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PowerTec OMRG25204 User's Manual

1. Ethylene Glycol Freeze Protection Limit 40 24 C 12 F 50 37 C 34 F 60 52 C 62 F Propylene Glycol Freeze Protection Limit 40 21 C 6 F 50 33 C 27 F 60 49 C 56 F DX COOL7 19 19DEC03 2 2 Supplemental Coolant Additives The concentration of coolant additives is gradually depleted during engine operation For all recommended coolants replenish additives between drain intervals by adding a supplemental coolant additive every 12 months or as determined necessary by coolant testing John Deere COOLANT CONDITIONER is recommended as a supplemental coolant additive in John Deere engines IMPORTANT Do not add a supplemenial coolant additive when the cooling system is drained and refilled with John DeereCOOL GARD COOL GARD is a trademark of Deere amp Company If other coolants are used consult the coolant supplier and follow the manufacturer s recommendation for use of supplemental coolant additives The use of non recommended supplemental coolant additives may result in additive drop out and gelation of the coolant Add the manufacturer s recommended concentration of supplemental coolant additive DO NOT add more than the recommended amount DX COOL4 19 07NOV03 1 1 1 0 1 5 110306 PN 41 Fuels Lubricants and Coolant Additives Engine coolants are a combination of three chemical components ethylene glycol or propy
2. OURGP12 0000041 _ 19 18OCT06 1 1 60 1 110306 PN 136 Specifications General OEM Engine Specifications 6 8 L Engines ITEM ENGINE 6068DF150 6068TF120 6068TF150 6068TF220 6068TF250 6068HF120 6068HF150 6068HF250 Number of Cylinders 6 6 6 6 6 6 6 6 Bore 106 mm 106 mm 106 mm 106 mm 106 mm 106 mm 106 mm 106 mm 4 19 in 4 19 in 4 19 in 4 19 in 4 19 in 4 19 in 4 19 in 4 19 in Stroke 127 mm 127 mm 127 mm 127 mm 127 mm 127 mm 127 mm 127 mm 5 0 in 5 0 in 5 0 in 5 0 in 5 0 in 5 0 in 5 0 in 5 0 in Displacement 6 8L 6 8L 6 8L 6 8L 6 8L 6 8L 6 8L 6 8L 414 cu in 414 cu in 414 cu in 414 cu in 414 cu in 414 cu in 414 cu in 414 cu in Compression 176 1 17 0 1 17 0 1 17 011 17 011 17 0 1 17 0 1 17 0 Max Crank Pressure 0 5 kPa 0 5 kPa 0 5 kPa 0 5 kPa 0 5 kPa 0 5 kPa 0 5 kPa 0 5 kPa 2 H20 2 H20 2 H20 2 H20 2 H20 2 H20 2 H20 2 H20 Governor Regulation 7 10 N A 7 10 7 10 7 10 N A 7 10 7 10 Industrial Governor Regulation 5 5 5 5 5 5 5 5 Generator Oil Pressure At Rated 345 kPa 345 kPa 50 345 kPa 345 kPa 345 kPa 345 kPa 345 kPa 345 kPa Speed Full Load 15 50 psi psi 50 psi 50 psi 50 psi 50 psi 50 psi 50 psi psi Oil Pressure At Low Idle 105 kPa 105 kPa 15 105 kPa 105 kPa 105 kPa 105 kPa 105 kPa
3. Engine Wiring Diagram VDO Instrument Panel Except North America Zesrenesergerresrerereessnd UN 13NOV98 D623P5 DPSG RG41 165931 19 19JUN00 1 1 50 5 110306 PN 124 Troubleshooting Engine Wiring Diagram Legend VDO Instrument Panel Except North America A 6 mm Red B 1 5 mm Black C 6 mm Blue D 4 mm Black E 0 75 mm Orange F 0 75 mm White G 0 75 mm Blue H 0 75 mm Purple I 0 75 mm Grey J 0 75 mm Brown K 0 75 mm Dark Blue L 0 75 mm Black M 0 75 mm Green Yellow N 0 75 mm Red O R Not Used S Preheater T Battery U Starter Motor V Electrical Shut Off W Alternator X Oil Pressure Sensor Y Coolant Temperature Sensor Z Fuel Tank Gauge DPSG RG41165 129 19 19JUN00 1 1 50 6 110306 PN 125 Troubleshooting Engine Troubleshooting Symptom Problem Solution Engine cranks but will not start Incorrect starting procedure Verify correct starting procedure No fuel Check fuel in tank and manual shut off valve Exhaust restricted Check and correct exhaust restriction Fuel filter plugged or full of water Replace fuel filter or drain water from filter Injection pump not getting fuel or air Check fuel flow at supply pump or in fuel system bleed fuel system Faulty injection pump or nozzles Consult authorized diesel repair station for repair o
4. 65 4 Service as Required ssunaa aeaaea 65 5 Emission System Warranty U S EPA Emissions Control Warranty EE SEENEN 70 1 Emissions Control System Certification Label 70 1 110306 PN 2 Record Keeping POWERTECH Medallion A medallion is located on the rocker arm cover which identifies each engine as a John Deere POWERTECH engine POWERIECH 4 5 liter RG11608 UN 170CT01 POWERIECH 6 8 liter RG11609 UN 170CT01 POWERTECH is a trademark of Deere amp Company RG RG34710 5505 19 04JAN02 1 1 Engine Serial Number Plate Each engine has a 13 digit John Deere engine serial number The first two digits identify the factory that produced the engine TO indicates the engine was built in Dubuque lowa CD indicates the engine was built in Saran France PE indicates the engine was built in Torreon Mexico JO indicates the engine was built in Rosario Argentina Your engine s serial number plate A is located on the Se right hand side of cylinder block behind the fuel filter 13 Digit Engine Serial Number Plate RG8007 UN 15JAN99 RG RG34710 5506 19 04JAN02 1 1 01 1 110306 PN 9 Record Keeping Record Engine Serial Number JOHN DEERE Record all of the numbers and letters found on your Engine Serial Number engine serial number plate in the spaces provided below T040457 123456 This information is very important f
5. 19 07JAN02 1 2 15 10 110306 PN 54 Engine Operating Guidelines NOTE Electronically controlled governor applications may be equipped with a rotary speed potentiometer on the throttle A on the instrument panel 4 On mechanical governor 7 10 regulation engines pull hand throttle A 1 3 of the way out Turn the handle in either direction to lock it in place 5 If equipped depress and hold reset button B while starting IMPORTANT Do not operate the starter for more than 30 seconds at a time To do so may overheat the starter If the engine does not start the first time wait at least 2 minutes before trying again If engine does not start after four attempts see Troubleshooting Section 6 Turn the key switch C clockwise to crank the engine When the engine starts release the key so that it returns to the ON position IMPORTANT If the key switch is released before the engine starts wait until the starter and the engine stop turning before trying again This will prevent possible damage to the starter and or flywheel 7 After the engine starts continue to hold the reset button in until the oil pressure gauge D reads at least 105 kPa 1 05 bar 15 psi The safety controls will not allow the engine to run at a lower oil pressure unless the reset button is held in IMPORTANT Should the engine die when operating under load immediately disengage PTO clutch and restart the engine Overh
6. 35 6 EE see nnn EE 15 15 Belts fan and alternator Operation EE ECKER ECKE 15 13 Replacing 0 00 c eee eee eee 45 8 Option COURS ye cd viata ae hate ha de tees 01 3 Bleeding fuel system 45 11 Power EM ge sae rere era rn ee raed 60 3 Breakin engine ol 10 6 Serial EE een deen asks den sg 01 1 EE 15 6 SC ee es ee ee eee 15 10 Burner EE 10 4 lU 15 16 Troubleshooting 50 7 Warming cscs ere 15 12 Engine coolant c Disposing of 10 18 o Engine mounts Chart service interval SEELEN EE 20 2 20 4 Checking cece eeeeeeeeeee 30 4 Check engine electrical ground 35 9 Engine oil Cold weather aide 15 14 Break In ccc ccc LLL 10 6 COMpICSSON Gif rasie e Eer Eer e a ih 45 10 Change 30 2 Coolant iC a ee Teer err errr ers 10 7 Adding 1 seen teen ete 45 2 Engine speed changing 15 15 Additional information 10 14 10 16 Diesel engine 10 12 DISPOSING EE 10 18 Replenishing supplemental additives 35 11 F Supplemental additives 10 15 TOSUNG Ne ea Ar waked 10 17 35 12 Fan belts 1 4 sacs aiia atari an 45 8 Warm temperature climates 10 18 Filter replace Cooling system Fuel entire hee ee EE 35 3 Adding coolant 00000 45 2 EIN 30 2 Index 1 110306 PN 1 Index Page Page Fire extinguisher service 30 1 L Fuel NIE Ee 10 4 Lubricant Elte TEE 10 4 MIXING EE 10 8 Di Sel ons seed ee ee ee eee 10
7. Continued on next page OURGP12 0000048 19 130CT06 1 4 25 1 110306 PN 68 Lubrication amp Maintenance Daily A 2 Check the coolant level when engine is cold Coolant level should be at bottom of filler neck Fill radiator A with proper coolant solution if level is low See CAUTION Explosive release of fluids from pressurized cooling system can cause serious burns Only remove filler cap when engine is cold or when cool enough to touch with bare hands Slowly loosen cap to first stop to relieve pressure before removing completely ADDING COOLANT in Service As Required Section Check overall cooling system for leaks NOTE Refer to your vehicle s operator s manual for recommendations for non John Deere supplied accessories A Fill Radiator Fill Radiator Continued on next page TS281 UN 23AUG88 RG4675 UN 14DEC88 OURGP12 0000048 19 130CT06 2 4 25 2 110306 PN 69 Lubrication amp Maintenance Daily 3 Check the single or dual fuel filters for water or debris If filter is fitted with a see through water separator bowl drain as needed based on a daily visual inspection IMPORTANT Drain water into a suitable container and dispose of properly a Loosen drain plugs B at bottom of each fuel filter or bowl if equipped two or three turns RG13542 UN 20JUL04 b Loosen air bleed plugs A two full turns on fuel filter
8. 15 15 Avoid Excessive Engine Idling 15 15 Stopping the Engine 15 16 Using a Booster Battery or Charger 15 17 Lubrication and Maintenance Observe Service Intervals 20 1 Use Correct Fuels Lubricants and Coolant 20 1 Lubrication and Maintenance Service Interval Chart Standard Industrial Engines 20 2 Lubrication and Maintenance Service Interval Chart Generator Standby Applications 20 4 Lubrication amp Maintenance Daily Daily Prestarting Checks 25 1 Lubrication amp Maintenance 250 Hour 6 Month Servicing Fire Extinguisher 30 1 Changing Engine Oil and Replacing Filter 30 2 Checking Engine Mounts 30 4 Servicing Battery 30 5 Manual Belt Tensioner Adjustment 30 7 Manual Belt Tensioner Adjustment Using Belt Tension Tool Alternate Method For Engines Without Auxiliary Drive 30 8 Lubrication amp Maintenance 500 Hour 12 Month Cleaning Crankcase Vent Tube 35 1 Checking Air Intake System 35 2 Replacing Fuel Filter Element Single Filter 35 3 Continued on next page All information illustrations and specifications in this manual are based on the latest information available at the time of publication The right is reserved to make changes at any time without notice COPYRIGHT 2006 DEERE amp COMPANY Moline Illinois All rights
9. 19 07JAN02 1 1 Avoid Excessive Engine Idling Prolonged idling may cause the engine coolant speed Slow idle speed for this engine is 850 rpm at temperature to fall below its normal range This in factory If an engine will be idling for more than 5 turn causes crankcase oil dilution due to incomplete minutes stop and restart later fuel combustion and permits formation of gummy deposits on valves pistons and piston rings It also NOTE Generator set applications where the governor promotes rapid accumulation of engine sludge and is locked at a specified speed may not have a unburned fuel in the exhaust system slow idle function These engines will idle at no load governed speed high idle Once an engine is warmed to normal operating temperatures engine should be idled at slow idle RG RG34710 5562 19 27JULO6 1 1 15 15 110306 PN 59 Engine Operating Guidelines Stopping the Engine 1 Disengage clutch if equipped controlling engine drivelines 2 Move the throttle A to slow idle on standard mechanical governor engines IMPORTANT Before stopping an engine that has been operating at working load idle engine at least 2 minutes at 1000 1200 rpm to cool hot engine parts For engines in generator set applications where the governor is locked at a specified speed and no slow idle function is available run engine for at least 2 minutes at fast idle and no load RG11299J UN
10. 90 C 195 F 92 C 197 F 96 C 205 F 99 C 210 F Initial Opening Range 69 72 C 156 162 F 74 78 C 166 172 F 80 84 C 175 182 F 86 90 C 187 194 F 89 93 C 192 199 F 89 93 C 193 200 F 94 97 C 201 207 F 96 100 C 205 212 F THERMOSTAT TEST SPECIFICATIONS Full Open Nominal 84 C 182 F 89 C 192 F 94 C 202 F 101 C 214 F 103 C 218 F 105 C 221 F 100 C 213 F 111 C 232 F Testing Thermostat Opening Temperature 5 Remove thermostat and observe its closing action as it cools In ambient air the thermostat should close completely Closing action should be smooth and slow 6 Replace any defective thermostat On a dual thermostat engine replace both thermostats Continued on next page RG5971 UN 23NOV97 DPSG RG34710 112 _ 19 07JAN02 3 5 40 8 110306 PN 101 Lubrication amp Maint 2000 Hour 24 Month To Install Thermostats IMPORTANT Install manifold gasket so that smaller round holes are at lower left and upper right corners of manifold matching studs A 1 Clean all gasket material from thermostat cover and housing mounting surfaces 2 Using guide studs A to keep gasket in place install a new gasket on cylinder head 3 Install thermostat s with jiggle wire facing up in the 12 o clock position 4 Using a screwdriver to hold thermostat s in place install thermosta
11. amp 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 accidentally burst when heat goes beyond the immediate flame area TS953 UN 15MAY90 DX TORCH 19 10DEC04 1 1 05 7 110306 PN 20 Safety Remove Paint Before Welding or Heating Avoid potentially toxic fumes and dust Hazardous fumes can be generated when paint is heated by welding soldering or using a torch Remove paint before heating e Remove paint a minimum of 100 mm 4 in from area to be affected by heating If paint cannot be removed wear an approved respirator before heating or welding If you sand or grind paint avoid breathing the dust Wear an approved respirator e f you use solvent or paint stripper remove stripper with soap and water before welding Remove solvent or paint stripper containers and other flammable material from area Allow fumes to disperse at least 15 minutes before welding or heating Do not use a chlorinated solvent in areas where welding will take place Do all work in an area that is well ventilated to carry toxic fumes and dust away Dispose of paint and s
12. 1560 155 208 6068HF158 16GT RE503051 3 5 1500 1560 155 208 16LY RE503836 3 5 1500 1560 155 208 16ML RE503746 3 5 1800 1400 1870 187 251 16MM RE504702 RE505049 3 5 1800 1400 1870 187 251 16MM RERE505049 3 5 1800 1400 1870 187 251 6068HF250 1622 RE595212 STD 2400 850 2600 168 225 1623 RE667612 3 5 1800 1870 148 198 16TV RE506398 STD 2400 800 2550 168 225 16YH RE59969 STD 2400 850 2600 138 185 6068HF252 169A RE522694 3 5 3000 850 3120 225 302 168Z RE522415 3 5 3000 850 3120 225 302 6068HF254 3 5 2800 850 3000 226 303 3 5 2800 850 3000 184 247 6068HF258 16TM 12V RE506885 3 5 1800 1870 210 282 16TN 24V RE506886 3 5 1800 1870 210 282 16TP 12V RE506883 3 5 1500 1560 183 245 16TQ 24V RE506884 3 5 1500 1560 183 245 6068TF120 16MX RE503740 3 5 1500 1400 1560 105 141 aln line fuel injection pump Continued on next page 60 8 OURGP11 000001D _ 19 130CT06 6 9 110306 PN 143 Specifications POWER RATINGS ON DYNAMOMETER FOR OEM ENGINES Injection Original Replaced Pump Injection By Injection Rated No Load Power Option Pump Part Pump Part Governor Speed rpm Slow Idle Fast Idle Rating Engine Model Code No No Regulation At Full Load rpm rpm kW HP 16MY RE505052 3 5
13. C 9 F below the expected low temperature Fuel lubricity should pass a minimum level of 3100 grams as measured by ASTM D6078 or maximum scar diameter of 0 45 mm as measured by ASTM D6079 or ISO 12156 1 Sulfur content IMPORTANT Do not mix used diesel engine oil or IMPORTANT Improper fuel additive usage may Diesel fuel quality and fuel sulfur content must comply with all existing emissions regulations for the area in which the engine operates Use of diesel fuel with sulfur content less than 0 10 1000 ppm is STRONGLY recommended Use of diesel fuel with sulfur content 0 10 1000 ppm to 0 50 5000 ppm may result in REDUCED oil and filter change intervals BEFORE using diesel fuel with sulfur content greater than 0 50 5000 ppm contact your John Deere dealer DO NOT use diesel fuel with sulfur content greater than 1 0 any other type of lubricating oil with diesel fuel cause damage on fuel injection equipment of diesel engines DX FUEL1 _ 19 17NOV05 1 1 Lubricity of Diesel Fuel Most diesel fuels manufactured in the United States Canada and the European Union have adequate lubricity to ensure proper operation and durability of fuel injection system components However diesel fuels manufactured in some areas of the world may lack the necessary lubricity IMPORTANT Make sure the diesel fuel used in your machine demonstrates good lubricity characteristics 10 1 Fuel lubricity should
14. PN 139 Specifications POWER RATINGS ON DYNAMOMETER FOR OEM ENGINES Injection Original Replaced Pump Injection By Injection Rated No Load Power Option Pump Part Pump Part Governor Speed rpm Slow Idle Fast Idle Rating Engine Model Code No No Regulation At Full Load rpm rpm kW HP 4045HF158 16GR RE503050 3 5 1500 1150 1560 100 134 16LW RE503832 3 5 1500 1150 1560 100 134 16ME RE503739 3 5 1800 1400 1870 123 165 16MF RE504698 RE504966 3 5 1800 1400 1870 123 170 16MF RE504966 3 5 1800 1400 1870 123 170 4045HF252 RE522414 3 5 3000 850 3120 125 168 RE522698 3 5 3000 850 3120 125 168 169E RE522414 3 5 3000 850 3120 152 204 169F RE522698 3 5 3000 850 3120 152 204 4045TF120 16MT RE503733 RE505989 3 5 1500 1400 1560 70 94 16MT RE506989 3 5 1500 1400 1560 0 94 16MU RE505050 RE506990 3 5 1500 1400 1560 0 94 16MU RE506990 3 5 1500 1400 1560 0 94 16ZW RE509527 3 5 1500 1400 1560 0 94 16ZX RE509528 3 5 1500 1400 1560 0 94 16ZY RE509529 3 5 1500 1400 1560 0 94 165D RE506989 3 5 1500 1560 0 94 165E RE506990 3 5 1500 1560 0 94 4045TF150 1605 RE61668 RE69781 STD 2500 850 2700 6 115 1605 RE69781 STD 2500 850 2700 6 115 1606 RE64133 RE505927 STD 2400 850 2600 3 125 1606 RE505927 STD 2400 850 2600 3 125 1656 R
15. T6829AB UN 180CT88 DX OILSCAN _ 19 02DEC02 1 1 Alternative and Synthetic Lubricants Conditions in certain geographical areas may require lubricant recommendations different from those printed in this manual Some John Deere brand coolants and lubricants may not be available in your location Consult your John Deere dealer to obtain information and recommendations Synthetic lubricants may be used if they meet the performance requirements as shown in this manual The temperature limits and service intervals shown in this manual apply to both conventional and synthetic oils Re refined base stock products may be used if the finished lubricant meets the performance requirements DX ALTER _ 19 15JUN00 1 1 10 9 110306 PN 35 Fuels Lubricants and Coolant Lubricant Storage Your equipment can operate at top efficiency only when clean lubricants are used Use clean containers to handle all lubricants Whenever possible store lubricants and containers in an area protected from dust moisture and other contamination Store containers on their side to avoid water and dirt accumulation Make certain that all containers are properly marked to identify their contents Properly dispose of all old containers and any residual lubricant they may contain DX LUBST 19 18MAR96 1 1 Oil Filters Filtration of oils is critical to proper operation and lubrication Always change
16. replenished as needed by adding a supplemental coolant additive the flushing interval may be extended to 5000 hours or 60 months whichever occurs first RG RG34710 5625 19 20MAY96 1 1 65 4 110306 PN 155 Lubrication and Maintenance Records Service as Required Add coolant Service air cleaner Replace poly vee belts Check fuses Check air compressor if equipped Bleed fuel system Hours Date Hours Date Hours Date Hours Date Hours Date Hours Date Hours Date Hours Date OURGP12 0000045 19 07JUL04 1 1 65 5 110306 PN 156 Emission System Warranty U S EPA Emissions Control Warranty Statement Emissions control related parts and components are warranted by John Deere for five years or 3000 hours of operation whichever occurs first John Deere further warrants that the engine covered by this warranty was designed built and equipped so as to conform at the time of sale with all U S emissions standards at the time of manufacture and that it is free of defects in materials and workmanship which would cause it not to meet these standards within the period of five years or 3000 hours of operation whichever occurs first Warranties stated in this manual refer only to emissions related parts and components of your engine The complete engine warranty less emis
17. 105 kPa Minimum 15 psi psi 15 psi 15 psi 15 psi 15 psi 15 psi 15 psi Length 1117 mm 1117 mm 1117 mm 1116 mm 1117 mm 1141 mm 1116 mm 1141 mm 44 0 in 44 0 in 44 0 in 43 9 in 44 0 in 44 9 in 43 9 in 44 9 in Width 598 mm 598 mm 598 mm 623 mm 598 mm 623 mm 623 mm 623 mm 23 5 in 23 5 in 23 5 in 24 5 in 23 5 in 24 5 in 24 5 in 24 5 in Height 956 mm 984 mm 984 mm 1012 mm 984 mm 1009 mm 1009 mm 1009 mm 37 6 in 38 7 in 38 7 in 39 9 in 38 7 in 39 7 in 39 7 in 39 7 in Weight 522 kg 533 kg 533 kg 551 kg 533 kg 568 kg 550 kg 568 kg 1149 Ib 1172 Ib 1172 Ib 1212 Ib 1172 Ib 1250 Ib 1210 Ib 1250 Ib NOTE Engine models listed with numbers ending in 120 and 220 are emission non certified Engines with model numbers ending in 150 and 250 are Tier 1 emission certified Later engines with model numbers ending in 270 275 or 475 are Tier 2 emission certified with mechanical or electronic fuel systems and are covered in another manual OMRG33324 OURGP12 0000042 19 07JUL04 1 1 60 2 110306 PN 137 Specifications NOTE The power specifications shown below apply to Dubuque Torreon and Saran built OEM engines Specifications are subject to change Refer to factory DTAC for assistance Engine speeds listed are as preset to factory specification In most cases slow idle speed will be reset depending upon specifi
18. 1150 1870 75 100 16LZ RE503735 3 5 1800 1400 1870 70 94 16MA RE504696 RE504931 3 5 1800 1400 1870 82 110 16MA RE504931 3 5 1800 1400 1870 82 110 16MT RE503733 RE505050 3 5 1500 1400 1560 70 94 16MT RE505050 3 5 1500 1400 1560 70 94 16MU RE504695 RE505050 3 5 1500 1400 1560 70 94 16MU RE505050 RE506990 3 5 1500 1400 1560 70 94 16MU RE506990 3 5 1500 1400 1560 70 94 16TG RE507941 STD 2000 850 2185 77 103 16YJ RE508834 STD 2000 850 2185 77 103 16YU RE508754 3 5 1800 1870 75 101 16ZC RE518780 STD 2200 950 2400 66 89 4045TF151 1677 RE60096 RE67563 3 5 1800 850 1870 75 100 1677 RE67563 3 5 1800 850 1870 75 100 16CU RE501192 STD 2200 850 2400 79 5 107 16NH RE505411 3 5 1800 1150 2240 75 100 4045TF152 16AX RE500551 STD 2400 850 2600 76 102 4045TF154 1605 RE69781 STD 2500 850 2700 86 115 4045TF155 16AX RE500551 STD 2400 850 2600 76 102 16JT RE500551 STD 2400 850 2600 76 102 4045TF157 16GQ RE503048 3 5 1500 1560 83 111 16LV RE503830 3 5 1500 1560 83 111 4045TF158 16GQ RE503048 3 5 1500 1560 83 111 16LZ RE503735 3 5 1800 1870 82 110 16MA RE504696 3 5 1800 1870 82 110 16MT RE503733 RE506989 3 5 1500 1560 70 94 16MT RE506989 3 5 1500 1560 70 94 16MU RE504695 RE505050 3 5 1500 1560 70 94 16MU RE505050 RE506990 3 5 1500 1560 70 94 16MU RE506990 3 5 1500 1560 70 94 4045TF161 16PZ RE500848 STD 2200
19. 11SEP00 3 Turn key switch B to OFF position to stop the North American Standard Instrument Panel Shown engine Remove ignition key IMPORTANT Make sure that exhaust stack cap rain cap is installed when engine is not running This will prevent water and dirt from entering engine A Throttle B Key Switch RG10616 UN 16JUN00 Exhaust Stack Rain Cap RG RG34710 5563 19 07JAN02 1 1 15 16 110306 PN 60 Engine Operating Guidelines Using a Booster Battery or Charger A 12 volt booster battery can be connected in parallel with battery ies on the unit to aid in cold weather starting ALWAYS use heavy duty jumper cables A CAUTION Gas given off by battery is explosive Keep sparks and flames away from battery Before connecting or disconnecting a battery charger turn charger off Make last connection and first disconnection at a point away from battery Always connect NEGATIVE cable last and disconnect this cable first WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling IMPORTANT Be sure polarity is correct before making connections Reversed polarity will damage electrical system Always connect positive to positive and negative to ground Always use 12 volt booster battery for 12 volt electrical systems and 24 volt booster battery
20. 1500 1400 1560 105 141 6068TF150 1614 RE61669 RE69789 STD 2500 850 2700 127 170 1614 RE69789 STD 2500 850 2700 127 170 1680 RE60105 RE69790 STD 2500 850 2700 127 170 1680 RE69790 STD 2500 850 2700 127 170 1681 RE60107 RE67571 3 5 1800 1150 1870 112 150 1681 RE67571 3 5 1800 1150 1870 112 150 1688 RE67572 3 5 1800 1150 1870 112 150 1696 RE67864 RE69787 STD 2500 850 2700 116 155 1696 RE69787 STD 2500 850 2700 116 155 1697 RE68740 RE69788 STD 2500 850 2700 116 155 1697 RE69788 STD 2500 850 2700 116 155 16BE RE63559 RE501302 STD 2200 950 2400 117 157 16BE RE501302 STD 2200 950 2400 117 157 16CN RE501522 RE509681 STD 2100 950 2300 110 5 148 16CN RE509681 STD 2100 950 2300 110 5 148 16CP RE501523 STD 2200 950 2400 94 126 16DK RE70938 STD 2100 900 2300 96 129 16DY RE501758 STD 2500 850 2700 116 155 16GM RE502693 STD 2300 850 2500 110 148 16GN RE502704 STD 2400 850 2600 116 155 16LS RE67572 3 5 1800 1150 1870 112 150 16MG RE503742 3 5 1800 1400 1870 123 165 16MH RE504967 3 5 1800 1400 1870 123 165 6068TF151 1681 RE60107 RE67651 3 5 1800 1150 1870 112 150 1681 RE67651 3 5 1800 1150 1870 112 150 16NJ RE505358 3 5 1800 1150 1870 112 150 1696 RE69787 STD 2500 850 2700 116 155 6068TF152 1696 RE69787 STD 2500 850 2700 116 155 16JU RE69787 STD 2500 850 2700 116 155 6068TF157 16GS RE503049 3 5 1500 1560 121 162 16LX RE503834 3 5 1500 1560 121 162 6068TF158
21. 16GS RE503049 3 5 1500 1560 121 162 165H RE503740 3 5 1500 1560 105 141 165J RE505052 3 5 1500 1560 105 141 16MG RE503742 3 5 1800 1870 123 165 16MH RE504966 RE504967 3 5 1800 1870 123 165 16MH RE504967 3 5 1800 1870 123 165 16MX RE503740 3 5 1500 1560 105 141 16MY RE504699 RE505052 3 5 1500 1560 105 141 16MY RE505052 3 5 1500 1560 105 141 Continued on next page 60 9 OURGP11 000001D _ 19 130CT06 7 9 110306 PN 144 Specifications POWER RATINGS ON DYNAMOMETER FOR OEM ENGINES Injection Original Replaced Pump Injection By Injection Rated No Load Power Option Pump Part Pump Part Governor Speed rpm Slow Idle Fast Idle Rating Engine Model Code No No Regulation At Full Load rpm rpm kW HP 6068TF159 16PD RE70938 STD 2100 850 2250 96 129 6068TF220 16GS RE503049 3 5 1500 1400 1560 121 162 16KK RE502694 STD 2500 850 2700 127 170 16LX RE503836 3 5 1500 1400 1560 121 162 16RK RE506083 3 5 2600 850 2700 138 185 16RJ RE506084 3 5 2100 950 2200 172 231 16SG RE506625 3 5 2100 950 2200 172 231 16SH RE506626 3 5 2600 850 2700 138 185 16ZL RE509424 3 5 2100 950 2200 172 231 16ZM RE509425 3 5 2100 950 2200 172 231 16ZN RE509426 ST
