John Deere CD4039DF008 manual

OPER A TOR'S MANUAL John Deere Usine de Saran OMCD16564 (03JAN00) Printed in Germany ENGLISH P OWER Units for Gensets (Saran) 2.9L/4039/4.5/6.8L (128/008/158/258)[...]

Introduction DPSG,CD03523,1 –19–01JUL99–1/1 THIS MANUAL COVERS the following engines for generator sets: ENGINE FAMILY ENGINE MODEL 300-SERIES CD3029DF128 CD4039DF008 CD4039TF008 POWERTECH  CD4045DF158 CD4045HF158 CD4045TF158 CD4045TF258 CD6068HF158 CD6068TF158 CD6068TF258 READ THIS MANUAL carefully to learn how to operate and service your[...]

Contents Page Page Identification Views Diesel Engine Coolant .................... 10-4 Identification views . . ..................... 01-1 Operating in Warm Temperature Climates ..... 10-5 Maintenance Records Operating the Engine Using maintenance records ................ 02-1 Break-in period .......................... 15-1 100 Hours of operation [...]

Contents Page Checking crankshaft vibration damper (6-CYLINDER ENGINE ONLY) ...... ..... 40-4 Maintenance/2500 hours/3 years Drain and flush cooling system . . ........... 45-1 Maintenance/As required Additional service information ............... 50-1 Do not modify fuel system ................. 50-1 Clean or replace air filter (one-piece) ........[...]

Identification Views DPSG,CD03523,3 –19–05JUL99–1/2 IDENTIFICATION VIEWS CD30744 –UN–23AUG99 4045HF158 Continued on next page 01-1 112699 PN=5[...]

Identification Views DPSG,CD03523,3 –19–05JUL99–2/2 CD30745 –UN–23AUG99 6068HF158 01-2 112699 PN=6[...]

Maintenance Records DPSG,CD03523,6 –19–05JUL99–1/1 USING MAINTENANCE RECORDS To obtain the best performance, economy and service life from your engine, ensure service is carried out according to this present manual and recorded in the following pages. It is recommended that your engine Distributor or your Dealer carry out this service work an[...]

Maintenance Records DPSG,CD03523,8 –19–05JUL99–1/1 500 HOURS OF OPERATION ❒ Engine oil, replace ❒ Engine oil filter, replace ❒ Fuel filter, replace ❒ Belt, check tension and wear (300-Series and POWERTech with manual tensioner) ❒ Valve clearance, adjust (300-Series) Number of hours: Comments: Dealer or distributor stamp Date: Job do[...]

Maintenance Records DPSG,CD03523,10 –19–05JUL99–1/1 1500 HOURS OF OPERATION ❒ Engine oil, replace ❒ Engine oil filter, replace ❒ Fuel filter, replace ❒ Belt, check tension and wear (300-Series and POWERTech with manual tensioner) ❒ Valve clearance, adjust (300-Series) Number of hours: Comments: Dealer or distributor stamp Date: Job [...]

Maintenance Records DPSG,CD03523,60 –19–16AUG99–1/1 2500 HOURS OF OPERATION ❒ Engine oil, replace ❒ Cooling system, drain and flush (if COOL-GARD is used) ❒ Engine oil filter, replace ❒ Fuel filter, replace ❒ Belt, check tension and wear (300-Series and POWERTech with manual tensioner) ❒ Valve clearance, adjust (300-Series) Number[...]

Maintenance Records DPSG,CD03523,62 –19–16AUG99–1/1 3500 HOURS OF OPERATION ❒ Engine oil, replace ❒ Engine oil filter, replace ❒ Fuel filter, replace ❒ Belt, check tension and wear (300-Series and POWERTech with manual tensioner) ❒ Valve clearance, adjust (300-Series) Number of hours: Comments: Dealer or distributor stamp Date: Job [...]

Maintenance Records DPSG,CD03523,64 –19–16AUG99–1/1 4500 HOURS OF OPERATION ❒ Engine oil, replace ❒ Vibration damper, replace (6 cyl.) ❒ Engine oil filter, replace ❒ Fuel filter, replace ❒ Belt, check tension and wear (300-Series and POWERTech with manual tensioner) ❒ Valve clearance, adjust (300-Series) Number of hours: Comments:[...]

