Service Engine - Diesel Units

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

MIF

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:

TS1411

· PLUS-50® - SAE 15W40

The following John Deere oils are also recommended:

· PLUS-4® - SAE 10W30

· TORQ-GARD SUPREME® - SAE 5W30

· TORQ-GARD SUPREME® - Europe

· UNI-GARD - Europe

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

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

· SAE 15W40 - API Service Classification CG-4,
CF-4, CF or MIL-L-46152B

· SAE 10W30 - API Service Classification CF-4, CF, or Military Specification MIL-L-2104F

· SAE 5W30 - API Service Classification CF

· CCMC Specification D5

· CCMC Specification D4

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

Oils meeting Military Specification MIL-L-46167B may be used as arctic oils.

Raising and Lowering Engine Cowling

c CAUTION: Avoid injury! Engine cowling is heavy. Handle weight safely. Carefully raise and lower the cowling to avoid pinching hands.


IMPORTANT: Avoid damage! To avoid damage to the greens mower, Do Not operate the machine with the cowling in the raised position.

1. Park greensmower on a hard, level surface.

2. Stop the engine and engage park brake.

M97380

Picture Note: Rear engine cowling on liquid cooled gas model shown.

3. Open rear engine cowling.

· Turn button (A) clockwise to unlock cowling.

· Pull cowling up to open.

4. Lower rear engine cowling.

M97468, M97379

· Turn button (A) counterclockwise to lock cowling in the lowered position.

Raising and Lowering Operator Seat

c CAUTION: Avoid injury! To help prevent injury:

Carefully raise and lower the seat to avoid pinching fingers.

NOTE: Adjust operator seat rearward as far as possible. See Adjusting Seat in the Operating section.

Raising the Seat

· Raise and tilt operator seat forward.

M97382

M97383

· Remove prop rod (A) secured in stored position under operator seat platform.

· Install prop rod in channel slot (B).

Lowering the Seat

· Push up on seat.

· Remove prop rod from channel slot.

· Secure prop rod in stored position under operator seat platform.

· Lower operator seat.

Checking Engine Oil


IMPORTANT: Avoid damage! DO NOT check or add oil while engine is running. To prevent extensive engine wear or damage, always maintain the proper engine oil level.

1. Park greensmower on a hard, level surface.

2. Stop engine and engage park brake.

3. Open rear engine cowling.


IMPORTANT: Avoid damage! Help prevent dirt and other contaminants from entering the oil dipstick tube location. Clean area around dipstick before removing.

4. Remove dipstick (A). Wipe with a clean cloth.

M95815

5. Install dipstick in tube.

6. Remove dipstick. Check oil level on dipstick; oil level should be between levels (B) and (C) on the dipstick.

M71680

· If oil is low, add oil to bring oil level no higher than level (B) on the dipstick. (See Engine Oil in this section for correct oil application.)

· If oil level is above level (B) on the dipstick, drain to proper level.

7. Install dipstick.

8. Close rear engine cowling.


MODEL	Without Filter	With Filter
2500 Diesel	1.9 L (2 qt)	2.2 L (2.3 qt)

Changing Engine Oil and Filter

NOTE: Change engine oil and filter after the first 50 hours of break-in operation.

1. Run engine to warm the oil.

2. Park greensmower on a hard, level surface.

3. Stop engine and engage park brake.

4. Open rear engine cowling.

5. Drain oil.

· Place container under oil drain location.

· Remove drain plug (A) located under left side of engine.

M97351

6. Remove oil filter (B).

M97352

· Locate filter under left side of engine.

· Turn filter counterclockwise to remove.

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

8. Install oil filter.

· Turn filter clockwise until gasket makes contact with mounting surface. Tighten 1/2-3/4 turn after gasket contact.

9. Install oil drain plug (A). DO NOT overtighten.

10. Remove oil fill cap (C).

11. Add approximately 2.2 L (2.3 qt.) of engine oil. (See Engine Oil in this section for the correct application.)

12. Install oil fill cap.

13. Start engine.

· Run engine at a slow "t" throttle speed for approximate two minutes.

· Check area under engine for oil leaks.

14. Stop engine.

15. After approximately two minutes check engine oil level.


IMPORTANT: Avoid damage! Help prevent dirt and other contaminants from entering the oil dipstick tube location. Clean area around dipstick before removing.

