Crane_Diesel_Manual.pdf

OPERATION AND

MAINTENANCE

MANUAL

Deere Power Systems Group

OMRG25204 (20MAY96)

LITHO IN U.S.A.

ENGLISH

POWERTECH 4.5 L & 6.8 L

4045 and 6068

OEM Diesel Engines

1996 EPA Certification Levels (U.S.A.)

Introduction

READ THIS MANUAL carefully to learn how to operate and service your engine correctly. Failure to do so could result in personal injury or equipment damage.

THIS MANUAL SHOULD BE CONSIDERED a permanent part of your engine and should remain with the engine when you sell it.

MEASUREMENTS IN THIS MANUAL are given in both metric and customary U.S. unit equivalents. Use only correct replacement parts and fasteners. Metric and inch fasteners may require a specific metric or inch wrench.

RIGHT-HAND AND LEFT-HAND sides are determined by standing at the drive or flywheel end (rear) of the engine and facing toward the front of the engine.

WRITE ENGINE SERIAL NUMBERS and option codes in the spaces indicated in the Record Keeping Section. Accurately record all the numbers. Your dealer also needs these numbers when you order parts. File the identification numbers in a secure place off the engine.

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

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

CALIFORNIA PROPOSITION 65 WARNING

Diesel engine exhaust and some of its constituents are know to the State of California to cause cancer, birth defects and other reproductive harm.

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.

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

UTILISATEURS DE MOTEURS JOHN DEERE:

N’attendez pas d’être obligé d’avoir recours a votre Concessionnaire ou Point de Service le plus proche pour vous adresser a lui.

Renseignez-vous des que possible pour l’identifier et le localiser. A la premiere occasion, prenez contact avec lui et faites-vous connaître. Il sera lui aussi heureux de faire votre connaissance et de savoir que vous pourrez compter sur lui le moment venu.

AN DEN BESITZER DES JOHN DEERE MOTORS:

Warten Sie nicht auf einen evt. Reparaturfall um den nächstgelegenen John Deere Händler kennen zu lernen.

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

PROPRIETARIO DEL MOTORE JOHN DEERE:

Non aspetti fino a quando ha bisogno della garanzia o di un altro tipo di assistenza per incontrarsi con il Suo Concessionario che fornisce l’assistenza tecnica.

Impari a conoscere chi è e dove si trova. Alla Sua prima occasione cerchi d’incontrarlo. Egli desidera farsi conoscere e conoscere le Sue necessità.

PROPIETARIO DE EQUIPO JOHN DEERE:

No espere hasta necesitar servicio de garantía o de otro tipo para conocer a su Distribuidor de Motores John Deere o al Concesionario de Servicio.

Entérese de quién es, y dónde está situado. Cuando tenga un momento, vaya a visitarlo. A él le gustará conocerlo, y saber cuáles podrían ser sus necesidades.

JOHN DEERE MOTORÄGARE:

Vänta inte med att besöka Din John Deere återförsäljare till dess att Du behöver service eller garanti reparation.

Bekanta Dig med var han är och vem han är. Tag första tillfälle att besöka honom. Han vill också träffa Dig för att få veta vad Du behöver och hur han kan hjälpa Dig.

Engine Owner

Identification Views

POWERTECH 4.5 L ENGINES

4045D Engine

4045T Engine

RG7999 RG7998

RG7996 RG7997

Identification Views

POWERTECH 6.8 L ENGINES

6068D Engine

6068T Engine

RG8003 RG8002

RG8001 RG8000

i

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.