Maintenance Records DPSG,CD03523,66 –19–16AUG99–1/1 5500 HOURS OF OPERATION ❒ Engine oil, replace ❒ Engine oil filter, replace ❒ Fuel filter, replace ❒ Belt, check tension and wear (300-Series and POWERTech with manual tensioner) ❒ Valve clearance, adjust (300-Series) Number of hours: Comments: Dealer or distributor stamp Date: Job [...]

Maintenance Records DPSG,CD03523,68 –19–16AUG99–1/1 6500 HOURS OF OPERATION ❒ Engine oil, replace ❒ Engine oil filter, replace ❒ Fuel filter, replace ❒ Belt, check tension and wear (300-Series and POWERTech with manual tensioner) ❒ Valve clearance, adjust (300-Series) Number of hours: Comments: Dealer or distributor stamp Date: Job [...]

Maintenance Records DPSG,CD03523,70 –19–16AUG99–1/1 7500 HOURS OF OPERATION ❒ Engine oil, replace ❒ Cooling system, drain and flush (if COOL-GARD is used) ❒ Engine oil filter, replace ❒ Fuel filter, replace ❒ Belt, check tension and wear (300-Series and POWERTech with manual tensioner) ❒ Valve clearance, adjust (300-Series) Number[...]

Maintenance Records DPSG,CD03523,72 –19–16AUG99–1/1 8500 HOURS OF OPERATION ❒ Engine oil, replace ❒ Engine oil filter, replace ❒ Fuel filter, replace ❒ Belt, check tension and wear (300-Series and POWERTech with manual tensioner) ❒ Valve clearance, adjust (300-Series) Number of hours: Comments: Dealer or distributor stamp Date: Job [...]

Maintenance Records DPSG,CD03523,74 –19–16AUG99–1/1 9500 HOURS OF OPERATION ❒ Engine oil, replace ❒ Engine oil filter, replace ❒ Fuel filter, replace ❒ Belt, check tension and wear (300-Series and POWERTech with manual tensioner) ❒ Valve clearance, adjust (300-Series) Number of hours: Comments: Dealer or distributor stamp Date: Job [...]

Record Keeping DPSG,CD03523,11 –19–05JUL99–1/1 POWERTECH  MEDALLION RG8041 –UN–15JAN99 A medallion is located on the rocker arm cover which identifies each engine as a John Deere POWERTECH  engine. POWERTECH is a trademark of Deere & Company DPSG,CD03523,12 –19–05JUL99–1/1 ENGINE SERIAL NUMBER PLATE RG8007 –UN–15JAN99 [...]

Record Keeping DPSG,CD03523,13 –19–05JUL99–1/1 RECORD ENGINE SERIAL NUMBER CD30705B –UN–24AUG99 300-Series engine plate CD30747 –UN–23AUG99 POWERTech engine plate 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 [...]

Record Keeping DPSG,CD03523,14 –19–05JUL99–1/2 ENGINE OPTION CODES CD30748A –UN–26AUG99 Engine option code label In addition to the serial number plate, OEM engines have an engine option code label affixed to the rocker arm cover. These codes indicate which of the engine options were installed on your engine at the factory. When in need o[...]

Record Keeping DPSG,CD03523,14 –19–05JUL99–2/2 Option Description Option Description Codes Codes Engine Base Code:________ 11____ Rocker Arm Cover 45____ Balancer Shaft 12____ Oil Filler Neck 46____ Cylinder Block With Liners and Camshaft 13____ Crankshaft Pulley 47____ Crankshaft and Bearings 14____ Flywheel Housing 48____ Connecting Rods an[...]

Record Keeping DPSG,CD03523,15 –19–07JUL99–1/1 RECORD FUEL INJECTION PUMP MODEL NUMBER CD30749 –UN–24SEP99 Record the fuel injection pump model and serial information found on the serial number plate (A). Model No. _____________________ RPM _______ Manufacturer’s No. __________________________ Serial No. ________________________________[...]