16. Remove dipstick (D). Wipe with a clean cloth.

M97362

17. Install dipstick in tube.

18. Remove dipstick. Check oil level on dipstick; oil level should be between levels (B) and (C) on the dipstick.

· If oil is low, add oil to bring oil level no higher than level (B) on the dipstick. (See Engine Oil in this section for correct oil application.)

· If oil level is above level (B) on the dipstick, drain to proper level. DO NOT overfill.

M71680

19. Install dipstick.

20. Close rear engine cowling.

Cleaning Rear Grill Screen

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


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

1. Park greensmower on a hard, level surface.

2. Stop engine and engage park brake.

3. Open rear engine cowling.

4. Remove rear grill screen (A) from position behind engine radiator.

M97328

5. Clean screen with compressed air.

6. Install grill screen.

M97344, M97334

· Install grill screen notches (B) onto each bracket mounting pin (C).

7. Close rear engine cowling.

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 coils and radiator cooling fins must be clean to prevent overheating.

1. Park greensmower on a hard, level surface.

2. Stop engine and engage park brake. Allow engine to cool.

3. Open rear engine cowling.

4. Remove rear grill screen. (See Cleaning Rear Grill Screen in this section.)

5. Release latches (A) securing oil cooler to the radiator mounting bracket.

· Carefully move oil cooler away from the radiator.


IMPORTANT: Avoid damage! Help prevent unnecessary damage to the engine. When cleaning oil cooler coils and radiator fins take precautions to prevent water and debris from entering the air intake hose (B).

6. Remove dirt and debris from oil cooler coils (C) and radiator fins (D) using compressed air or water.

M97345

M97329

· Check oil cooler coils and radiator fins for damage.

7. Install oil cooler.

8. Install grill screen.

9. Close rear engine cowling.

Checking Air Restriction Indicator

1. Park greensmower on a hard, level surface.

2. Stop engine and engage park brake. Allow engine to cool.

3. Open rear engine cowling.

NOTE: Indicator will not function correctly if plastic indicator housing is damaged.

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

M97350

· When yellow plunger (A) inside indicator is visible inside the green zone, no air cleaner service is required.

· When yellow plunger (A) inside indicator is visible inside the red zone, air cleaner requires immediate service. (See Servicing Air Cleaner Element in this section.)

5. Close rear engine cowling.

Servicing Air Cleaner Element


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

Primary Air Filter Element

1. Park greensmower on a hard, level surface.

2. Stop engine and engage park brake. Allow engine to cool.

3. Open rear engine cowling.

4. Release latches (A) and remove air cleaner canister cover (B).

M97357

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

M97358

6. Install air cleaner canister cover (B).

M97357

· Check instruction molded into canister cover for proper installation.

· Rubber dust unloading valve (D) should be pointed downward when the cover is properly installed.

· Engage latches (A).

7. Push reset button (E) on air restriction indicator.

M97350

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

9. Stop engine. Check air restriction indicator. If yellow plunger inside air restriction indicator is visible inside the red zone, replace secondary air filter element.

Secondary Air Filter Element

1. Remove air cleaner canister cover.

2. Remove primary air filter element.

3. Remove and discard secondary air filter element (F). Replace with a new secondary air filter element.

M97359

4. Install primary air filter element.

5. Replace air cleaner canister cover.

6. Close rear engine cowling.

Clean Rubber Dust Unloading Valve


IMPORTANT: Avoid damage! Never operate engine without air cleaner element and rubber dust unloading valve installed.

1. Park greensmower on a hard, level surface.

2. Stop engine and engage park brake. Allow engine to cool.

3. Open rear engine cowling.

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

M97357

5. Install dust unloading valve.

6. Close rear engine cowling.

Check Radiator Hoses, Air Intake Hose and Clamps

1. Park greensmower on a hard, level surface.

2. Stop engine and engage park brake. Allow engine to cool.

3. Open rear engine cowling.

4. Check air intake hose (A).

M97333

· Tighten hose clamp (B).

· Check hose for cracks or damage.

· Replace if necessary.

5. Check upper radiator hose (C).

· Tighten hose clamps (B).

· Check hose for cracks or damage.

· Replace if necessary.

