SERVICE ENGINE

Maintenance, repair, or replacement of the emission control devices and systems on this engine, which are being done at the customers expense, may be performed by any nonroad engine repair establishment or individual. Warranty repairs must be performed by an authorized John Deere dealer.

Avoid Fumes

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c CAUTION: Avoid injury! Engine exhaust fumes can cause sickness or death:

If it is necessary to run an engine in an enclosed area, use an exhaust pipe extension to remove the fumes.

Always try to work in a well ventilated area.

Engine Oil

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

The following John Deere oils are preferred:

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· PLUS-50® (SAE 15W-40)

· TORQ-GARD SUPREME® (SAE 5W-30)

The following John Deere oils are also recommended, based on their specified temperature range:

· TURF-GARD® (SAE 10W-30)

· PLUS-4® (SAE 10W-30)

· TORQ-GARD SUPREME® (SAE 30)

Other oils may be used if above John Deere oils are not available, provided they meet one of the following specifications:

· SAE 15W-40-API Service Classification CF-4 or higher.

· SAE 5W-30-API Service Classification CC or higher.

· SAE 10W-30-API Service Classification CF or higher.

· SAE 30-API Service Classification CF or higher.

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

Checking Engine Oil Level

Service Interval: Check engine oil every 10 hours of operation or on a daily basis.

NOTE: Check engine oil when oil is cold.

1. Park tractor on a level surface. Engage park brake.

2. Stop engine. Allow engine to cool.

3. Raise and secure tractor hood into an open position. (See Opening Hood in the Operating section.)

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4. Remove dipstick (A). Wipe it clean with a rag.

5. Install dipstick.

6. Remove dipstick. Check oil level on dipstick; oil should be between ADD and FULL marks (B).

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7. If oil level is low:

· Remove service shield (C) on right side of tractor.

· Remove oil filler cap (D).

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8. Add engine oil if necessary. Oil level should be no higher than the FULL mark on the dipstick. DO NOT overfill. (See Engine Oil in this section for the preferred oil application.)

9. Install dipstick.

10. Install and tighten oil fill cap.

11. Install right service shield.

12. Lower hood.

Changing Engine Oil and Filter

Service Interval: Change engine oil and filter after first 50 hours of operation, then every 100 hours of operation.

1. Run engine a few minutes to warm oil.

2. Park tractor on a level surface.

3. Stop engine and engage park brake.

4. Raise and secure tractor hood into an open position. (See Opening Hood in the Operating section.

5. Loosen and remove oil drain plug (A). Allow engine oil to drain into a drain pan.

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6. Remove service shield on right side of tractor.

7. Remove oil filter (B). Turn filter to the left to remove.

8. Apply a film of clean engine oil on rubber gasket of new filter.

9. Install filter. Turn filter to the right until gasket makes contact with the mounting surface. Tighten 1/2 to 3/4 turn after gasket contact.

10. Install and tighten drain plug.

11. Remove oil filler cap (C).

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12. Add approximately 2.7 L (2.8 qt) of oil into filler opening. (See Engine Oil in this section for the correct oil application.)

13. Install and tighten oil fill cap.

14. Start engine. Run engine at a slow speed and check for leaks.

15. Stop engine.

16. emove oil dipstick (D). Wipe clean with a rag.

17. Install dipstick.

18. Remove dipstick. Check oil level on dipstick; oil should be between ADD and FULL marks (E).

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19. Add engine oil if necessary. Oil level should be no higher than the FULL mark on the dipstick. DO NOT overfill.

20. Install dipstick.

21. Install right service shield.

22. Lower hood.

Clean Air Filter Rubber Dust Unloading Valve

c CAUTION: Avoid injury! Allow engine to cool before attempting removal of the dust unloading valve.


IMPORTANT: Avoid damage! Prevent damage to the engine. Never operate engine without air cleaner elements and rubber dust unloading valve installed.

Service Interval: Check rubber dust unloading valve every 10 hours of operation or on a daily basis.