Safety DX,ALERT –19–29SEP98–1/1 RECOGNIZE SAFETY INFORMATION T81389 –UN–07DEC88 This is a safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. Follow recommended precautions and safe operating practices. DX,SIGNAL –19–03MAR93–1/1 UNDERSTAND SIGNAL WORDS TS187[...]

Safety DPSG,CD03523,95 –19–06OCT99–1/1 ENGINE LIFTING PROCEDURE RG7784 –UN–11NOV97 CAUTION: The only recommended method for lifting the engine is with JDG23 Engine Lifting Sling (A) and safety approved lifting straps (B) that come with engine. Use extreme caution when lifting and NEVER permit any part of the body to be positioned under an[...]

Safety DX,READ –19–03MAR93–1/1 FOLLOW SAFETY INSTRUCTIONS TS201 –UN–23AUG88 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[...]

Safety DX,FIRE1 –19–03MAR93–1/1 HANDLE FUEL SAFELY—AVOID FIRES TS202 –UN–23AUG88 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, grea[...]

Safety DX,WEAR –19–10SEP90–1/1 WEAR PROTECTIVE CLOTHING TS206 –UN–23AUG88 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 uncomfortabl[...]

Safety DX,MSDS,NA –19–03MAR93–1/1 HANDLE CHEMICAL PRODUCTS SAFELY TS1132 –UN–26NOV90 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 detail[...]

Safety DX,SERV –19–17FEB99–1/1 PRACTICE SAFE MAINTENANCE TS218 –UN–23AUG88 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 equ[...]

Safety DX,FLUID –19–03MAR93–1/1 AVOID HIGH-PRESSURE FLUIDS X9811 –UN–23AUG88 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. Protec[...]

Safety DX,PAINT –19–03MAR93–1/1 REMOVE PAINT BEFORE WELDING OR HEATING TS220 –UN–23AUG88 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[...]

Safety DX,DUST –19–15MAR91–1/1 AVOID HARMFUL ASBESTOS DUST TS220 –UN–23AUG88 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,[...]

Fuels, Lubricants and Coolant DX,FUEL1 –19–17FEB99–1/1 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[...]

Fuels, Lubricants and Coolant DX,ENOIL4 –19–10OCT97–1/1 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 rebuil[...]

Fuels, Lubricants and Coolant CD,ENOIL –19–10OCT97–1/1 DIESEL ENGINE OIL TS1661 –UN–10OCT97 Use oil viscosity based on the expected air temperature range during the period between oil changes. The following oil is preferred: • John Deere PLUS-50  The following oil is also recommended: • John Deere TORQ-GARD SUPREME TORQ-GARD SUPREM[...]

Fuels, Lubricants and Coolant DX,LUBMIX –19–18MAR96–1/1 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 lubr[...]

Fuels, Lubricants and Coolant DX,COOL6 –19–18MAR96–1/1 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 cool[...]

Operating the Engine DPSG,CD03523,17 –19–09JUL99–1/1 BREAK-IN PERIOD Within first 100 hours of operation During the first 100 hours of operation, avoid overloading, excessive idling and no-load operation. See ENGINE BREAK-IN OIL for eventual addition of oil. NOTE: During the break-in period a higher-than-usual oil consumption should be consid[...]

Operating the Engine DPSG,CD03523,19 –19–09JUL99–2/4 CD30750 –UN–03SEP99 Air intake heater Air intake heater is either a grid-type (A) for POWERTech engines or a glow plug-type (B) for 300-Series engines installed in the air intake channel. CAUTION: NEVER use Ether Starting Fluid when air intake heater is used to start the engine. Activat[...]

Operating the Engine DPSG,CD03523,20 –19–09JUL99–1/1 USING A BOOSTER BATTERY OR CHARGER TS204 –UN–23AUG88 RG4678 –UN–14DEC88 12-Volt System RG4698 –UN–14DEC88 24-Volts System A—12-Volt Machine battery/batteries B—12-Volt Booster battery/batteries C—Booster cable D—Cable to starter motor A 12-volt booster battery can be con[...]

Operating the Engine DPSG,CD03523,21 –19–09JUL99–1/1 ENGINE OPERATION Warming engine Operate engine at high idle for 1 to 2 minutes before applying the load. NOTE: This procedure does not apply to standby generator sets where the engine is loaded immediately upon reaching rated speed. Normal engine operation Compare engine coolant temperature[...]