22. 19 0 20 1 19 0 20 1 1909 19 0 20 1 20 0 21 1 1924 23 7 25 0 1944 20 0 21 1 19 0 20 1 1948 20 0 21 1 1950 20 0 21 1 20 0 21 1 1956 18 0 19 0 1968 32 0 34 0 20 0 21 1 6068HF157 1950 20 0 21 1 21 5 22 7 6068HF 158 1950 20 0 21 1 19 0 20 1 19 0 20 1 6068HF250 1907 19 0 20 1 19 0 20 1 1908 19 0 20 1 20 0 21 1 1909 19 0 20 1 20 0 21 1 1924 23 7 25 0 20 0 21 1 1944 20 0 21 1 18 0 19 0 1948 20 0 21 1 1961 32 0 34 0 19 0 20 1 1968 32 0 34 0 19 0 20 1 19AC 28 0 29 6 19 0 20 1 23 7 25 0 6068HF252 1907 19 0 20 1 20 0 21 1 20 0 21 1 6068HF258 1968 32 0 34 0 20 0 21 1 18 0 19 0 32 0 34 0 28 0 29 6 OURGP11 000001E_ 19 310CT06 4 4 60 1 4 110306 PN 149 Specifications Unified Inch Bolt and Screw Torque Values TS1671 UN 01MAY03 O O Ooo 8 amp Bolt or SAE Grade 1 SAE Grade 2 SAE Grade 5 5 1 or 5 2 SAE Grade 8 or 8 2 Screw Lubricated Dry Lubricated Dry Lubricated Dry Lubricated Dry Size Nem Ib in Nem Ib in Nem Ib in Nem Ib in Nem Ib in Nem Ib in Nem Ib in Nem Ib in 1 4 3 7 33 4 7 42 6 53 7 5 66 9 5 84 12 106 13 5 120 17 150 Nem Ib ft Nem lb ft 5 16 TT 68 9 8 86 12 106 15 5 137 19 5 172 25 221 28 20 5 35 26 Nem lb ft Nem lb ft 3 8 13 5 120 17
23. 19 08JAN02 2 2 15 5 110306 PN 49 Engine Operating Guidelines Engine Break In Service l 3 1A The engine is ready for normal operation However extra y gel care during the first 250 hours of operation will result in A more satisfactory long term engine performance and life WI DO NOT exceed 250 hours of operation with break in oil D 1 This engine is factory filled with John Deere ENGINE BREAK IN OIL Operate the engine at heavy loads with minimal idling during the break in period NG d RG8009 UN O6JAN99 2 If the engine has significant operating time at idle constant speeds and or light load usage or makeup Check Engine Oil oil is required in the first 250 hour period a longer break in period may be required In these situations an additional 250 hour break in period is recommended using a new change of John Deere ENGINE BREAK IN OIL and a new John Deere oil filter Continued on next page OURGP12 0000076 19 09SEP04 1 4 15 6 110306 PN 50 Engine Operating Guidelines RG8028A UN 15JAN99 IMPORTANT DO NOT add makeup oil until the oil level is BELOW the ADD mark on dipstick John Deere ENGINE BREAK IN OIL TY22041 should be used to make up any oil consumed during the Crosshatch Pattern On Oil Dipstick break in period A Crosshatch Pattern On Oil Dipstick 3 Check engine oil level more frequently during engine break in period If oil must be added d
24. 3 Slide alternator or tensioner bracket D in slot by hand to remove all excess slack in belt em Adjust Belt Tension IMPORTANT Do not pry against alternator rear frame A Belt Tension Gauge B Cap Screw 4 Stretch belt by prying outward on alternator front frame C Cap Screw or tensioner bracket Observing tension gauge stretch D Tensioner Bracket the belt until specified tension is achieved Specification New Belt Temsion scsscsesseseesees 470 650 N 105 145 Ib force Used Belt Tension 400 580 N 90 130 Ib force 5 Tighten cap screws B and C NOTE After ten minutes run in new belts are considered used Belt tension must then be rechecked per used belt specifications 6 Run engine for ten minutes and immediately re check belt tension per used belt specification above 7 Reset belt tension as necessary OURGP11 0000008 _ 19 24JUN04 1 1 30 7 110306 PN 78 Lubrication amp Maintenance 250 Hour 6 Month Manual Belt Tensioner Adjustment Using Belt Tension Tool Alternate Method For Engines Without Auxiliary Drive NOTE The JDG1520 Belt Tension Tool may not be compatible with all alternators In that case use the preceding method for belt tensioning NOTE Inspect belts for cracks fraying or stretched out areas Replace if necessary As a reference check twist belt in the middle of a 254 305 mm 10 12 in span with two fingers A properly tensioned belt wi
25. 37 C 34 F If protection at lower temperatures is required consult your John Deere dealer for recommendations John Deere COOL GARD Prediluted Coolant is preferred for service John Deere COOL GARD Prediluted Coolant is available in a concentration of either 50 ethylene glycol or 55 propylene glycol Additional recommended coolants The following engine coolant is also recommended e John Deere COOL GARD Coolant Concentrate in a 40 to 60 mixture of concentrate with quality water John Deere COOL GARD coolants do not require use of supplemental coolant additives except for periodic replenishment of additives during the drain interval Other fully formulated coolants Other fully formulated low silicate ethylene or propylene glycol base coolants for heavy duty engines may be used if they meet one of the following specifications e ASTM D6210 prediluted 50 coolant e ASTM D6210 coolant concentrate in a 40 to 60 mixture of concentrate with quality water Coolants meeting ASTM D6210 do not require use of supplemental coolant additives except for periodic replenishment of additives during the drain interval Coolants requiring supplemental coolant additives Other low silicate ethylene glycol base coolants for heavy duty engines may also be used if they meet one of the following specifications e ASTM D4985 ethylene glycol base prediluted 50 coolant e ASTM D4985 ethylene glycol base coolant concentrate in
26. 50 5000 ppm is used reduce the service interval by 50 PLUS 50 is a trademark of Deere amp Company TORQ GARD SUPREME is a trademark of Deere amp Company Q i S 5 3 ip ee JE wr S lt u o lt w lt Ve SAE OW A0 50 C 40 C 20 C 10 C 0 C 10 C 20 C 30 C 40 C 1220F 1049F 86 F 68 F 50 F 32 F 14 F Art 220F Ab SAE 30 SAE 40 gt Oil Viscosities for Air Temperature Ranges 10 7 Continued on next page DX ENOIL 19 13SEP06 1 2 TS1681 UN 09OCT06 110306 PN 33 Fuels Lubricants and Coolant DO NOT use diesel fuel with sulfur content greater than 1 00 10 000 ppm DX ENOIL 19 13SEP06 2 2 Extended Diesel Engine Oil Service Intervals When John Deere PLUS 50 oil is used with the specified John Deere filter the service interval for engine oil and filter changes may be increased by 50 but not to exceed a maxium of 500 hours When ACEA E7 ACEA E6 ACEA E5 or ACEA EA oils are used with specified John Deere filter use engine oil analysis to determine if the service interval for engine oil and filter changes may be increased by a maximum of 50 but not to exceed 500 hours If John Deere PLUS 50 ACEA E7 ACEA E6 ACEA E5 or ACEA E4 oils are used with other than the PLUS 50 is a trademark of Deere amp Company TORQ GARD SUPREME is a trademark of Deere amp Compa
27. 850 2400 73 98 4045TF162 16GL RE502706 STD 2300 850 2500 78 104 4045TF220 16GQ RE503048 RE506544 3 5 1500 1400 1560 83 111 16GQ RE506544 3 5 1500 1400 1560 83 111 16LV RE503830 RE506545 3 5 1500 1400 1560 83 111 16LV RE506545 3 5 1500 1400 1560 83 111 16MT RE503733 3 5 1500 1400 1560 70 94 16MV RE503736 3 5 1800 1400 1870 100 134 16MW RE504682 3 5 1800 1400 1870 100 134 16NT RE504465 STD 2500 850 2700 86 115 Continued on next page OURGP11 000001D 19 130CT06 4 9 60 6 110306 PN 141 Specifications POWER RATINGS ON DYNAMOMETER FOR OEM ENGINES Injection Original Replaced Pump Injection By Injection Rated No Load Power Option Pump Part Pump Part Governor Speed rpm Slow Idle Fast Idle Rating Engine Model Code No No Regulation At Full Load rpm rpm kW HP 16NU RE504466 STD 2500 850 2700 86 115 16ZZ RE508613 STD 2100 850 2200 107 143 161A RE509525 STD 2100 850 2200 107 143 161B RE509526 STD 2100 850 2200 107 143 168Q RE521143 3 5 1500 e 1560 3 111 168R RE522388 3 5 1500 1560 3 111 4045TF250 1606 RE64133 RE505927 STD 2400 850 2600 3 125 1606 RE505927 STD 2400 850 2600 3 125 1608 RE67564 3 5 1800 1400 1870 4 113 1667 RE59968 STD 2400 850 2600 3 125 1682 RE67566 3 5 1800 1400 1870 4 113 1683
28. Fuses In Instrument Panels 45 9 Checking Air Compressors 45 10 Bleeding the Fuel System 45 11 Troubleshooting General Troubleshooting Information 50 1 Engine Wiring Diagram Legend Standard Instrument Panel For North A Ee EE 50 3 Wiring Diagram Standard Instrument Panel For North America 50 4 Engine Wiring Diagram VDO Instrument Panel Except North America 50 5 Engine Wiring Diagram Legend VDO Instrument Panel Except North America 50 6 Engine Troubleshooting 0 50 7 Storage Engine Storage Guidelines 55 1 Preparing Engine for Long Term Storage 55 2 Removing Engine from Long Term Storage 55 3 Page Specifications General OEM Engine Specifications 4 5 L ENNES feces ber bbb bebe EEEE eeu Wa ie 60 1 General OEM Engine Specifications 6 8 L ENQIN S i10ci 4044 exe 004 ELE EE eae x 60 2 Engine Power Ratings And Fuel Injection Pump Specifications 60 3 Engine Crankcase Oil Fill Quantities 60 11 Unified Inch Bolt and Screw Torque Values 60 15 Metric Bolt and Screw Torque Values 60 16 Lubrication and Maintenance Records Using Lubrication and Maintenance Records 65 1 Daily Prestarting Service 65 1 250 Hour 6 Month Service 65 2 500 Hour 12 Month Service 65 3 2000 Hour 24 Month Service
29. N A 7 10 N A 7 10 N A 7 10 Governor Regulation Generator N A 5 5 5 5 5 5 5 Oil Pressure Rated Speed Full 345 kPa 345 kPa 345 kPa 345 kPa 345 kPa 345 kPa 345 kPa 345 kPa Load 15 psi 50 psi 50 psi 50 psi 50 psi 50 psi 50 psi 50 psi 50 psi Oil Pressure Low Idle Minimum 105 kPa 105 kPa 105 kPa 105 kPa 105 kPa 105 kPa 105 kPa 105 kPa 15 psi 15 psi 15 psi 15 psi 15 psi 15 psi 15 psi 15 psi Length 844 0 mm 861 0 mm 861 0 mm 861 0 mm 861 0 mm 861 0 mm 861 0 mm 861 0 mm 33 2 in 33 9 in 33 9 in 33 9 in 33 9 in 33 9 in 33 9 in 33 9 in Width 550 mm 598 mm 598 mm 598 mm 598 mm 598 mm 598 mm 598 mm 21 7 in 23 5 in 23 5 in 23 5 in 23 5 in 23 5 in 23 5 in 23 5 in Height 871 mm 854 mm 980 mm 980 mm 980 mm 980 mm 980 mm 980 mm 34 3 in 33 6 in 38 6 in 38 6 in 38 6 in 38 6 in 38 6 in 38 6 in Weight 429 kg 387 kg 396 kg 396 kg 396 kg 396 kg 396 kg 396 kg 945 Ib 851 Ib 872 Ib 872 Ib 872 Ib 872 Ib 872 Ib 872 Ib NOTE Engine models listed with numbers ending in 120 and 220 are emission non certified Engines with model numbers ending in 150 and 250 are Tier 1 emission certified Later engines with model numbers ending in 270 275 or 475 are Tier 2 emission certified with mechanical or electronic fuel systems and are covered in another manual OMRG33324
30. RE60124 RE505926 STD 2400 850 2600 3 125 1683 RE505926 STD 2400 850 2600 3 125 160R RE70941 3 5 1800 1400 1870 4 113 16CV RE501346 STD 2200 950 2400 5 114 16GQ RE503048 3 5 1500 1150 1560 3 111 16LQ RE67564 3 5 1800 1400 1870 4 113 16LV RE503830 3 5 1500 1150 1560 3 111 16MB RE503737 3 5 1800 1400 1870 91 122 16MC RE504932 3 5 1800 1400 1870 91 122 161C RE507525 RE506881 3 5 1800 1400 1870 100 134 161D RE507526 RE506882 3 5 1800 1400 1870 100 134 163Z RE505927 STD 2400 850 2600 93 125 4045TF251 1606 RE64133 RE505927 STD 2400 850 2600 93 125 1606 RE505927 STD 2400 850 2600 93 125 4045TF252 169P RE522714 3 5 3000 850 3120 119 160 169Q RE522697 3 5 3000 850 3120 119 160 4045TF253 16TE RE507257 STD 2400 850 2600 5 114 4045TF257 16GQ RE503048 3 5 1500 1560 3 111 16LV RE503830 3 5 1500 1560 3 111 4045TF258 16GQ RE503048 3 5 1500 1560 3 111 16LV RE503830 3 5 1500 1560 3 111 16MB RE503737 3 5 1800 1400 1870 1 122 16MC RE504932 3 5 1800 1400 1870 1 122 16MV RE503736 3 5 1800 1400 1870 100 134 16MW RE504682 3 5 1800 1400 1870 100 134 6068DF150 1613 RE59861 STD 2500 850 2700 93 125 1678 RE60101 STD 2500 850 2700 93 125 16LR RE59861 STD 2500 850 2700 93 125 6068HF120 16GT RE503051 3 5 1500 1400 1560 155 208 16LY RE503834 3 5 1500 1400 1560 155 208 Continued on next page OURGP11 000001D 19 130CT06 5 9 60 7 110306 PN 1
31. a 40 to 60 mixture of concentrate with quality water Coolants meeting ASTM D4985 require an initial charge of supplemental coolant additives formulated for protection of heavy duty diesel engines against corrosion and cylinder liner erosion and pitting They also require periodic replenishment of additives during the drain interval Other coolants It is possible that neither John Deere COOL GARD nor coolants meeting one of the coolant standards listed above is available in the geographical area where service is performed If these coolants are unavailable use a coolant concentrate or prediluted coolant with a quality additive package that provides cylinder liner cavitation protection and protects the cooling system metals cast iron aluminum alloys and copper alloys such as brass from corrosion The additive package must be part of one of the following coolant mixtures e ethylene glycol or propylene glycol base prediluted 40 to 60 coolant e ethylene glycol or propylene glycol base coolant concentrate in a 40 to 60 mixture of concentrate with quality water Water quality COOL GARD is a trademark of Deere amp Company Continued on next page DX COOL3 19 270CT05 1 2 10 12 110306 PN 38 Fuels Lubricants and Coolant Water quality is important to the performance of the IMPORTANT Do not mix ethylene glycol and cooling system Distilled deionized or demineralized propylene glycol base coolants water
32. and check thermostat See Engine Overheats Remove and check thermostat Replace fuel filter element Drain flush fill and bleed system Change to better quality fuel Have authorized servicing dealer or engine distributor check injectors Remove and check thermostat Check gauge sender and connections OUOD006 000004C 19 130CT06 2 7 50 8 110306 PN 127 Troubleshooting Symptom Lack of power Low oil pressure Problem Engine overloaded Intake air restriction Clogged fuel filter Improper type of fuel Overheated engine Below normal engine temperature Improper valve clearance Dirty or faulty injection nozzles Injection pump out of time Turbocharger not functioning Turbocharger engines only Leaking exhaust manifold gasket Defective aneroid control line Restricted fuel hose Low fast idle speed Low oil level Improper type of oil Continued on next page Solution Reduce load Service air cleaner Replace filter elements Use proper fuel See Engine Overheats Remove and check thermostat See your authorized servicing dealer or engine distributor Have authorized servicing dealer or engine distributor check injectors See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor See your a
33. and no load for several minutes Warm up carefully and check all 3 Install fan alternator poly vee belt if removed gauges before placing engine under load 4 Fill fuel tank 8 On the first day of operation after storage check overall engine for leaks and check all gauges for 5 Perform all appropriate prestarting checks See correct operation DAILY PRESTARTING CHECKS in Lubrication and Maintenance Daily Section RG RG34710 5613 19 110CT06 1 1 55 3 110306 PN 135 Specifications General OEM Engine Specifications 4 5 L Engines ITEM ENGINE 4045DF120 4045DF150 4045TF120 4045TF150 4045TF220 4045TF250 4045HF120 4045HF150 Number of Cylinders 4 4 4 4 4 4 4 4 Bore 106 mm 106 mm 106 mm 106 mm 106 mm 106 mm 106 mm 106 mm 4 19 in 4 19 in 4 19 in 4 19 in 4 19 in 4 19 in 4 19 in 4 19 in Stroke 127 mm 127 mm 127 mm 127 mm 127 mm 127 mm 127 mm 127 mm 5 0 in 5 0 in 5 0 in 5 0 in 5 0 in 5 0 in 5 0 in 5 0 in Displacement 4 5L 4 5L 4 5L 4 5L 4 5L 4 5L 4 5L 4 5L 276 cu 276 cu 276 cu 276 cu 276 cu 276 cu 276 cu 276 cu in in in in in in in in Compression Ratio 17 8 1 17 6 1 17 0 1 17 0 1 17 0 1 17 071 17 0 1 17 0 1 Max Crank Pressure 0 5 kPa 0 5 kPa 0 5 kPa 0 5 kPa 0 5 kPa 0 5 kPa 0 5 kPa 0 5 kPa 2 HO 2 H20 2 H20 2 HO 2 H20 2 H20 2 H20 2 HO Governor Regulation Industrial 7 10 7 10
34. based ion the expected air temperature range between oil changes and proper concentration of low silicate antifreeze as recommended See DIESEL ENGINE OIL and ENGINE COOLANT requirements this section Diesel Fuel Flow Additive Use John Deere Premium Diesel Fuel Conditioner Winter or equivalent to treat fuel during the cold weather season This winter formulation is a combination diesel fuel conditioner and anti gel additive IMPORTANT Treat fuel when outside temperature drops below 0 C 32 F For best results use with untreated fuel Follow all recommended instructions on label Winterfronts Use of fabric cardboard or solid winterfronts is not recommended with any John Deere engine Their use can result in excessive engine coolant oil and charge air temperatures This can lead to reduced engine life loss of power and poor fuel economy Winterfronts may also put abnormal stress on fan and fan drive components potentially causing premature failures Continued on next page DX FUEL10 19 16DEC05 1 2 1 0 5 110306 PN 31 Fuels Lubricants and Coolant If winterfronts are used they should never totally close off the grill frontal area Approximately 25 area in the center of the grill should remain open at all times At no time should the air blockage device be applied directly to the radiator core Radiator Shutters If equipped with a thermostatically controlled radiator shutter system this system
35. bracket vibration isolators and mounting bolts on support frame and engine block for tightness Tighten as necessary 2 Inspect overall condition of vibration isolators if equipped Replace isolators if rubber has deteriorated or mounts have collapsed as necessary 30 4 DPSG RG34710 111 _ 19 07JAN02 1 1 110306 PN 75 Lubrication amp Maintenance 250 Hour 6 Month Servicing Battery CAUTION Battery gas can explode Keep sparks and flames away from batteries Use a flashlight to check battery electrolyte level Never check battery charge by placing a metal object across the posts Use a voltmeter or hydrometer Always remove grounded NEGATIVE battery clamp first and replace it last WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling 1 On regular batteries check electrolyte level Fill each cell to bottom of filler neck with distilled water NOTE Low maintenance or maintenance free batteries should require little additional service However electrolyte level can be checked by cutting the center section of decal on dash line and removing cell plugs If necessary add clean soft water to bring level to bottom of filler neck 2 Keep batteries clean by wiping them with a damp cloth Keep all connections clean and tight Remove any corrosion and
36. by positioning a dial indicator A so probe contacts damper outer diameter 4 With engine at operating temperature rotate crankshaft using either JDE83 or JD81 1 Flywheel Turning Tool 5 Note dial indicator reading If runout exceeds specifications given below replace vibration damper RG7508 UN 23NOV97 Specification Vibration Damper Maximum Radial PUNOU eieiei 1 50 mm 0 060 in Check Runout RG RG34710 5585 _ 19 16JAN02 1 1 40 3 110306 PN 96 Lubrication amp Maint 2000 Hour 24 Month Flushing and Refilling Cooling System CAUTION Explosive release of fluids from pressurized cooling system can cause serious burns Shut off engine Only remove filler cap when cool enough to touch with bare hands Slowly loosen cap to first stop to relieve pressure before removing completely TS281 UN 23AUG88 NOTE When John Deere COOL GARD is used the drain interval is 3000 hours or 36 months The drain interval may be extended to 5000 hours or 60 months of operation provided that the coolant is tested annually AND additives are replenished as needed by adding a supplemental coolant additive SCA If COOL GARD is not used the flushing interval is 2000 hours or 24 months of operation Drain old coolant flush the entire cooling system test thermostats and fill with recommended clean coolant per the following procedure 1 Pressure test entire cooling system and pressure cap if
37. connections Clean and tighten loose connections Continued on next page OQUOD006 000004C _ 19 130CT06 6 7 50 1 2 110306 PN 131 Troubleshooting Symptom Problem Solution Starter and hour meter functions Blown fuse on magnetic switch Replace fuse rest of electrical system does not function Entire electrical system does not Faulty battery connection Clean and tighten connections function Sulfated or worn out batteries See your authorized servicing dealer or engine distributor Blown main system fuse MDL 25 Replace fuse OQUOD006 000004C _ 19 130CT06 7 7 50 1 3 110306 PN 132 Storage Engine Storage Guidelines 1 John Deere engines can be stored outside for up to 4 John Deere engines expected to be stored more three 3 months with no long term preparation IF than six 6 months MUST have long term storage COVERED BY WATERPROOF COVERING No preparation See PREPARING ENGINE FOR outside storage is recommended without a LONG TERM STORAGE later in this section waterproof covering 5 Long term storage includes the use of a stabilized 2 John Deere engines can be stored in a standard rust preventive oil to protect internal metal overseas shipping container for up to three 3 components of the engine This oil should be an months with no long term preparation SAE 10 oil with 1 4 percent morpholine or equivalent vapor corrosion inhibitor These rust 3 John Deere engines can be stored i
38. contact surfaces of A Timing Rotation Hole valve tips and rocker arm wear pads B Timing Pin Hole Check all parts for excessive wear breakage or cracks Replace parts that show visible damage Rocker arms that exhibit excessive valve clearance should be inspected more thoroughly to identify damaged parts 2 Remove plastic plugs or cover plate from engine timing rotation hole A and timing pin hole B NOTE Some engines are equipped with flywheel housings which do not allow use of an engine flywheel rotation tool These engines may be rotated from front nose of engine using JDG966 Crankshaft Front Rear Rotation Adapter 3 Using JDE83 or JD81 1 Flywheel Turning Tool rotate engine flywheel in running direction clockwise viewed from front until No 1 cylinder is at TDC compression stroke Insert JDG1571 or JDE81 4 Timing Pin in flywheel If No 1 cylinder rocker arms are loose the engine is at No 1 TDC compression If No 1 cylinder rocker arms are not loose rotate engine one full revolution 360 to No 1 TDC compression Continued on next page DPSG RG41165 137 19 16JAN02 1 5 40 10 110306 PN 103 Lubrication amp Maint 2000 Hour 24 Month 4 With engine lock pinned at TDC of No 1 piston s compression stroke check valve clearance to following specifications Use sequence for 4 cylinder or 6 cylinder engines as outlined on next page Specification Intake Valve Clearance For C
39. cover removed ALWAYS fully depress the air restriction indicator reset button if equipped to assure accurate readings 6 If equipped fully depress air restriction indicator reset button and release to reset indicator RG41165 000008A 19 12NOV01 2 2 45 5 110306 PN 110 Service as Required Replacing Radial Seal Air Cleaner Filter Element IMPORTANT ALWAYS REPLACE primary air cleaner element when air restriction indicator shows a vacuum of 625 mm 25 in H20 is torn or visibly dirty UN 08SEP00 NOTE This procedure applies to John Deere 2 stage radial seal air cleaner kits Refer to manufacturers instructions for servicing air cleaners not supplied by John Deere RG11321A Dust Cup Cover 1 Unlatch and remove dust cup cover A of air cleaner 2 Move end of filter B back and forth gently to break seal 3 Pull filter B off outlet tube and out of housing 4 Thoroughly clean all dirt from inside housing and from outlet bore UN 08SEP00 IMPORTANT Remove secondary safety element C ONLY for replacement DO NOT attempt to clean wash or reuse secondary element Replacement of secondary element is usually necessary ONLY when primary element has a hole in it RG11322A Primary Filter Element 5 To replace secondary element C pull filter element out gently Immediately replace secondary element with new element to prevent dust from entering air int
40. filters regularly as specified in this manual Use filters meeting John Deere performance specifications DX FILT 19 18MAR96 1 1 10 10 110306 PN 36 Fuels Lubricants and Coolant Grease Use grease based on NLGI consistency numbers and the expected air temperature range during the service interval John Deere SD POLYUREA GREASE is preferred The following greases are also recommended e John Deere HD LITHIUM COMPLEX GREASE e John Deere HD WATER RESISTANT GREASE e John Deere GREASE GARD John Deere SD POLYUREA John Deere HD LITHIUM COMPLEX John Deere HD WATER RESISTANT Other greases may be used if they meet the following NLGI Performance Classification GC LB IMPORTANT Some types of grease thickeners are not compatible with others Consult your grease supplier before mixing different types of grease GREASE GARD is a trademark of Deere amp Company D John Deere GREASE GARD 50 C 40 C 30 C 10 C 0 C 10 C 20 C 30 C 40 C 122 F 104 F 86 F 50 F 32 F 14 F 40F 220F 40 F wv NLGI Number 1 oF NLGI Number 2 DN NLGI Number 0 a TS1673 UN 310CT03 DX GREA1 19 07NOV03 1 1 10 11 110306 PN 37 Fuels Lubricants and Coolant 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
41. not previously done See PRESSURE TESTING COOLING SYSTEM in the Lubrication and Maintenance 500 Hour 12 Month Section 2 Slowly open the engine cooling system filler cap or radiator cap A to relieve pressure and allow coolant to drain faster RG12833 UN 13FEB03 Radiator Cap Continued on next page OURGP11 000000C 19 24JUN04 1 3 40 4 110308 PN 97 Lubrication amp Maint 2000 Hour 24 Month 3 Open engine block drain valve A on left side of engine Drain all coolant from engine block NOTE These engines use several different oil filter adapters Use either drain plug B or C to drain coolant whichever is more accessible for the oil filter adapter on your engine UN 19JUNO00 4 Open radiator drain valve Drain all coolant from radiator Ia RG8019A 5 Remove thermostats at this time if not previously done Install cover without thermostats using old Engine Block Drain Valve gasket and tighten cap screws to 47 Nem 35 lb ft A Engine Block Drain Valve B Engine Block Drain Plug 6 Test thermostat opening temperature See Inspecting C Engine Block Drain Plug Thermostats And Testing Opening Temperature in Service As Required Section 7 Close all drain valves after coolant has drained A CAUTION Do not run engine longer than 10 minutes Doing so may cause engine to overheat which may cause burns when radiator water is draining 8 Fill the cooling sys
