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.

Fuel Injection Pump


IMPORTANT: Avoid damage! DO NOT clean a warm or hot 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.)

NOTE: The fuel injection pump is calibrated by the engine manufacturer and should not require any adjustments.

If engine is hard to start, lacks power, or runs rough, see Troubleshooting Section of this manual.

After performing the check in the troubleshooting section and your engine is still not performing correctly, contact your John Deere dealer.

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.

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%.

Opening Hood

c CAUTION: Avoid injury! To prevent injury from moving parts, stop engine and remove ignition key before opening the hood.

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1. Pull hood latch (A) out and lift hood

2. Remove hood support rod (B) from clip (C).

3. Put hood support rod (B) in holders (D).

Lowering Hood

c CAUTION: Avoid injury! To prevent injury, release hood latch (B) only when hood is supported to control the lowering of the hood.

1. LIFT hood slightly to remove weight from hood latch.

2. Put hood support rod (B) in clip (C) and lower hood.

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3. Push down on front of hood to lock latch.

Removing and Installing Side Service Shields

1. Open hood.

2. Open and turn spring loaded fastener (A) to the horizontal position. Repeat for rear fastener.

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3. Lift shield off two lower rod supports to remove.

4. Repeat for other side.

Removing Front Grille

1. Pull front grille down.

2. Remove springs (A).

NOTE: The bottom of the grille has two alignment tabs (B) which sit in grooves in the tractor frame.

3. Lift grille high enough to clear alignment tabs (B) and remove grille.

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Checking Engine Oil Level

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 hood and latch open.

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

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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 right side engine shield from tractor.

· Remove oil filler cap (C).

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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 engine side shield.

12. Lower hood.

Changing Engine Oil and Filter

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 hood and latch open.

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

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6. Remove right side engine shield from tractor.

7. Remove oil filter (B). Turn filter counterclockwise to remove.

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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 4.1 L (4.3 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. Remove oil dipstick (D). Wipe clean with a rag.

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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 side engine shield.

22. Lower hood.

Clean Air Filter Rubber Dust Unloading Valve


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

NOTE: Rubber dust unloading valve is self-cleaning. Check rubber dust unloading valve every 10 hours of operation or on a daily basis for particles too large to pass through bottom slot of valve.

1. Stop engine and engage park brake.

2. Raise hood and latch open.

3. Squeeze wide edges of unloading valve (A) to open bottom slot and allow particles to drop out. Replace if damaged.

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4. Lower hood.

Replacing Air Filter Elements


IMPORTANT: Avoid damage! DO NOT attempt to clean a primary or secondary air filter element when red plunger inside air restriction indicator is visible. The red plunger indicates the primary or secondary air filter element is dirty and needs replacement.

Primary Air Filter Element

1. Stop engine and engage park brake.

2. Raise hood and latch open.

NOTE: Air intake tube might be pulled out of position when air cleaner is serviced. Return tube to recessed area (A) of panel in front of radiator when service is completed.

3. Remove cover nut (B).

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4. Remove and discard primary element (C). Replace with a new primary element.

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5. If installed push reset button on top of air restriction indicator.

· · START engine. Allow engine to run approximately one minute at maximum.

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

Secondary Air Filter Element

1. Remove primary air filter element.

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

3. Install primary element (C).

4. Lower hood.

Checking Air Filter Intake Hoses and Clamps

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

2. Raise hood and latch open.

3. Remove right engine side shield from tractor.

NOTE: Air intake tube slides into recessed area (A) of panel in front of radiator.

4. Tighten hose clamps.

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· Tighten upper air intake hose clamp (B).

· Tighten lower intake hose clamps (C).

5. Install right side engine shield.

6. Lower hood.

Checking Optional Air Restriction Indicator

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

2. Raise hood and latch open.

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

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

4. 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.

Replacing Thermostat

Replace thermostat every 2 years or 2000 hours.

See your John Deere dealer for this service.

Checking Engine Speeds

Check engine speeds when engine is warmed up and not under load.