OMRG25204 (20May96)

COPYRIGHT 1996

DEERE POWER SYSTEMS GROUP

Waterloo, Iowa All rights reserved

A John Deere ILLUSTRUCTION Manual

Page Page

Contents

Record Keeping

POWERTECH Medallion Engine Serial Number Plate Record Engine Serial Number Engine Option Codes Record PTO Serial Number Record Fuel Injection Pump Model Number

Safety

Fuels, Lubricants, and Coolant

Diesel Fuel Lubricity of Diesel Fuels Diesel Fuel Storage Filling Fuel Tank Minimizing the Effect of Cold Weather on Diesel

Engines Engine Break-in Oil Diesel Engine Oil Mixing of Lubricants OILSCAN and CoolScan Alternative and Synthetic Lubricants Lubricant Storage Grease Diesel Engine Coolant Recommendations Engine Coolant Specifications Testing Diesel Engine Coolant Replenishing Supplemental Coolant Additives

(SCAs) Between Coolant Changes Operating in Warm Temperature Climates Disposing of Coolant

Engine Operating Guidelines

Instrument (Gauge) Panel Normal Engine Operation Break-in Service Auxiliary Gear Drive Limitations Standby Power Units Starting the Engine Cold Weather Operation

Warming Engine Changing Engine Speed–Standard (Mechanical)

Governor Idling Engine Stopping the Engine Using a Booster Battery or Charger

Lubrication and Maintenance

Observe Service Intervals Use Correct Fuels, Lubricants, and Coolant Lubrication & Maintenance Service Interval Chart 44

Lubrication & Maintenance/Daily

Daily Prestarting Checks

Lubrication & Maintenance/50 Hour/2 Weeks

Checking Fuel Filter Lubricating PTO Clutch Shaft Bearings

Lubrication and Maintenance/250 Hour

Servicing Fire Extinguisher Servicing Battery Changing Engine Oil and Replacing Oil Filter Checking PTO Clutch Adjustment

Lubrication & Maintenance/600 Hour/12 Month

Lubricating PTO Clutch Internal Levers & Linkage 57 Cleaning Crankcase Vent Tube Checking Air Intake System Replacing Fuel Filter Element Checking Belt Tensioner Spring Tension and

Belt Wear Checking Cooling System Checking Effectiveness of Coolant Solution Adding Supplemental Coolant Additives ii

Contents

Page Page

Lubrication & Maintenance/1200 Hour/24 Month

Adjusting Variable Speed (Droop) on Generator Set Engines

Checking Crankshaft Vibration Damper (6-Cylinder Engine Only)

Pressure Testing Cooling System Flushing Cooling System

Lubrication and Maintenance/2000 Hour

Checking and Adjusting Engine Valve Clearance. 71

Service As Required

Additional Service Information Do Not Modify Fuel System Adding Coolant Replacing Air Cleaner Filter Elements Inspecting Primary Filter Element Cleaning Primary Filter Element Washing Primary Filter Element Element Storage Replacing Fan and Alternator Belts Power Take-off (PTO) Clutch Checking Fuses Bleeding the Fuel System

Troubleshooting

General Troubleshooting Information Engine Wiring Diagram Legend Wiring Diagram Engine Troubleshooting Electrical Troubleshooting

Storage

Engine Storage Guidelines Use AR41785 Engine Storage Kit Preparing Engine for Long Term Storage Removing Engine from Long Term Storage

Specifications

General OEM Engine Specifications Fuel Injection Pump Specifications Engine Crankcase Oil Fill Quantities Unified Inch Bolt and Cap Screw Torque Values 105 Metric Bolt and Cap Screw Torque Values

Lubrication and Maintenance Records

Emission System Warranty

Service Literature

Order Form

Index

Record Keeping

POWERTECH MEDALLION

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

ENGINE SERIAL NUMBER PLATE

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

“T0” indicates the engine was built in Dubuque, Iowa “CD” indicates the engine was built in Saran, France

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

RG8041

RG8007

A

RECORD ENGINE SERIAL NUMBER

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

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

Engine Serial Number (B)

Engine Model Number(C)

Coefficient of Absorption Value (D)

Dubuque Serial Number Plate

Saran Serial Number Plate

RG7936

C

B

RG7935

D

B

C

ENGINE OPTION CODES

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. At times it will be necessary to furnish this base code to differentiate two identical option codes for the same engine model.

The first two digits of each code identify a specific group, such as alternators. The last two digits of each code identify one specific option provided on your engine, such as a 12-volt, 55-amp alternator.