42. 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 amp Company Medical Department in Moline Illinois or other knowledgeable medical source 1 Close fuel shut off valve if equipped 2 Thoroughly clean fuel filter assembly and surrounding area 3 Loosen drain plug C and drain fuel into a suitable container NOTE Lifting up on retaining ring as it is rotated helps to get it past raised locators 4 Firmly grasp the retaining ring A and rotate it clockwise 1 4 turn when viewed from top Remove ring with filter element B 5 Inspect filter mounting base for cleanliness Clean as required NOTE Raised locators on fuel filter canister must be indexed properly with slots in mounting base for correct installation 6 Install new filter element onto mounting base Be sure element is properly indexed and firmly seated on base It may be necessary to rotate filter for correct alignment High Pressure Fluids Fuel Filter A Retaining Ring B Filter Element C Drain Plug D Bleed Plug Continued on next page 35 3 OURGP11 000000A X9811 UN 23AUG88 RG7721 UN 15JAN99 19 24JUN04 1 2 11
43. parts may occur when oil flow is stopped cause before resuming operation e Sudden drop in oil pressure e Abnormal coolant temperatures Operate the engine under a lighter load and at slower e Unusual noise or vibration than normal speed for first 15 minutes after start up e Sudden loss of power DO NOT run engine at slow idle e Excessive black exhaust e Excessive fuel consumption IMPORTANT Should the engine die while e Excessive oil consumption operating under load immediately e Fluid leaks RG RG34710 5552 19 20MAY96 1 1 15 13 110306 PN 57 Engine Operating Guidelines Cold Weather Operation CAUTION Ether injector starting fluid is highly flammable DO NOT use starting fluid on engines equipped with air intake heaters DO NOT use siarting fluid near fire sparks or flames DO NOT incinerate or puncture a starting fluid container Engines may be equipped with intake air heaters coolant heaters or ether injectors as a cold weather starting aid Starting aids are required below 32 F 0 C They will enhance starting performance above these temperatures and may be needed to start applications that have high parasitic loads during cranking and or start acceleration to idle 140 Go CH Using correct grade of oil per engine and machine operator s manual is critical to achieving adequate cold weather cranking speed ech a Other cold weather starting aids are required at temperatures
44. pass a minimum load level of 3100 grams as measured by ASTM D6078 or a maximum scar diameter of 0 45 mm as measured by ASTM D6079 or ISO 12156 1 If fuel of low or unknown lubricity is used add John Deere PREMIUM DIESEL FUEL CONDITIONER or equivalent at the specified concentration DX FUEL5 19 270CT05 1 1 110306 PN 27 Fuels Lubricants and Coolant Handling and Storing Diesel Fuel When using bio diesel fuel the fuel filter may require A CAUTION Handie tel care tilly Da morti more frequent replacement due to premature plugging the fuel tank when engine is running Check engine oil level daily prior to starting engine A rising oil level may indicate fuel dilution of the engine oil DO NOT smoke while you fill the fuel tank or service the fuel system Fill the fuel tank at the end of each day s operation to prevent water condensation and freezing during cold weather IMPORTANT The fuel tank is vented through the filler cap If a new filler cap is required always replace it with an Keep all storage tanks as full as practicable to original vented cap minimize penaensaton 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 Ensure that all fuel tank caps and covers are installed properly to prevent moisture from entering Monitor water
45. should be regulated in such a way that the shutters are completely open by the time the coolant reaches 93 C 200 F to prevent excessive intake manifold temperatures Manually controlled systems are not recommended If air to air aftercooling is used the shutters must be completely open by the time the intake manifold air temperature reaches the maximum allowable temperature out of the charge air cooler For more information see your John Deere dealer DX FUEL10 19 16DEC05 2 2 Diesel Engine Break In Oil New engines are filled at the factory with John Deere ENGINE BREAK IN OIL During the break in period add John Deere ENGINE BREAK IN OIL as needed to maintain the specified oil level Change the oil and filter after the first 100 hours of operation of a new or rebuilt engine After engine overhaul fill the engine with John Deere ENGINE BREAK IN OIL If John Deere ENGINE BREAK IN OIL is not available use a diesel engine oil meeting one of the following during the first 100 hours of operation API Service Classification CE API Service Classification CD API Service Classification CC ACEA Oil Sequence E2 ACEA Oil Sequence E1 PLUS 50 is a trademark of Deere amp Company 10 6 After the break in period use John Deere PLUS 50 or other diesel engine oil as recommended in this manual IMPORTANT Do not use PLUS 50 oil or engine oils meeting any of the following during the first 100 hours of operat
46. vehicle s air system refer to vehicle technical manual for complete air system checks and services See your John Deere engine distributor or servicing dealer for diagnostic and troubleshooting information If diagnosis leads to an internal fault in the compressor replace the complete compressor as a new or remanufactured unit RG12836 UN 27FEB03 Air Compressor Optional OURGP12 00001EO 19 26FEB03 1 1 45 10 110306 PN 115 Service 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 X9811 UN 23AUG88 High Pressure Fluids 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 amp Company Medical Department in Moline Illinois or other knowledgeable medical source Bleed the fuel system anytime the fuel system has been opened up This includes After fuel filter changes After injection pump or nozzle replacement Anytime fuel lines have been disconnected After engine has run
47. wash terminals with a solution of 1 part baking soda and 4 parts water Tighten all connections securely NOTE Coat battery terminals and connectors with a mixture of petroleum jelly and baking soda to retard corrosion 3 Keep battery fully charged especially during cold weather If a battery charger is used turn charger off before connecting charger to battery ies Attach POSITIVE battery charger lead to POSITIVE battery post Then attach NEGATIVE battery charger lead to a good ground Continued on next page 30 5 Exploding Battery TS204 UN 23AUG88 RG RG34710 5568 19 27JUL06 1 2 110306 PN 76 Lubrication amp Maintenance 250 Hour 6 Month CAUTION Sulfuric acid in battery electrolyte is poisonous It is strong enough to burn skin eat holes in clothing and cause blindness if splashed into eyes Avoid the hazard by 1 Filling batteries in a well ventilated area 2 Wearing eye protection and rubber gloves 3 Avoiding breathing fumes when electrolyte is added 4 Avoiding spilling or dripping electrolyte 5 Use proper jump start procedure If you spill acid on yourself 1 Flush your skin with water 2 Apply baking soda or lime to help neutralize the acid 3 Flush your eyes with water for 10 15 minutes Get medical attention immediately H acid is swallowed 1 Drink large amounts of water or milk 2 Then drink milk of magnesia beaten eggs or veget
48. with oil at normal operating temperature of 115 C 240 F NOTE On certain engines the oil pressure and coolant temperature gauges are replaced by indicator warning lights The lights must be OFF when engine is running 2 Watch coolant temperature gauge B Do not place engine under full load until it is properly warmed up The normal engine coolant temperature range is 82 94 C 180 202 F NOTE It is a good practice to operate the engine under a lighter load and at lower speeds than normal for the first few minutes after start up Standard VDO Instrument Panel Except North America A Oil Pressure Gauge B Coolant Temperature Gauge RG11612 UN 170CT01 RG10613 UN 210CT99 RG RG34710 5560 _ 19 08JAN02 1 1 15 12 110306 PN 56 Engine Operating Guidelines Normal Engine Operation Observe engine coolant temperature and engine oil pressure Temperatures and pressures will vary between engines and with changing operating conditions temperatures and loads Normal engine coolant operating temperature range is 82 94 C 180 202 F If coolant temperature rises above 112 C 234 F reduce load on engine Unless temperature drops quickly stop engine and determine Stop engine immediately if there are any signs of part failure Symptoms that may be early signs of engine problems are remove load and restart the engine Overheating of the turbocharger
49. 0306 PN 83 Lubrication amp Maintenance 500 Hour 12 Month 7 Align keys on filter element with slots in filter base 8 Install retaining ring onto mounting base making certain dust seal is in place on filter base Hand tighten ring about 1 3 turn until it snaps into the detent DO NOT overtighten retaining ring NOTE The proper installation is indicated when a click is heard and a release of the retaining ring is felt A plug is provided with the new element for plugging the used element 9 Open fuel shut off valve and bleed the fuel system See BLEEDING FUEL SYSTEM in Service As Required Section Tighten bleed plug D OURGP11 000000A_ 19 24JUN04 2 2 35 4 110306 PN 84 Lubrication amp Maintenance 500 Hour 12 Month Replacing Fuel Filter Elements Dual Filters 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 X9811 UN 23AUG88 High Pressure Fluids 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 th
50. 06 PN 147 Specifications Engine Model Oil Pan Option Crankcase Oil Engine Model Oil Pan Option Crankcase Oil Code s Capacity L qt Code s Capacity L qt 1904 13 5 14 3 4045TF258 1949 12 5 13 2 1923 15 0 15 8 1949 12 5 13 2 6068DF150 1907 19 5 20 6 19AE 14 7 15 5 1908 19 0 20 1 1909 19 0 20 1 1944 20 0 21 1 1948 20 0 21 1 1950 20 0 21 1 Continued on next page OURGP11 000001E_ 19 310CT06 3 4 60 13 110306 PN 148 Specifications Engine Crankcase Oil Fill Quantities Continued Engine Model 6068TF120 6068TF150 6068TF151 6068TF152 6068TF157 6068TF158 6068TF159 6068TF220 6068TF250 Oil Pan Option Code s 1907 1908 1909 1944 1956 1907 1908 1909 1944 1948 1950 1956 1907 1909 1944 1909 1950 1950 1963 1907 1908 1909 1944 1948 1950 1956 1907 1908 1909 1924 1944 1948 1950 1956 1961 19AC Crankcase Oil Engine Model Oil Pan Option Crankcase Oil Capacity L qt Code s Capacity L qt 19 0 20 1 6068TF251 1909 19 0 20 1 19 0 20 1 19 0 20 1 6068TF257 1950 20 0 21 1 20 0 21 1 18 0 19 0 6068TF258 1950 20 0 21 1 19 0 20 1 6068HF120 1907 19 0 20 1 19 0 20 1 1908 19 0 20 1 19 0 20 1 1909 19 0 20 1 20 0 21 1 1950 20 0 21 1 20 0 21 1 1956 18 0 19 0 20 0 21 1 1961 32 0 34 0 18 0 19 0 6068HF150 1907 19 0 20 1 19 0 20 1 1908
51. 1 10 3 SIOA Jerri aa aa aa ta ee ee 10 10 Handling and stong 10 2 Lubrication and Maintenance EE EE 10 4 Service Interval Chart 20 2 20 4 E E nek nes fees be be ke ke be ee es 10 4 Lubricity of diesel fue 10 1 LUDIICIY aie ddicedidet eae meme menenenenenaas 10 1 Fuel filter Ghecking a ae aa 02s 69696 2446 1496 24446 94 25 1 M Draining water 25 1 P Replace EE ee ee eee eee 35 3 Maintenance interval chait uel injection pump model number 01 5 a Fuel system Generator Standby applications EE 20 4 Bleeding ccccceeeeeceeeeees 45 11 Standard industrial applications 20 2 Fuses checking ooo 45 9 Manual belt tensioner EE DEE 30 7 i Manual belt tensioner using belt tension tool 30 8 Mixing lubricants 10 8 Mounts engine G CHECKIN Sereia aia a ee aeae a era e aiaa 30 4 Gauge Dance 15 2 15 4 ENEE 15 2 15 4 15 12 O Generator Standby Applications 20 4 Grease Oil Extreme pressure and multipurpose 10 11 DIDSUCKi anasto ate season ee aaa maes see ax 25 1 Fill quantity 2 2 0 0 eee eee 60 11 Filler locations 000 25 1 Oil filter change 30 2 H HE 10 10 Oil pressure gauge s susuan nunana 15 2 15 4 Handihrottleissssccreisrsiecuinisirwat 15 2 15 4 Operating engine Break in 1 2 0 000 cece eee 15 6 Cold weather cee eee 15 14 Normal operation 15 13 l e 01 3 Idling enge 15 15 Instrument panne 15 2 15 4 P Poly vee belts J ee EE 45
52. 151 CD4045DF 152 CD4045DF 153 CD4045DF 154 CD4045DF157 CD4045DF 158 TORREON BUILT TIER 1 CERTIFIED ENGINES Emission certified for United States as EPA Tier 1 and European Union as Stage 1 CD4045TF150 CD4045TF152 CD4045TF154 CD4045TF155 CD4045TF157 CD4045TF158 CD4045TF161 CD4045TF162 CD4045T F250 CD4045TF251 CD4045T F252 CD4045T F253 CD4045TF257 CD4045T F258 CD4045HF 150 CD4045HF 152 CD4045HF 157 CD4045HF 158 CD4045HF252 CD6068DF 150 CD6068TF150 CD6068TF151 CD6068TF152 CD6068TF157 CD6068TF158 CD6068TF159 CD6068T F250 CD6068TF251 CD6068TF257 CD6068T F258 CD6068HF 150 CD6068HF 157 CD6068HF 158 CD6068HF250 CD6068HF252 CD6068HF254 CD6068HF258 PE4045DF150 PE4045TF150 OURGP11 0000004_ 19 270CT06 1 2 110306 PN 2 Introduction PE4045TF151 PE4045HF 150 PE4045HF252 PE6068DF 150 PE6068TF150 PE6068TF151 PE6068TF250 PE6068HF 150 PE6068HF250 DUBUQUE BUILT TIER 1 CERTIFIED ENGINES e T04045DF150 T04045DF 151 T04045DF 152 T04045DF 153 T04045TF150 T04045TF151 T04045TF152 T04045TF250 T04045TF251 T04045HF 120 T04045HF 150 TO6068DF 150 TO6068TF150 TO6068TF151 TO6068T F250 TO6068HF 150 TO6068HF250 NOTE Before 2005 all Non certified and Tier 1 Certified Saran built engines used the following serial number sequences e CDxxxxD500000 CDxxxxD799999 e CDxxxxT500000 CDxxxxT799999 e CDxxxxH500000 CDxxxxH799999 Since 2005 non certified engines have the sev
53. 258 STD 2250 850 2450 36 48 16KE RE503560 STD 2500 850 2700 52 70 16LM RE502711 STD 2500 850 2700 53 71 16LN RE67558 RE505070 3 5 1800 1150 1870 53 71 16LN RE505070 RE506132 3 5 1800 1150 1870 53 71 16LN RE506132 3 5 1800 1150 1870 53 71 16RB RE503729 3 5 1500 1400 1560 44 59 16RC RE504693 3 5 1500 1400 1560 44 59 165W RE500949 STD 2500 1600 2700 60 80 4045DF151 1663 RE71089 RE500949 STD 2500 1600 2700 60 80 1663 RE500949 STD 2500 1600 2700 60 80 4045DF152 1601 RE67557 STD 2500 850 2700 60 80 16GB RE502711 STD 2500 850 2700 60 80 4045DF154 16AY RE500505 STD 2400 850 2600 62 83 16JS RE500505 STD 2400 850 2600 62 83 4045HF120 16GR RE503050 RE506965 3 5 1500 1400 1560 102 137 16LW RE503832 RE506966 3 5 1500 1400 1560 102 137 4045HF150 1610 RE68826 RE505928 STD 2400 850 2600 104 140 1611 RE60237 3 5 1800 1400 1870 95 127 160B RE68827 3 5 1800 1400 1870 95 127 160C RE69588 RE505959 STD 2400 850 2600 104 140 16GR RE503050 3 5 1500 1150 1560 100 134 16LW RE503832 3 5 1500 1150 1560 100 134 16ME RE503739 3 5 1800 1870 120 161 16MF RE504966 3 5 1800 1870 123 164 16QZ RE503050 3 5 1800 1400 1870 111 149 16RA RE503832 3 5 1800 1400 1870 111 149 4045HF152 16RM RE505959 STD 2400 850 2600 104 140 4045HF157 16GR RE503050 1500 1560 102 137 16LW RE503832 1500 1560 102 137 Continued on next page OURGP11 000001D 19 130CT06 2 9 60 4 110306
54. 42 Specifications POWER RATINGS ON DYNAMOMETER FOR OEM ENGINES Injection Original Replaced Pump Injection By Injection Rated No Load Power Option Pump Part Pump Part Governor Speed rpm Slow Idle Fast Idle Rating Engine Model Code No No Regulation At Full Load rpm rpm kW HP 16RL RE506085 3 5 2100 950 2200 197 264 16SJ RE506627 3 5 2100 950 2200 197 264 16TP RE506883 3 5 1500 1150 1560 183 245 16TQ RE506884 3 5 1500 1150 1560 183 245 16ZQ RE509428 3 5 2100 950 2200 197 264 16ZR RE509429 3 5 2100 950 2200 197 264 6068HF150 1621 RE66575 RE505930 STD 2400 850 2600 157 210 1621 RE505930 STD 2400 850 2600 157 210 160D RE69589 RE505962 STD 2400 850 2600 157 210 160D RE505962 STD 2400 850 2600 157 210 16CY RE501345 STD 2200 1350 2400 143 192 16GT RE503051 3 5 1500 1400 1560 153 205 16LY RE503836 3 5 1500 1400 1560 153 205 16ML RE503746 3 5 1800 1400 1870 187 251 16MM RE504702 RE505049 3 5 1800 1400 1870 187 251 16MM RE505049 3 5 1800 1400 1870 187 251 16QV RE503051 3 5 1800 1400 1870 166 223 16QW RE503836 3 5 1800 1400 1870 166 223 16TM RE506885 3 5 1800 1870 210 282 16TN RE506886 3 5 1800 1870 210 282 6068HF157 16GT RE503051 3 5 1500 1560 155 208 16LY RE503836 3 5 1500
55. 5 155 22 194 27 240 35 26 44 32 5 49 36 63 46 Nem Ib ft Nem Ib ft Nem Ib ft 7 16 22 194 28 20 5 35 26 44 32 5 56 41 70 52 80 59 100 74 Nem Ib ft 1 2 34 25 42 31 53 39 67 49 85 63 110 80 120 88 155 115 9 16 48 35 5 60 45 76 56 95 70 125 92 155 115 175 130 220 165 5 8 67 49 85 63 105 77 135 100 170 125 215 160 240 175 305 225 3 4 120 88 150 110 190 140 240 175 300 220 380 280 425 315 540 400 7 8 190 140 240 175 190 140 240 175 490 360 615 455 690 510 870 640 1 285 210 360 265 285 210 360 265 730 540 920 680 1030 760 1300 960 1 1 8 400 300 510 375 400 300 510 375 910 670 1150 850 1450 1075 1850 1350 1 1 4 570 420 725 535 570 420 725 535 1280 945 1630 1200 2050 1500 2600 1920 1 3 8 750 550 950 700 750 550 950 700 1700 1250 2140 1580 2700 2000 3400 2500 1 1 2 990 730 1250 930 990 730 1250 930 2250 1650 2850 2100 3600 2650 4550 3350 Torque values listed are for general use only based on the strength of the Replace fasteners with the same or higher grade If higher bolt or screw DO NOT use these values if a different torque value or grade fasteners are used tighten these to the strength of the tightening procedure is given for a specific application For plastic insert or original Make sure fastener threads are clean and that you crimped steel type lock nuts for stainless steel fasteners or for nuts on properly
56. 5 oil is used along with a John Deere oil filter the oil and filter change interval may be extended by 50 percent OURGP12 0000043 19 310CT06 1 1 65 2 110306 PN 153 Lubrication and Maintenance Records 500 Hour 12 Month Service Clean crankcase vent tube Check air intake hoses connections and system Replace single or dual fuel filter elements Check automatic belt tensioner and belt wear Check engine speeds Check engine electrical ground connection Check cooling system Coolant solution analysis add SCAs as needed Pressure test cooling system Hours Date Hours Date Hours Date Hours Date Hours Date Hours Date Hours Date Hours Date OURGP12 0000044 19 07JUL04 1 1 65 3 110306 PN 154 Lubrication and Maintenance Records 2000 Hour 24 Month Service e Check crankshaft vibration damper 6 cylinder only e Test thermostats e Flush cooling system e Check and adjust valve clearance Hours Date Hours Date Hours Date Hours Date Hours Date Hours Date Hours Date Hours Date lf John Deere COOL GARD is used the flushing interval may be extended to 3000 hours or 36 months If John Deere COOL GARD is used and the coolant is tested annually AND additives are
57. 6 PN 145 Specifications POWER RATINGS ON DYNAMOMETER FOR OEM ENGINES Injection Original Replaced Pump Injection By Injection Rated No Load Power Option Pump Part Pump Part Governor Speed rpm Slow Idle Fast Idle Rating Engine Model Code No No Regulation At Full Load rpm rpm kW HP 16MJ RE503744 3 5 1800 1870 142 190 16MK RE504701 RE504968 3 5 1800 1870 142 190 16MK RE504968 3 5 1800 1870 142 190 OURGP11 000001D _ 19 130CT06 9 9 Engine Crankcase Oil Fill Quantities NOTE Crankcase oil capacity may vary slightly from amount shown ALWAYS fill crankcase to within crosshatch on dipstick DO NOT overfill To determine the option code for the oil fill quantity of your engine refer to the engine option code label affixed to the rocker arm cover The first two digits of the code 19 identify the oil pan option group The last two digits of each code identify the specific oil pan on your engine The following table lists engine crankcase oil fill quantities for each 19__ option code for these engines Continued on next page OURGP11 000001E 19 310CT06 1 4 60 1 1 110306 PN 146 Specifications Engine Model Oil Pan Option Crankcase Oil Engine Model Oil Pan Option Crankcase
58. 671 RE502714 STD 2500 850 2700 1673 RE60085 RE67560 3 5 1800 1400 1870 1673 RE67560 RE506130 3 5 1800 1400 1870 1673 RE506130 3 5 1800 1400 1870 1674 RE60089 RE67561 3 5 1800 1400 1870 1674 RE67561 RE506131 3 5 1800 1400 1870 1674 RE506131 3 5 1800 1400 1870 1691 RE61649 RE500831 STD 2500 850 2700 1691 RE500831 RE500948 STD 2500 850 2700 1691 RE500948 STD 2500 850 2700 16BG RE69778 RE502712 STD 2500 850 2700 16BG RE502712 STD 2500 850 2700 Continued on next page OURGP11 000001D 19 130CT06 1 9 110306 PN 138 Specifications POWER RATINGS ON DYNAMOMETER FOR OEM ENGINES Injection Original Replaced Pump Injection By Injection Rated No Load Power Option Pump Part Pump Part Governor Speed rpm Slow Idle Fast Idle Rating Engine Model Code No No Regulation At Full Load rpm rpm kW HP 16BH RE500873 RE502715 STD 2500 850 2700 63 85 16BH RE502715 STD 2500 850 2700 63 85 16BJ RE500589 STD 2250 850 2450 36 48 16CL RE501364 RE502713 STD 2200 950 2400 58 78 16CL RE502713 STD 2200 950 2400 58 78 16DL RE70452 STD 2400 850 2600 61 82 16EN RE502019 STD 2500 850 2700 60 80 16GB RE502711 STD 2500 850 2700 60 80 16GC RE502716 STD 2500 850 2700 60 80 16HJ RE500948 STD 2500 1400 2700 60 80 16HK RE500949 STD 2500 1600 2700 60 80 16HV RE503
59. 6NOVS90 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 Oy ite D O lt el T z j KE KE oO Kai E BR Ba Wear close fitting clothing Stop the engine and be sure PTO driveline is stopped before making adjustments connections or performing any type of service on the engine or PTO driven equipment Rotating Drivelines QU01004 0000BD8_ 19 110CT06 1 1 05 5 110306 PN 18 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 i
60. 7 19 5 172 Nem lb ft Nem Ib ft Nem Ib ft Nem Ib ft M8 11 5 102 14 5 128 22 194 27 5 243 32 23 5 40 29 5 37 27 5 47 35 Nem Dt Nem Ib ft Nem lb ft M10 23 204 29 21 43 32 55 40 63 46 80 59 75 55 95 70 Nem lb ft M12 40 29 5 50 37 75 55 95 70 110 80 140 105 130 95 165 120 M14 63 46 80 59 120 88 150 110 175 130 220 165 205 150 260 190 M16 100 74 125 92 190 140 240 175 275 200 350 255 320 235 400 300 M18 135 100 170 125 265 195 330 245 375 275 475 350 440 325 560 410 M20 190 140 245 180 375 275 475 350 530 390 675 500 625 460 790 580 M22 265 195 330 245 510 375 650 480 725 535 920 680 850 625 1080 800 M24 330 245 425 315 650 480 820 600 920 680 1150 850 1080 800 1350 1000 M27 490 360 625 460 950 700 1200 885 1350 1000 1700 1250 1580 1160 2000 1475 M30 660 490 850 625 1290 950 1630 1200 1850 1350 2300 1700 2140 1580 2700 2000 M33 900 665 1150 850 1750 1300 2200 1625 2500 1850 3150 2325 2900 2150 3700 2730 M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2770 4750 3500 Torque values listed are for general use only based on the strength Shear bolts are designed to fail under predetermined loads Always of the bolt or screw DO NOT use these values if a different torque replace shear bolts with identical property class Replace fasteners value or tightening procedure is given for a specific applica
61. 8 Power rangs 0 0 eee 60 3 Jor Molo erranen ies Chk Be eet eee haan 10 4 R K Radiator E EE 35 13 Recordkeeping Key switch 0000000 0 15 2 15 4 Engine option code 01 3 Index 2 110306 PN 2 Index Page Page Engine serial number 01 1 Vibration damper 0000 ee 40 3 Injection pump model number 01 5 S Ww Warming engine 15 12 SE number Wiring diagram Gate KEE Si 5 Except North America 50 5 ee EE North Amerca 50 3 Service BANE erer tat EE 30 5 Fire extinguisher aaa aaaaaaaaaaaannun 30 1 lat EE 20 2 20 4 Specifications Battery capabilities 30 5 Belt tensioner 00 eee eee eee 35 6 Rule EE 40 3 Engine crankcase oil fill 60 11 Fuel injection pump ee 60 3 ENEE 60 1 GE 60 2 Standby power unt 15 9 Starting engine 15 10 Stopping engine 15 16 Storage GUIGCIINGS see ee eee eae eee ee eae eee 8 55 1 Long rem 55 2 Removing from 55 3 Storing ue 10 2 Storing lubricants 00002000s 10 10 Supplemental coolant additives Replenishing ee eee 35 11 T Temperature gauge coolant 15 2 15 4 Tensioner belt DIER io stent ee ee ob be eee eo ewes 35 6 Manual seek ceicaecuey ee una ee enue cee 30 7 Thermostat Install pessas eh eee b ee Rh ee REE Ra e e 40 7 REMOVE 25 2 cb eleeuess 84 954594945045 40 7 Test opening temperature 40 7 Troublesh
62. 99 North American Standard Instrument Panels check the fuse in fuse holder E on front face of instrument panel Replace as necessary with an equivalent 14 amp fuse 3 For VDO Instrument Panels the fuse is located on the electronic control card inside the panel s rear access cover Remove cover and check fuse F If defective replace with a 10 amp fuse There is a spare fuse G available on the card in the SPARE terminal RG4496A UN 01JUNO1 A i North American 1998 Standard Instrument Panel Shown NOTE For main electrical system fuses see engine wiring diagrams later in this manual in Troubleshooting Section A 25 Amp Fuse B Ammeter C Key Switch D 14 Amp Fuse E Fuse Holder F 10 Amp Fuse G Spare Fuse RG11937 UN 170CT01 RG12067 UN 29JAN02 VDO Instrument Panel RG RG34710 5601__ 19 07JAN02 1 1 45 9 110306 PN 114 Service as Required Checking Air Compressor If Equipped Air compressors are offered as options with John Deere OEM engines to provide compressed air to operate air powered devices like vehicle air brakes Air compressors are engine driven piston types They are either air cooled or cooled with engine coolant The compressors are lubricated with engine oil The compressor runs continuously as gear or spline driven by the auxiliary drive of the engine but has loaded and unloaded operating modes This is controlled by the
63. D 2600 850 2800 138 185 16ZP RE509427 STD 2600 850 2800 138 185 165K RE503049 3 5 1500 1560 120 161 165L RE503834 3 5 1500 1560 120 161 6068TF250 1615 RE62366 RE69791 STD 2400 850 2600 138 185 1615 RE69791 STD 2400 850 2600 138 185 1619 RE67573 3 5 1800 1150 1870 124 166 1668 RE599692 STD 2400 850 2600 138 185 1685 RE67574 3 5 1800 1150 1870 124 166 1686 RE60131 RE69792 STD 2400 850 2600 138 185 1686 RE69792 STD 2400 850 2600 138 185 16CW RE501344 STD 2200 950 2400 106 142 16CX RE70390 STD 2300 900 2500 128 172 16GS RE503049 3 5 1500 1400 1560 120 161 16LT RE69791 STD 2400 850 2600 138 185 16LU RE67573 3 5 1800 1150 1870 124 166 16LX RE503834 3 5 1500 1400 1560 120 161 16MJ RE503744 3 5 1800 1400 1870 142 190 16MK RE504701 RE504968 3 5 1800 1400 1870 142 190 16MK RE504968 3 5 1800 1400 1870 142 190 163D RE516159 STD 2200 850 2400 125 168 16UG RE506956 RE504321 STD 2400 925 2600 149 200 16UG RE504321 STD 2400 925 2600 149 200 16YH RE59969 STD 2400 850 2600 138 185 6068TF251 1615 RE62366 STD 2400 850 2600 138 185 16ZH RE62366 STD 2400 850 2600 138 185 6068TF257 16GS RE503049 3 5 1500 1560 121 162 16LX RE503834 3 5 1500 1560 155 208 6068TF258 16GS RE503049 3 5 1500 1560 121 162 16LX RE503834 3 5 1500 1560 155 208 aln line fuel injection pump Continued on next page 60 10 OURGP11 000001D _ 19 130CT06 8 9 11030
