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P
Units for
OWER
Gensets (Saran)
2.9L/4039/4.5/6.8L
(128/008/158/258)
OPERATOR'S
MANUAL
John Deere Usine de Saran
OMCD16564 (03JAN00)
Printed in Germany
ENGLISH
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Summary of Contents

  • Page 1

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

  • Page 2

    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 engine correctly. Failure to do so could result in personal injury or equipment damage.

  • Page 3: Table Of Contents

    Adjust speed droop governor ....40-3 COPYRIGHT DEERE & COMPANY European Office Mannheim A John Deere ILLUSTRUCTION Manual Page Continued on next page 1999 All rights reserved...

  • Page 4: Table Of Contents

    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 .

  • Page 5: Identification Views

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

  • Page 6

    Identification Views 6068HF158 DPSG,CD03523,3 –19–05JUL99–2/2 01-2 112699 PN=6...

  • Page 7: Using Maintenance Records, Hours Of Operation

    Hose connections, check Number of hours: Date: Job done by: John Deere oils and coolants have been formulated to give maximum protection and performance to your engine. We recommend only genuine John Deere service products and replacement parts. To protect your rights under the warranty ensure all scheduled services are carried out and recorded.

  • Page 8: Hours Of Operation, Hours Of Operation

    500 HOURS OF OPERATION Engine oil, replace Engine oil filter, replace Fuel filter, replace Belt, check tension and wear (300-Series and POWERTech with manual tensioner) Valve clearance, adjust (300-Series) Number of hours: Date: Job done by: 1000 HOURS OF OPERATION Engine oil, replace Engine oil filter, replace Fuel filter, replace...

  • Page 9

    1500 HOURS OF OPERATION Engine oil, replace Engine oil filter, replace Fuel filter, replace Belt, check tension and wear (300-Series and POWERTech with manual tensioner) Valve clearance, adjust (300-Series) Number of hours: Date: Job done by: 2000 HOURS OF OPERATION Engine oil, replace Engine oil filter, replace Fuel filter, replace...

  • Page 10

    2500 HOURS OF OPERATION Engine oil, replace Engine oil filter, replace Fuel filter, replace Belt, check tension and wear (300-Series and POWERTech with manual tensioner) Valve clearance, adjust (300-Series) Number of hours: Date: Job done by: 3000 HOURS OF OPERATION Engine oil, replace Engine oil filter, replace Fuel filter, replace...

  • Page 11

    3500 HOURS OF OPERATION Engine oil, replace Engine oil filter, replace Fuel filter, replace Belt, check tension and wear (300-Series and POWERTech with manual tensioner) Valve clearance, adjust (300-Series) Number of hours: Date: Job done by: 4000 HOURS OF OPERATION Engine oil, replace Engine oil filter, replace Fuel filter, replace...

  • Page 12

    4500 HOURS OF OPERATION Engine oil, replace Engine oil filter, replace Fuel filter, replace Belt, check tension and wear (300-Series and POWERTech with manual tensioner) Valve clearance, adjust (300-Series) Number of hours: Date: Job done by: 5000 HOURS OF OPERATION Engine oil, replace Engine oil filter, replace Fuel filter, replace...

  • Page 13

    5500 HOURS OF OPERATION Engine oil, replace Engine oil filter, replace Fuel filter, replace Belt, check tension and wear (300-Series and POWERTech with manual tensioner) Valve clearance, adjust (300-Series) Number of hours: Date: Job done by: 6000 HOURS OF OPERATION Engine oil, replace Engine oil filter, replace Fuel filter, replace...

  • Page 14

    6500 HOURS OF OPERATION Engine oil, replace Engine oil filter, replace Fuel filter, replace Belt, check tension and wear (300-Series and POWERTech with manual tensioner) Valve clearance, adjust (300-Series) Number of hours: Date: Job done by: 7000 HOURS OF OPERATION Engine oil, replace Engine oil filter, replace Fuel filter, replace...

  • Page 15

    7500 HOURS OF OPERATION Engine oil, replace Engine oil filter, replace Fuel filter, replace Belt, check tension and wear (300-Series and POWERTech with manual tensioner) Valve clearance, adjust (300-Series) Number of hours: Date: Job done by: 8000 HOURS OF OPERATION Engine oil, replace Engine oil filter, replace Fuel filter, replace...