Operating the Engine DPSG,CD03523,23 –19–09JUL99–1/1 STOPPING THE ENGINE 1. Before stopping, run engine for at least 2 minutes at fast idle and no load. 2. Stop the engine. 15-5 112699 PN=42[...]

Maintenance DPSG,CD03523,24 –19–09JUL99–1/1 OBSERVE SERVICE INTERVALS Using hour meter as a guide, perform all services at the hourly intervals indicated on following pages. At each scheduled maintenance interval, perform all previous maintenance operations in addition to the ones specified. Keep a record of hourly intervals and services perf[...]

Maintenance DPSG,CD03523,26 –19–09JUL99–1/1 MAINTENANCE INTERVAL CHART Item 10 H / 500 H 1000 H / 2000 H / 2500 H / As daily 1 year 2 years 3 years required Check engine oil and coolant level • Check air filter restriction indicator a • Change engine oil and filter b • Replace fuel filter element • Check belt tension and automatic ten[...]

Maintenance/Daily or every 10 hours DPSG,CD03523,27 –19–12JUL99–1/3 DAILY PRESTARTING CHECKS CD30753 –UN–26AUG99 POWERTech engine CD30754 –UN–26AUG99 300-Series engine CD30755 –UN–24SEP99 FD000047 –UN–13MAR96 Do the following BEFORE STARTING THE ENGINE for the first time each day: IMPORTANT: DO NOT top up with fresh oil until [...]

Maintenance/Daily or every 10 hours DPSG,CD03523,27 –19–12JUL99–2/3 TS281 –UN–23AUG88 CD30756 –UN–26AUG99 2. 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 p[...]

Maintenance/500 hours DPSG,CD03523,29 –19–12JUL99–1/2 CHANGING ENGINE OIL AND FILTER CD30758 –UN–26AUG99 CD30759 –UN–26AUG99 POWERTEch engine CD30760 –UN–26AUG99 300-Series engine NOTE: Change engine oil and filter for the first time after 100 hours maximum of operation, then every 500 hours thereafter. Change oil and filter at le[...]

Maintenance/500 hours DPSG,CD03523,29 –19–12JUL99–2/2 CD30761 –UN–24SEP99 FD000047 –UN–13MAR96 8. Fill engine crankcase with correct John Deere engine oil through rocker arm cover opening (C); see DIESEL ENGINE OIL. To determine the correct oil fill quantity for your engine, see “Engine Oil Quantities” in Specifications Section. N[...]

Maintenance/500 hours DPSG,CD03523,30 –19–12JUL99–1/1 REPLACING FUEL FILTER ELEMENT X9811 –UN–23AUG88 RG7721 –UN–15JAN99 A—Retaining ring B—Filter element C—Drain plug D—Bleed plug CAUTION: CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting fuel or other [...]

Maintenance/500 hours DPSG,CD03523,31 –19–12JUL99–1/1 CHECKING BELT (300-SERIES ENGINES) CD30644 –UN–04MAY98 CD30645 –UN–04MAY98 CD30646 –UN–04MAY98 1. Inspect belt for cracks, fraying, or stretched out areas. Replace as necessary. 2. Check belt tension using one of following methods: a) Use of JDG529 Tension Gauge (A) Belt tensio[...]

Maintenance/500 hours DPSG,CD03523,57 –19–16AUG99–1/1 CHECKING BELT (POWERTECH ENGINES WITH MANUAL TENSIONER) RG9132 –UN–04OCT99 A—Belt gauge B—Cap screw C—Cap screw Inspect belt for cracks, fraying, or stretched out areas. Replace if necessary. NOTE: Belt adjustment is measured using a gauge stamped on the top edge of the alternato[...]

Maintenance/1000 hours/1 year DPSG,CD03523,32 –19–12JUL99–1/1 CLEANING CRANKCASE VENT TUBE CD30773 –UN–27AUG99 If you operate the engine in dusty conditions, clean the tube at shorter intervals. 1. Remove and clean crankcase vent tube (A). 2. Install the vent tube. Be sure the O-ring fits correctly in the rocker arm cover bore for elbow a[...]