64. DEC02 1 1 05 9 110306 PN 22 Safety Avoid Harmful Asbestos Dust Avoid breathing dust that may be generated when handling components containing asbestos fibers Inhaled asbestos fibers may cause lung cancer Components in products that may contain asbestos fibers are brake pads brake band and lining assemblies clutch plates and some gaskets The asbestos used in these components is usually found in a resin or sealed in some way Normal handling is not hazardous as long as airborne dust containing asbestos is not generated Avoid creating dust Never use compressed air for cleaning Avoid brushing or grinding material containing asbestos When servicing wear an approved respirator A special vacuum cleaner is recommended to clean asbestos If not available apply a mist of oil or water on the material containing asbestos Keep bystanders away from the area TS220 UN 23AUG88 DX DUST 19 15MAR91 1 1 Prevent Battery Explosions Keep sparks lighted matches and open flame away from the top of battery Battery gas can explode Never check battery charge by placing a metal object across the posts Use a volt meter or hydrometer Do not charge a frozen battery it may explode Warm battery to 16 C 60 F TS204 UN 23AUG88 DX SPARKS _ 19 03MAR93 1 1 05 10 110306 PN 23 Safety Handling Batteries Safely CAUTION Battery gas can explode Keep spa
65. Deere OEM Engines They may be provided by the equipment manufacturer instead of John Deere The following information applies only to those controls and gauges provided by John Deere IMPORTANT Any time an electric gauge or meter does not register correctly replace it with a new one Do not attempt to repair it Two types of instrument panels are offered on 4 5 L and 6 8 L engines as shown on this page See following for complete information on each type of instrument panel RG11299 UN 12SEP00 cuang conteo UN 19JUN00 3 T E ES i t VDO Instrument Panel Except North America RG10606A DPSG RG34710 107 _ 19 10JAN02 1 1 15 1 110306 PN 45 Engine Operating Guidelines Instrument Gauge Panel North America All controls and gauges are optional equipment for John Deere OEM Engines They may be provided by the equipment manufacturer instead of John Deere The following information applies only to those controls and gauges provided by John Deere IMPORTANT Any time an electric gauge or meter does not register correctly replace it with a new one Do not attempt to repair it Following is a brief description of the components on the instrument gauge panel A Oil Pressure Gauge This gauge indicates oil pressure It also has an adjustable electrical contact which activat
66. Deere equipment include such items as oil fuel coolant brake fluid filters and batteries Use leakproof containers when draining fluids Do not use food or beverage containers that may mislead someone into drinking from them Do not pour waste onto the ground down a drain or into any water source Air conditioning refrigerants escaping into the air can damage the Earth s atmosphere Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center or from your John Deere dealer TS1133 UN 26NOV90 DX DRAIN _ 19 03MAR93 1 1 05 13 110306 PN 26 Fuels Lubricants and Coolant Diesel Fuel Consult your local fuel distributor for properties of the diesel fuel available in your area In general diesel fuels are blended to satisfy the low temperature requirements of the geographical area in which they are marketed Diesel fuels specified to EN 590 or ASTM D975 are recommended Required fuel properties In all cases the fuel shall meet the following properties Cetane number of 45 minimum Cetane number greater than 50 is preferred especially for temperatures below 20 C 4 F or elevations above 1500 m 5000 ft Cold Filter Plugging Point CFPP below the expected low temperature OR Cloud Point at least 5
67. E63610 RE67562 3 5 1800 1150 1870 5 100 1656 RE67562 3 5 1800 1150 1870 5 100 1675 RE60091 RE69782 STD 2500 850 2700 6 115 1675 RE69782 STD 2500 850 2700 6 115 1676 RE60093 RE61668 STD 2500 850 2700 6 115 1676 RE61668 STD 2500 850 2700 6 115 1677 RE60096 RE67563 3 5 1800 1150 1870 5 100 1677 RE67563 3 5 1800 1150 1870 5 100 1692 RE61668 RE500881 STD 2500 1400 2700 6 115 1692 RE500881 RE502416 STD 2500 1400 2700 6 115 1692 RE502416 STD 2500 1400 2700 6 115 1694 RE67863 RE69779 STD 2500 850 2700 5 100 1694 RE69779 STD 2500 850 2700 5 100 1695 RE69739 RE69780 STD 2500 850 2700 5 100 1695 RE69780 STD 2500 850 2700 5 100 16AB RE69779 STD 2500 850 2700 5 100 16BF RE500848 STD 2200 950 2400 3 98 16CE RE501180 STD 2500 850 2700 75 100 16CM RE501365 STD 2200 950 2400 66 6 89 16GL RE502706 STD 2300 850 2500 78 105 Continued on next page 60 5 OURGP11 000001D _ 19 130CT06 3 9 110306 PN 140 Specifications POWER RATINGS ON DYNAMOMETER FOR OEM ENGINES Injection Original Replaced Pump Injection By Injection Rated No Load Power Option Pump Part Pump Part Governor Speed rpm Slow Idle Fast Idle Rating Engine Model Code No No Regulation At Full Load rpm rpm kW HP 16LP RE67562 3 5 1800
68. Enges 10 5 Diesel Engine Break In Oil 10 6 Diesel Engine OU 10 7 Extended Diesel Engine Oil Service Intervals 10 8 Mixing of Lubricants aaau anaana 10 8 OILSCAN and COOLSCAN 10 9 Alternative and Synthetic Lubricants 10 9 Lubricant Storage ee eae 10 10 lat 10 10 EE 10 11 Diesel Engine Coolant 10 12 Drain Intervals for Diesel Engine Coolant 10 13 Additional Information About Diesel Engine Coolants and Supplemental Coolant ee IEN 10 14 Supplemental Coolant Additives 10 15 Additional Information About Diesel Engine Coolants and Supplemental Coolant AGGIIVGS iva oid uid diets ae Ra ha ae Powe gadads 10 16 Testing Diesel Engine Coolant 10 17 Operating in Warm Temperature Climates 10 18 Disposing of Coolant 10 18 Engine Operating Guidelines Instrument Gauge Panels 15 1 Page Instrument Gauge Panel North America 15 2 VDO Instrument Gauge Panel Except North AMECA ccc ccosee eee cee eee eee ewe 15 4 Engine Break In Service 15 6 Auxiliary Gear Drive Limitations 15 9 Generator Set Standby Applications 15 9 Starting the Engine venras ancr aa aaa aa 15 10 Warming Engine 0 eee eee eee 15 12 Normal Engine Operation 15 13 Cold Weather Operation 15 14 Changing Engine Speed
69. OOL9_ 19 19DEC03 1 1 1 0 1 7 110306 PN 43 Fuels Lubricants and Coolant Operating in Warm Temperature Climates John Deere engines are designed to operate using glycol base engine coolants Always use a recommended glycol base engine coolant even when operating in geographical areas where freeze protection is not required IMPORTANT Water may be used as coolant 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 DX COOL6 19 18MAR96 1 1 Disposing of Coolant Improperly disposing of engine coolant can threaten the environment and ecology Use leakproof containers when draining fluids Do not use food or beverage containers that may mislead someone into drinking from them Do not pour waste onto the ground down a drain or into any water source Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center or from your John Deere engine distributor or servicing dealer TS1133 UN 26NOV390 Recycle Waste RG RG34710 7543 _ 19 110OCT06 1 1 10 18 110306 PN 44 Engine Operating Guidelines Instrument Gauge Panels All controls and gauges are optional equipment for John
70. Oil Code s Capacity L qt Code s Capacity L qt 4045DF120 1901 7 5 8 0 4045TF150 1903 12 0 12 7 1902 8 0 8 5 1904 13 5 14 3 1903 12 0 12 7 1923 15 0 15 8 1904 13 5 14 3 1949 12 5 13 2 1923 15 0 15 8 19AE 14 7 15 5 1949 12 0 12 7 19AE 14 7 15 5 4045TF151 1903 12 0 12 7 1934 12 5 13 2 4045DF150 1901 7 5 8 0 1936 12 5 13 2 1902 8 0 8 5 1903 12 0 12 7 4045TF152 1937 12 5 13 2 1904 13 5 14 3 1923 15 0 15 8 4045TF154 1904 13 5 14 3 1949 12 5 13 2 19AE 15 0 15 8 4045TF155 1937 12 5 13 2 4045DF 151 1901 7 5 8 50 4045TF157 1949 12 5 13 2 4045DF152 1902 8 0 8 5 4045TF158 1949 12 5 13 2 4045DF154 1937 12 5 13 2 4045TF161 1903 12 0 12 7 4045HF 120 1904 13 5 14 3 4045TF162 1903 12 0 12 7 1923 15 0 15 8 1949 12 5 13 2 4045TF220 1903 12 0 12 7 19AE 14 7 15 5 1904 13 5 14 3 1923 15 0 15 8 4045HF150 1904 13 5 14 3 1949 12 5 13 2 1921 16 5 17 4 19AE 14 7 15 5 1922 16 5 17 4 4045TF250 1903 12 0 12 7 1923 15 0 15 8 1904 13 5 14 3 1949 12 5 13 2 1923 15 0 15 8 19AE 14 7 15 5 1949 12 5 13 2 19AE 14 7 15 5 4045HF152 1962 14 0 14 8 4045TF251 1904 13 5 14 3 4045HF157 1949 12 5 13 2 4045TF252 19AE 14 7 15 5 4045HF158 1949 12 5 13 2 4045TF253 1937 12 5 13 2 4045HF252 19AE 14 7 15 5 4045TF257 1949 12 5 13 2 4045TF120 1903 12 0 12 7 Continued on next page 60 12 OURGP11 000001E__ 19 310CT06 2 4 1103
71. PowerTech 4 5 L and 6 8 L Non Certified and Tier 1 Certified OEM Diesel Engines OPERATOR S MANUAL PowerTech 4 5 L and 6 8 L Non Certified and Tier 1 Certified OEM Diesel Engines OMRG25204 Issue 02Nov06 ENGLISH CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm If this product contains a gasoline engine A WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm The State of California requires the above two warnings John Deere Power Systems LITHO IN U S A Introduction Foreword This manual contains information to operate and service the following 4 5 L amp 6 8 L non certified and Tier 11 emission certified OEM engines built at Dubuque lowa T0 Saran France CD and Torreon Mexico PE from 1996 on These engines have mechanically controlled fuel systems SARAN BUILT NON CERTIFIED ENGINES TORREON BUILT NON CERTIFIED ENGINES DUBUQUE BUILT NON CERTIFIED ENGINES SARAN BUILT TIER 1 CERTIFIED ENGINES CD4045DF 120 CD4045TF120 CD4045TF220 CD4045HF 120 CD6068TF120 CD6068TF220 CD6068HF 120 PE4045TF120 PE4045TF220 PE4045HF 120 PE6068TF120 PE6068TF220 PE6068HF 120 T04045DF 120 T04045TF120 T04045TF220 T04045HF 120 CD4045DF 150 CD4045DF
72. able oil Sulfuric Acid 3 Get medical attention immediately TS203 UN 23AUG88 In freezing weather run engine at least 30 minutes to assure thorough mixing after adding water to battery If necessary to replace battery ies replacements must meet or exceed the following recommended capacities at 18 C 0 F Specification 12 Volt Standard Duty Starter Gold Graking Bue 640 12 Volt Heavy Duty Starter Cold Cranking AMPS EE 800 24 Volt Standard Duty Starter Cold er Claus BEE 570 RG RG34710 5568_ 19 27JUL06 2 2 30 6 110306 PN 77 Lubrication amp Maintenance 250 Hour 6 Month Manual Belt Tensioner Adjustment NOTE Two types of manual tensioners shown NOTE Inspect belts for cracks fraying or stretched out areas Replace if necessary As a reference check twist belt in the middle of a 254 305 mm 10 12 in span with two fingers A properly tensioned belt will turn 75 85 degrees If belt turns more it needs to be tightened If belt turns less it needs to be loosened RG10556 UN 21DEC99 NOTE If timing gear cover or alternator bracket interfere with installation centering of belt tension gauge A install gauge with face toward engine 1 Install JDG1341 Belt Tension Gauge A on belt halfway between pulleys as shown JDG1341 Belt Tension Gauge available from local John Deere Dealer or Distributor 2 Loosen cap screws B and C RG10557 UN 21DEC99
73. ake system UN 08SEP00 6 Install new primary filter element Apply pressure by hand at outer rim of filter RG11327A IMPORTANT Do NOT use latches on cover to force Secondary Filter Element filter into air cleaner Using cover to force filter will damage cleaner housing A Du st Cap Cover B Primary Filter Element C Secondary Filter Element 7 Close housing with dust unloader valve aimed down and latch latches Continued on next page RG41165 000008B_ 19 27JUL06 1 2 45 6 110306 PN 111 Service as Required IMPORTANT Whenever the air cleaner has been serviced or cover has been removed ALWAYS fully depress the air restriction indicator reset button if equipped to assure accurate readings 8 If equipped fully depress air restriction indicator reset button and release to reset indicator RG41165 000008B_ 19 27JUL06 2 2 45 7 110306 PN 112 Service as Required Replacing Fan and Alternator Belts Refer to CHECKING BELT TENSIONER SPRING TENSION AND BELT WEAR in Lubrication and Maintenance 250 Hour 6 Month Section for additional information on the belt tensioner 1 5 6 Inspect belts for cracks fraying or stretched out areas Replace if necessary To replace belt with automatic tensioner release tension on belt using a breaker bar and socket if required on tension arm To replace belt with manual tensioner release tension at b
74. and COOLSCAN PLUS For a more thorough evaluation of your coolant perform a COOLSCAN or COOLSCAN PLUS analysis where available See your John Deere dealer for information DX COOL9_ 19 19DEC03 1 1 35 1 2 110306 PN 92 Lubrication amp Maintenance 500 Hour 12 Month Pressure Testing Cooling System Test Radiator Cap A CAUTION Explosive release of fluids from pressurized cooling system can cause serious burns Shut off engine Only remove filler cap when cool enough to touch with bare hands Slowly loosen cap to first stop to relieve pressure before removing completely Test Radiator Cap 1 Remove radiator cap and attach to D05104ST Tester as shown 2 Pressurize cap to specification listed Gauge should hold pressure for 10 seconds within the normal range if cap is acceptable If gauge does not hold pressure replace radiator cap Specification Radiator Cap Holding Pressure Not Opening For 10 Secondek Pressure A 70 kPa 0 7 bar 10 psi minimum 3 Remove the cap from gauge turn it 180 and retest cap This will verify that the first measurement was accurate Test Cooling System NOTE Engine should be warmed up to test overall cooling system RG6557 UN 20JAN93 RG6558 UN 20JAN93 Test Cooling System 1 Allow engine to cool then carefully remove radiator cap 2 Fill radiator with coolant to the normal operating level IMPORTANT DO NOT apply excessive pr
75. 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 TS201 UN 23AUG88 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 05 1 110306 PN 14 Safety Replace Safety Signs Replace missing or damaged safety signs See the machine operator s manual for correct safety sign placement TS201 UN 23AUG88 DX SIGNS1 _ 19 04JUN90 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 TS177 UN 11JAN89 DX BYPAS1_ 19 29SEP98 1 1 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 accumul
76. arness and instrument gauge panel Wiring diagrams are shown for the two types of instrument panels offered for these engines Later in this section is a list of possible engine problems that may be encountered accompanied by possible causes and corrections The illustrated diagrams and troubleshooting information are of a general nature final design of the overall system for your engine application may be different See your engine distributor or servicing dealer if you are in doubt A reliable program for troubleshooting engine problems should include the following basic diagnostic thought process e Know the engine and all related systems e Study the problem thoroughly e Relate the symptoms to your knowledge of engine and systems Diagnose the problem starting with the easiest things first e Double check before beginning the disassembly e Determine cause and make a thorough repair e After making repairs operate the engine under normal conditions to verify that the problem and cause was corrected RG RG34710 5605 19 07JAN02 1 1 50 1 110306 PN 120 Troubleshooting 50 2 110306 PN 121 Troubleshooting Engine Wiring Diagram Legend Standard Instrument Panel For North America A1 Speed Control Unit B1 Magnetic Speed Sensor B2 Coolant Temperature Sensor B3 Oil Pressure Sensor F1 Starting Circuit Fuse 14 amp F3 Fuse Early Models G1 Ba
77. ated trash grease and debris Always clean up spilled fuel TS202 UN 23AUG88 DX FIRE1 19 03MAR93 1 1 05 2 110306 PN 15 Safety Prepare for Emergencies Be prepared if a fire starts Keep a first aid kit and fire extinguisher handy Keep emergency numbers for doctors ambulance service hospital and fire department near your telephone TS291 UN 23AUG88 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 TS1356 UN 18MAR92 DX FIRE3 19 16APR92 1 1 Handle Fluids Safely Avoid Fires When you work around fuel do not smoke or work near heaters or other fire hazards Store flammable fluids away from fire hazards Do not incinerate or puncture pressurized containers Make sure machine is clean of trash grease and debris Do not store oily rags they can ignite and burn spontaneously 05 3 TS227 UN 23AUG88 DX FLAME _ 19 29SEP98 1 1 110306 PN 16 Safety Service Machines Safely Tie long hair behind your head Do not wear a necktie scarf loose clothing or necklace when you work near machine tools or moving parts If
78. ay Spray from high pressure nozzles can penetrate the skin and cause serious injury Keep spray from contacting hands or body If an accident occurs see a doctor immediately Any high pressure spray injected into the skin must be surgically removed within a few hours or gangrene may result Doctors unfamiliar with this type of injury should reference a knowledgeable medical source Such information is available from Deere amp Company Medical Department in Moline Illinois U S A TS1343 UN 18MAR92 DX SPRAY 19 16APR92 1 1 Use Proper Lifting Equipment Lifting heavy components incorrectly can cause severe injury or machine damage Follow recommended procedure for removal and installation of components in the manual TS226 UN 23AUG88 S DX LIFT 19 04JUN90 1 1 in ET Use tools appropriate to the work Makeshift tools and procedures can create safety hazards Use power tools only to loosen threaded parts and fasteners For loosening and tightening hardware use the correct size tools DO NOT use U S measurement tools on metric fasteners Avoid bodily injury caused by slipping wrenches TS779 UN 08NOV89 Use only service parts meeting John Deere specifications DX REPAIR 19 17FEB99 1 1 05 12 110306 PN 25 Safety Dispose of Waste Properly Improperly disposing of waste can threaten the environment and ecology Potentially harmful waste used with John
79. below 22 F 30 C or at altitudes above Minimum Cranking RPM SE 1500 m 5000 ft 103 100 1 Follow steps 1 4 as listed under then proceed as follows according to the instrument gauge panel on 100 your engine 100 2 Switch on the air intake heater for 30 seconds or activate ether injector by following suppliers RG11521 instructions 3 Follow remaining steps 5 8 as listed under earlier in this section Additional information on cold weather operation is available from your authorized servicing dealer Se Ss Handle Starting Fluid with Care 3 41 F H s c 2 2 3 32 F Wl orc YEL S H y 14 F H 10c A o F Wl 18 C 4 F 20 C 13 F H 25 C 22 F H 30 C 31 F H AC ee Ze 40 F H 40 C Cold Weather Starting Guidelines RG RG34710 5050 _ 19 08JAN02 1 1 TS1356 UN 18MAR92 RG11521 19 10JAN01 15 14 110306 PN 58 Engine Operating Guidelines Changing Engine Speed To increase engine speed turn throttle handle A if equipped to the horizontal position and pull out until desired engine speed is obtained Turn the handle in either direction to lock throttle position The handle is pushed inward to decrease engine speed NOTE On engines without handle use throttle lever to control engine speed A Throttle Handle UN 11SEP00 RG112991 North American Standard Instrument Panel Shown RG RG34710 5561 _
80. c vehicle application requirements Refer to your Engine Power Ratings And Fuel Injection Pump Specifications machine technical manual for engine speeds that are different from those preset at the factory Power ratings specify flywheel power for a bare engine without the drag effect of a cooling fan or other accessories like an air compressor 60 3 POWER RATINGS ON DYNAMOMETER FOR OEM ENGINES Injection Original Replaced Pump Injection By Injection Rated No Load Option Pump Part Pump Part Governor Speed rpm Slow Idle Fast Idle Engine Model Code No No Regulation At Full Load rpm rpm 4045DF120 16MR RE504463 STD 2500 850 2700 16MS RE504464 STD 2500 850 2700 165F RE503729 3 5 1500 1560 165G RE504693 3 5 1500 1560 16RB RE503729 3 5 1500 1560 16RC RE504693 3 5 1500 1560 16ZW RE509527 3 5 2500 850 2700 16ZX RE509528 3 5 2500 850 2700 16ZY RE509529 3 5 2500 850 2700 4045DF150 1601 RE61649 RE67557 STD 2500 850 2700 1601 RE67557 STD 2500 850 2700 1602 RE59809 STD 2500 850 2700 1603 RE63555 RE67558 3 5 1800 1150 1870 1603 RE67558 RE505070 3 5 1800 1150 1870 1603 RE505070 RE506132 3 5 1800 1150 1870 1603 RE506132 3 5 1800 1150 1870 1663 RE71089 RE500949 STD 2500 1600 2700 1663 RE500949 STD 2500 1600 2700 1671 RE67559 RE502714 STD 2500 850 2700 1
81. ck positions to unlock the throttle J Tachomeier Binary Code The tachometer is calibrated to the number of flywheel gear teeth read The dip switch to set the binary code is located in back of tachometer and must be set at 10110011 to operate at 30 pulses per revolution DPSG RG34710 108 19 08JAN02 2 2 15 3 110306 PN 47 Engine Operating Guidelines VDO Instrument Gauge Panel Except North America All controls and gauges are optional equipment for John Deere OEM Engines They may be provided by the equipment manufacturer instead of John Deere The following information applies only to those controls and gauges provided by John Deere IMPORTANT Any time an electric gauge or meter does not register correctly replace it with a new one Do not attempt to repair it Following is a brief description of the components on the instrument gauge panel A Oil Pressure Gauge The oil pressure gauge indicates engine oil pressure B Coolant Temperature Gauge The coolant temperature gauge indicates coolant temperature C Tachometer The tachometer indicates engine speed in hundreds of revolutions per minute rpm The engine control system consists of the following D Engine Control Light The engine control light illuminates after the engine has started and oil pressure is up to specification The light indicates that the engine protection circuitry is activated E Preheater Li
82. content of the fuel regularly DX FUEL4 19 19DEC03 1 1 Testing Diesel Fuel DIESELSCAN is a John Deere fuel analysis program that can be used to monitor the quality of your fuel The DIESELSCAN analysis verifies fuel type cleanliness water content suitability for cold weather operation and whether the fuel meets specifications Check with your John Deere dealer for availability of DIESELSCAN kits DIESELSCAN is a trademark of Deere amp Company DX FUEL6 19 14NOV05 1 1 10 2 110306 PN 28 Fuels Lubricants and Coolant Bio Diesel Fuel Consult your local fuel distributor for properties of the bio diesel fuel available in your area Bio diesel fuels may be used ONLY if the bio diesel fuel properties meet the latest edition of ASTM D6751 EN 14214 or equivalent specification It is recommended to purchase bio diesel fuel blended with B100 from a BQ 9000 Accredited Producer or a BQ 9000 Certified Marketer as recommended by the National Bio diesel Board The maximum allowable bio diesel concentration is a 5 blend also known as B5 in petroleum diesel fuel It has been found that bio diesel fuels may improve lubricity in concentrations up to this 5 blend When using a blend of bio diesel fuel the engine oil level must be checked daily when the air temperature is 10 C 14 F or lower If oil becomes diluted with fuel shorten oil change intervals accordingly IMPORTANT Raw pressed ve
83. cooling system 3 Remove thermostat cover to water pump tube A and seal A Cover To Coolant Pump Tube Thermostat Cover to Water Pump Tube ice D Z lt EN Vi T z 7 RG8115A DPSG RG34710 112 19 07JAN02 1 5 TS281 UN 23AUG88 4 Remove thermostat cover B with gasket 5 Remove thermostat s 6 Remove and discard all gasket material Clean gasket surfaces 7 Clean and check cover for cracks or damage B Thermostat Cover Thermostat Cover 40 7 UN 13NOV97 RG7921A Continued on next page DPSG RG34710 112 19 07JAN02 2 5 110306 PN 100 Lubrication amp Maint 2000 Hour 24 Month Testing Thermostats Opening Temperature 1 Remove thermostat s 2 Visually inspect thermostat s for corrosion or damage If dual thermostats replace as a matched set as necessary A CAUTION DO NOT allow thermostat or thermometer to rest against the side or bottom of container when heating water Either may rupture if overheated 3 Suspend thermostat and a thermometer in a container of water 4 Stir the water as it heats Observe opening action of thermostat and compare temperatures with the specification given in chart below NOTE Due to varying tolerances of different suppliers initial opening and full open temperatures may vary slightly from specified temperatures Rating 71 C 160 F 77 C 170 F 82 C 180 F 89 C 192 F
84. d the flushing interval may be extended to 3000 hours or 36 months If John Deere COOL GARD is used and the coolant is tested annually AND additives are replenished as needed by adding a supplemental coolant additive the flushing interval may be extended to 5000 hours or 60 months whichever occurs first Continued on next page 20 2 OURGP11 0000006_ 19 130CT06 1 2 110306 PN 64 Lubrication and Maintenance Lubrication and Maintenance Service Intervals 250 Hour 500 Hour 2000 Hour Item Daily 6 Month 12 Month 24 Month As Required Check Air Compressor If Equipped e Bleed Fuel System OURGP11 0000006 _ 19 130CT06 2 2 20 3 110306 PN 65 Lubrication and Maintenance Lubrication and Maintenance Service Interval Chart Generator Standby Applications NOTE Use service intervals listed below for generator standby applications Match service items below to titles in Lubrication and Maintenance Sections for procedures Lubrication and Maintenance Service Intervals Every 2 250 Hours or 500 Hours or 2000 Hours Item Weeks 12 Months 12 Months or 24 Months As Required Operate Engine at Rated Speed and 50 70 Load a Minimum of 30 Minutes Check Engine Oil and Coolant Level e Check Fuel Filter s Water Separator Bowl e Check Air Cleaner Du
85. dealer or engine distributor QUOD006 000004C _ 19 130CT06 4 7 50 10 110306 PN 129 Troubleshooting Symptom Problem Solution Engine overheats Engine overloaded Reduce load Low coolant level Fill radiator to proper level check radiator and hoses for loose connections or leaks Faulty radiator cap Have serviceman check Stretched poly vee belt or defective Check automatic belt tensioner and belt tensioner check belts for stretching Replace as required Low engine oil level Check oil level Add oil as required Cooling system needs flushing Flush cooling system Defective thermostat Remove and check thermostat Defective temperature gauge or Check water temperature with sender thermometer and replace if necessary Incorrect grade of fuel Use correct grade of fuel High fuel consumption Improper type of fuel Use proper type of fuel Clogged or dirty air cleaner Service air cleaner Engine overloaded Reduce load Improper valve clearance See your authorized servicing dealer or engine distributor Injection nozzles dirty See your authorized servicing dealer or engine distributor Engine out of time See your authorized servicing dealer or engine distributor Defective turbocharger See your authorized servicing dealer or engine distributor Low engine temperature Check thermostat Continued on next page OQUOD006 000004C_ _ 19 130CT06 5 7 50 1 1 110306 PN 130 T