NOTE: These option codes are based on the latest information available at the time of publication.

The right is reserved to make changes at any time without notice.

If an engine is ordered without a particular component, the last two digits of that functional group option code will be 99, 00, or XX. The list on the next page shows only the first two digits of the code numbers. For future reference such as ordering repair parts, it is important to have these code numbers available. To ensure this availability, enter the third and fourth digits shown on your engine option code label in the spaces provided on the following page.

NOTE: Your engine option code label may not contain all option codes if an option has been added after the engine left the producing factory.

If option code label is lost or destroyed, consult your servicing dealer or engine distributor selling the engine for a replacement.

1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500 2600 2700 2800 2900 3000 3100 3200 3500 3600 3700 3900 4000 4100 4300 4400 4500 4600 4700 4800 4900 5000 5100 5200 5500 5600 5700 5900 6000 6200 6400 6500 6600 6700 6800 6900 7400 7500 7600 8600 8700 8800 9100 9700 9800

JOHN DEERE

Customer No. 0000000000000 OPTION CODES

6068TF150 6.8 L 2135F

Number T06068T000000

Option Code Label

RG7984

ENGINE OPTION CODES—CONTINUED

Engine Base Code: __________________________

Option Codes Description

11_______ Rocker Arm Cover

12_______ Oil Filler Neck

13_______ Crankshaft Pulley

14_______ Flywheel Housing

15_______ Flywheel

16_______ Fuel Injection Pump

17_______ Air Inlet

18_______ Air Cleaner

19_______ Oil Pan

20_______ Water Pump

21_______ Thermostat Cover

22_______ Thermostat

23_______ Fan Drive

24_______ Fan Belt

25_______ Fan

26_______ Engine Coolant Heater

27_______ Radiator

28_______ Exhaust Manifold

29_______ Ventilator System

30_______ Starting Motor

31_______ Alternator

32_______ Instrument Panel

35_______ Fuel Filter

36_______ Front Plate

37_______ Fuel Transfer Pump

39_______ Thermostat Housing

40_______ Oil Dipstick

41_______ Belt Driven Front Auxiliary Drive

43_______ Starting Aid

44_______ Timing Gear Cover With Gears

Option Codes Description

45_______ Balancer Shaft

46_______ Cylinder Block With Liners and Camshaft

47_______ Crankshaft and Bearings

48_______ Connecting Rods and Pistons

49_______ Valve Actuating Mechanisms

50_______ Oil Pump

51_______ Cylinder Head With Valves

52_______ Auxiliary Gear Drive

55_______ Shipping Stand

56_______ Paint Option

57_______ Water Pump Inlet

59_______ Oil Cooler

60_______ Add-on Auxiliary Drive Pulley

62_______ Alternator Mounting

64_______ Exhaust Elbow

65_______ Turbocharger

66_______ Temperature Switch

67_______ Electronic Tachometer Sensor

68_______ Damper

69_______ Engine Serial Number Plate

74_______ Air Conditioner Compressor Mounting

75_______ Air Restriction Indicator

76_______ Oil Pressure Switch

86_______ Fan Pulley

87_______ Automatic Belt Tensioner

88_______ Oil Filter

91_______ Special Equipment (Factory Installed)

97_______ Special Equipment (Field Installed)

98_______ Shipping

RECORD PTO SERIAL NUMBER

Serial number and model number are located on cover plate (A) of PTO housing. Record the numbers in the following spaces:

Serial Number

Model Number

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. _________________________________

RG4622

A

RG8008

Safety

RECOGNIZE SAFETY INFORMATION

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

Follow recommended precautions and safe operating practices.

UNDERSTAND SIGNAL WORDS

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

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

T81389

TS187

FOLLOW SAFETY INSTRUCTIONS

Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in good condition. Replace missing or damaged safety signs. Be sure new equipment components and repair parts include the current safety signs. Replacement safety signs are available from your John Deere dealer.

Learn how to operate the machine and how to use controls properly. Do not let anyone operate without instruction.

Keep your machine in proper working condition.