Maintenance/1000 hours/1 year DPSG,CD03523,33 –19–12JUL99–2/2 RG4687 –UN–20DEC88 4. If engine has a rubber dust unloading valve (C), inspect the valve on bottom of air filter for cracks or plugging. Replace as necessary. 5. Service air filter as necessary. DPSG,CD03523,34 –19–13JUL99–1/2 CHECKING AUTOMATIC BELT TENSIONER (POWERTECH [...]

Maintenance/1000 hours/1 year DPSG,CD03523,34 –19–13JUL99–2/2 RG7977 –UN–14NOV97 • Checking tensioner spring tension A belt tension gauge will not give an accurate measure of the belt tension when automatic spring tensioner is used. Measure tensioner spring tension using a torque wrench and procedure outlined below: a. Release tension o[...]

Maintenance/1000 hours/1 year DPSG,CD03523,35 –19–13JUL99–2/4 CD30545 –UN–19MAY98 RG6307 –UN–03AUG92 3. Check and adjust valve clearance to specifications according to following procedures. Valve clearance (engine cold)—Specification Intake 0.35 mm (0.014 in.) .........................................................................[...]

Maintenance/1000 hours/1 year DPSG,CD03523,35 –19–13JUL99–4/4 RG4776 –UN–31OCT97 A—Front of engine B—No.1 Piston at TDC compression stroke C—No.4 Piston at TDC compression stroke E—Exhaust valve I—Intake valve • 4-Cylinder Engine: NOTE: Firing order is 1-3-4-2. a. Lock No. 1 piston at TDC compression stroke (B). b. Adjust valv[...]

Maintenance/2000 hours/2 years DPSG,CD03523,36 –19–13JUL99–1/4 CHECK AND ADJUST ENGINE VALVE CLEARANCE (POWERTECH ENGINE) CD30544 –UN–19MAY98 Adjust engine valve clearance as follows or have your authorized servicing dealer or engine distributor adjust the engine valve clearance. 1. Remove rocker arm cover and crankcase vent tube. 2. Usin[...]

Maintenance/2000 hours/2 years DPSG,CD03523,36 –19–13JUL99–3/4 RG4776 –UN–31OCT97 A—Front of engine B—No.1 Piston at TDC compression stroke C—No.4 Piston at TDC compression stroke E—Exhaust valve I—Intake valve • 4-Cylinder Engine: NOTE: Firing order is 1-3-4-2. a. Lock No. 1 piston at TDC compression stroke (B). b. Adjust val[...]

Maintenance/2000 hours/2 years DPSG,CD03523,38 –19–13JUL99–1/1 CHECKING ENGINE SPEED CD30763 –UN–24SEP99 NOTE: Most engines for generator set application (1500 rpm for 50 Hz or 1800 rpm for 60 Hz) run only at fast idle and therefore they do not have slow idle. Fast idle—Specification 50 Hz Generator set 1550—1580 rpm .................[...]

Maintenance/2000 hours/2 years DPSG,CD03523,40 –19–13JUL99–1/1 CHECKING CRANKSHAFT VIBRATION DAMPER (6-CYLINDER ENGINE ONLY) RG8018 –UN–15JAN99 RG7508 –UN–23NOV97 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 [...]

Maintenance/2500 hours/3 years DPSG,CD03523,41 –19–13JUL99–1/3 DRAIN AND FLUSH COOLING SYSTEM TS281 –UN–23AUG88 RG4894 –UN–14DEC88 ZX016192 –UN–11JAN99 CD30765 –UN–27AUG99 NOTE: Drain and flush cooling system every 2500 hours/3 years when John Deere COOL-GARD coolant is used. Otherwise every 2000 hours/2 years. CAUTION: Explos[...]

Maintenance/2500 hours/3 years DPSG,CD03523,41 –19–13JUL99–2/3 10. Check cooling system hoses for proper condition. Replace as necessary. 11. Close all drain orifices and fill the cooling system with specified coolant (see DIESEL ENGINE COOLANT). Cooling system capacity—Specification CD3029DF128 14.5 L (15.5 qt) ............................[...]