86. dicator Gauge RG7332A A Dust Unloader Valve 5 Make a thorough inspection of the engine B Air Restriction Indicator compartment Look for oil or coolant leaks worn fan and accessory drive belts loose connections and trash build up Remove trash buildup and have repairs made as needed if leaks are found NOTE Wipe all fittings caps and plugs before performing any maintenance to reduce the chance of system contamination Inspect e Radiator for leaks and trash build up e Air intake system hoses and connections for cracks and loose clamps e Fan alternator and accessory drive belts for cracks breaks or other damage e Water pump for coolant leaks NOTE It is normal for a small amount of leakage to occur as the engine cools down and parts contract Excessive coolant leakage may indicate the need to replace the water pump seal Contact your engine distributor or servicing dealer for repairs OURGP12 0000048 _ 19 130CT06 4 4 25 4 110306 PN 71 Lubrication amp Maintenance 250 Hour 6 Month Servicing Fire Extinguisher A fire extinguisher A is available from your authorized servicing dealer or engine distributor Read and follow the instructions which are packaged with it The extinguisher should be inspected at least every 250 hours of engine operation or once a month Once extinguisher is operated no matter how long it must be recharged Keep record of inspections on the
87. e 250 Hour 6 Month 9 Fill engine crankcase with correct John Deere engine oil through rocker arm cover opening B or either side oil filler C depending on engine application See DIESEL ENGINE OIL in Fuels Lubricants and Coolant Section for determining correct engine oil To determine the correct oil fill quantity for your engine see ENGINE CRANKCASE OIL FILL QUANTITIES in the Specifications Section of this manual IMPORTANT Immediately after completing any oil change crank engine for 30 seconds without permitting engine to start This will help insure adequate lubrication to engine components before engine starts NOTE Crankcase oil capacity may vary slightly ALWAYS fill crankcase to full mark or within crosshatch on dipstick whichever is present DO NOT overfill 10 Start engine and run to check for possible leaks 11 Stop engine and check oil level after 10 minutes Oil level reading should be within crosshatch of dipstick Side Oil Filler B Rocker Arm Cover Oil Filler C Side Oil Filler UN 19JUNO0 RG8025A o S Ka 2 E 7 ya I a st D O Es O a OURGP12 0000078 _ 19 310CT06 3 3 Checking Engine Mounts Engine mounting is the responsibility of the vehicle or generator manufacturer Follow manufacturer s guidelines for mounting specifications IMPORTANT Use only Grade SAE 8 or higher grade of hardware for engine mounting 1 Check the engine mounting
88. e Deere amp Company Medical Department in Moline Illinois or other knowledgeable medical source 1 Close fuel shut off valve if equipped 2 Thoroughly clean fuel filter assemblies and surrounding area RG13543 UN 21JUL04 Dual Fuel Filters Final Filter at Left Primary Filter with Bowl at NOTE Perform the following steps on each fuel filter Right 3 Loosen drain plug C and drain fuel into a suitable A Retaining Ring container B Filter Element C Drain Plug NOTE Lifting up on retaining ring as it is rotated helps to D BieediPlug get it past raised locators 4 Firmly grasp the retaining ring A and rotate it clockwise 1 4 turn when viewed from top Remove ring with filter element B 5 Inspect filter mounting base for cleanliness Clean as required 6 On primary filter with water separator remove filter element from water separator bowl Drain and clean separator bowl Dry with compressed air Install water separator bowl onto new element Tighten securely Continued on next page OURGP12 000004B 19 130CT06 1 2 35 5 110306 PN 85 Lubrication amp Maintenance 500 Hour 12 Month NOTE Raised locators on fuel filter canister must be indexed properly with slots in mounting base for correct installation 7 Install new filter element onto mounting base Be sure element is properly indexed and firmly seated on base It may be necessary to rotate filter for correct alignmen
89. eating of turbocharger parts may occur when oil flow is stopped 8 Check all gauges for normal engine operation If operation is not normal stop the engine and determine the cause 15 11 UN 180CT01 RG11299X ENGINE CONTROL On d r e E RG11610 UN 170CT01 VDO Standard Instrument Panel Except North America A Hand Throttle B Reset Button C Key Start Switch D Oil Pressure Gauge RG RG34710 5557 _ 19 07JAN02 2 2 110306 PN 55 Engine Operating Guidelines Warming Engine IMPORTANT To assure proper lubrication operate engine at or below 1200 rpm with no load for 1 2 minutes Extend this period 2 4 minutes when operating at temperatures below freezing Engines used in generator set applications where the governor is locked at a specified speed may not have a slow idle function Operate these engines at high idle for 1 to 2 minutes before applying the load This procedure does not apply to standby generator sets where the engine is loaded immediately upon reaching rated speed 1 Check oil pressure gauge A as soon as engine starts If gauge needle does not rise above minimum oil pressure specification of 105 kPa 1 05 bar 15 0 psi within 5 seconds stop the engine and determine the cause Normal engine oil pressure is 345 kPa 3 45 bar 50 psi at rated full load speed 1800 2500 rpm
90. ed from cooling system when system is refilled Loosen temperature sending unit fitting at rear of cylinder head or plug in thermostat housing to allow air to escape when filling system Retighten fitting or plug when all the air has been expelled 1 Visually check entire cooling system for leaks Tighten all clamps securely 2 Thoroughly inspect all cooling system hoses for hard flimsy or cracked condition Replace hoses if any of the above conditions are found High Pressure Fluids TS281 UN 23AUG88 RG RG34710 5580 _ 19 20MAY96 1 1 35 10 110306 PN 90 Lubrication amp Maintenance 500 Hour 12 Month Replenishing Supplemental Coolant Additives SCAs Between Coolant Changes RG6261 UN 08DEC97 RG6241 Radiator Coolant Check IMPORTANT Do not add supplemenial coolant additives when the cooling system is drained and refilled with John Deere COOL GARD NOTE If system is to be filled with coolant that does not contain SCAs the coolant must be precharged Determine the total system capacity and premix with 3 John Deere Coolant Conditioner Through time and use the concentration of coolant additives is gradually depleted during engine operation Periodic replenishment of inhibitors is required even when John Deere COOL GARD is used The cooling system must be recharged with additional supplemental coolant additives available in the form of liquid coolant conditioner Ma
91. elt tensioner See MANUAL BELT TENSIONER ADJUSTMENT in Lubrication and Maintenance 250 Hour 6 Month Section Remove poly vee belt from pulleys and discard belt Install new belt making sure belt is correctly seated in all pulley grooves Refer to belt routing at right for your application Apply tension to belt with tensioner Remove socket Start engine and check belt alignment Measured from crank centerline to fan drive center A Alternator CSP Crankshaft Pulley FC Freon A C Compressor FD Fan Drive I Idler Pulley T Tensioner CP Coolant Pump 290 mm 11 4 in Fan Height and Lower 338 mm 13 3 in Fan Height and Higher Without Freon Compressor 402 mm 15 8 in Fan Height With Freon Compressor OURGP12 000004C _ 19 29JUL04 1 1 RG11950 UN 07NOV01 RG11951 UN 07NOV01 RG11952 UN 07NOV01 45 8 110306 PN 113 Service as Required Checking Fuses In Instrument Panels The following instructions apply to engines equipped with John Deere instrument panels 1 On Engines With The North American Standard Instrument Panel 1998 check the fuse A between the ammeter B and key switch C located on back side of instrument panel If defective replace with an equivalent 25 amp fuse RG4493 UN 14DEC88 Also check the fuse D mounted on the bottom of the magnetic safety switch If defective install an equivalent 14 amp fuse 2 On later 19
92. enth digit of the serial number as B while Tier 1 certified engines have the seventh digit as C READ THIS MANUAL carefully to learn how to operate and service your engine correctly Failure to do so could result in personal injury or equipment damage THIS MANUAL SHOULD BE CONSIDERED a permanent part of your engine and should remain with the engine when you sell it MEASUREMENTS IN THIS MANUAL are given in both metric and customary U S unit equivalents Use only correct replacement parts and fasteners Metric and inch fasteners may require a specific metric or inch wrench RIGHT HAND AND LEFT HAND sides are determined by standing at the drive or flywheel end rear of the engine and facing toward the front of the engine WRITE ENGINE SERIAL NUMBERS and option codes in the spaces indicated in the Record Keeping Section Accurately record all the numbers Your dealer also needs these numbers when you order parts File the identification numbers in a secure place off the engine SETTING FUEL DELIVERY beyond published factory specifications or otherwise overpowering will result in loss of warranty protection for this engine CERTAIN ENGINE ACCESSORIES such as radiator air cleaner and instruments are optional equipment on John Deere OEM Engines These accessories may be provided by the equipment manufacturer instead of John Deere This operator s manual applies only to the engine and those options available through the Jo
93. er Engine NOTE Firing order is 1 3 4 2 1 Using JDE81 4 Timing Pin lock No 1 piston at TDC compression stroke B Adjust valve clearance on No 1 and 3 exhaust valves and No 1 and 2 intake valves Turn crankshaft 360 Lock No 4 piston at TDC compression stroke C 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 TDC Compression C No 4 Piston TDC Compression E Exhaust Valve I Intake Valve RG4776 UN 310CT97 Cylinder Engine Valve Adjustment DPSG RG41165 137 _ 19 16JAN02 4 5 6 Cylinder Engine NOTE Firing order is 1 5 3 6 2 4 1 2 Lock No 1 piston at TDC compression stroke B Adjust valve clearance on No 1 3 and 5 exhaust valves and No 1 2 and 4 intake valves Turn crankshaft 360 Lock No 6 piston at TDC compression stroke C Adjust valve clearance on No 2 4 and 6 exhaust valves and No 3 5 and 6 intake valves RG4777 UN 310CT97 6 Cylinder Engine Valve Adjustment A Front of Engine B No 1 Piston TDC Compression C No 6 Piston TDC Compression E Exhaust Valve I Intake Valve DPSG RG41165 137 _ 19 16JAN02 5 5 40 12 110306 PN 105 Service as Required Additional Service Information This is not a detailed service manual If you want more detailed service information use the form in the back of this
94. es the safety switch when oil pressure goes below the pressure set point This will automatically stop the engine RG11299B UN 17AUG00 B Coolant Temperature Gauge This gauge indicates coolant temperature It also has an electrical contact which activates the safety switch when coolant temperature goes above the temperature set point This will automatically stop the engine C Key Switch The key switch is used to start and stop the engine A key is required to operate the switch so as to prevent unauthorized operation of the engine D Tachometer The tachometer indicates engine speed in hundreds of revolutions per minute rpm RG10607 UN 190CT99 E Safety Switch Reset Button The safety switch Hour Meter And Tachometer Codes de energizes the fuel shut off solenoid or injection rack puller to stop the engine if one or more conditions are A Oil Pressure Gauge t B Coolant Temperature Gauge Mer C Key Switch D Tachometer e Low or no oil pressure E Reset Safety Switch e High coolant temperature F Fuse Holder 14 Amp Fuse e Low crankcase oil level if equipped with engine oil level G Ammeter itch H Hourmeter switch l l l a I Hand Throttle High crankcase oil level if equipped with engine oil J Tachometer Binary Code level switch Continued on next page DPSG RG34710 108 19 08JAN02 1 2 1 5 2 110306 PN 46 Engine Operating Guidelines The reset button has t
95. essure to cooling system doing so may damage radiator and hoses 3 Connect gauge and adapter to radiator filler neck Pressurize cooling system to specification listed for radiator cap 4 With pressure applied check all cooling system hose connections radiator and overall engine for leaks If leakage is detected correct as necessary and pressure test system again If no leakage is detected but the gauge indicated a drop in pressure coolant may be leaking internally within the system or at the block to head gasket Have your engine distributor or servicing dealer correct this problem immediately RG RG34710 5586 _ 19 07JAN02 1 1 35 1 3 110306 PN 93 Lubrication amp Maint 2000 Hour 24 Month Adjusting Variable Speed Droop on Generator Set Engines Stanadyne Mechanical Injection Pumps Only 1 Warm engine to normal operating temperature 2 When necessary disconnect throttle linkage or cable 3 Adjust slow idle C and adjust fast idle B speed when necessary 4 Run engine at fast idle then apply load until reaching S rated speed 5 Check power Adjust with the screw A if needed g 6 Remove load from engine g Droop Adjustment Screw 7 Again check and adjust fast idle if screw A has been A Adjustment Screw turned B Fast Idle Adjustment C Slow Idle Adjustment 8 Repeat procedure until both the engine power and the fast idle speed are correct 9 Reinstall throttle
96. ext page OURGP11 0000007 19 310CT06 1 2 20 4 110306 PN 66 Lubrication and Maintenance Lubrication and Maintenance Service Intervals Every 2 250 Hours or 500 Hours or 2000 Hours Item Weeks 12 Months 12 Months or 24 Months As Required Replace Poly Vee Belt e Check Fuses Check Air Compressor If Equipped Bleed Fuel System OURGP11 0000007 19 31OCT06 2 2 20 5 110306 PN 67 Lubrication amp Maintenance Daily 7 Daily Prestarting Checks Do the following BEFORE STARTING THE ENGINE for the first time each day IMPORTANT DO NOT add makeup oil until the oil level is BELOW the add mark 1 Check engine oil level on dipstick Add as required using seasonal viscosity grade oil See DIESEL ENGINE OIL in Fuels Lubricants and Coolant Section for oil specifications Depending on application oil may be added at left A or right B side oil filler cap and rocker arm cover filler cap C locations IMPORTANT DO NOT fill above the top mark on the dipstick Oil levels anywhere within crosshatch D are considered in the acceptable operating range A Left Side Oil Filler Cap B Right Side Oil Filler Cap C Cover Oil Filler Cap D Crosshatch On Dipstick Rocker Arm Cover Filler Cap RG8028B UN 15JAN99 Crosshatch on Dipstick UN 16JUNO00 lt x E So Es O a UN 16JUNO00 RG8054A RG8025B UN 16JUN00
97. g the light will illuminate and protection circuitry will stop the engine The battery light will remain on indicating the engine was stopped due to the alternator not charging H Oil Pressure Light The oil pressure light illuminates when the key switch is turned to the bulb test position position I The light will remain on until the engine is started and the specified oil pressure is reached If oil pressure is lost during engine operation the light will illuminate and protection circuitry will stop the engine The oil pressure light will remain on indicating that the engine was stopped due to a low oil pressure condition I Coolant Temperature Light The coolant temperature light illuminates when the key is turned to the bulb test position position I It should go off after approximately five seconds After the engine is running if the engine overheats the light will illuminate and protection circuitry will stop the engine The coolant temperature light will remain on indicating the engine was stopped due to the engine overheating Other components on the instrument panel J Key Siart Switch The four position key start switch controls the electrical system K Hour Meter The hour meter is an integral part of the tachometer It shows the accumulated hours of engine service The hour meter operates when the engine is running and accumulated hours are displayed in hours and tenths of hours DPSG RG34710 109 _
98. ge OURGP11 0000005 19 24JUN04 2 2 01 4 110306 PN 12 Record Keeping Record Fuel Injection Pump Model Number Record the fuel injection pump model and serial information found on the serial number plate A Model No RPM Manufacturer s No Serial No A Serial Number Plate UN 13JUNO00 RG8008A a Record Injection Pump Serial Number RG RG34710 5511 19 20MAY96 1 1 01 5 110306 PN 13 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 T81389 UN 07DEC88 DX ALERT 19 29SEP98 1 3 1 Understand Signal Words 4 DANGER 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 A WARNING specific hazards General precautions are listed on CAUTION safety signs CAUTION also calls attention to safety messages in this manual A CAUTION DX SIGNAL _ 19 03MAR93 1 1 TS187 19 30SEP88 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
99. getable oils are NOT acceptable for use as fuel in any concentration in John Deere engines These oils do not burn completely and will cause engine failure by leaving deposits on injectors and in the combustion chamber A major environmental benefit of bio diesel fuel is its ability to biodegrade This makes proper storage and handling of bio diesel fuel especially important Areas of concern include e Quality of new fuel e Water content of the fuel e Problems due to aging of the fuel Potential problems resulting from deficiencies in the above areas when using bio diesel fuel in concentrations above 5 may lead to the following symptoms Power loss and deterioration of performance Fuel leakage Corrosion of fuel injection equipment Coked and or blocked injector nozzles resulting in engine misfire Filter plugging Lacquering and or seizure of internal components Sludge and sediments Reduced service life of engine components Consult your fuel supplier for additives to improve storage and performance of bio diesel fuels DX FUEL7 19 14NOV05 1 1 10 3 110306 PN 29 Fuels Lubricants and Coolant Aviation Jet Fuels Aviation jet fuels may be used with the following restrictions Type Comments Jet A Lower viscosity and density than base No 2 D diesel fuel Power loss up to 10 can be expected Jet A 1 Lower viscosity and density than base No 2 D diesel f
100. ght The preheater light illuminates when the key is turned to the bulb test position position 1 It should go off after approximately five seconds When the key switch is held in position Il the engine preheater is energized and the preheater light illuminates F Fuel Level Light The fuel level light illuminates when the key is turned to the bulb test position position 1 It should go off after approximately five seconds After the engine is running if the engine runs out of fuel the light will illuminate and protection circuitry will stop the engine The fuel level light will remain on indicating the engine was stopped due to the fuel tank being empty ENGINE CONTROL dl Olai VDO Instrument Panel A Oil Pressure Gauge B Coolant Temperature Gauge C Tachometer D Engine Control Light E Preheater Light F Fuel Level Light G Battery Light H Oil Pressure Light I Coolant Temperature Light J Key Start Switch K Hour Meter RG10606B UN 200CT99 Continued on next page DPSG RG34710 109 19 O08JAN02 1 2 15 4 110306 PN 48 Engine Operating Guidelines G Baittery Light The battery light illuminates when the key is turned to the bulb test position position I It should go off after approximately five seconds After the engine is running if the alternator stops chargin
101. hecking Rocker Arm to Valve Tip Engine Cold Clearance ceeeeceeseeeeeeeneeeeeeees 0 31 0 38 mm 0 012 0 015 in Exhaust Valve Clearance For Checking Rocker Arm to Valve Tip Engine Cold Clearance eeeeeeeeseseeeeeneeneeeees 0 41 0 48 mm 0 016 0 019 in DPSG RG41165 137 19 16JAN02 2 5 5 If valves need adjusting use the appropriate valve clearance adjustment procedure on the next page and adjust to specifications below Loosen the jam nut A 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 jam nut to specifications Recheck clearance again after tightening jam nut Readjust clearance as necessary Specification o E O lt o T Zz j E Gi N O oc Intake Valve Clearance For Adjusting Rocker Arm to Valve Tip Engine Cold Clearance ceeeeseeeeeereeees 0 36 mm 0 014 in Exhaust Valve Clearance For Adjusting Rocker Arm to Valve Adjusting Valves A Adjusting Screw Jam Nut Tip Engine Cold Clearance ceeeeeseeeereenes 0 46 mm 0 018 in Rocker Arm Adjusting Screw Jam NUT Ree TEE 27 Nem 20 lb ft 6 Replace rocker arm cover and crankcase ventilator tube Continued on next page DPSG RG41165 137__ 19 16JAN02 3 5 40 11 110306 PN 104 Lubrication amp Maint 2000 Hour 24 Month 4 Cylind
102. hn Deere distribution network NOTE This operators manual covers only engines provided to OEM Outside Equipment Manufacturers For engines in Deere machines refer to the machine operators manual OURGP11 0000004_ 19 270CT06 2 2 110306 PN 3 Introduction Engine Owner John Deere Engine Owner Don t wait until you need warranty or other service to meet your local John Deere Engine Distributor or Service Dealer To register your engine for warranty via the Internet use the following URL http www johndeere com enginewarranty Learn who your dealer is and where he is At your first convenience go meet him Hell want to get to know you and to learn what your needs might be Aux Utilisateurs De Moteurs John Deere N attendez pas d tre oblig d avoir recours a votre concessionnaire John Deere ou au point de service le plus proche pour vous adresser a lui Pour enregistrer votre moteur pour la garantie via Internet utilisez l adresse suivante http www johndeere com enginewarranty Renseignez vous d s que possible pour l identifier et le localiser A la premi re occasion prenez contact avec lui et faites vous conna tre sera lui aussi heureux de faire votre connaissance et de vous proposer ses services le moment venu An Den Besitzer Des John Deere Motors Warten Sie nicht auf einen evt Reparaturfall um den nachstgelegenen John Deere Handler kennen zu lernen Zur Registrierung Ihre
103. ies for 24 volt electrical systems 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 CH post of the booster battery 5 ALWAYS complete the hookup by making the last connection of the NEGATIVE cable to a good ground on the engine frame and away from the battery ies 2 O 2 lt x E A Sal t S N ZS O UI H Z R g 0 es 2 O UI H Z 2 0 e 24 Volt System A 12 Volt Machine Battery ies B 12 Volt Booster Battery ies C Booster Cable D Cable to Starting Motor Continued on next page RG RG34710 5564 19 27JUL06 1 2 15 17 110306 PN 61 Engine Operating Guidelines 6 Start the engine Disconnect jumper cables immediately after engine starts Disconnect NEGATIVE cable first RG RG34710 5564 19 27JUL06 2 2 15 18 110306 PN 62 Lubrication and Maintenance Observe Service Intervals Using hour meter A as guide perform all services at the hourly intervals indicated on following pages At each scheduled maintenance interva
104. igh idle adjusting screw until 1500 rpm is obtained at the specified power Screw in idle bumper spring until engine speed increases 5 10 rpm Repeat steps 4 through 7 until governor regulation is within the 5 7 range 10 Replace all cap nuts onto adjusting screws and tighten lock nuts securely D S O S Ss Zz D D 0 D DENSO In Line Injection Pump A Fast Idle Stop Screw B Droop Adjusting Screw Access Plug Location C Droop Adjusting Screw D Slow Idle Adjusting Screw E lIdle Bumper Spring F Throttle Lever G Mechanical Shutoff Lever Continued on next page RG RG34710 5583 19 28JAN02 2 3 40 2 110306 PN 95 Lubrication amp Maint 2000 Hour 24 Month Delphi Lucas Injection Pumps Only See your authorized Delphi Lucas Repair Station for speed droop adjustment This service requires that an internal pump adjustment be made RG RG34710 5583 _ 19 28JAN02 3 3 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 60 months whichever occurs first E E zZz ES E Dei 7 Es I ES SS Ei Es O a 3 Check vibration damper radial runout
105. ighlights of safety operating maintenance and service information These tapes may be available in multiple languages and formats TECHNICAL MANUALS outlining service information for your machine Included are specifications illustrated assembly and disassembly procedures hydraulic oil flow diagrams and wiring diagrams Some products have separate manuals for repair and diagnostic information Some components such as engines are available in separate component technical manuals FUNDAMENTAL MANUALS detailing basic information regardless of manufacturer Agricultural Primer series covers technology in farming and ranching featuring subjects like computers the Internet and precision farming Farm Business Management series examines real world problems and offers practical solutions in the areas of marketing financing equipment selection and compliance Fundamentals of Services manuals show you how to repair and maintain off road equipment 15 1 Continued on next page THE PRECISION FARMING GUIDE FOR AGAICULTURISTS il e ga TS224 UN 17JAN89 TS189 UN 17JAN89 A TS191 UN 02DEC88 TS1663 UN 100CT97 DX SERVLIT _ 19 31JUL03 1 2 110306 PN 158 John Deere Service Literature Available Fundamentals of Machine Operation manuals explain machine capacities and adjustments how to improve machine performance and how to eliminate unnecessary fie