Unauthorized modifications to the machine may impair the function and/or safety and affect machine life.

If you do not understand any part of this manual and need assistance, contact your John Deere dealer.

PREVENT BYPASS STARTING

Avoid possible injury or death from engine runaway.

Do not start engine by shorting across starter terminal.

Engine will start with PTO engaged if normal circuitry is bypassed.

Start engine only from operator's station with PTO disengaged or in neutral.

TS201

RG5419

HANDLE FUEL SAFELY—AVOID FIRES

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

Always stop engine before refueling machine. Fill fuel tank outdoors.

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

PREPARE FOR EMERGENCIES

Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.

HANDLE STARTING FLUID SAFELY

Starting fluid is highly flammable.

Keep all sparks and flame away when using it. Keep starting fluid away from batteries and cables.

To prevent accidental discharge when storing the pressurized can, keep the cap on the container, and store in a cool, protected location.

Do not incinerate or puncture a starting fluid container.

TS202

TS291

TS1356

WEAR PROTECTIVE CLOTHING

Wear close fitting clothing and safety equipment appropriate to the job.

Prolonged exposure to loud noise can cause impairment or loss of hearing.

Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.

Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine.

PROTECT AGAINST NOISE

Prolonged exposure to loud noise can cause impairment or loss of hearing.

Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.

TS206

TS207

HANDLE CHEMICAL PRODUCTS SAFELY

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

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

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

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

STAY CLEAR OF ROTATING DRIVELINES

Entanglement in rotating driveline can cause serious injury or death.

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

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

TS1132

TS1644

PRACTICE SAFE MAINTENANCE

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

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

Stop the engine. Remove the key. Allow machine to cool.

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

Keep all parts in good condition and properly installed.

Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or debris.

Disconnect battery ground cable (-) before making adjustments on electrical systems or welding on machine.

WORK IN VENTILATED AREA

Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension.

If you do not have an exhaust pipe extension, open the doors and get outside air into the area.

TS218

TS220

AVOID HIGH-PRESSURE FLUIDS

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

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids.

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A.

AVOID HEATING NEAR PRESSURIZED

FLUID LINES

Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area.

X9811

TS953

REMOVE PAINT BEFORE WELDING OR

HEATING

Avoid potentially toxic fumes and dust.

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

Do all work outside or in a well ventilated area. Dispose of paint and solvent properly.

Remove paint before welding or heating:

• If you sand or grind paint, avoid breathing the dust.

Wear an approved respirator.

• If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

SERVICE COOLING SYSTEM SAFELY

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

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

TS281

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.

DISPOSE OF WASTE PROPERLY

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

Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

Do not pour waste onto the ground, down a drain, or into any water source.

Air conditioning refrigerants escaping into the air can damage the Earth's atmosphere. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants.

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

TS1133

Fuels, Lubricants, and Coolant

DIESEL FUEL

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

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

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

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

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

• Cold Filter Plugging Point (CFPP) below the expected low temperature OR Cloud Point at least 5° C (9° F) below the expected low temperature.

• Fuel Lubricity should pass a minimum of 3100 gram load level as measured by the BOCLE scuffing test.

• Sulfur Content

— Sulfur content should not exceed 0.5%. Sulfur content less than 0.05% is preferred.

— If diesel fuel with sulfur content greater than 0.5% sulfur content is used, reduce the service interval for engine oil and filter by 50%.

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

Bio-diesel fuels with properties meeting DIN 51606 or equivalent specification may be used.

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

LUBRICITY OF DIESEL FUELS

Diesel fuel must have adequate lubricity to ensure proper operation and durability of fuel injection system components.

Diesel fuels for highway use in the United States and Canada now require sulfur content less than 0.05%.

Diesel fuel in the European Union will require sulfur content less than 0.05% by 1 October 1996.

Experience shows that some low sulfur diesel fuels may have inadequate lubricity and their use may reduce performance in fuel injection systems due to inadequate lubrication of injection pump components.

The lower concentration of aromatic compounds in these fuels also adversely affects injection pump seals and may result in leaks.