  • Page 16

    8500 HOURS OF OPERATION Engine oil, replace Engine oil filter, replace Fuel filter, replace Belt, check tension and wear (300-Series and POWERTech with manual tensioner) Valve clearance, adjust (300-Series) Number of hours: Date: Job done by: 9000 HOURS OF OPERATION Engine oil, replace Engine oil filter, replace Fuel filter, replace...

  • Page 17

    9500 HOURS OF OPERATION Engine oil, replace Engine oil filter, replace Fuel filter, replace Belt, check tension and wear (300-Series and POWERTech with manual tensioner) Valve clearance, adjust (300-Series) Number of hours: Date: Job done by: 10000 HOURS OF OPERATION Engine oil, replace Engine oil filter, replace Fuel filter, replace...

  • Page 18: Powertech Medallion, Engine Serial Number Plate

    POWERTECH is a trademark of Deere & Company ENGINE SERIAL NUMBER PLATE POWERTech engine Each engine has a 13–digit John Deere serial number. The first two digits identify the factory that produced the engine: “CD” indicates the engines was built in Saran, France.

  • Page 19: Record Engine Serial Number

    Record Keeping RECORD ENGINE SERIAL NUMBER Record all of the numbers and letters found on your engine serial number plate in the spaces provided below. This information is very important for repair parts or warranty information. Engine Serial Number (B) ___________________ 300-Series engine plate Engine Model Number (C)

  • Page 20: Engine Option Codes

    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.

  • Page 21

    Option Description Codes Engine Base Code:________ 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____ Coolant pump 21____ Thermostat Cover 22____ Thermostat 23____...

  • Page 22: Record Fuel Injection Pump Model Number

    Record Keeping RECORD FUEL INJECTION PUMP MODEL NUMBER Record the fuel injection pump model and serial information found on the serial number plate (A). Model No. _____________________ RPM _______ Manufacturer’s No. __________________________ Serial No. _________________________________ DPSG,CD03523,15 –19–07JUL99–1/1 03-5 112699 PN=22...

  • Page 23: Safety

    Safety RECOGNIZE SAFETY INFORMATION This is a safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. Follow recommended precautions and safe operating practices. DX,ALERT –19–29SEP98–1/1 UNDERSTAND SIGNAL WORDS A signal word—DANGER, WARNING, or CAUTION—is used with the safety-alert symbol.

  • Page 24

    ENGINE LIFTING PROCEDURE CAUTION: The only recommended method for lifting the engine is with JDG23 Engine Lifting Sling (A) and safety approved lifting straps (B) that come with engine. Use extreme caution when lifting and NEVER permit any part of the body to be positioned under an engine being lifted or suspended.

  • Page 25

    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.

  • Page 26

    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.

  • Page 27

    Safety WEAR PROTECTIVE CLOTHING Wear close fitting clothing and safety equipment appropriate to the job. Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.

  • Page 28

    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...

  • Page 29

    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.

  • Page 30

    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.

  • Page 31

    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.

  • Page 32

    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.

  • Page 33: Diesel Fuel, Handling And Storing Diesel Fuel

    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.

  • Page 34: Engine Break-in Oil

    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.

  • Page 35: Diesel Engine Oil, Lubricant Storage

    The following oil is preferred: John Deere PLUS-50 The following oil is also recommended: John Deere TORQ-GARD SUPREME TORQ-GARD SUPREME Other oils may be used if they meet one or more of the following:...

  • Page 36: Mixing Of Lubricants, Diesel Engine Coolant

    -37 C (-34 F). John Deere COOL-GARD is preferred for service. If John Deere COOL-GARD is not available, use a low silicate ethylene glycol base coolant concentrate in a 50% mixture of concentrate with quality water.

  • Page 37: Operating In Warm Temperature Climates

    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.

  • Page 38: Break-in Period, Starting The Engine, Cold Weather Operation

    Operating the Engine BREAK-IN PERIOD Within first 100 hours of operation During the first 100 hours of operation, avoid overloading, excessive idling and no-load operation. See ENGINE BREAK-IN OIL for eventual addition of oil. NOTE: During the break-in period a higher-than-usual oil consumption should be considered as normal.

  • Page 39

    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.

  • Page 40: Using A Booster Battery Or Charger

    USING A BOOSTER BATTERY OR CHARGER A 12-volt booster battery can be connected in parallel with battery(ies) on the unit to aid in cold weather starting. ALWAYS use heavy duty jumper cables. CAUTION: Gas given off by batteries is explosive. Keep sparks and flames away from batteries.