106. ightly loosen fuel return line connector A at fuel injection pump 2 Operate fuel supply pump primer lever until fuel without air bubbles flows from fuel return line connection 3 Tighten return line connector to 27 Nem 20 lb ft 4 Primer lever is spring loaded and will return to normal position Stanadyne Rotary Fuel Injection Pump A Fuel Return Line Connector OURGP11 000000D RG6264 UN 03NOV97 19 180CT06 4 7 On Lucas rotary pumps 1 Loosen bleed screw B on pump cover NOTE On Models DP200 201 203 Injection Pumps bleed screw is located on top of cover near the fuel return line 2 Operate fuel supply pump primer lever or turn ignition switch to ON 3 Wait until fuel flow is free of air bubbles Tighten bleed screw 4 Primer lever is spring loaded and will return to normal position CAUTION NEVER loosen screw C securing pump head otherwise pump damage may occur B Bleed Screw C Screw Continued on next page 2 Lucas Rotary Fuel Injection Pumps OURGP11 000000D RG7948 UN 13NOV97 19 18OCT06 5 7 45 13 110306 PN 118 Service as Required On DENSO and Moitorpal in line pumps 1 On DENSO pump shown unscrew hand primer on fuel supply pump until it can be pulled by hand 2 Open fuel filter port plug 3 Operate the hand primer until a smooth flow of fuel free of bubbles comes out of the filter plug hole 4 S
107. igits of each code identify a specific group such as alternators The last two digits of each code identify one specific option provided on your engine such as a 12 volt 55 amp alternator NOTE These option codes are based on the latest information available at the time of publication The right is reserved to make changes at any time without notice If an engine is ordered without a particular component the last two digits of that functional group option code will be 99 00 or XX The list on the next page shows only the first two digits of the code numbers For future reference such as ordering repair parts it is important to have these code numbers available To ensure this availability enter the third and fourth digits shown on your engine option code label in the spaces provided on the following page Continued on next page OURGP11 0000005 19 24JUN04 1 2 01 3 110306 PN 11 Record Keeping NOTE Your engine option code label may not contain An additional option code label may also be all option codes if an option has been added delivered with the engine Place this sticker or after the engine left the producing factory tag for reference either on this page or in the engine owner s warranty booklet under If option code label is lost or destroyed OPTION CODES title consult your servicing dealer or engine distributor selling the engine for a replacement Option Codes Description Option Codes Descriptio
108. imultaneously stroke the hand primer down and close the filter port plug This prevents air from entering the system Tighten plug securely DO NOT overtighten IMPORTANT Be sure hand primer is all the way down in barrel before tightening to prevent internal thread damage 5 On DENSO pump shown lock hand primer in position RG8069 UN 23NOV97 7 DENSO Fuel Injection Pump Shown OURGP11 000000D _ 19 18OCT06 6 7 At Fuel Injection Nozzles 1 Move the engine speed control lever to half throttle position On engines equipped with electronic fuel shut off solenoid energize solenoid 2 Using two open end wrenches loosen fuel line connection at injection nozzle as shown 3 Crank engine over with starter motor but do not start engine until fuel free from bubbles flows out of loosened connection 4 Retighten connection to 27 Nem 20 lb ft 5 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 45 14 RG7725 UN 08JAN97 Fuel Line Connection OURGP11 000000D _ 19 18OCT06 7 7 110306 PN 119 Troubleshooting General Troubleshooting Information Troubleshooting engine problems can be difficult An engine wiring diagram is provided in this section to help isolate electrical problems on power units using John Deere wiring h
109. intaining the correct coolant conditioner concentration SCAs and freeze point is essential in COOL GARD is a registered trademark of Deere amp Company COOLSCAN is a registered trademark of Deere amp Company G6262 UN O05DEC97 a Q O N Ed H R JT07298 Coolant Battery Tester your cooling system to protect against rust liner pitting and corrosion and freeze ups due to incorrect coolant dilution John Deere LIQUID COOLANT CONDITIONER is recommended as a supplemental coolant additive in John Deere engines DO NOT mix one brand of SCA with a different brand Test the coolant solution every 500 hours or 12 months of operation using either John Deere coolant test strips or a COOLSCAN analysis If a COOLSCAN analysis is not available recharge the system per instructions printed on label of John Deere Liquid Coolant Conditioner Continued on next page DPSG OUOD002 1921 19 O07JAN02 1 2 35 1 1 110306 PN 91 Lubrication amp Maintenance 500 Hour 12 Month IMPORTANT ALWAYS maintain coolant at correct level and concentration DO NOT operate engine without coolant even for a few minutes If frequent coolant makeup is required the glycol concentration should be checked with JTO7298 Coolani Batiery Tester to ensure that the desired freeze point is maintained Follow manufacturer s instructions provided with Coolani Batiery Tester Add the manufacturer s recommended concentration of supp
110. ioN Torque cececeeseeseeeeeeeeeeeaee 18 22 Nem 13 16 lb ft NOTE Threads on earlier belt tensioner roller cap screw are LEFT HAND threads RG12065 UN 28JAN02 Align Torque Wrench With Pulley And Tensioner A Mark On Swing Arm B Mark On Tensioner Mounting Base C Torque Wrench OURGP12 000004A _ 19 28JUL04 3 3 35 8 110306 PN 88 Lubrication amp Maintenance 500 Hour 12 Month Checking Engine Speeds Observe tachometer A reading on the instrument panel to verify engine speeds while running engine Refer to Specifications section later in this manual for engine speed specifications If engine speeds need adjustment contact your engine dealer or distributor A Tachometer RG11299A UN 17AUG00 Check Engine Speed On Tachometer OURGP11 000000B_ 19 24JUN04 1 1 Checking Engine Electrical Ground Connections Keep all engine ground connections clean and tight to prevent electrical arcing which can damage electronic components OUOD002 0000169 19 080CT01 1 1 35 9 110306 PN 89 Lubrication amp Maintenance 500 Hour 12 Month Checking Cooling System CAUTION Explosive release of fluids from pressurized cooling system can cause serious burns Shut off engine Only remove filler cap when cool enough to touch with bare hands Slowly loosen cap to first stop to relieve pressure before removing completely IMPORTANT Air must be expell
111. ion and ADDING COOLANT in Service As Required Section 4 Pour three 3 ounces of rust preventive oil into the turbocharger intake It may be necessary to temporarily install a short intake elbow on the turbocharger inlet to receive the oil 5 Prepare a tank with a solution of diesel fuel and rust preventive oil at ten 10 ounces of rust preventive oil per gallon of diesel fuel 6 Remove existing lines plugs as required and run a temporary line from the tank to the engine fuel intake and another temporary line from the fuel return manifold to the tank so rust preventive oil solution is circulated through the injection system during cranking 7 Crank the engine several revolutions with starter do not allow the engine to start This will allow rust preventive oil solution to circulate 8 Remove temporary lines installed in Step 6 above and replace any lines plugs previously removed NOTE One gallon of fuel oil solution can be used to treat 100 engines two gallons to treat 200 engines etc The oil could then be replenished by adding an additional five 5 ounces of rust preventive oil per gallon of solution However starting over with a new solution is recommended to dispose of any water or other impurities 9 Loosen or remove and store fan alternator poly vee belt 10 Remove and clean batteries Store them in a cool dry place and keep them fully charged 11 Disengage the clutch for any driveline 12 C
112. ion of a new or rebuilt engine API CJ 4 ACEA E7 API Cl 4 PLUS ACEA E6 API Cl 4 ACEA E5 API CH 4 ACEA E4 API CG 4 ACEA E3 API CF 4 API CF 2 API CF These oils will not allow the engine to break in properly DX ENOIL4 19 13SEP06 1 1 110306 PN 32 Fuels Lubricants and Coolant Diesel Engine Oil Use oil viscosity based on the expected air temperature range during the period between oil changes John Deere PLUS 50 oil is preferred Oils meeting one of the following specifications are also recommended ACEA Oil Sequence E7 ACEA Oil Sequence E6 ACEA Oil Sequence E5 ACEA Oil Sequence E4 Extended service intervals may apply when John Deere PLUS 50 ACEA E7 ACEA E6 ACEA E5 or ACEA E4 engine oils are used Consult your John Deere dealer for more information Other oils may be used if they meet one or more of the following John Deere TORQ GARD SUPREME API Service Category CJ 4 API Service Category Cl 4 PLUS API Service Category Cl 4 API Service Category CH 4 API Service Category CG 4 API Service Category CF 4 ACEA Oil Sequence E3 ACEA Oil Sequence E2 If oils meeting API CG 4 API CF 4 or ACEA E2 are used reduce the service interval by 50 Multi viscosity diesel engine oils are preferred Diesel fuel quality and fuel sulfur content must comply with all existing emissions regulations for the area in which the engine operates If diesel fuel with sulfur content greater than 0
113. ional information and local availability of cold weather aids Use Winter Grade Fuel When temperatures fall below 5 C 40 F winter grade fuel Grade No 1 D fuel in North America is best suited for cold weather operation Winter grade fuel has a lower cloud point and a lower pour point Cloud point is the temperature at which wax will begin to form in the fuel and this wax causes fuel filters to plug Pour point is the temperature at which fuel begins to thicken and becomes more resistant to flow through fuel pumps and lines NOTE On an average winter grade fuel has a lower BTU heat content rating Using winter grade fuel may reduce power and fuel efficiency but should not cause any other engine performance effects Check the grade of fuel being used before troubleshooting for low power complaints in cold weather operation Air Intake Heater An air intake heater is an available option to aid cold weather starting CAUTION Do not use any starting fluid with an air intake heater Starting Fluid A starting fluid port on the intake is available to aid cold weather starting Minimizing the Effect of Cold Weather on Diesel Engines CAUTION Do not use any starting fluid with an engine equipped with glow plugs Coolant Heater An engine block heater coolant heater is an available option to aid cold weather starting Seasonal Viscosity Oil and Proper Coolant Concentration Use seasonal grade viscosity engine oil
114. is recommended for mixing with ethylene glycol and propylene glycol base engine coolant concentrate IMPORTANT Do not use cooling system sealing additives or antifreeze that contains sealing additives DX COOL3 19 270CT05 2 2 Drain Intervals for Diesel Engine Coolant Drain the factory fill engine coolant flush the cooling system and refill with new coolant after the first 3 years or 3000 hours of operation Subsequent drain intervals are determined by the coolant used for service At each interval drain the coolant flush the cooling system and refill with new coolant When John Deere COOL GARD is used the drain interval may be extended to 5 years or 5000 hours of operation provided that the coolant is tested annually AND additives are replenished as needed by adding a supplemental coolant additive If John Deere COOL GARD is used but the coolant is not tested OR additives are not replenished by adding a supplemental coolant additive the drain interval is 3 years or 3000 hours of operation If COOL GARD is not used the drain interval is reduced to 2 years or 2000 hours of operation COOL GARD is a trademark of Deere amp Company DX COOL11 19 19DEC03 1 1 10 13 110306 PN 39 Fuels Lubricants and Coolant Additives Engine coolants are a combination of three chemical components ethylene glycol or propylene glycol antifreeze inhibiting coolant additives and quality water Co
115. l perform all previous maintenance operations in addition to the ones specified Keep a record of hourly intervals and services performed using charts provided in Lubrication and Maintenance Records Section IMPORTANT Recommended service intervals are for normal operating conditions Service MORE OFTEN if engine is operated under adverse conditions Neglecting maintenance can result in failures or permanent damage to the engine A Hour Meter RG11299A UN 17AUG00 North American Instrument Panel Hour Meter Shown DPSG OQUOE003 20 19 07JAN02 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 TS100 UN 23AUG88 DPSG QUOQE003 20 _ 19 06JAN99 1 1 20 1 110306 PN 63 Lubrication and Maintenance Lubrication and Maintenance Service Interval Chart Standard Industrial Engines NOTE The service intervals below are for standard industrial engines See details in Sections which follow these charts Item Daily Lubrication and Maintenance Ser
116. lar observation of hour meter IMPORTANT The service recommendations 2 Check your record regularly to learn when your covered in this manual are for the engine needs service accessories that are provided by John Deere Follow manufacturer s 3 DO ALL the services within an interval section service recommendations for Write the number of hours from your service servicing engine driven equipment records and the date in the spaces provided For a not supplied by Deere RG RG34710 5620 19 27JUL06 1 1 Daily Prestarting Service e Check engine oil level e Check coolant level IMPORTANT Drain water by rotating drain valve on fuel water separator bowl counterclockwise Premature injection pump failure may occur if water is not drained daily e Check fuel filter water separator bowl e Check air cleaner dust unloader valve and air restriction indicator if equipped e Visual walkaround inspection RG RG34710 5621 19 07JAN02 1 1 65 1 110306 PN 152 Lubrication and Maintenance Records 250 Hour 6 Month Service e Change engine oil and filter e Service battery e Service fire extinguisher e Check automatic belt tensioner and belt wear e Check engine mounts Hours Date Hours Date Hours Date Hours Date Hours Date Hours Date Hours Date Hours Date lf John Deere PLUS 50 or ACEA E4 E
117. ld operations DX SERVLIT 19 31JUL03 2 2 75 2 110306 PN 159 John Deere Service Literature Available 75 3 110306 PN 160 Page Page A CNS Cie eeh bee eae ee a 35 10 MUS EE EE 40 4 ACIG DUMNS chk ahteere eee Reese os oo oy bo oe 30 5 Pressure test 35 13 Air cleaner Pressure test radiator cap 35 13 Air intake restriction indicator 25 1 bet eu grob Rech ape AE Beds we 40 4 Dust unloader valve 25 1 Crankcase vent tube clean 35 1 Replace single stage element 45 3 Crankshaft vibration damper 40 3 Air COMPreSSOr 1 aa a aea a eea 45 10 Air intake system check 35 2 Alternator belts n a anaana aaan 45 8 Ammeter 00cccceceeeeeeeeees 15 2 15 4 D Auxiliary gear drive limitations 15 9 Aviation fuels 9 d edd NEE RSR EA A 10 4 Damper checking 2 202 seers eee 40 3 Diesel engine ol 10 7 Diesel fuel 0 00000 c eee eee 10 1 10 3 B Batteries E Charge Boost e taeae eaoat paota ptah 15 17 Seice teenaa eara r a rer 30 5 Emissions Battery acid burns 64404 seh annann ununun 30 5 EPA Statement a deg tania mro 70 1 Battery explosion EE 30 5 Label EE eee 70 1 Belt tensioner Engine Manual tensioner adjust 30 7 BIOdICIN EE EE 15 6 Manual tensioner adjust with tool 30 8 Check electrical ground c ctict tat teh antes 35 9 Belt tensioner automatic
118. lean the exterior of the engine with salt free water and touch up any scratched or chipped painted surfaces with a good quality paint 13 Coat all exposed machined metal surfaces with grease or corrosion inhibitor if not feasible to paint 14 Seal all openings on engine with plastic bags and tape Continued on next page OURGP11 000006C 19 27JUL06 1 2 55 2 110306 PN 134 Storage 15 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 OURGP11 000006C 19 27JUL06 2 2 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 6 Crank engine for 20 seconds with starter do not Unseal all openings in engine and remove covering allow the engine to start Wait 2 minutes and crank from electrical systems engine an additional 20 seconds to assure bearing surfaces are adequately lubricated 2 Remove the batteries from storage Install batteries fully charged and connect the terminals 7 Start engine and run at low idle
119. lemental coolant additive DO NOT add more than the recommended amount The use of non recommended supplemental coolant additives may result in additive drop out and gelation of the coolant If other coolants are used consult the coolant supplier and follow the manufacturer s recommendation for use of supplemental coolant additives See DIESEL ENGINE COOLANTS AND SUPPLEMENTAL ADDITIVE INFORMATION for proper mixing of coolant ingredients before adding to the cooling system DPSG OUOD002 1921 19 07JAN02 2 2 Testing Diesel Engine Coolant Testing Diesel Engine Coolant Maintaining adequate concentrations of glycol and inhibiting additives in the coolant is critical to protect the engine and cooling system against freezing corrosion and cylinder liner erosion and pitting Test the coolant solution at intervals of 12 months or less and whenever excessive coolant is lost through leaks or overheating Coolant test strips Coolant test strips are available from your John Deere dealer These test strips provide a simple effective COOLSCAN is a trademark of Deere amp Company COOLSCAN PLUS is a trademark of Deere amp Company method to check the freeze point and additive levels of your engine coolant Compare the results to the supplemental coolant additive SCA chart to determine the amount of inhibiting additives in your coolant and whether more John Deere COOLANT CONDITIONER should be added COOLSCAN
120. lene glycol antifreeze inhibiting coolant additives and quality water Coolant specifications Some products including John Deere COOL GARD Prediluted Coolant are fully formulated coolants that contain all three components in their correct concentrations Do not add an initial charge of supplemental coolant additives to these fully formulated products Coolants meeting ASTM D6210 do not require an initial charge of supplemental coolant additives Some coolant concentrates including John Deere COOL GARD Coolant Concentrate contain both glycol antifreeze and inhibiting coolant additives Mix these products with quality water but do not add an initial charge of supplemental coolant additives Coolants meeting ASTM D4985 require an initial charge of supplemental coolant additives Replenish coolant additives The concentration of coolant additives is gradually depleted during engine operation Periodic replenishment of inhibitors is required even when John Deere COOL GARD or another fully formulated coolant is used Follow the recommendations in this manual for the use of supplemental coolant additives Why use supplemental coolant additives Operating without proper coolant additives will result in increased corrosion cylinder liner erosion and pitting and other damage to the engine and cooling system A COOL GARD is a trademark of Deere amp Company Additional Information About Diesel Engine Coolants and Supple
121. linkage if previously removed Continued on next page RG RG34710 5583 19 28JAN02 1 3 40 1 110306 PN 94 Lubrication amp Maint 2000 Hour 24 Month DENSO In Line Injection Pumps Only 1 Check for specified no load frequency If governor regulation is within 5 7 range no adjustment is necessary If governor regulation is above 7 or below 5 stop engine and remove cap nuts from adjusting screws before making adjustments Remove droop adjusting screw access plug B shown removed from top of governor housing Back out slow idle adjusting screw D and bumper screw Pull back on throttle lever F toward rear of governor housing by hand until the droop adjusting screw C inside housing can be adjusted through the access plug hole Screw the droop screw in clockwise counting the turns until screw bottoms out Then return screw to original setting NOTE A noticeable click will occur at each 1 4 turn of droop adjusting screw One click clockwise will increase no load speed approximately 10 rpm counterclockwise will reduce speed by 10 rpm 6 Screw in the droop screw clockwise no more than 1 2 turn two clicks at a time to reduce governor droop Turn counterclockwise no more than two clicks at a time to increase governor droop to reduce governor sensitivity Replace access plug in top of governor housing Start engine apply full 100 load and readjust h
122. ll turn 75 85 degrees If belt turns more it needs to be tightened If belt turns less it needs to be loosened 1 Loosen upper A and lower B alternator bracket cap screws Lower cap screw must remain tight enough to prevent excessive alternator play but allow alternator to pivot by hand 2 Insert JDG1520 Belt Tension Tool C behind belt D and over alternator mounting screw Belt Tension Tool A Upper Alternator Bracket Cap Screw B Lower Alternator Bracket Cap Screw C JDG1520 Belt Tension Tool D Belt Continued on next page o E Q O T E j Di ES E iz Oo Gg RG11813 UN 310CT01 OURGP11 0000009_ 19 24JUN04 1 2 30 8 110306 PN 79 Lubrication amp Maintenance 250 Hour 6 Month 3 Place torque wrench C on belt tensioning tool B at 90 to tool Pivot alternator A until desired torque is achieved according to specification using the following table Specification New Belt Temnsion ccssccsseeseesees 470 650 N 105 145 Ib force Used Belt Tension cece 400 580 N 90 130 Ib force JDG1520 Belt Tensioning Tool Torque Table Desired Belt Tension Applied Torque On Tool N Ib force Nem lb ft 445 100 108 90 489 110 115 85 534 120 122 90 623 140 135 100 4 While holding tension with torque wrench B scribe a reference mark D on alternator in line with notch E on upper al
123. mal seasonal viscosity grade oil See DIESEL ENGINE OIL in Fuels Lubricants and Coolant Section RG7961B UN 22JAN99 NOTE Some increase in oil consumption may be Changing Oil And Oil Filter Before First 250 Hours expected when low viscosity oils are used Check oil levels more frequently If air temperature is below 10 C 14 F use an engine block heater OURGP12 0000076_ 19 09SEP04 3 4 6 Watch coolant temperature gauge A closely If coolant temperature rises above 112 C 234 F reduce load on engine Unless temperature drops quickly stop the engine and determine the cause before resuming operation NOTE When the coolant temperature gauge reads approximately 115 C 239 F the engine will shutdown automatically if equipped with safety controls 7 Check poly vee belt for proper alignment and seating in pulley grooves A Coolant Temperature Gauge RG11299F UN 17AUG00 North American 1999 Instrument Panel Shown OURGP12 0000076 _ 19 09SEP04 4 4 15 8 110306 PN 52 Engine Operating Guidelines Auxiliary Gear Drive Limitations IMPORTANT When attaching an air compressor hydraulic pump or other accessory to be driven by the auxiliary gear drive A engine timing gear train at front of engine power requirements of the accessory must be limited to values listed below e 30 kW 40 hp Continuous Operation at 2500 rpm e 37 kW 50 hp Intermittent Operatio
124. manual to order a component technical manual RG4624 UN 15DEC88 Component Technical Manual RG RG34710 5591 19 20MAY96 1 1 Do Not Modify Fuel System IMPORTANT Modification or alteration of the injection pump arrow the injection pump timing or the fuel injectors in ways not recommended by the manufacturer will terminate the warranty obligation to the purchaser UN 19JUNO00 In addition tampering with fuel system e gt lt which alters emission related g za l S equipment on engines may result in A TI E K iz fines or other penalties per EPA Fuel Injection Pump regulations or other local emission laws 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 Never steam clean or pour cold water on an injection pump while it is still warm To do so may cause seizure of pump parts OURGP12 000004D__ 19 03AUG04 1 1 45 1 110308 PN 106 Service as Required Adding Coolant 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 IMPORTANT Never pour cold liquid into a hot engine as it may crack cylinder head or block DO NOT operate engine wi
125. mental Coolant Continued on next page DX COOL7 19 19DEC03 1 2 simple mixture of ethylene glycol or propylene glycol and water will not give adequate protection Use of supplemental coolant additives reduces corrosion erosion and pitting These chemicals reduce the number of vapor bubbles in the coolant and help form a protective film on cylinder liner surfaces This film acts as a barrier against the harmful effects of collapsing vapor bubbles Avoid automotive type coolants Never use automotive type coolants Such as those meeting ASTM D3306 These coolants do not contain the correct additives to protect heavy duty diesel engines They often contain a high concentration of silicates and may damage the engine or cooling system Water quality Water quality is important to the performance of the cooling system Distilled deionized or demineralized water is recommended for mixing with ethylene glycol and propylene glycol base engine coolant concentrate All water used in the cooling system should meet the following minimum specifications for quality Chlorides Sulfates lt 40 mg L lt 100 mg L Total dissolved solids lt 340 mg L Total hardness lt 170 mg L pH 5 5 to 9 0 Freeze protection The relative concentrations of glycol and water in the engine coolant determine its freeze protection limit 1 0 1 6 110306 PN 42 Fuels Lubricants and Coolant Ethylene Glycol Freeze P
126. mmediately 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 bel D or welding on machine lo On towed implements disconnect wiring harnesses from 5 tractor before servicing electrical system components or 2 welding on machine D 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 S If you do not have an exhaust pipe extension open the 2 doors and get outside air into the area 3 Oo NI p DX AIR 19 17FEB99 1 1 05 6 110306 PN 19 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 X9811 UN 23AUG88 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