Use of low lubricity diesel fuels may also cause accelerated wear, injection nozzle erosion or corrosion, engine speed instability, hard starting, low power, and engine smoke.

Fuel lubricity should pass a minimum of 3100 gram load level as measured by the BOCLE scuffing test.

ASTM D975 and EN 590 specifications do not require fuels to pass a fuel lubricity test.

If fuel of low or unknown lubricity is used, add John Deere PREMIUM DIESEL FUEL CONDITIONER (or equivalent) at the specified concentration. John Deere PREMIUM DIESEL FUEL CONDITIONER is available in winter and summer formulas. Consult your John Deere engine distributor or servicing dealer for more information.

DIESEL FUEL STORAGE

Proper fuel storage is critically important. Use clean storage and transfer tanks. Periodically drain water and sediment from bottom of tank. Store fuel in a convenient place away from buildings.

IMPORTANT: DO NOT store diesel fuel in galvanized containers. Diesel fuel stored in galvanized containers reacts with zinc coating on container to form zinc flakes. If fuel contains water, a zinc gel will also form. The gel and flakes will quickly plug fuel filters, damage injection nozzles and injection pump.

DO NOT use brass-coated containers for fuel storage. Brass is an alloy of copper and zinc.

Store diesel fuel in plastic, aluminum, and steel containers specially coated for diesel fuel storage.

Avoid storing fuel over long periods of time. If fuel is stored for more than a month prior to use, or there is a slow turnover in fuel tank or supply tank, add a fuel conditioner such as John Deere PREMIUM DIESEL FUEL CONDITIONER or equivalent to stabilize the fuel and prevent water condensation. John Deere PREMIUM DIESEL FUEL CONDITIONER is available in winter and summer formulas. Fuel conditioner also reduces fuel gelling and controls wax separation during cold weather.

Consult your John Deere engine distributor or servicing dealer for recommendations and local availability.

Always follow manufacturer's directions on label.

FILLING FUEL TANK

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

DO NOT smoke while filling fuel tank or servicing fuel system.

IMPORTANT: The fuel tank is vented through the filler cap. If a new filler cap is required, always replace it with an original vented cap.

Fill fuel tank at the end of each day's operation to prevent condensation in tank as moist air cools and freezing during cold weather.

TS202

MINIMIZING THE EFFECT OF COLD WEATHER ON DIESEL ENGINES

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

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

Use Grade No. 1-D Fuel

When temperatures fall below 5° C (40° F), Grade No.

1-D fuel is best suited for cold weather operation.

Grade No. 1-D 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 become more resistant to flow through fuel pumps and lines.

NOTE: On an average, Grade No. 1-D fuel has a lower BTU (heat content) rating than Grade No. 2-D fuel. When using Grade No. 1-D fuel you may notice a drop in power and fuel efficiency, but should not experience any other engine performance effects. Check the grade of fuel being used before troubleshooting for low power complaints in cold weather operation.

Coolant Heaters

Engine block heaters (coolant) are an available option to aid cold weather starting.

Seasonal Viscosity Oil and Proper Coolant Concentration

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

Diesel Fuel Flow 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.

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.

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.

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

Radiator Shutters

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

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

• ACEA Specification E1

• CCMC Specification D4

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

IMPORTANT: Do not use John Deere PLUS-50 oil or engine oils meeting API CG4, API CF4, ACEA E3, ACEA E2, or CCMC D5 performance levels during the first 100 hours of operation of a new or rebuilt engine. These oils will not allow the engine to break-in properly.

DIESEL ENGINE OIL

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

The following oil is preferred.

• John Deere PLUS-50

If John Deere PLUS-50 engine oil and a John Deere oil filter are used, the service interval for oil and filter changes may be extended by 50 hours.

The following oil is also recommended:

• John Deere TORQ-GARD SUPREME

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

• John Deere UNI-GARD

• API Service Classification CG-4

• API Service Classification CF-4

• ACEA Specification E3

• ACEA Specification E2

• CCMC Specification D5

• CCMC Specification D4

Multi-viscosity diesel engine oils are preferred.