  • Page 41: Engine Operation, Standby Power Units

    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 and engine oil pressure with specifications below: Minimum oil pressure at full load rated speed...

  • Page 42: Stopping The Engine

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

  • Page 43: Observe Service Intervals, Use Correct Fuels, Lubricants And Coolant

    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.

  • Page 44: Maintenance Interval Chart, Drain And Flush Cooling System

    1000 hours thereafter on 300-Series engines. Every 2000 hours on POWERTech engines. Have your authorized dealer or engine distributor replace the vibration damper every 4500 hours/5 years. Drain and flush cooling system every 2500 hours/3 years when John Deere COOL-GARD coolant is used. Otherwise every 2000 hours/2 years.

  • Page 45: Daily Prestarting Checks

    Maintenance/Daily or every 10 hours DAILY PRESTARTING CHECKS POWERTech engine Do the following BEFORE STARTING THE ENGINE for the first time each day: IMPORTANT: DO NOT top up with fresh oil until the oil level is BELOW the add mark. 1.

  • Page 46

    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. 3.

  • Page 47: Changing Engine Oil And Filter

    Maintenance/500 hours CHANGING ENGINE OIL AND FILTER NOTE: Change engine oil and filter for the first time after 100 hours maximum of operation, then every 500 hours thereafter. Change oil and filter at least once a year. 1. Run engine approximately 5 minutes to warm up oil. Shut engine off.

  • Page 48

    8. Fill engine crankcase with correct John Deere engine oil through rocker arm cover opening (C); see DIESEL ENGINE OIL. To determine the correct oil fill quantity for your engine, see “Engine Oil Quantities” in Specifications Section. NOTE: Crankcase oil capacity may vary slightly.

  • Page 49: Replacing Fuel Filter Element

    REPLACING FUEL FILTER ELEMENT A—Retaining ring B—Filter element CAUTION: CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting fuel or other lines. Tighten all connections before applying pressure. Keep hands and body away from pinholes and nozzles which eject fluids under high pressure.

  • Page 50: Checking Belt (300-series Engines)

    CHECKING BELT (300-SERIES ENGINES) 1. Inspect belt for cracks, fraying, or stretched out areas. Replace as necessary. 2. Check belt tension using one of following methods: a) Use of JDG529 Tension Gauge (A) Belt tension—Specification New belt 578—622 N (130—140 lb-force) Used belt 378—423 N (85—94 lb-force) NOTE: Belt is considered used after 10 minutes of...

  • Page 51

    CHECKING BELT (POWERTECH ENGINES WITH MANUAL TENSIONER) Inspect belt for cracks, fraying, or stretched out areas. Replace if necessary. NOTE: Belt adjustment is measured using a gauge stamped on the top edge of the alternator bracket. 1. Loosen cap screws (B) and (C). 2.

  • Page 52: Cleaning Crankcase Vent Tube, Checking Air Intake System

    Maintenance/1000 hours/1 year CLEANING CRANKCASE VENT TUBE If you operate the engine in dusty conditions, clean the tube at shorter intervals. 1. Remove and clean crankcase vent tube (A). 2. Install the vent tube. Be sure the O-ring fits correctly in the rocker arm cover bore for elbow adapter.

  • Page 53

    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. CHECKING AUTOMATIC BELT TENSIONER (POWERTECH ENGINES) Belt drive systems equipped with automatic (spring) belt tensioners cannot be adjusted or repaired.

  • Page 54

    Checking tensioner spring tension A belt tension gauge will not give an accurate measure of the belt tension when automatic spring tensioner is used. Measure tensioner spring tension using a torque wrench and procedure outlined below: a. Release tension on belt using a breaker bar and socket on tension arm.

  • Page 55

    3. Check and adjust valve clearance to specifications according to following procedures. Valve clearance (engine cold)—Specification Intake Exhaust NOTE: If rocker arm is equipped with adjusting screw and lock nut (A), tighten lock nut to 27 N • m (20 lb-ft) after adjusting valve clearance.

  • Page 56

    4-Cylinder Engine: NOTE: Firing order is 1-3-4-2. a. Lock No. 1 piston at TDC compression stroke (B). b. Adjust valve clearance on No. 1 and 3 exhaust valves and No.1 and 2 intake valves. c. Rotate flywheel 360 . Lock No. 4 piston at TDC compression stroke (C).