1. Stop engine and engage park brake.

2. Raise and secure tractor hood into an open position. (See Opening Hood in the Operating section.)

3. Remove and clean dust unloading valve (A). Replace if damaged.

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4. Lower hood.

Checking Air Restriction Indicator

Service Interval: Check air filter air restriction indicator every 10 hours of operation or on a daily basis.

1. Stop engine and engage park brake.

2. Raise and secure tractor hood into an open position. (See Opening Hood in the Operating section.

3. Locate and check air restriction indicator (A).

· When red plunger inside indicator is visible, air cleaner requires immediate service. (See Replacing Air Cleaner Elements in this section.)

4. Lower hood.

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Replacing Air Filter Elements

Service Interval:

· Primary Air Filter - As needed per air filter air restriction indicator. Every 500 hours of operation, more often in extremely dirty conditions.

· Secondary Air Filter - As needed per air filter air restriction indicator. Replace after every third Primary Air Filter.


IMPORTANT: Avoid damage! DO NOT attempt to clean a primary or secondary air filter element when red plunger inside air restriction indicator is visible.

Primary Air Filter Element

1. Stop engine and engage park brake.

2. Raise and secure tractor hood into an open position. (See Opening Hood in the Operating section.

NOTE: Air intake tube (B) will move from its position when air cleaner canister is serviced. Return to position on top of radiator when service is completed.

3. Release rubber air cleaner canister retaining strap (A).

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4. Release latches (C) and remove air cleaner canister cover (D).

5. Remove and discard primary element (E). Replace with a new primary element.

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6. Install air cleaner canister cover. Engage latches (C).

· Check instruction molded into canister cover to ensure proper installation.

· Rubber dust unloading valve (F) will be pointed downward when cover is properly installed.

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7. Push reset button (G) on top of air restriction indicator.

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8. START engine. Allow engine to run approximately one minute at maximum speed.

9. STOP engine. Check air restriction indicator. If red plunger inside air restriction indicator is visible, replace secondary air filter element.

Secondary Air Filter Element

1. Remove primary air filter element. (Refer to instructions given for replacing the primary air filter element.

2. Remove and discard secondary element (H). Replace with a new secondary element.

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3. Install primary element.

4. Install air cleaner canister cover.

5. Install canister retaining strap. Return air intake tube to its original position on top of radiator.

6. Lower hood.

Checking Air Filter Hoses and Clamps

Service Interval: Check air filter hose clamps during first 100 hours of operation, then every 500 hours of operation.

1. Park tractor on a level surface. Engage park brake.

2. Raise and secure tractor hood into an open position. (See Opening Hood in the Operating section.

3. Remove service shield on right side of tractor.

4. Tighten air intake hose clamps (A). Check hoses for cracks or damage. Replace if necessary.

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5. Install right service shield.

6. Lower hood.

Service Cooling System Safely

c CAUTION: Avoid injury! Explosive release of fluids from pressurized cooling system can cause serious burns:

· Shut off engine.

· Only remove filler cap when radiator is cool enough to touch with bare hands. Slowly release cap to the first stop to relieve pressure before removing completely.

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Engine Coolant

The following John Deere coolant is preferred:

· PRE-DILUTED DIESEL ENGINE ANTI-FREEZE/SUMMER COOLANT (TY16036).

If preferred pre-diluted coolant is not available, the following John Deere concentrate is recommended:

· DIESEL ENGINE ANTI-FREEZE/SUMMER COOLANT CONCENTRATE (TY16034).

If neither of the above coolants are available, use a ethylene glycol base coolant. These coolants usually have labels stating "For Automobile and Light Duty Service." These products are also often labeled for use in aluminum engines and meet the following specification:

· ASTM D3306 (JDM H24C1).

Check container label before using.


IMPORTANT: Avoid damage! To prevent engine damage, DO NOT use pure antifreeze or more than 50% antifreeze in the cooling system. DO NOT mix or add any other type additives to the cooling system.