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

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 engine distributor or servicing dealer to obtain specific information and recommendations.

TS1647

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.

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.

T6829AB

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.

GREASE

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

The following greases are preferred:

• John Deere HIGH TEMPERATURE EP GREASE

• John Deere MOLY HIGH TEMPERATURE EP

GREASE

• John Deere GREASE-GARD

Other greases may be used if they meet one of the following:

• NLGI Performance Classification GC-LB

-55 °C

50 °C

40 °C

30 °C

20 °C

10 °C

0 °C

-10 °C

-20 °C

-30 °C

-40 °C -67 °F

122 °F

104 °F

86 °F

68 °F

50 °F

32 °F

14 °F

-4 °F

-22 °F

-40 °F

JD

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LG

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LG

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JD

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RG7241

DIESEL ENGINE COOLANT RECOMMENDATIONS

Contact your engine distributor or servicing dealer to determine what the cooling system of this engine is filled with and the winter freeze protection level.

Solutions of antifreeze and supplemental coolant additives MUST be used year-round for freeze protection, boil-over protection, and to provide a stable, noncorrosive environment for seals, hoses and metal engine parts.

The following engine coolant is preferred for service:

— John Deere PREDILUTED

ANTIFREEZE/SUMMER COOLANT

— John Deere COOL-GARD, where available

The following engine coolant is also recommended:

— John Deere ANTIFREEZE/SUMMER COOLANT CONCENTRATE in a 40 to 60 percent mixture of concentrate with quality water

• JOHN DEERE PREDILUTED

ANTIFREEZE/SUMMER COOLANT

This product contains all the necessary ingredients that make up the proper coolant solution: chemically pure water, ethylene glycol (low silicate antifreeze), and supplemental coolant additives (SCAs). It is ready to use; no mixing is required.

John Deere Prediluted Antifreeze/Summer Coolant permits extended service life to 3000 hours or 36 months of operation.

• JOHN DEERE COOL-GARD

In certain geographical areas, John Deere COOL-GARD is marketed for use in the engine cooling system. This product contains all the necessary ingredients that make up the proper coolant solution:

chemically pure water, ethylene glycol (low silicate antifreeze), and supplemental coolant additives (SCAs). It is ready to add to cooling system as is; no mixing or supplemental coolant additives required.

Contact your John Deere Parts Network for local availability.

John Deere COOL-GARD has a service life of 2000 hours or 24 months of operation.

• JOHN DEERE ANTIFREEZE/SUMMER COOLANT

CONCENTRATE

This product contains ethylene glycol (low silicate antifreeze) and supplemental coolant additives (SCAs).

It must be mixed with quality water, as described later in this section, before adding to the engine cooling system. The proportion of water to be used depends upon the lowest freeze protection temperature desired according to the following table:

% CONCENTRATE FREEZE PROTECTION LIMIT

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

John Deere Antifreeze/Summer Coolant Concentrate has a service life of 2000 hours or 24 months of operation.

ENGINE COOLANT SPECIFICATIONS

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

Coolant solutions of quality water, ethylene glycol concentrate (antifreeze), and supplemental coolant additives (SCAs) MUST be used year-round to protect against freezing, boil-over, liner erosion or pitting, and to provide a stable, noncorrosive environment for seals, hoses, and metal engine parts.

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

Some coolant concentrates, including John Deere

ANTIFREEZE/SUMMER COOLANT CONCENTRATE,

contain both ethylene glycol antifreeze and inhibiting coolant additives. Mix these products and quality water, but do not add an initial charge of supplemental coolants additives.

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

Water Quality:

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

Water Quality Specifications

Parts Grains Per Per

Item Million U.S. Gallon

Chlorides (maximum) . . . . . . . . . . . . . . 40 2.5 Sulfates (maximum). . . . . . . . . . . . . . . . 100 5.9 Total Dissolved Solids (maximum). . . . . 340 20 Total Hardness (maximum) . . . . . . . . . . 170 10 pH Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5—9.0

Ethylene Glycol Concentrate (Antifreeze):

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

The use of John Deere coolant products, as outlined on the previous page, is strongly recommended .