  • Page 57

    Maintenance/2000 hours/2 years CHECK AND ADJUST ENGINE VALVE CLEARANCE (POWERTECH ENGINE) Adjust engine valve clearance as follows or have your authorized servicing dealer or engine distributor adjust the engine valve clearance. 1. Remove rocker arm cover and crankcase vent tube. 2.

  • Page 58

    4-Cylinder Engine: NOTE: Firing order is 1-3-4-2. a. Lock No. 1 piston at TDC compression stroke (B). b. Adjust valve clearance on No. 1 and 3 exhaust valves and No.1 and 2 intake valves. c. Rotate flywheel 360 . Lock No. 4 piston at TDC compression stroke (C).

  • Page 59: Checking Engine Speed, Adjust Speed Droop Governor

    CHECKING ENGINE SPEED NOTE: Most engines for generator set application (1500 rpm for 50 Hz or 1800 rpm for 60 Hz) run only at fast idle and therefore they do not have slow idle. Fast idle—Specification 50 Hz Generator set 60 Hz Generator set NOTE: Fast idle is settled by the factory then the idle adjusting screw (A) is sealed to prevent from...

  • Page 60

    CHECKING CRANKSHAFT VIBRATION DAMPER (6-CYLINDER ENGINE ONLY) 1. Remove belts (shown removed). 2. Grasp vibration damper with both hands and attempt to turn it in both directions. If rotation is felt, damper is defective and should be replaced. IMPORTANT: The vibration damper assembly is not repairable and should be replaced every 4500 hours or 5 years, whichever occurs first.

  • Page 61

    Maintenance/2500 hours/3 years DRAIN AND FLUSH COOLING SYSTEM NOTE: Drain and flush cooling system every 2500 hours/3 years when John Deere COOL-GARD coolant is used. Otherwise every 2000 hours/2 years. CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns.

  • Page 62

    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 CD4039DF008 CD4039TF008 CD4045DF158 CD4045HF158 CD4045TF158 CD4045TF258 CD6068HF158 CD6068TF158 CD6068TF258 12.

  • Page 63: Additional Service Information, Do Not Modify Fuel System

    Maintenance/As required ADDITIONAL SERVICE INFORMATION This manual does not allow a complete repair of your engine. If you want want more detailled service information the following publications are available from your regular parts channel. PC2451 — Parts Catalog CTM3274 — Component Technical Manual for 300-Series engines (English) CTM104 —...

  • Page 64: Clean Or Replace Air Filter (one-piece)

    CLEAN OR REPLACE AIR FILTER (ONE-PIECE) Clean air filter when restriction indicator (A) is red. Air filter can be cleaned up to six times. Thereafter, or at least once a year, it must be replaced. Proceed as follows: 1. Thoroughly clean all dirt around air filter area. 2.

  • Page 65: Clean Or Replace Air Filter Element

    CLEAN OR REPLACE AIR FILTER ELEMENT 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 element cleaning or at least once a year.

  • Page 66

    REPLACING FAN AND ALTERNATOR BELT (POWERTECH ENGINES) NOTE: Refer to CHECKING BELT TENSIONER SPRING TENSION AND BELT WEAR for additional information on the belt tensioner. 1. Inspect belts for cracks, fraying, or stretched out areas. Replace if necessary. 2. On engines with automatic belt tensioner, release tension on belt using a breaker bar and socket on tension arm.

  • Page 67: Checking Fuel Filter

    CHECKING FUEL FILTER Periodically the fuel filter should be checked for water or debris. IMPORTANT: Drain water into a suitable container and dispose of properly. 1. Loosen drain plug (B) at bottom of fuel filter two or three turns. 2. Loosen air bleed plug two full turns (A) on fuel filter base and drain water from bottom until fuel starts to drain out.

  • Page 68: Bleeding The Fuel System

    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.

  • Page 69

    At Fuel Injection Pump: a. Slightly loosen fuel return line connector (C) at fuel injection pump. b. Operate fuel supply pump primer lever until fuel, without air bubbles, flows from fuel return line connection. c. Tighten return line connector to 16 N•m (12 lb-ft). d.

  • Page 70: Engine Troubleshooting

    ENGINE TROUBLESHOOTING Symptom Engine cranks but will not start Engine hard to start or will not start Troubleshooting Problem Incorrect starting procedure. No fuel. Exhaust restricted. Fuel filter plugged or full of water. Injection pump not getting fuel or air in fuel system.

  • Page 71

    Symptom Engine knocks Engine runs irregularly or stalls frequently Below normal engine temperature Lack of power Troubleshooting Problem Injection pump shut-off not reset. Low engine oil level. Injection pump out of time. Low coolant temperature. Engine overheating. Low coolant temperature. Clogged fuel filter.

