . . . . . . 10-5
Crankcase vent tube
M
Maintenance records . . . . . . . . . . . . . . . . . . . . . 02-1
Maintenance
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . .03-1, 35-1
1000 hours/1 year
Check and adjust valve clearance
(300-Series) . . . . . . . . . . . . . . . . . . . . . . . 35-3
Checking air intake system . . . . . . . . . . . . . 35-1
Checking automatic belt tensioner
D
(POWERTech) . . . . . . . . . . . . . . . . . . . . . 35-2
Cleaning crankcase vent tube . . . . . . .03-1, 35-1
2000 hours/2 years
Adjust speed droop governor. . . . . . . . . . . . 40-3
Adjust valve clearance (POWERTech) . . . . 40-1
Check engine speed . . . . . . . . . . . . . . . . . . 40-3
Damper check . . . . . . . . . . . . . . . . . . . . . . . 40-4
2500 hours/3 years
Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-4
Diesel engine oil. . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
E
Drain and flush cooling system . . . . . . . . . . 45-1
50 hours/2 weeks
Checking fuel filter. . . . . . . . . . . . . . . . . . . . 50-5
500 hours
Changing engine oil and filter . . . . . . . . . . . 30-1
Checking belt. . . . . . . . . . . . . . . . . . . . . . . . 30-4
Replace fuel filter. . . . . . . . . . . . . . . . . . . . . 30-3
As required
Engine oil
Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
Engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-3
F
Additional service information . . . . . . . . . . . 50-1
Clean or replace air filter (one-piece). . . . . . 50-2
Clean or replace air filter element . . . . . . . . 50-3
Do not modify fuel system . . . . . . . . . . . . . . 50-1
Fuel filter
Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . 30-3
Index-1
112699
PN=1
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Index
Page
Page
Replace fan and alternator belts
V
(POWERTech) . . . . . . . . . . . . . . . . . . . . . 50-4
Daily or every 10 hours. . . . . . . . . . . . . . . . . . 25-1
Observe service intervals . . . . . . . . . . . . . . . . 20-1
Use correct fuel, lubricant and coolant . . . . . . 20-1
Metric torque values . . . . . . . . . . . . . . . . . . . . . . 65-5
Mixing lubricants. . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Valve clearance
Adjust (300-Series) . . . . . . . . . . . . . . . . . . . . . 35-3
Adjust (POWERTech) . . . . . . . . . . . . . . . . . . . 40-1
O
Operating the engine
Break-in period . . . . . . . . . . . . . . . . . . . . . . . . 15-1
Engine operation. . . . . . . . . . . . . . . . . . . . . . . 15-4
Standby power units . . . . . . . . . . . . . . . . . . . . 15-4
Starting the engine . . . . . . . . . . . . . . . . . . . . . 15-1
Stopping the engine . . . . . . . . . . . . . . . . . . . . 15-5
Using a booster battery or charger . . . . . . . . . 15-3
R
Record keeping
Engine option codes . . . . . . . . . . . . . . . . . . . . 03-3
Engine serial number plate . . . . . . . . . . . . . . . 03-1
POWERTech medallion . . . . . . . . . . . . . . . . . 03-1
Record engine serial number . . . . . . . . . . . . . 03-2
Record fuel injection pump model number . . . 03-5
S
Specifications
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65-1
Storage
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-1
Storing fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Storing lubricants . . . . . . . . . . . . . . . . . . . . . . . . 10-3
T
Torque values
Inch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65-4
Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65-5
Troubleshooting
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-6
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-1
Index-2
112699
PN=2
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