Maintenance/As required DPSG,CD03523,42 –19–15JUL99–1/1 ADDITIONAL SERVICE INFORMATION RG4624 –UN–15DEC88 This manual does not allow a complete repair of your engine. If you want want more detailled service information the following publications are available from your regular parts channel. • PC2451 — Parts Catalog • CTM3274 — Co[...]

Maintenance/As required DPSG,CD03523,44 –19–15JUL99–1/1 CLEAN OR REPLACE AIR FILTER (ONE-PIECE) CD30766 –UN–06SEP99 RG9912 –UN–25FEB99 Clean air filter when restriction indicator (A) is red. Air filter can be cleaned up to six times. Thereafter, or at least once a year, it must be replaced. Proceed as follows: 1. Thoroughly clean all [...]

Maintenance/As required DPSG,CD03523,58 –19–16AUG99–1/1 CLEAN OR REPLACE AIR FILTER ELEMENT CD30772 –UN–27AUG99 A—Primary element C—Air restriction indicator B—Secondary (safety) D—Wing nut element Clean air filter when restriction indicator (C) is red. Replace both primary (A) and secondary (B) filter elements every 6 primary ele[...]

Maintenance/As required DPSG,CD03523,45 –19–15JUL99–1/1 REPLACING FAN AND ALTERNATOR BELT (POWERTECH ENGINES) CD30769 –UN–01SEP99 Installation on 4 cyl. engines CD30770 –UN–01SEP99 Installation on 6 cyl. engines ALT—Alternator CP—Crankshaft Pulley FD—Fan Drive I—Idler Pulley T—Tensioner WP—Water Pump NOTE: Refer to CHECKIN[...]

Maintenance/As required DPSG,CD03523,28 –19–12JUL99–1/1 CHECKING FUEL FILTER RG9868 –UN–15JAN99 RG8013B –UN–15JAN99 Periodically the fuel filter should be checked for water or debris. IMPORTANT: Drain water into a suitable container and dispose of properly. 1. Loosen drain plug (B) at bottom of fuel filter two or three turns. 2. Loose[...]

Maintenance/As required DPSG,CD03523,46 –19–10AUG99–1/2 BLEEDING THE FUEL SYSTEM X9811 –UN–23AUG88 RG7947 –UN–13NOV97 RG8013A –UN–15JAN99 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.[...]

Maintenance/As required DPSG,CD03523,46 –19–10AUG99–2/2 CD30771 –UN–24SEP99 RG7725 –UN–08JAN97 • At Fuel Injection Pump: a. Slightly loosen fuel return line connector (C) at fuel injection pump. b. Operate fuel supply pump primer lever until fuel, without air bubbles, flows from fuel return line connection. c. Tighten return line co[...]

Troubleshooting DPSG,CD03523,49 –19–10AUG99–1/5 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[...]

Troubleshooting DPSG,CD03523,49 –19–10AUG99–2/5 Symptom Problem Solution Injection pump shut-off not reset. Turn key switch to “OFF” then to “ON”. Engine knocks Low engine oil level. Add oil to engine crankcase. Injection pump out of time. See your authorized servicing dealer or engine distributor. Low coolant temperature. Remove and [...]

Troubleshooting DPSG,CD03523,49 –19–10AUG99–3/5 Symptom Problem Solution Injection pump out of time. See your authorized servicing dealer or engine distributor. Turbocharger not functioning. See your authorized servicing dealer or engine distributor. Leaking exhaust manifold gasket. See your authorized servicing dealer or engine distributor. [...]

Troubleshooting DPSG,CD03523,49 –19–10AUG99–4/5 Symptom Problem Solution Engine emits black or grey Improper type of fuel. Use proper fuel. exhaust smoke Clogged or dirty air cleaner. Service air cleaner. Engine overloaded. Reduce load. Injection nozzles dirty. See your authorized servicing dealer or engine distributor. Engine out of time. Se[...]

Troubleshooting DPSG,CD03523,49 –19–10AUG99–5/5 Symptom Problem Solution 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 d[...]