  • Page 72

    Symptom Low oil pressure High oil consumption Engine emits white smoke Troubleshooting Problem Injection pump out of time. Turbocharger not functioning. Leaking exhaust manifold gasket. Defective aneroid control line. Restricted fuel hose. Low fast idle speed. Low oil level. Improper type of oil. Crankcase oil too light.

  • Page 73

    Symptom Engine emits black or grey exhaust smoke Engine overheats High fuel consumption Troubleshooting Problem Improper type of fuel. Clogged or dirty air cleaner. Engine overloaded. Injection nozzles dirty. Engine out of time. Turbocharger not functioning. Engine overloaded. Low coolant level. Faulty radiator cap.

  • Page 74

    Symptom Troubleshooting Problem Engine overloaded. Improper valve clearance. Injection nozzles dirty. Engine out of time. Defective turbocharger. Low engine temperature. 55-5 Solution Reduce load. See your authorized servicing dealer or engine distributor. See your authorized servicing dealer or engine distributor. See your authorized servicing dealer or engine distributor.

  • Page 75: Electrical Troubleshooting

    ELECTRICAL TROUBLESHOOTING Symptom Undercharged system Battery uses too much water Battery will not charge Starter will not crank Troubleshooting Problem Excessive electrical load from added accessories. Excessive engine idling. Poor electrical connections on battery, ground strap, starter or alternator. Defective battery. Defective alternator.

  • Page 76

    Symptom Starter cranks slowly Entire electrical system Troubleshooting Problem Low battery output. Crankcase oil too heavy. Loose or corroded connections. Faulty battery connection. Sulfated or worn-out battery. Blown fuse. 55-7 Solution See your authorized servicing dealer or engine distributor. Use proper viscosity oil. Clean and tighten loose connections.

  • Page 77: Engine Storage Guidelines, Use Ar41785 Engine Storage Kit

    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.

  • Page 78: Preparing Engine For Long Term Storage

    PREPARING ENGINE FOR LONG TERM STORAGE The following storage preparations are good for long term engine storage up to one year. After that, the engine should be started, warmed up, and retreated for an extended storage period. IMPORTANT: Any time your engine will not be used for over six (6) months, the following recommendations for storing it and removing it from...

  • Page 79: Removing Engine From Long Term Storage

    REMOVING ENGINE FROM LONG TERM STORAGE Refer to the appropriate section for detailed services listed below or have your authorized servicing dealer or engine distributor perform services that you may not be familiar with. 1. Remove all protective coverings from engine. Unseal all openings in engine and remove covering from electrical systems.

  • Page 80: General Engine Specifications

    GENERAL ENGINE SPECIFICATIONS ITEM UNIT OF MEASURE Number of Cylinders Fuel Bore Stroke Displacement Compression Ratio POWER kW (hp) 1500 rpm (Prime) POWER kW (hp) 1500 rpm (Standby) POWER kW (hp) 1800 rpm (Prime) POWER kW (hp) 1800 rpm (Standby) Width (overall) Length (overall) Height (overall)

  • Page 81

    ITEM UNIT OF MEASURE Number of Cylinders Fuel Bore Stroke Displacement Compression Ratio POWER kW (hp) 1500 rpm (Prime) POWER kW (hp) 1500 rpm (Standby) POWER kW (hp) 1800 rpm (Prime) POWER kW (hp) 1800 rpm (Standby) Width (overall) Length (overall) Height (overall) Weight (dry) Engine oil quantity...

  • Page 82

    ITEM UNIT OF MEASURE Number of Cylinders Fuel Bore Stroke Displacement Compression Ratio POWER @ 1500 rpm kW (hp) (Prime) POWER @ 1500 rpm kW (hp) (Standby) POWER @ 1800 rpm kW (hp) (Prime) POWER @1800 rpm kW (hp) (Standby) Width (overall) Length (overall) Height (overall)

  • Page 83: Values

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

  • Page 84: Metric Bolt And Cap Screw Torque Values

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

  • Page 85

    Air filter Clean or replace (one-piece)....50-2 Clean or replace element ....50-3 Air intake system Checking.

  • Page 86

    Replace fan and alternator belts (POWERTech) ..... 50-4 Daily or every 10 hours....25-1 Observe service intervals .

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  • Mushtaq Dec 26, 2013 08:40:
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