127. mountings and drain water from bottom until fuel starts to drain out c When fuel starts to drain out tighten drain plugs securely After draining water from the fuel filter the filter must be primed by bleeding all air from the fuel system a Operate primer lever of the fuel supply pump C until fuel flow is free from air bubbles UN 16JUNO00 b Tighten bleed plugs securely and continue operating hand primer until pumping action is not felt Primer lever is spring loaded and will return to RG7317A Priming At Fuel Supply Pump normal position A Air Bleed Plugs B Drain Plugs If the fuel system needs further bleeding of air see C Fuel Supply Pump Primer Lever BLEEDING FUEL SYSTEM in Service As Required Section later in this manual Continued on next page OURGP12 0000048 19 130CT06 3 4 25 3 110306 PN 70 Lubrication amp Maintenance Daily 4 If the air cleaner has an automatic dust unloader valve i A squeeze the unloader valve on air cleaner assembly to clear away any dust buildup If equipped with air intake restriction indicator gauge B check gauge to determine if air cleaner needs to be serviced UN 22JAN99 IMPORTANT Maximum air intake resiriction is 6 25 kPa 0 06 bar 1 0 psi 25 in H O A clogged air cleaner element will cause excessive intake restriction and a engt Jeane A Lee reduced air supply to the engine Dust Unloader Valve and In
128. n 11 Rocker Arm Cover Ap Balancer Shafts 13 OU Fill Inlet A8 Cylinder Block With Liners and Camshaft 13 Crankshaft Pulley Ai Crankshaft and Bearings 14 Flywheel Housing A8 Connecting Rods and Pistons 15 Flywheel A0 Valve Actuating Mechanism Ip Fuel Injection Pump PU OU Pump II Air Inlet bi Cylinder Head With Valves 18 Air Cleaner bi Auxiliary Gear Drive 19 OU Ban 55S Shipping Stand 20 Coolant Pump bp Paint Option 21 Thermostat Cover 57__ Coolant Pump Inlet 29 Thermostat b Oil Cooler 23 Fan Drive DU Add on Auxiliary Drive Pulley 24 Fan Belt 62 Altermator Mounting Bracket 28 Fan 64 Eahaust Elbow 26 Engine Coolant Heater Ep Turbocharger 27 Radiator D Coolant Temperature Switch 28 Exhaust Manifold Di Electronic Tachometer Sensor 20 Crankcase Ventilator System D Crankshaft Rear Damper 20 Starter Motor 69__ Engine Serial Number Plate 21 Alternator 74 Air Conditioning Freon Compressor 32 Instrument Panel 75s Air Restriction Indicator 33 Tachometer 18 Oil Pressure Switch 28 Fuel Filters 18 Air Compressor 28 FrontPlate Di Mater Separator 37 Fuel Transfer Pump 26 Fan Pulley 20 Tbermostat Housing Di Belt Tensioner A0 Oil Dipstick sgs__ OU Filter A1 Belt Driven Front Auxiliary Drive Op Special Equipment Factory Installed 43 Starting Aid OI Special Equipment Field Installed A4 Timing Gear Cover With Gears 08 Shipping 00 Service Only Items Engine Base Code See A on previous pa
129. n at 2500 rom A Auxiliary Gear Drive UN 22JAN99 RG7634A Auxiliary Gear Drive RG RG34710 5555 19 27JUL06 1 1 Generator Set Standby Applications To assure that your engine will deliver efficient standby operation when needed start engine and run at rated speed with 50 70 load for 30 minutes every 2 weeks DO NOT allow engine to run extended period of time with no load RG RG34710 5556 19 27JUL06 1 1 15 9 110306 PN 53 Engine Operating Guidelines Starting the Engine The following instructions apply to the optional controls and instruments available through the John Deere Parts Distribution Network The controls and instruments for your engine may be different from those shown here always follow manufacturer s instructions A CAUTION Before starting engine in a confined building install proper outlet exhaust ventilation equipment Always use safety approved fuel storage and piping TS220 UN 23AUG88 Use Proper Ventilation NOTE If temperature is below 0 C 32 F it may be necessary to use cold weather starting aids See COLD WEATHER OPERATION later in this section 1 Perform all prestarting checks outlined in Lubrication amp Maintenance Daily Section later in this manual 2 Open the fuel supply shut off valve if equipped 3 Disengage clutch if equipped controlling any engine drivelines Continued on next page RG RG34710 5557
130. nd California regulations on heavy duty non road diesel cycle engines Exhaust Emission Control System EM TC Family No YJDXLO6 8015 Engine Model 6068TN052 Displacement 6 8L Valve Clearance Intake 0 356 mm Exhaust 0 457 mm Fuel Rate 95 7 mm3 stroke 200 hp 149 kW 2400 rpm Injection Timing 16 2 BTDC No Other Adjustments Required John Deere Engine Manufacturing R503149 For Engine Service and Parts Call 1 800 JD ENGINE RG11940 UN 170CT01 Emissions Label OQUOD006 000004D_ 19 130CT06 1 1 110306 PN 157 John Deere Service Literature Available Technical Information Technical information can be purchased from John Deere Some of this information is available in electronic media such as CD ROM disks and in printed form There are many ways to order Contact your John Deere dealer Call 1 800 522 7448 to order using a credit card Search online from http www JohnDeere com Please have available the model number serial number and name of the product Available information includes e PARTS CATALOGS list service parts available for your machine with exploded view illustrations to help you identify the correct parts It is also useful in assembling and disassembling OPERATOR S MANUALS providing safety operating maintenance and service information These manuals and safety signs on your machine may also be available in other languages OPERATOR S VIDEO TAPES showing h
131. newarranty Din terf rs ljare vill mycket g rna tr ffa dig f r att lara kanna dina behov och hur bast han kan hjalpa dig OURGP11 0000251_ 19 110CT06 1 1 110306 PN 4 Introduction POWERTECH 4 5 L Engines With Mechanical Controls Tier 1 Emission Certified S 2 g 3 7 g 4045D Engine g S e F 2 3 S T Es es 4045T Engine 4045T Engine POWERTECH s a trademark of Deere amp Company RG RG34710 5501 19 04JAN02 1 1 110306 PN 5 Introduction POWERTECH 6 8 L Engines With Mechanical Controls Tier 1 Emission Certified 5 7 i al E zZ Sch zZ a 3 S Ed oc S S de gt Z 1 3 2 gt 5 S ZS S S 6068T Engine 6068T Engine POWERTECH s a trademark of Deere amp Company RG RG34710 5503 _ 19 04JAN02 1 1 110306 PN 6 Contents Page Record Keeping PowerTech Medallion a na auaa aaa 01 1 Engine Serial Number Plate 01 1 Record Engine Serial Number 01 2 Engine Option Codes asssaa anaua 01 3 Record Fuel Injection Pump Model Number 01 5 SST 12 AY EAEAN EENE AATA EEA 05 1 Fuels Lubricants and Coolant Diesel Fuel 10 1 Lubricity of Diesel Fuel 10 1 Handling and Storing Diesel Fuel 10 2 Testing Diesel Fuel 10 2 Bio Diesel Fuel 10 3 Aviation Jet Fuels 10 4 Burner Fuels 2000000 eee s 10 4 Minimizing the Effect of Cold Weather on Diesel
132. nside for up to preventive oils are available from area distributors six 6 months with no long term preparation OURGP12 00000DF_ 19 110CT06 1 1 55 1 110306 PN 133 Storage Preparing Engine for Long Term Storage The following storage preparations are used for long term engine storage up to one year After that the engine should be started warmed up and retreated for an extended storage period IMPORTANT Any time your engine will not be used for over six 6 months the following recommendations for storing it and removing it from storage will help to minimize corrosion and deterioration 1 Change engine oil and replace filter See CHANGE ENGINE OIL AND FILTER in Lubrication and Maintenance 500 Hour Section Used oil will not give adequate protection Add one 1 ounce of rust preventive oil to the engine crankcase for every quart of oil This rust preventive oil should be an SAE 10 oil with 1 4 percent morpholine or equivalent vapor corrosion inhibitor 2 Service air cleaner See REPLACING AIR CLEANER FILTER ELEMENTS in Service As Required Section 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 RECOMMENDED ENGINE COOLANT in Fuels Lubricants and Coolant Sect
133. ny specified John Deere filter change the engine oil and filter at the normal service interval If John Deere TORQ GARD SUPREME API Cu 4 API Cl 4 PLUS API Cl 4 API CH 4 or ACEA E3 oils are used change the engine oil and filter at the normal service interval If API CG 4 API CF 4 or ACEA E2 oils are used change the engine oil and filter at 50 of the normal service interval DX ENOIL6 19 13SEP06 1 1 Mixing of Lubricants In general avoid mixing different brands or types of oil Oil manufacturers blend additives in their oils to meet certain specifications and performance requirements Mixing different oils can interfere with the proper functioning of these additives and degrade lubricant performance Consult your John Deere dealer to obtain specific information and recommendations DX LUBMIX_ 19 18MAR96 1 1 10 8 110306 PN 34 Fuels Lubricants and Coolant OILSCAN and COOLSCAN OILSCAN and COOLSCAN are John Deere sampling programs to help you monitor machine performance and identify potential problems before they cause serious damage Oil and coolant samples should be taken from each system prior to its recommended change interval Check with your John Deere dealer for the availability of OILSCAN and COOLSCAN kits OILSCAN is a registered trademark of Deere amp Company COOLSCAN is a trademark of Deere amp Company T6828AB UN 15JUN89
134. o be held in when starting the engine The button allows the safety switch to override the shut down circuits until safe engine oil pressure is maintained Once engine oil pressure is within specifications the safety switch will latch and the reset button can be released F Fuse Holder Contains 14 amp fuse G Ammeter The ammeter indicates the rate of charge or discharge of the battery When the engine is first started the ammeter will usually indicate a charge rate of approximately 30 amps After a short period of operation the ammeter needle will point slightly to the right of O indicating the charging system is operating normally A problem with the charging system is indicated if the ammeter needle points to the left of O during engine operation H Hour Meter The hour meter operates when the engine is operating or when the reset button is manually held in while the key switch is in the ON position The accumulated hours are displayed in hours and tenths of hours On some panels the hourmeter may be separate from the tachometer I Hand Throttle The hand throttle is used to manually control engine speed If the hand throttle is electronic as shown turn the knob clockwise or counterclockwise to change engine speed If the hand throttle is mechanical not shown turning the handle either clockwise or counterclockwise will lock the throttle position Turn the handle half way between the two lo
135. olant specifications Some products including John Deere COOL GARD Prediluted Coolant are fully formulated coolants that contain all three components in their correct concentrations Do not add an initial charge of supplemental coolant additives to these fully formulated products Coolants meeting ASTM D6210 do not require an initial charge of supplemental coolant additives Some coolant concentrates including John Deere COOL GARD Coolant Concentrate contain both glycol antifreeze and inhibiting coolant additives Mix these products with quality water but do not add an initial charge of supplemental coolant additives Coolants meeting ASTM D4985 require an initial charge of supplemental coolant additives Replenish coolant additives The concentration of coolant additives is gradually depleted during engine operation Periodic replenishment of inhibitors is required even when John Deere COOL GARD or another fully formulated coolant is used Follow the recommendations in this manual for the use of supplemental coolant additives Why use supplemental coolant additives Operating without proper coolant additives will result in increased corrosion cylinder liner erosion and pitting and other damage to the engine and cooling system A COOL GARD is a trademark of Deere amp Company Additional Information About Diesel Engine Coolants and Supplemental Coolant Continued on next page DX COOL7 19 19DEC03 1 2 simple mixt
136. olvent properly TS220 UN 23AUG88 DX PAINT 19 24JUL02 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 TS281 UN 23AUG88 DX RCAP _ 19 04JUN90 1 1 05 8 110306 PN 21 Safety Install Fan Guards Rotating cooling system fans can cause serious injury Keep fan guards in place at all times during engine operation Wear close fitting clothes Stop the engine and be sure fan is stopped before making adjustments or connections or cleaning near the front of the engine TS677 UN 21SEP89 Rotating Fan OUOD006 000009D 19 110CT06 1 Avoid Hot Parts Avoid skin contact with exhaust manifolds turbochargers and mufflers Keep flammable materials clear of the turbocharger External dry exhaust parts become very hot during operation Turbochargers may reach temperatures as high as 500 C 932 F under full load and naturally aspired exhaust manifolds may reach 600 C 1112 F under full load This may ignite paper cloth or wooden materials Parts on engines that have been at full load and reduced to no load idle will maintain approximately 150 C 302 F DDH E TS271 UN 23AUG88 Hot Surface OQUOD006 000009E_ 19 04
137. ooting General engine 50 7 V Valves Clearance check and adjust 40 10 Index 3 110306 PN 3 Index Index 4 110306 PN 4
138. or repair parts or warranty information T04045TF150 Engine Serial Number B RG7936 UN 13NOV97 Engine Model Number C Coefficient of Absorption Value D Saran Engines Only Abs CD4045TF150 Coeff X XX DEERE amp COMPANY MOLINE ILLINOIS MADE IN FRANCE UN 13NOV97 RG7935 Saran Engine Serial Number Plate JOHN DEERE Engine Serial Number _ FO PE4045T123456 B S OD DEERE amp COMPANY MOLINE ILLINOIS MADE IN MEXICO RG9062 UN 16MAR98 Torreon Engine Serial Number Plate RG RG34710 5507 _ 19 04JAN02 1 1 01 2 110306 PN 10 Record Keeping Engine Option Codes 6068T000000 1100 1200 1300 1400 1500 1600 e SE 2000 2100 Se Ges 2400 2600 2800 2900 3000 3100 3500 3600 3700 3900 4000 4100 4400 4600 4700 4800 4900 5000 5100 5200 5500 5600 5700 5900 6000 6200 6400 6500 6800 6900 7400 7500 7600 8800 9100 9700 9800 TTT Engine Option Codes UN 15JUNO00 RG10603A A Engine Base Code In addition to the serial number plate OEM engines have an engine option code label affixed to the rocker arm cover These codes indicate which of the engine options were installed on your engine at the factory When in need of parts or service furnish your authorized servicing dealer or engine distributor with these numbers The engine option code label includes an engine base code A This base code must also be recorded along with the option codes The first two d
139. out of fuel IMPORTANT DO NOT pressurize fuel tank to push fuel through system as the pressure can damage fuel injection pump seals Continued on next page OURGP11 000000D_ 19 18O0CT06 1 7 45 11 110306 PN 116 Service as Required IMPORTANT Do not operate the engine at high speeds or full loads just before bleeding the fuel system as this may cause fuel injection pump failure 1 Loosen the air bleed vent screws A two full turns by hand on fuel filter base One screw with single filter ww un vest A option arcs Air Bleed Vent Screws Final Filter at Left Primary Filter with Separator Bowl at Right A Air Bleed Vent Screws RG13544 UN 29JUL04 OURGP11 000000D _ 19 18OCT06 2 7 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 Q D Z lt 3 Vi T z 7 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 RG8013A Fuel Supply Pump Primer Lever B Fuel Supply Pump Primer Lever Continued on next page OURGP11 000000D _ 19 18OCT06 3 7 45 12 110306 PN 117 Service as Required At Fuel Injection Pump On Stanadyne rotary pumps 1 Sl
140. r replacement Engine hard to start or will not Engine starting under load Disengage driveline start Improper starting procedure Review starting procedure No fuel Check fuel tank Air in fuel line Bleed fuel line Cold weather Use cold weather starting aids Slow starter speed See Starter Cranks Slowly Crankcase oil too heavy Use oil of proper viscosity Improper type of fuel Consult fuel supplier use proper type fuel for operating conditions Water dirt or air in fuel system Drain flush fill and bleed system Clogged fuel filter Replace filter element Dirty or faulty injection nozzles Have authorized servicing dealer or engine distributor check injectors Injection pump shut off not reset Turn key switch to OFF then to ON Continued on next page OQUOD006 000004C 19 130CT06 1 7 50 7 110306 PN 126 Troubleshooting Symptom Engine knocks Engine runs irregularly or stalls frequently Below normal engine temperature Problem Low engine oil level Injection pump out of time Low coolant temperature Engine overheating Low coolant temperature Clogged fuel filter Water dirt or air in fuel system Poor quality fuel Dirty or faulty injection nozzles Defective thermostat Defective temperature gauge or sender Continued on next page Solution Add oil to engine crankcase See your authorized servicing dealer or engine distributor Remove
141. reserved A John Deere ILLUSTRUCTION Manual Previous Editions Copyright 1996 2000 2002 2004 110306 PN 1 Contents Page Replacing Fuel Filter Elements Dual Filters 35 5 Checking Belt Tensioner Spring Tension and Belt Wear Automatic Tensioner 35 6 Checking Engine Speeds aeuaunana 35 9 Checking Engine Electrical Ground Connections 2 2 000 eee eee eee 35 9 Checking Cooling System 35 10 Replenishing Supplemental Coolant Additives SCAs Between Coolant Changes cece eee eee 35 11 Testing Diesel Engine Coolant 35 12 Pressure Testing Cooling System 35 13 Lubrication amp Maint 2000 Hour 24 Month Adjusting Variable Speed Droop on Generator Set Engines 40 1 Checking Crankshaft Vibration Damper 6 Cylinder Engine Only 40 3 Flushing and Refilling Cooling System 40 4 Testing Thermostats Opening Temperature 40 7 Check and Adjust Valve Clearance 40 10 Service as Required Additional Service Information 45 1 Do Not Modify Fuel System 45 1 Adding Coolant 000 0c eee e eae 45 2 Replacing Single Stage Air Cleaner 45 3 Replacing Axial Seal Air Cleaner Filter Elemen eege ir t owe he EEEE ERAR 45 4 Replacing Radial Seal Air Cleaner Filter Element 3 Adr AE EE ME AER AA 45 6 Replacing Fan and Alternator Belts 45 8 Checking
142. rks and flames away from batteries Use a flashlight to check battery electrolyte level Never check battery charge by placing a metal object across the posts Use a voltmeter or hydrometer Always remove grounded battery clamp first and replace it last A CAUTION Sulfuric acid in battery electrolyte is poisonous It is strong enough to burn skin eat holes in clothing and cause blindness if splashed into eyes Avoid the hazard by 1 Filling batteries in a well ventilated area 2 Wearing eye protection and rubber gloves 3 Avoiding breathing fumes when electrolyte is added 4 Avoiding spilling or dripping electrolyte 5 Using proper jump start procedure If you spill acid on yourself 1 Flush your skin with water 2 Apply baking soda or lime to help neutralize the acid 3 Flush your eyes with water for 15 30 minutes Get medical attention immediately H acid is swallowed 1 Do not induce vomiting 2 Drink large amounts of water or milk but do not exceed 2 L 2 qt 3 Get medical attention immediately WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling 05 11 Explosion Acid TS204 UN 23AUG88 TS203 UN 23AUG88 DPSG OQUO01004 2758 19 110CT06 1 1 110306 PN 24 Safety Protect Against High Pressure Spr
143. rotection Limit 40 24 C 12 F 50 37 C 34 F 60 52 C 62 F Propylene Glycol Freeze Protection Limit 40 21 C 6 F 50 33 C 27 F 60 49 C 56 F DO NOT use a coolant water mixture greater than 60 ethylene glycol or 60 propylene glycol DX COOL7 19 19DEC03 2 2 Testing Diesel Engine Coolant Testing Diesel Engine Coolant Maintaining adequate concentrations of glycol and inhibiting additives in the coolant is critical to protect the engine and cooling system against freezing corrosion and cylinder liner erosion and pitting Test the coolant solution at intervals of 12 months or less and whenever excessive coolant is lost through leaks or overheating Coolant test strips Coolant test strips are available from your John Deere dealer These test strips provide a simple effective COOLSCAN is a trademark of Deere amp Company COOLSCAN PLUS is a trademark of Deere amp Company method to check the freeze point and additive levels of your engine coolant Compare the results to the supplemental coolant additive SCA chart to determine the amount of inhibiting additives in your coolant and whether more John Deere COOLANT CONDITIONER should be added COOLSCAN and COOLSCAN PLUS For a more thorough evaluation of your coolant perform a COOLSCAN or COOLSCAN PLUS analysis where available See your John Deere dealer for information DX C
144. roubleshooting Symptom Problem Solution Undercharged electrical system Excessive electrical load from added Remove accessories or install higher accessories output alternator Excessive engine idling Increase engine rom when heavy electrical load is used Poor electrical connections on Inspect and clean as necessary battery ground strap starter or alternator Defective battery Test battery Defective alternator Test charging system Battery uses too much water Cracked battery case Check for moisture and replace as necessary Defective battery Test battery Battery charging rate too high Test charging system Batteries will not charge Loose or corroded connections Clean and tighten connections Sulfated or worn out batteries See your authorized servicing dealer or engine distributor Stretched poly vee belt or defective Adjust belt tension or replace belts belt tensioner Starter will not crank Engine driveline engaged Disengage engine driveline Loose or corroded connections Clean and tighten loose connections Low battery output voltage See your authorized servicing dealer or engine distributor Faulty start circuit relay See your authorized servicing dealer or engine distributor Blown main system fuse MDL 25 Replace fuse 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
145. s Motors f r die Garantie dient folgende Internet Adresse http www johndeere com enginewarranty Machen Sie sich bei ihm bekannt und nutzen Sie sein Service Angebot Proprietario del motore John Deere Non aspetti fino al momento di far valere la garanzia o di chiedere assistenza per fare la conoscenza del distributore dei motori John Deere o del concessionario che fornisce l assistenza tecnica Per registrare via Internet la garanzia del suo motore si collegi al seguente sito URL http www johndeere com enginewarranty Lo identifichi e si informi sulla sua ubicazione Alla prima occasione utile lo contatti Egli desidera fare la sua conoscenza e capire quali potrebbero essere le sue necessita Propietario De Equipo John Deere No espere hasta necesitar servicio de garantia o de otro tipo para conocer a su Distribuidor de Motores John Deere o al Concesionario de Servicio Registre su motor para la garant a en la siguiente direcci n de internet http www johndeere com enginewarranty Ent rese de qui n es y d nde esta situado Cuando tenga un momento vaya a visitarlo A l le gustar conocerlo y saber cu les podr an ser sus necesidades Till gare av John Deere motorer Ta reda p vem din terf rs ljare r och bes k honom s snart tillf lle ges V nta inte tills det r dags f r service eller eventuellt garantiarbete Din motor garantiregistrerar Du via Internet p http www johndeere com engi
146. sions related parts and components is provided separately as the John Deere New Off Highway Engine Warranty OQUOD006 000004E_ 19 01NOVO6 1 1 Emissions Control System Certification Label CAUTION Statutes providing severe penalties for tampering with emissions controls may apply to the user or dealer The emissions warranty described above applies only to those engines marketed by John Deere that have been certified by the United States Environmental Protection Agency EPA and or California Air Resources Board CARB and used in the United States and Canada The presence of an emissions label like the one shown signifies that the engine has been certified with the EPA and or CARB The EPA and CARB warranties only apply to new engines having the certification label affixed to the engine and sold as stated above in the geographic areas The presence of an EU number in the third line of the label signifies that the engine has been certified with the European Union countries per Directive 97 68 EC The emissions warranty does not apply to the EU countries NOTE The hp kW rating on the engine emissions certification label specifies the gross engine hp kW which is flywheel power without fan In most applications this will not be the same rating as the advertised vehicle hp kW rating 70 1 IMPORTANT ENGINE INFORMATION This engine is certified to run on Diesel Fuel This engine conforms to 2001 Model Year US EPA a
147. st Unloader Valve amp Indicator e Perform Visual Walkaround Inspection Service Fire Extinguisher e Change Engine Oil and Replace Oil Filter H Check Engine Mounts Service Battery e Clean Crankcase Vent Tube Check Air Intake Hoses Connections amp System Replace Single or Dual Fuel Filter Elements Check Belt Tensioner and Belt Wear H Check Engine Speeds Check Engine Electrical Ground Connection Check Cooling System e Coolant Solution Analysis Add SCAs as required Pressure Test Cooling System e Check Variable Speed Droop Gen Sets Check Crankshaft Vibration Damper 6 8 L Engines H Flush Cooling System e Test Thermostats e Check and Adjust Engine Valve Clearance Add Coolant D Replace Air Cleaner Elements KR Replace primary air cleaner element when restriction indicator shows a vacuum of 625 mm 25 in H20 Change the oil for the first time after 100 hours maximum of break in operation For subsequent oil and filter intervals see recommendations in section 10 Replace crankshaft damper every 4500 hours or 60 months whichever occurs first alf John Deere COOL GARD is used the flushing interval may be extended to 3000 hours or 36 months If John Deere COOL GARD is used and the coolant is tested annually AND additives are replenished as needed by adding a supplemental coolant additive the flushing interval may be extended to 5000 hours or 60 months whichever occurs first Continued on n
148. start thread engagement When possible lubricate U bolts see the tightening instructions for the specific application Shear plain or zinc plated fasteners other than lock nuts wheel bolts bolts are designed to fail under predetermined loads Always replace shear or wheel nuts unless different instructions are given for the bolts with identical grade specific application aGrade 2 applies for hex cap screws not hex bolts up to 6 in 152 mm long Grade 1 applies for hex cap screws over 6 in 152 mm long and for all other types of bolts and screws of any length Lubricated means coated with a lubricant such as engine oil fasteners with phosphate and oil coatings or 7 8 in and larger fasteners with JDM F13C zinc flake coating Dry means plain or zinc plated without any lubrication or 1 4 to 3 4 in fasteners with JDM F13B zinc flake coating 60 15 DX TORQ1_ 19 24APR03 1 1 110306 PN 150 Specifications Metric Bolt and Screw Torque Values gt LS Le Liss TS1670_ UN 01MAY03 Bolt or Class 4 8 Class 8 8 or 9 8 Class 10 9 Class 12 9 Screw Lubricated Dry Lubricated Dry Lubricated Dry Lubricated Dry Size Nem Ib in Nem Ib in Nem Ib in Nem Ib in Nem Ib in Nem Ib in Nem Ib in Nem Ib in M6 4 7 42 6 53 8 9 79 11 3 100 13 115 16 5 146 15 5 13