Troubleshooting DPSG,CD03523,50 –19–10AUG99–1/2 ELECTRICAL TROUBLESHOOTING Symptom Problem Solution Undercharged system Excessive electrical load from added Remove accessories or install higher accessories. output alternator. Excessive engine idling. Increase engine rpm when heavy electrical load is used. Poor electrical connections on Inspec[...]

Troubleshooting DPSG,CD03523,50 –19–10AUG99–2/2 Symptom Problem Solution Starter cranks slowly Low battery output. See your authorized servicing dealer or engine distributor. Crankcase oil too heavy. Use proper viscosity oil. Loose or corroded connections. Clean and tighten loose connections. Entire electrical system Faulty battery connection[...]

Storage DPSG,CD03523,51 –19–10AUG99–1/1 ENGINE STORAGE GUIDELINES 1. John Deere engines can be stored outside for up to three (3) months with no long term preparation IF COVERED BY WATERPROOF COVERING. 2. John Deere engines can be stored in a standard overseas shipping container for up to three (3) months with no long term preparation. 3. Joh[...]

Storage DPSG,CD03523,53 –19–10AUG99–1/1 PREPARING ENGINE FOR LONG TERM STORAGE The following storage preparations are good for long term engine storage up to one year. After that, the engine should be started, warmed up, and retreated for an extended storage period. IMPORTANT: Any time your engine will not be used for over six (6) months, the[...]

Storage DPSG,CD03523,54 –19–10AUG99–1/1 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. 1. Remove all protective coverings from engine. Unseal all openings in engine and [...]

Specifications DPSG,CD03523,55 –19–10AUG99–1/3 GENERAL ENGINE SPECIFICATIONS ITEM UNIT OF MEASURE 3029DF128 4039DF008 4039TF008 Number of Cylinders 3 4 4 Fuel Diesel Diesel Diesel Bore mm 106.5 106.5 106.5 Stroke mm 110 110 110 Displacement L 2.9 3.9 3.9 Compression Ratio 17.8:1 17.8:1 17.8:1 POWER a @ kW (hp) 26 (35) 35 (48) 55 (75) 1500 rpm[...]

Specifications DPSG,CD03523,55 –19–10AUG99–2/3 ITEM UNIT OF MEASURE 4045HF158 4045TF158 4045TF258 4045DF158 Number of Cylinders 4 4 4 4 Fuel Diesel Diesel Diesel Diesel Bore mm 106.5 106.5 106.5 106.5 Stroke mm 127 127 127 127 Displacement L 4.5 4.5 4.5 4.5 Compression Ratio 17.0:1 17.0:1 17.0:1 17.6:1 POWER a @ kW (hp) 88 (120) 61 (83) 72 (9[...]

Specifications DPSG,CD03523,55 –19–10AUG99–3/3 ITEM UNIT OF 6068HF158 6068TF158 6068TF258 MEASURE Number of Cylinders 6 6 6 Fuel Diesel Diesel Diesel Bore mm 106.5 106.5 106.5 Stroke mm 127 127 127 Displacement L 6.8 6.8 6.8 Compression Ratio 17.0:1 17.0:1 17.0:1 POWER a @ 1500 rpm kW (hp) 134 (182) 92 (125) 105 (143) (Prime) POWER a @ 1500 r[...]

Specifications DX,TORQ1 –19–20JUL94–1/1 UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUES TS1656 –19–02APR97 65-4 112699 PN=83[...]

Specifications DX,TORQ2 –19–20JUL94–1/1 METRIC BOLT AND CAP SCREW TORQUE VALUES TS1657 –19–02APR97 65-5 112699 PN=84[...]

Index Page Page A Fuel system Bleeding ............................. 50-6 Fuel Air filter Diesel ............................... 10-1 Clean or replace (one-piece) . . . ........... 50-2 Handling and storing .................... 10-1 Clean or replace element ........... ..... 50-3 Air intake system Checking ............................. 35-1 I B Ide[...]

Index Page Page Replace fan and alternator belts V (POWERTech) .... ................. 50-4 Daily or every 10 hours .................. 25-1 Valve clearance Adjust (300-Series) ..................... 35-3 Observe service intervals ................ 20-1 Use correct fuel, lubricant and coolant . ..... 20-1 Adjust (POWERTech) . . ................. 40-1 M[...]