If John Deere coolant products are not used, other low silicate ethylene glycol base coolants for heavy-duty diesel engines may be used when mixed with quality water and supplemental coolant additives (SCAs), if they meet one of the following specifications:

• ASTM D5345 (prediluted coolant)

• ASTM D4985 (coolant concentrate) in a 40% to 60% mixture of concentrate with quality water.

Coolants meeting these specifications require addition of supplemental coolant additives (SCAs), formulated for heavy-duty diesel engines, for protection against corrosion and cylinder liner erosion and pitting.

IMPORTANT: Never use automotive-type coolants (such as those meeting ASTM D3306 or ASTM D4656). These coolants do not contain the correct additives to protect heavy-duty diesel engines.

They often contain a high concentration of silicates and may damage the engine or cooling system.

ENGINE COOLANT SPECIFICATIONS—CONTINUED

Supplemental Coolant Additives (SCAs):

IMPORTANT: DO NOT over-inhibit antifreeze solutions, as this can cause silicate-dropout. When this happens, a gel-type deposit is created which retards heat transfer and coolant flow causing engine to overheat.

NOTE: John Deere Prediluted Antifreeze/Summer Coolant, John Deere Antifreeze/Summer Coolant Concentrate, and John Deere COOL-GARD contain supplemental coolant additives (SCAs). However, as the coolant solution loses its effectiveness, additives will need to be added.

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

The 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.

Inhibit the antifreeze-coolant mix with a non-chromate inhibitor. John Deere Liquid Coolant Conditioner is recommended as a supplemental coolant additive in John Deere engines.

IMPORTANT: Check inhibitors between drain intervals every 600 hours or 12 months of operation. Replenish inhibitors by the addition of a supplemental coolant additive as necessary.

DO NOT use soluble oil.

Additives eventually lose their effectiveness and must be recharged with additional supplemental coolant additives available in the form of liquid coolant conditioner. See TESTING ENGINE COOLANT and

REPLENISHING SUPPLEMENTAL COOLANT

ADDITIVES (SCAs) BETWEEN COOLANT CHANGES, as described later in this section.

John Deere Liquid Coolant Conditioner

RG7276

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 600 hours or 12 month intervals and whenever excessive coolant is lost through leaks or overheating to ensure the necessary protection.

Coolant Test Strips

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

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

COOLSCAN

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

RG7297

RG7397

REPLENISHING SUPPLEMENTAL COOLANT ADDITIVES (SCAs) BETWEEN COOLANT

CHANGES

IMPORTANT: Do not add supplemental coolant additives when the cooling system is drained and refilled with John Deere ANTIFREEZE/SUMMER COOLANT or John Deere COOL-GARD.

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 ANTIFREEZE/SUMMER COOLANT or John Deere COOL-GARD is used. The cooling system must be recharged with additional supplemental coolant additives available in the form of liquid coolant conditioner.

Maintaining the correct coolant conditioner concentration (SCAs) and freeze point is essential in your cooling system to protect against rust, liner pitting and corrosion, and freeze-ups due to incorrect coolant dilution.

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

Test the coolant solution at 600 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 system per instructions printed on label of John Deere Liquid Coolant Conditioner.

IMPORTANT: ALWAYS maintain coolant at correct level and concentration. DO NOT operate engine without coolant for even a few minutes.

If frequent coolant makeup is required, the glycol concentration should be checked with JT05460 Refractometer to assure that the desired freeze point is maintained.

Follow manufacturer's instructions provided with refractometer.

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

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

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

See ENGINE COOLANT SPECIFICATIONS earlier in this section for proper mixing of coolant ingredients before adding to the cooling system.

RG6261 RG6262

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.

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 dealer.

TS1133

Engine Operating Guidelines

INSTRUMENT (GAUGE) PANEL

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 John Deere instrument (gauge) panel:

A—Oil Pressure Gauge - Indicates engine oil pressure.