Mix approximately 50 percent antifreeze with 50 percent distilled or deionized water. This mixture will provide freeze protection to -37 degrees C (-34 degrees F).

Certain geographical areas may require lower temperature protection. See the label on your antifreeze container or consult your John Deere dealer to obtain the latest information and recommendations.

The preferred antifreeze provides:

· Adequate heat transfer.

· Corrosion-resistant environment within the cooling system.

· Compatibility with cooling system hose and seal material.

· Protection during cold and hot weather operations.

Engine Coolant Drain Interval

When using John Deere Pre-Diluted (TY16036) Automobile and Light Duty Engine Service coolants, drain and flush the cooling system and refill with fresh coolant mixture every 36 months or 3,000 hours of operation, whichever comes first.

When using John Deere Concentrate (TY16034) Automobile and Light Duty Engine Service coolants, drain and flush the cooling system and refill with fresh coolant mixture every 24 months or 2,000 hours of operation, whichever comes first.

If above John Deere Automobile and Light Duty Engine Service coolants are not being used; drain, flush, and refill the cooling system according to instructions found on product container or in equipment Operator's Manual or Technical Manual.

Checking Radiator Coolant Level

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c CAUTION: Avoid injury! DO NOT remove radiator cap to check the radiator coolant level. When engine is hot the explosive release of fluids from the pressurized cooling system could cause serious burns.


IMPORTANT: Avoid damage! To prevent engine damage: · DO NOT operate engine without coolant. · DO NOT pour coolant into the radiator when the engine is hot. · To prevent engine overheating, never exceed more than 50% antifreeze in cooling system. · Cooling system capacity approximately is 2.4 L (2.5 qt.).

Service Interval: Check radiator coolant level every 10 hours of operation or on a daily basis.

1. Park tractor on a level surface. Engage park brake.

2. Raise and secure tractor hood into an open position. (See Opening Hood in the Operating section.

3. Remove service shield on right side of tractor.

4. Check coolant level:

· If engine is warm, coolant level should be between the FULL line (A) and the LOW line (B) on the coolant overflow tank.

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· If engine is cold, coolant level should be at the LOW line (A) on the coolant overflow tank.

5. Remove cap (C) to add coolant.

6. If coolant is low, add specified ratio of antifreeze and water. (See Engine Coolant in this section for the correct application.

7. Install and tighten overflow tank cap.

8. Clean debris from the grill screen, both service panel air intake screens and the radiator screen. (See Cleaning Grill and Service Panel Screens and Cleaning Radiator Screen in this section.

9. Check condition of the radiator hoses and clamps. Check for leaks or loose connections. (See Checking Radiator Hoses and Clamps in this section.)

10. Lower hood.

Draining Cooling System

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c CAUTION: Avoid injury! DO NOT remove the radiator cap unless the engine is cool. Slowly loosen cap to the first stop. Release all pressure before removing cap. When the engine is hot the explosive release of fluids from the pressurized cooling system could cause serious burns.

Antifreeze is hazardous to the environment. Dispose of antifreeze in a proper container.


IMPORTANT: Avoid damage! To prevent engine damage: DO NOT operate engine without coolant. DO NOT pour coolant into the radiator when the engine is hot.

Service Interval: Change radiator coolant every 2 years.

1. Park tractor on a level surface and engage the park brake.

2. STOP engine. Allow engine to cool.

3. Raise and secure tractor hood into an open position. (See Opening Hood in the Operating section.

4. Remove service shield on right side of tractor.

5. Slowly remove the radiator cap (A).

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6. Open radiator petcock (B). Drain coolant into a pan.

7. Loosen and remove block drain plug (C). Allow coolant to drain from engine block.

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8. After all coolant has drained, close radiator petcock and install block drain plug.

9. Flush cooling system. (See Flushing Cooling System in this section.)

Flushing Cooling System

c CAUTION: Avoid injury! Help prevent personal injury. Engine and coolant will be hot. Remove radiator cap using a thick rag of glove to prevent serious burns.