6. Check lower radiator hose (D).

M97336

· Tighten hose clamps (B).

· Check hose for cracks or damage.

· Replace if necessary.

7. Close rear engine cowling.

Service Cooling System Safely

MIF

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 loosen cap to first stop to relieve pressure before removing completely.

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).

These coolants exceed industry specifications: ASTM D5345, D4656, D4985, D3306, and GM6038. They are designed with 5-year or 5000 hour long life formulation (subject to testing annually for conditioner level) for use in all heavy duty diesel engines. These coolants have a coolant conditioner added to help protect against liner pitting and cavitation.

If neither of the above coolants is available, use an ethylene glycol base coolant that meets the following specification:

· ASTM D4985 (JDM H24A2).

Check container label before using to be sure it has the appropriate specifications for your machine. Use coolant with conditioner or add conditioner to coolant 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.

If using concentrate, mix approximately 50 percent antifreeze with 50 percent distilled or deionized water before adding to cooling system. 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.

· Protection against liner pitting and cavitation.

· Compatibility with cooling system hose and seal material.

· Protection during cold and hot weather operations.

Engine Coolant Drain Interval

When using PRE-DILUTED DIESEL ENGINE ANTI-FREEZE/SUMMER COOLANT or DIESEL ENGINE ANTI-FREEZE/SUMMER COOLANT CONCENTRATE (TY16034) coolants, drain and flush the cooling system and refill with fresh coolant mixture every 60 months or 5,000 hours of operation, whichever comes first.

If above John Deere Service coolants are not being used: drain, flush, and refill the cooling system with fresh coolant mixture every 24 months or 600 hours of operation, whichever comes first.

Checking Coolant Level


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. · Use antifreeze approved for use in aluminum engine. · To prevent engine overheating, do not exceed more than 50 percent antifreeze in cooling system. · Cooling system capacity is 3.5 L (3.7 U.S. qt).

1. Park greensmower on a hard, level surface.

2. Stop engine and engage park brake. Allow engine to cool.

3. Open rear engine cowling.

4. Check recovery tank (A) coolant level:

M97330

· If engine is warm, coolant level should be between the "H" (HIGH) line (B) and the "L" (LOW) line (C).

· If engine is cold, coolant level should be at the "L" (LOW) line (C) on the recovery tank.

5. Remove recovery tank cap (D) 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 recovery tank cap.

8. Clean debris from rear grill screen, oil cooler coils and radiator cooling fins. (See Cleaning Rear Grill Screen and Cleaning Oil Cooler Coils and Radiator Cooling Fins in this section.)

9. Check condition of hoses. Check for leaks or loose connections. (See Check Radiator Hoses, Air Intake Hose and Clamps in this section.)

Draining Cooling System

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! Help prevent damage to the engine: · DO NOT operate engine without coolant. · DO NOT pour coolant into the radiator when the engine is hot.

1. Park greensmower on a hard, level surface.

2. Stop engine and engage park brake. Allow engine to cool.

3. Open rear engine cowling.

4. Slowly open radiator cap (A) to the first stop to release all pressure.

M97364

5. Close radiator cap tightly.

NOTE: A section of plastic or rubber hose can be used to divert fluid away from the greensmower.

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

M97373

7. When coolant drains from the recovery tank, remove radiator cap.

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

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

Flushing Cooling System

c CAUTION: Avoid injury! Engine and coolant will be hot.

Turn radiator cap using a thick rag or glove to protect your hand.


IMPORTANT: Avoid damage! To prevent engine damage: · 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 the can.

2. Install and tighten radiator cap (A).

M97364

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

4. Stop engine.

5. Open radiator petcock (B).

M97373

· Drain cooling system immediately before rust and dirt settle. (See Draining Cooling System in this section).

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 3.5 L (3.7 qt).

1. Fill cooling system. (See Engine Coolant in this section for proper antifreeze application.)

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

· John Deere Cooling System Sealer or its equivalent may be added to the radiator to seal leaks. Do not use any other additives in the cooling system.

2. Install and tighten radiator cap.

3. Run engine until it reaches operating temperature.

4. Stop engine.

5. Check recovery tank (A) coolant level:

M97330

· If engine is warm, coolant level should be between the "H" (HIGH) line (B) and the "L" (LOW) line (C).