B—Ammeter - Indicates charging current within electrical system.

C—Coolant Temperature Gauge - Indicates the engine coolant temperature.

D—Key Switch - The four position key switch controls the electrical system.

E—Reset (Safety) Switch - Overrides safety shutdown switch when depressed and held in during engine start-up. Hold button in until engine oil pressure is at a safe operating level. Switch will shut engine down when oil pressure drops below or coolant temperature rises above a (preset) safe operating level.

F—Tachometer with Electric Hour Meter - Tachometer senses engine speed from a speed sensor in front timing gear cover and indicates engine speed in revolutions per minute (rpm). Hour meter indicates the operating hours of the engine while key switch is in the “ON” position. The hour meter should be used as a guide for scheduling periodic service.

G—Hand Throttle - Controls engine speed.

H—Tachometer Binary Code - Located in back of tachometer and must be set at “00010011” to operate at 27 pulses per revolution.

A—Oil Pressure Gauge B—Ammeter C—Coolant Temperature Gauge D—Key Switch E—Reset (Safety) Switch F—Tachometer with Hour Meter G—Hand Throttle H—Tachometer Binary Code

RG8027

G

E

A

C

F

D

B

RG6861

F

H

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 105° C (221° F), reduce load on engine. Unless temperature drops quickly, stop engine and determine cause before resuming operation.

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

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

— Sudden drop in oil pressure

— Abnormal coolant temperatures

— Unusual noise or vibration

— Sudden loss of power

— Excessive black exhaust

— Excessive fuel consumption

— Excessive oil consumption

— Fluid leaks

BREAK-IN SERVICE

The engine is ready for normal operation. However, extra care during the first 100 hours of operation will result in more satisfactory long-term engine performance and life. DO NOT exceed 100 hours of operation with break-in oil.

1. This engine is factory-filled with John Deere Engine Break-in Oil. Operate the engine at heavy loads with minimal idling during the break-in period.

2. If the engine has significant operating time at idle, constant speeds, and/or light load usage, or makeup oil is required in the first 100 hour period, a longer break-in period may be required. In these situations, an additional 100 hour break-in period is recommended using a new change of John Deere Engine Break-In Oil and a new John Deere oil filter.

IMPORTANT: DO NOT add makeup oil until the oil level is BELOW the ADD mark on dipstick. John Deere Engine Break-In Oil (TY22041) should be used to make up any oil consumed during the break-in period.

3. Check engine oil level more frequently during engine break-in period. If oil must be added during this period, John Deere Engine Break-In Oil is preferred. See ENGINE BREAK-IN OIL, in Fuels, Lubricants, and Coolant Section.

IMPORTANT: DO NOT use PLUS-50 Engine Oil during the break-in period of a new engine or engine that has had a major overhaul. PLUS-50 oil will not allow a new or overhauled engine to properly wear during this break-in period.

IMPORTANT: 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.

ENGINE SPECIFICATIONS*

Oil Pressure at Full Load Rated Speed . . . . . . . . . . . . 345 ± 103 kPa (3.45 ± 1.03 bar) (50 ± 15 psi)

Minimum Oil Pressure at Rated Speed . . . . . . . . . . . . 275 (2.75 bar) (40 psi)

Minimum Oil Pressure at 850 rpm . . . . . . . . . . . . 103 kPa (1.03 bar) (15 psi)

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

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

RG8009

RG7330

BREAK-IN SERVICE—CONTINUED

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. After the first 100 hours (maximum), change engine oil and replace engine oil filter (A). (See CHANGE ENGINE OIL AND FILTER in Lubrication and Maintenance/250 Hour Section.) Fill crankcase with seasonal viscosity grade oil. (See DIESEL ENGINE OIL, in Fuels, Lubricants, and Coolant Section.)

NOTE: Some increase in oil consumption may be expected when low viscosity oils are used.

Check oil levels more frequently.

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

6. Watch coolant temperatures (A) closely. If coolant temperature rises above 112° C (234° F), reduce load on engine.