IMPORTANT: Avoid damage! To prevent damage to cylinder head or block: · DO NOT pour water into radiator when engine is hot. · DO NOT operate engine without coolant.

1. Fill cooling system with clean water and John Deere Cooling System Cleaner, or John Deere Cooling System Quick Flush, or an equivalent. Follow directions on can.

2. Install and tighten radiator cap.

3. START and run engine until it reaches operating temperature.

4. STOP engine.

5. Open radiator petcock (A) and drain cooling system immediately before rust and dirt settle.

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6. Close radiator petcock.

Filling Cooling System


IMPORTANT: Avoid damage! To prevent engine damage, DO NOT use straight antifreeze or more than 50% antifreeze in the cooling system. DO NOT mix or add any other type additives to the cooling system. Cooling system capacity is approximately 2.4 L (2.5 qt.).

1. Fill cooling system:

· Add specified ratio of antifreeze and water to the radiator. A chart on the antifreeze container will indicate the amount of antifreeze needed to maximize freeze protection in a given area. If engine is operated in extremely cold temperatures, see your John Deere dealer for information on arctic operation. (See Engine Coolant in this section for the proper antifreeze application.)

2. Install and tighten radiator cap.

3. START and run engine until it reaches operating temperature.

4. STOP engine.

5. Check coolant overflow tank fluid level.

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· If engine is warm, coolant level should be between the FULL line (A) and the LOW line (B) on the coolant overflow tank.

· After engine cools, coolant level should be at the LOW line (B).

6. Remove cap (C) to add coolant if necessary.

7. Check condition of the radiator hoses and clamps. Check for leaks or loose connections. (See Checking Radiator Hoses and Clamps in this section.)

8. Install right service shield.

9. Lower hood.

Checking Radiator Hoses and Clamps

Service Interval: Check air filter hose clamps during first 100 hours of operation, then every 500 hours of operation.

1. Park tractor on a level surface. Engage park brake.

2. Raise and secure tractor hood into an open position. (See Opening Hood in the Operating section.

3. Remove service shield on right side of tractor.

4. Tighten radiator hose clamps (A). Check hoses for cracks or damage. Replace if necessary.

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5. Install right service shield.

6. Lower hood.

Checking Fuel Sediment Bowl

Service Interval: Check Fuel Filter Sediment Bowl - Check fuel filter sediment bowl every 10 hours of operation or on a daily basis.

1. Park tractor on a level surface and engage the park brake.

2. STOP engine.

3. Raise and secure tractor hood into an open position. (See Opening Hood in the Operating section.

4. Remove service shield on right side of tractor.

5. Check for water and deposits in the sediment bowl (A).

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6. If necessary, remove and clean sediment bowl and replace fuel filter. (See Cleaning Fuel Filter Sediment Bowl in this section.)

Cleaning Fuel Filter Sediment Bowl

c CAUTION: Avoid injury! Keep cigarettes, sparks, and flames away from the fuel system. Engine must be cool.

Service Interval:

· Clean Fuel Filter Sediment Bowl - Clean fuel filter sediment bowl every 200 hours of operation.

· Replace Fuel Filter - Replace fuel filter every 500 hours of operation.

1. Park tractor on a level surface and engage the park brake.

2. STOP engine. Allow engine to cool.

3. Raise and secure tractor hood into an open position. (See Opening Hood in the Operating section.

4. Remove service shield on right side of tractor.

5. Close fuel shut-off valve (A).

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6. Turn collar (B) to remove bowl and filter. Discard filter.

7. Clean bowl.

8. Install new filter and the bowl.

9. Tighten collar.

10. Open fuel shut-off valve.

NOTE: Fuel system is self bleeding. Crank engine to allow system to bleed itself.

Checking and Adjusting Alternator Belt Tension

c CAUTION: Avoid injury! Help prevent bodily injury due to entanglement in a belt or pulley. Stop engine and wait for all moving parts to stop.