· If engine is cold, coolant level should be at the "L" (LOW) line (C) on the recovery tank.

6. Remove cap (D) from recovery tank to add coolant if necessary.

7. Check condition of coolant system hoses and clamps. (See Check Radiator Hoses, Air Intake Hose and Clamps in this section.)

8. Close rear engine cowling.

Checking Fuel Filter Sediment Bowl

c CAUTION: Avoid injury! Keep cigarettes, sparks, and flames away from fuel system. Make sure engine is cool.

1. Park greensmower on a hard, level surface.

2. Stop engine and engage park brake. Allow engine to cool.

3. Open rear engine cowling.

4. Check for water in sediment bowl (A):

M97349

· Orange ring will float on top of the water.

5. If necessary, clean bowl and replace filer. (See Cleaning Fuel Filter Sediment Bowl).

Cleaning Fuel Filter Sediment Bowl

c CAUTION: Avoid injury! Wait until fuel is low before replacing fuel filter OR be prepared to drain fuel into a safe container when disconnecting fuel line.

1. Park greensmower on a hard, level surface.

2. Stop engine and engage park brake. Allow engine to cool.

3. Open rear engine cowling.

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

M97370

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

6. Clean bowl.

7. Install new filter and bowl.

8. Tighten collar.

9. Open fuel shut-off valve.

10. Close rear engine cowling.

Using the Fuel Pump Primer

NOTE: The following procedure should be used when the greensmower needs to be restarted after completely running out of fuel.

c CAUTION: Avoid injury! Help prevent serious personal injury. DO NOT refuel greensmower while smoking or when near open flames or sparks. Allow engine to cool before refueling.

1. Engage park brake. Allow engine to cool.

2. Check fuel gauge and fill as required. (See Fuel and Filling Fuel Tank in the Service-Miscellaneous section.)

3. Open rear engine cowling.

4. Locate fuel priming lever (A) on left side of engine.

M97375

NOTE: Make sure fuel shut-off valve is in the "O" (open) position. (See Using Fuel Shut-Off Valve in the Operating section.)

5. Pump fuel priming lever until fuel is visible in the fuel filter sediment bowl (B).


IMPORTANT: Avoid damage! Fuel system is self bleeding. Crank engine to allow system to bleed itself. Help prevent possible damage to the starter. DO NOT operate starter more than twenty seconds. If engine will not start, wait two minutes before trying again.

6. Start engine.

Checking and Adjusting Alternator Belt

c CAUTION: Avoid injury! Help prevent serious bodily injury due to entanglement in a belt, pulley or contact with a rotating fan blade. Stop engine and wait for all moving parts to stop.

Check Belt Tension

1. Park greensmower on a hard, level surface.

2. Stop engine and engage park brake. Allow engine to cool.

3. Open rear engine cowling.

4. Check alternator belt (A):

M97346

· Inspect belt for excessive wear, damage or stretching while in position on the fan, alternator and flywheel sheaves.

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

Adjusting Belt Tension

1. Loosen adjustment bolt (B).

M97361

Picture Note: Alternator located on right side of engine.

2. Loosen alternator mounting bolt (C).

3. Apply outward pressure to the alternator housing.

4. Tighten alternator adjustment bolt (B) and mounting bolt (C).

5. Check belt tension:

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

6. Close rear engine cowling.

Replacing Alternator Belt

c CAUTION: Avoid injury! Help prevent serious bodily injury due to entanglement in a belt, pulley or contact with a rotating fan blade. Stop engine and wait for all moving parts to stop.

1. Park greensmower on a hard, level surface.

2. Stop engine and engage park brake. Allow engine to cool.

3. Open rear engine cowling.

4. Loosen adjustment bolt (A).

M97361

Picture Note: Alternator located on right side of engine.

5. Loosen alternator mounting bolt (B).

6. Apply inward pressure to the alternator housing.

7. Remove worn belt from alternator, fan and flywheel sheaves.

8. Install new belt.

9. Apply outward pressure to the alternator housing.

10. Tighten alternator adjustment bolt (A) and mounting bolt (B).

11. Check belt tension:

M97346

· Apply thumb pressure to the belt (C) approximately halfway between the sheaves. Belt should deflect inward approximately 9.5 mm (3/8 in.).

12. Close rear engine cowling.