Observe tachometer.

· Fast idle (no load)-2810 rpm

· Slow idle (no load)-925 rpm

If above engine speeds are not to specifications, see your John Deere dealer.

Checking Radiator Coolant Level

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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.

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

2. Raise hood and latch open.

3. Remove right side engine shield from 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 (B) on the coolant overflow tank.

5. Remove cap (C) to add coolant.

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6. If coolant is low, add specified ratio of antifreeze and water.

7. Install and tighten overflow tank cap.

8. Clean debris from the grill screen, both left and right side engine shield air intake screens and the radiator screen.

9. Check condition of the radiator hoses and clamps. Check for leaks or loose connections.

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.

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

2. STOP engine. Allow engine to cool.

3. Raise hood and latch open.

4. Remove service shield on left side of tractor.

5. Slowly remove the radiator cap (A).

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

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7. After all coolant has drained, close radiator petcock.

8. 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 or 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. After draining the coolant system, pour the contents of a can of John Deere Cooling System Cleaner, or John Deere Cooling System Quick Flush, or an equivalent into the radiator. Fill cooling system with clean water. 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) on the left side and drain cooling system immediately before rust and dirt settle.

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6. After all the flushing solution has drained, close radiator petcock.

7. Fill the cooling system. (See Filling Cooling System in this section.)

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.

1. Fill cooling system. Capacity is 4.8 L (1.25 gal). Add specified ratio of antifreeze and water to the radiator. (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.

· 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.

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7. Check condition of the radiator hoses and clamps. Check for leaks or loose connections.

8. Install right service shield.

9. Lower hood.

Checking Radiator Hoses and Clamps

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

2. Raise hood and latch open.

3. Remove both service shields on tractor.

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

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NOTE: Top photo shows upper radiator hose and clamp locations with the left service panel removed. Bottom photo shows lower radiator hose and clamp locations with the right service panel removed

5. Install engine service shields.

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6. Lower hood.

Checking Fuel Filter Sediment Bowl

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

2. STOP engine.

3. Raise hood and latch open.

4. Remove right side engine shield.

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

· There is a red ring in the bottom of the sediment bowl which will float on top of any water that is present in the bowl. If the red ring is floating up in the bowl, it is an indication that it is time to clean out the sediment bowl.

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6. If necessary, remove and clean sediment bowl and replace fuel filter.

Cleaning Fuel Filter Sediment Bowl and Replacing Filter

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

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

2. STOP engine. Allow engine to cool.

3. Raise hood and latch open.

4. Remove right side engine shield.

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

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6. Turn sediment bowl retainer collar (B) in direction of arrow to remove bowl and filter. Discard filter.

7. Clean bowl, keeping the red plastic ring.

8. Install new filter and the bowl.

9. Tighten collar.

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

10. Open fuel shut-off valve.

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.

CHECKING BELT TENSION

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

2. STOP engine. Allow engine to cool.

3. Raise hood and latch open.

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.

6. Replace alternator belt if worn or damaged.

7. Install tractor service shields.

8. Lower hood.

Cleaning Grille and Side Screens


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

1. Check grille (A) and both side screens (B) for dirt, grass clippings and debris.

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

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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.

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

2. STOP engine. Allow engine to cool.

3. Raise hood and latch open.

4. Remove both side engine shields.

5. Lift and remove radiator screen (A).

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

7. Install radiator screen.

8. Install both engine service panels.

9. Lower hood.

Cleaning 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! Radiator cooling fins must be clean to prevent overheating.

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

2. STOP engine. Allow engine to cool.

3. Raise hood and latch open.

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 this section.)

7. Remove dirt and debris from radiator fins (A) using low pressure 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.

Adjusting Throttle

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

2. STOP engine. Allow engine to cool.

3. Raise hood and latch open.

4. Remove right side service shield.

5. Locate locknut (A) on end of throttle lever.

6. Adjust throttle lever friction drag:

· Loosen nut (A) to decrease drag.

· Tighten nut (A) to increase drag.

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