Allow engine to cool.

Service Interval: Check alternator belt tension after first 50 hours of operation. During first 100 hours of operation, then every 200 hours of operation.

Service Interval: Adjust alternator belt tension as needed.

Service Interval: Replace alternator belt as needed.

CHECKING BELT TENSION

1. Park tractor on a level surface and engage the park brake.

2. STOP engine. Allow engine to cool.

3. Raise and secure tractor hood into an open position. (See Opening Hood in the Operating section.

4. Remove both engine service shields.

5. Apply moderate thumb pressure to the belt halfway between the pulleys. Belt should deflect inward approximately 9.5 mm (3/8 in.)

ADJUSTING BELT TENSION

1. Loosen adjusting bolt (A).

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Picture Note: Alternator located on left side of engine.

2. Loosen alternator mounting bolt (B).

3. Apply outward pressure to the alternator housing.

4. Tighten bolts (A) and (B).

5. Check belt tension again.

6. Replace alternator belt if worn or damaged.

7. Install tractor service shields.

8. Lower hood.

Cleaning Grille and Service Panel Cooling Screens


IMPORTANT: Avoid damage! Grille and service panel cooling screens must be clean to prevent engine from overheating and to allow adequate air intake.

Service Interval: Check and clean grille and service panel cooling screens every 10 hours of operation or on a daily basis.

1. Check grille and both service panel screens for dirt, grass clippings and debri.

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2. If grille and service panel screens are dirty, clean with a brush or cloth.

Cleaning Radiator Cooling Screen

c CAUTION: Avoid injury! Help prevent personal injury. Wear personal eye protection when using compressed air for cleaning purposes.


IMPORTANT: Avoid damage! The radiator cooling screen must be clean to prevent engine from overheating and to allow adequate air intake.

Service Interval: Check and clean radiator cooling screen every 10 hours of operation or on a daily basis.

1. Park tractor on a level surface and engage the park brake.

2. STOP engine. Allow engine to cool.

3. Raise and secure tractor hood into an open position. (See Opening Hood in the Operating section.

4. Remove both engine service shields.

5. Remove air intake (A) from its position on top of radiator.

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6. Lift and remove radiator screen (B).

7. Clean screen with compressed air, brush or cloth.

8. Install radiator screen. Return air intake to its position on top of radiator.

9. Install both engine service panels.

10. Lower hood.

Cleaning Oil Cooler Coils and Radiator Cooling Fins

c CAUTION: Avoid injury! Help prevent personal injury. Wear personal eye protection when using compressed air for cleaning purposes.


IMPORTANT: Avoid damage! Oil cooler fins and radiator cooling fins must be clean to prevent overheating.

Service Interval: Clean oil cooler and radiator cooling fins every 200 hours of operation.

1. Park tractor on a level surface and engage the park brake.

2. STOP engine. Allow engine to cool.

3. Raise and secure tractor hood into an open position. (See Opening Hood in the Operating section.

4. Remove both engine service shields.

5. Remove radiator cooling screen. (See Cleaning Radiator Cooling Screen in this section.)

6. Remove front grille. (See Removing Front Grille in the Operating section.)

7. Remove dirt and debri from oil cooler coils (A) and radiator fins (B) using compressed air or water. Check for damage.

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8. Install radiator cooling screen.

9. Install grille and both engine service shields.

10. Lower hood.

Do Not Change Fuel Injection Pump


IMPORTANT: Avoid damage! DO NOT clean a warm fuel injection pump with steam or water. Clear debris from under injection pump regularly.

Changing the fuel injection pump in any way is not approved by the manufacturer and would void the warranty. (See the Warranty section.)

Do Not Service Fuel Injection Nozzles


IMPORTANT: Avoid damage! DO NOT service or remove fuel injection nozzles. Service life of injection nozzles may be shortened by overheating, improper operation, poor fuel quality, or excessive idling.

If injection nozzles are not working correctly or are dirty, engine will run poorly. See your John Deere dealer for service.