149. structions for servicing air cleaners not supplied by John Deere 1 If equipped loosen body clamp 2 Loosen clamp around outlet neck A 3 Remove air cleaner 4 Install new filter so that overlap B of air cleaner outlet neck and engine intake pipe is to specification below Specification Air Cleaner Neck to Engine lntakK6 OVE Nap is se ceecs seers teenie aidi 38 mm 1 5 in 5 Tighten neck clamp A to specification below Specification Air Cleaner Neck Clamp Toroue 6 8 Nem 60 Ib in IMPORTANT Do NOT overtighten body clamp Overtightening may cause crushing of air cleaner body Tighten body clamp only until snug 6 If equipped tighten body clamp until snug IMPORTANT Whenever the air cleaner has been serviced or removed ALWAYS fully depress the air restriction indicator reset button if equipped to assure accurate readings 7 If equipped fully depress air restriction indicator reset button and release to reset indicator 45 3 Installation of Single Stage Air Cleaner A Outlet Neck Clamp B Filter to Engine Overlap UN 06SEP00 RG11319A RG11320 UN 07SEP00 RG RG34710 5594 19 07JAN02 1 1 110306 PN 108 Service as Required Replacing Axial Seal Air Cleaner Filter Element IMPORTANT ALWAYS REPLACE primary air cleaner element when air restriction indicator shows a vacuum of 625 mm 25 in H20 is torn or visibly dirty NOTE This procedure applies
150. t 8 Align keys on filter element with slots in filter base 9 Install retaining ring onto mounting base making certain dust seal is in place on filter base Hand tighten ring about 1 3 turn until it snaps into the detent DO NOT overtighten retaining ring NOTE The proper installation is indicated when a click is heard and a release of the retaining ring is felt A plug is provided with the new element for plugging the used element 10 Open fuel shut off valve and bleed the fuel system See BLEEDING FUEL SYSTEM in Service As Required Section Tighten bleed plug D OURGP12 000004B 19 130CT06 2 2 Checking Belt Tensioner Spring Tension and Belt Wear Automatic Tensioner Belt drive systems equipped with automatic spring belt tensioners cannot be adjusted or repaired The automatic belt tensioner is designed to maintain proper belt tension over the life of the belt If tensioner spring tension is not within specification replace tensioner assembly Continued on next page OURGP12 000004A 19 28JUL04 1 3 35 6 110306 PN 86 Lubrication amp Maintenance 500 Hour 12 Month Checking Belt Wear The belt tensioner is designed to operate within the limit of arm movement provided by the cast stops A and B when correct belt length and geometry is used Visually inspect cast stops A and B on belt tensioner assembly If the tensioner stop on swing arm A is hitting
151. t s and water manifold thermostat cover 5 Tighten cover cap screws to 70 Nem 52 lb ft 6 Lubricate new O ring with PT507 Multi Purpose Grease Install seal B in thermostat cover A Guide Studs B Seal UN 06NOV97 RG7614A S Installing Thermostat Cover Fo AE RG7921B UN 13NOV97 Thermostat Cover Seal DPSG RG34710 112 19 07JAN02 4 5 7 Install coolant manifold thermostat cover to coolant pump tube C Tighten clamps 8 If not already done fill cooling system and check for leaks IMPORTANT Air must be expelled from cooling system when filling Loosen temperature sending unit fitting at rear of cylinder head or plug in thermostat housing to allow air to escape when filling system Tighten fitting or plug when all air has been expelled 40 9 ka D z E B T z 5 T m wo dE ks O iva Cover To Coolant Pump Tube C Cover To Coolant Pump Tube DPSG RG34710 112 19 07JAN02 5 5 110306 PN 102 Lubrication amp Maint 2000 Hour 24 Month Check and Adjust Valve Clearance A CAUTION To prevent accidental starting of engine while performing valve adjustments always disconnect NEGATIVE battery terminal IMPORTANT Valve clearance MUST BE checked and F adjusted with engine COLD RG7408 UN O06AUG96 1 Remove rocker arm cover and crankcase ventilator A l tube Flywheel Housing Timing Holes IMPORTANT Visually inspect
152. tag which comes with the extinguisher instruction booklet J RwW4918 UN 15DEC88 A Fire Extinguisher Fire Extinguisher RG RG34710 5567 19 20MAY96 1 1 30 1 110306 PN 72 Lubrication amp Maintenance 250 Hour 6 Month Changing Engine Oil and Replacing Filter NOTE Change engine oil and oil filter for the first time after 100 hours maximum of operation then every 250 hours thereafter If John Deere PLUS 50 or ACEA E4 or E5 engine oil and a John Deere oil filter are used the oil and filter change interval may be extended by 50 percent OILSCAN or OILSCAN PLUS is a John Deere sampling 4 program to help you monitor machine performance and identify potential problems before they cause serious damage OILSCAN and OILSCAN PLUS kits are available from your John Deere engine distributor or engt am servicing dealer Oil samples should be taken prior to the oil change Refer to instructions provided with kit To change engine oil and oil filter 1 Run engine approximately 5 minutes to warm up oil S Shut engine off a I 2 Remove oil pan drain plug arrow 3 E 3 Drain crankcase oil from engine while warm Oil Pan Drain Plug S NOTE Drain plug location may vary depending on the A Oil Filter Element application PLUS 50 is a trademark of Deere amp Company OILSCAN is a trademark of Deere amp Company OILSCAN PLUS is a trademark of Deere amp Company Con
153. tem with clean water Run the engine about 10 minutes to stir up possible rust or sediment 9 Stop engine pull off lower radiator hose and remove radiator cap Immediately drain the water from system before rust and sediment settle 10 After draining water close drain valves Reinstall radiator cap and radiator hose and clamp Fill the cooling system with clean water and a heavy duty cooling system cleaner such as Fleetguard RESTORE and RESTORE PLUS Follow manufacturer s directions on label Fleetguard is a trademark of Cummins Engine Company Inc RESTORE is a trademark of Fleetguard RESTORE PLUS is a trademark of Fleetguard Continued on next page OURGP11 000000C_ 19 24JUNO4 2 3 40 5 110306 PN 98 Lubrication amp Maint 2000 Hour 24 Month 11 After cleaning the cooling system drain cleaner and fill with water to flush the system Run the engine about 10 minutes remove radiator cap and pull off lower radiator hose to drain out flushing water 12 Close all drain valves on engine and radiator Reinstall radiator hose and tighten clamps securely Install thermostats using a new gasket See TESTING THERMOSTATS OPENING TEMPERATURE later in this section IMPORTANT Air must be expelled from cooling system when system is refilled Loosen temperature sending unit fitting at rear of cylinder head or plug in thermostat housing to allow air to escape when filling system Retighten fitting or plug af
154. ter filling cooling system NOTE Coolant capacity may vary depending on application 13 Add coolant to radiator until coolant touches bottom of filler neck See specification for capacity Install radiator cap Specification 4 5 L Engine Coolant Canach 8 5 L 9 gt 6 8 L Engine Coolant Canach 11 3 L 12 qt 14 Run engine until it reaches operating temperature This mixes the solution uniformly and circulates it through the entire system The normal engine coolant temperature range is 82 94 C 180 202 F 15 After running engine check coolant level and entire cooling system for leaks 16 Inspect the fan belt for wear and check belt tension See Checking Belt Tensioner Spring Tension and Belt Wear in Lubrication and Maintenance 500 Hour 12 Month section 40 6 OURGP11 000000C 19 24JUN04 3 3 110306 PN 99 Lubrication amp Maint 2000 Hour 24 Month Testing Thermostats Opening Temperature To Remove Thermostat s NOTE On some engines the coolant manifold thermostat housing is an integral part of the cylinder head CAUTION Explosive release of fluids from pressurized cooling system can cause serious burns DO NOT drain coolant until it has cooled below operating temperature Always loosen radiator pressure cap or drain valve slowly to relieve pressure 1 Visually inspect area around thermostat housing for leaks 2 Remove radiator pressure cap and partially drain
155. ternator bracket 5 Continue to hold tension with torque wrench and tighten upper alternator bracket cap screw 6 Check position of reference mark to see if alternator moved while tightening If alternator moved loosen upper alternator bracket cap screw and repeat the tension adjustment procedure 7 Remove belt tension tool and tighten lower alternator bracket cap screw A Alternator B Belt Tensioning Tool C Torque Wrench D Reference Mark E Alternator Upper Bracket Notch S kej O O T Zz tt E o Fa RG11815 UN 310CT01 Scribe Reference Mark OURGP11 0000009 _ 19 24JUN04 2 2 30 9 110306 PN 80 Lubrication amp Maintenance 500 Hour 12 Month Cleaning Crankcase Vent Tube If you operate the engine in dusty conditions clean the tube at shorter intervals 1 Remove and clean crankcase vent tube A 2 Install the vent tube Be sure the O ring fits correctly in the rocker arm cover for elbow adapter Tighten hose clamp securely ke e E gt es D T z T RG8017A A Crankcase Vent Tube Crankcase Vent Tube RG RG34710 5574 19 08JAN02 1 1 35 1 110306 PN 81 Lubrication amp Maintenance 500 Hour 12 Month Checking Air Intake System IMPORTANT The air intake system must not leak Any leak no matter how small may result in internal engine damage due to abrasive dirt and dust entering the intake s
156. the fixed stop B check mounting brackets alternator belt tensioner idler pulley etc and the belt length Replace belt as needed see REPLACING FAN AND ALTERNATOR BELTS in Service As Required Section A Cast Stops B Cast Stop Continued on next page OURGP12 000004A 19 28JUL04 2 3 RG8098 UN 18NOV97 Cast Stops 35 7 110306 PN 87 Lubrication amp Maintenance 500 Hour 12 Month Checking Tensioner Spring Tension A belt tension gauge will not give an accurate measure of the belt tension when automatic spring tensioner is used Measure tensioner spring tension using a torque wrench and procedure outlined below NOTE Later engines have a 12 7 mm 1 2 in square drive hole in tensioner so no socket drive is required RG7977 UN 14NOV97 1 Release tension on belt using a breaker bar and socket if required on tension arm Remove belt from pulleys 2 Release tension on tension arm and remove breaker bar 3 Put a mark A on swing arm of tensioner as shown 4 Measure 21 mm 0 83 in from A and put a mark B on tensioner mounting base 5 Install torque wrench C so that it is aligned with center of pulley and tensioner Rotate the swing arm with the torque wrench until marks A and B are aligned RG12054 UN 08JAN02 6 Record torque wrench measurement and compare with specification below Replace tensioner assembly as required Specification Spring TenS
157. these items were to get caught severe injury could result Remove rings and other jewelry to prevent electrical 2 shorts and entanglement in moving parts 7 Sal DX LOOSE 19 04JUN90 1 1 Wear Protective Clothing aN TA Wear close fitting clothing and safety equipment i appropriate to the job e 3 Prolonged exposure to loud noise can cause impairment or loss of hearing g S Wear a suitable hearing protective device such as 3 earmuffs or earplugs to protect against objectionable or 7 uncomfortable loud noises reel S N H 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 a uncomfortable loud noises 2 DX NOISE _ 19 03MAR93 1 1 05 4 110306 PN 17 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 TS1132 UN 2
158. thout coolant for even a few minutes John Deere TY15161 Cooling System Sealer may be added to the radiator to stop leaks DO NOT use any other stop leak additives in the system Air must be expelled from cooling system when coolant is added 1 Loosen temperature sending unit fitting at rear of cylinder head or plug in side of thermostat housing to allow air to escape when filling system IMPORTANT When adding coolant to the system use the appropriate coolant solution See ENGINE COOLANT SPECIFICATIONS in Fuels Lubricants and Coolant Section for mixing of coolant ingredients before adding to cooling system Radiator Filler Cap Do not overfill cooling system A pressurized system needs space for heat expansion without overflowing at top of radiator A Radiator Filler Cap 2 Remove radiator cap A and fill until coolant level touches bottom of radiator filler neck 3 Tighten plugs and fittings when air has been expelled from system 4 Run engine until it reaches operating temperature 45 2 TS281 UN 23AUG88 RG12833 UN 13FEB03 OURGP12 0000049 19 22JUL04 1 1 110306 PN 107 Service as Required Replacing Single Stage Air Cleaner IMPORTANT ALWAYS REPLACE air cleaner when air restriction indicator shows a vacuum of 625 mm 25 in H20 is torn or visibly dirty NOTE This procedure applies to John Deere single stage air cleaner kits Refer to manufacturers in
159. tinued on next page RG11616 UN 240CT01 Oil Filter OURGP12 0000078 _ 19 310CT06 1 3 30 2 110306 PN 73 Lubrication amp Maintenance 250 Hour 6 Month 4 Turn filter element A counterclockwise using a suitable filter wrench to remove Discard oil filter element NOTE Depending on engine application oil filter may be located on either side of the engine 5 Remove oil filter packing and clean filter mounting pad IMPORTANT Filtration of oils is critical to proper lubrication Always change filter regularly Use filter meeting John Deere performance specifications Removing Oil Filter Element 6 Oil new packing and install new filter element Hand A DIL Filter Element tighten element according to values printed on filter element If values are not provided tighten element approximately 3 4 1 1 4 turn after packing contacts filter housing DO NOT overtighten filter element 7 Install oil pan drain plug with O ring or copper washer If copper washer is used install with raised center against plug If O ring or washer is damaged replace it 8 Tighten drain plug to specifications Specification Oil Pan Drain Plug With Copper ERTE aa Ko 0E E 70 Nem 52 Ib ft Oil Pan Drain Plug With O Ring ee TEE 50 Nem 37 lb ft Continued on next page UN 22JAN99 RG7961A OURGP12 0000078 _ 19 310CT06 2 3 30 3 110306 PN 74 Lubrication amp Maintenanc
160. tion For with the same or higher property class If higher property class stainless steel fasteners or for nuts on U bolts see the tightening fasteners are used tighten these to the strength of the original Make instructions for the specific application Tighten plastic insert or sure fastener threads are clean and that you properly start thread crimped steel type lock nuts by turning the nut to the dry torque engagement When possible lubricate plain or zinc plated fasteners shown in the chart unless different instructions are given for the other than lock nuts wheel bolts or wheel nuts unless different specific application instructions are given for the specific application Lubricated means coated with a lubricant such as engine oil fasteners with phosphate and oil coatings or M20 and larger fasteners with JDM F13C zinc flake coating Dry means plain or zinc plated without any lubrication or M6 to M18 fasteners with JDM F13B zinc flake coating 60 DX TORQ2 _ 19 24APR03 1 1 16 110306 PN 151 Lubrication and Maintenance Records Using Lubrication and Maintenance Records Refer to specific Lubrication and Maintenance Section complete listing of all items to be performed and the for detailed service procedures service intervals required refer to the quick reference chart near the front of the 1 Keep a record of the number of hours you operate Lubrication and Maintenance Section your engine by regu
161. to John Deere 2 stage axial seal air cleaner kits Refer to manufacturers instructions for servicing air cleaners not supplied by John Deere 1 Remove wing nut and remove canister cover shown in small illustration inset 2 Remove wing nut A and remove primary element B from canister 3 Thoroughly clean all dirt from inside canister NOTE Some engines may have a dust unloader valve C on the air cleaner If equipped squeeze valve tip to release any trapped dirt particles IMPORTANT Remove secondary safety element E ONLY for replacement DO NOT attempt to clean wash or reuse secondary element Replacement of secondary element is usually necessary ONLY when primary element has a hole in it 4 To replace secondary element remove retaining nut D and secondary element E Immediately replace secondary element with new element to prevent dust from entering air intake system 5 Install new primary element and tighten wing nut securely Install cover assembly and tighten retaining wing nut securely C Retaining Nut and Secondary Element A Wing Nut B Primary Element C Dust Unloader Valve D Retaining Nut E Secondary Element ontinued on next page RG41165 000008A ends RG4687 UN 20DEC88 RG4686 UN 20DEC88 RG11068 UN 26JUNO00 19 12NOV01 1 2 45 4 110306 PN 109 Service as Required IMPORTANT Whenever the air cleaner has been serviced or had
162. ttery G2 Alternator P6 Ammeter R1 Resistor 48 ohm S1 Key Switch S2 Magnetic Safety Switch North American Auto Override Module European Saran W1 Ground on K1 Starter Relay Mounting Stud Y1 Starter Solenoid Y2 Fuel Shut off Solenoid H1 Coolant Temperature Indicator Lamp BLK Black H2 Oil Pressure Indicator Lamp BLU Blue H3 Alternator Indicator Lamp BRN Brown K1 Starter Relay DK BLU Dark Blue M1 Starter Motor GRN Green P1 Coolant Temperature Gauge ORG Orange P2 Oil Pressure Gauge PUR Purple P3 Crankcase Oil Level Switch Gauge RED Red P4 Tachometer YEL Yellow P5 Hourmeter Early Models 1 P4 tachometer has a built in hourmeter On some earlier engines a separate hourmeter P5 and fuse F3 were used P4 tachometer has a built in hourmeter On some engines a separate hourmeter P5 and fuse F3 are usea 3 Later harnesses have two parallel 100 ohm resistors for the alternator DPSG RG41165 126 19 19JUN00 1 1 50 3 110306 PN 122 Troubleshooting Wiring Diagram Standard Instrument Panel For North America 1 KEY SWITCH LB TG Jaco on Ter Ier We e ee een ACC RED OR BRN RED OR BRN KI S S S 5 z 6 D R gg x D Y2 pi B Su S S K T 5 misa j M1 wi G2 Bi z DPSG RG41165 127 _ 19 19JUN00 1 1 50 4 110306 PN 123 Troubleshooting
163. uel Power loss up to 10 can be expected Jet B Not Recommended Lower density and extremely low viscosity compared to base No 2 D diesel fuel Power loss up to 14 can be expected JP 4 Not Recommended Lower density and extremely low viscosity compared to base No 2 D diesel fuel Power loss up to 12 can be expected JP 5 Lower viscosity and density than base No 2 D diesel fuel Power loss up to 9 can be expected JP 7 Lower viscosity and density than base No 2 D diesel fuel Power loss up to 10 can be expected JP 8 Lower viscosity and density than base No 2 D diesel fuel Power loss up to 10 can be expected OURGP12 000003F __ 19 07JUL04 1 1 Burner Fuels Burner fuels like kerosene may be used with the following restrictions Type Comments No 2 Higher density and specific gravity than base No 2 D diesel fuel Power increase up to 3 can be expected No 1 Lower viscosity than base No 2 D diesel fuel Power loss up to 2 can be expected 10 4 OURGP12 0000040 _ 19 07JUL04 1 1 110306 PN 30 Fuels Lubricants and Coolant John Deere diesel engines are designed to operate effectively in cold weather However for effective starting and cold weather operation a little extra care is necessary The information below outlines steps that can minimize the effect that cold weather may have on starting and operation of your engine See your John Deere dealer for addit
164. ure of ethylene glycol or propylene glycol and water will not give adequate protection Use of supplemental coolant additives reduces corrosion erosion and pitting These chemicals reduce the number of vapor bubbles in the coolant and help form a protective film on cylinder liner surfaces This film acts as a barrier against the harmful effects of collapsing vapor bubbles Avoid automotive type coolants Never use automotive type coolants Such as those meeting ASTM D3306 These coolants do not contain the correct additives to protect heavy duty diesel engines They often contain a high concentration of silicates and may damage the engine or cooling system Water quality Water quality is important to the performance of the cooling system Distilled deionized or demineralized water is recommended for mixing with ethylene glycol and propylene glycol base engine coolant concentrate All water used in the cooling system should meet the following minimum specifications for quality Chlorides Sulfates lt 40 mg L lt 100 mg L Total dissolved solids lt 340 mg L Total hardness lt 170 mg L pH 5 5 to 9 0 Freeze protection The relative concentrations of glycol and water in the engine coolant determine its freeze protection limit 1 0 1 4 110306 PN 40 Fuels Lubricants and Coolant DO NOT use a coolant water mixture greater than 60 ethylene glycol or 60 propylene glycol
165. uring this period John Deere ENGINE BREAK IN OIL is preferred See ENGINE BREAK IN OIL in Fuels Lubricants and Coolant Section IMPORTANT DO NOT use PLUS 50 Engine Oil during the break in period of a new engine or engine that has had a major overhaul PLUS 50 oil will not allow a new or overhauled engine to properly wear during this break in period DO NOT fill above the crosshatch pattern A or the FULL mark whichever is present Oil levels anywhere within the crosshatch are considered in the acceptable operating range Specification Engine Oil Pressure at Full Load Rated Speed AAA 345 103 kPa 3 45 1 03 bar 50 15 psi Minimum Oil Pressure at Rated e WEE 275 2 75 bar 40 psi Minimum Oil Pressure at 850 rpm 105 kPa 1 05 bar 15 psi Coolant Temperature Hange 82 94 C 180 202 F PLUS 50 is a trademark of Deere amp Company 1At normal operating temperature of 115 C 240 F sump Continued on next page OURGP12 0000076 19 09SEP04 2 4 15 7 110306 PN 51 Engine Operating Guidelines 4 During the first 20 hours avoid prolonged periods of engine idling or sustained maximum load operation If engine will idle longer than 5 minutes stop engine 5 Before the first 250 hours maximum change engine oil and replace engine oil filter See CHANGING ENGINE OIL AND REPLACING OIL FILTER in Lubrication and Maintenance 250 Hour 6 Month Section Fill crankcase with the nor
166. uthorized servicing dealer or engine distributor Clean or replace fuel hose See your authorized servicing dealer or engine distributor Add oil Drain fill crankcase with oil of proper viscosity and quality QUOD006 000004C__ 19 130CT06 3 7 50 9 110306 PN 128 Troubleshooting Symptom High oil consumption Engine emits white smoke Engine emits black or gray exhaust smoke Problem Crankcase oil too light Oil leaks Restricted crankcase vent tube Defective turbocharger Improper type of fuel Low engine temperature Defective thermostat Defective injection nozzles Engine out of time Improper type of fuel Clogged or dirty air cleaner Engine overloaded Injection nozzles dirty Engine out of time Turbocharger not functioning Continued on next page Solution Use proper viscosity oil Check for leaks in lines gaskets and drain plug Clean vent tube See your authorized servicing dealer or engine distributor Use proper fuel Warm up engine to normal operating temperature Remove and check thermostat See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor Use proper fuel Service air cleaner Reduce load See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor See your authorized servicing
167. vice Intervals 250 Hour 6 Month 500 Hour 12 Month 2000 Hour 24 Month As Required Check Engine Oil and Coolant Level Check Fuel Filter s Water Separator Bowl Check Air Cleaner Dust Unloader Valve amp Indicator Perform Visual Walkaround Inspection Service Fire Extinguisher Change Engine Oil And Replace Oil Filter Check Engine Mounts Service Battery Check Manual Belt Tensioner and Belt Wear Clean Crankcase Vent Tube Check Air Intake Hoses Connections amp System Replace Single or Dual Fuel Filter Elements Check Automatic Belt Tensioner and Belt Wear Check Engine Speeds Check Engine Electrical Ground Connection Check Cooling System Coolant Solution Analysis Add SCAs as required Pressure Test Cooling System Check Crankshaft Vibration Damper 6 8 L Engines Flush Cooling System Test Thermostats Check and Adjust Engine Valve Clearance Add Coolant Replace Air Cleaner Elements Replace Poly Vee Belt Check Fuses aReplace primary air cleaner element when restriction indicator shows a vacuum of 625 mm 25 in H20 Change the oil for the first time after 100 hours maximum of break in operation For subsequent oil and filter intervals see recommendations in section 10 Replace crankshaft damper every 4500 hours or 60 months whichever occurs first dif John Deere COOL GARD is use
168. ystem S a 1 Inspect all intake hoses piping for cracks Replace as 2 necessary 7 2 Check clamps A on piping which connect the air z cleaner engine and if present turbocharger Tighten Check Clamps clamps as necessary This will help prevent dirt from Gang entering the air intake system through loose connections causing internal engine damage 3 If engine has a rubber dust unloader valve B inspect the valve on bottom of air cleaner for cracks or plugging Replace as necessary IMPORTANT ALWAYS REPLACE primary air cleaner element when air restriction indicator shows a vacuum of 625 mm 25 in HO is torn or visibly dirty RG7332B UN 22JAN99 d ZE Ay Unloader Valve and Air Restriction Indicator 4 Test air restriction indicator C for proper operation Replace indicator as necessary A Clamps B Dust Unloader Valve IMPORTANT If not equipped with air restriction C Air Restriction Indicator indicator replace air cleaner elements at 500 Hours or 12 Months whichever occurs first RG RG34710 5575 _ 19 07JAN02 1 1 35 2 110306 PN 82 Lubrication amp Maintenance 500 Hour 12 Month Replacing Fuel Filter Element Single Filter CAUTION Escaping fluid under pressure can penetrate the skin causing serious injury Relieve pressure before disconnecting fuel or other lines Tighten all connections before applying pressure Keep hands and body away from pinholes and

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