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 non-road engine repair establishment or individual. Warranty repairs must be performed by an authorized John Deere dealer.

Avoid Fumes

c CAUTION: Avoid injury! Engine exhaust fumes contain carbon monoxide and can cause serious illness or death.

Move the vehicle to an outside area before running the engine.

Do not run an engine in an enclosed area without adequate ventilation.

· Connect a pipe extension to the engine exhaust pipe to direct the exhaust fumes out of the area.

· Allow fresh outside air into the work area to clear the exhaust fumes out.

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:

· PLUS-50®

· PLUS-4®

· TORQ-GARD SUPREME®

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

· API Service Classification SG or higher

Checking Engine Speeds

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

Observe tachometer.

· Slow idle (no load) - 1025 rpm

· Fast idle (no load) - 2860 rpm

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

Raising and Lowering Hood

Raising

1. Park machine safely. (See Parking Safely in the SAFETY section.)

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

MX9036a, MX9035

2. Push down on hood release lever (A).

3. Raise hood until latch support rod (B) engages position (C) in channel slot.

Lowering

1. Lift hood slightly to remove weight from support rod.

2. Push support rod (B) rearward.

3. Slowly lower hood, support rod will slide along slotted channel.

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

Removing and Installing Engine Side Panels

Removing

1. Park machine safely. (See Parking Safely in the SAFETY section.)

2. Raise hood.

MX9037

3. Lift side panel (A) off upper mounting studs (B).

Installing

MX9038

1. Install lower side panel stud (C) into bracket (D).

2. Install side panel onto upper mounting studs (B).

3. Lower hood.

Removing and Installing Front Grille

Removing

1. Park machine safely. (See Parking Safely in the SAFETY section.)

2. Raise hood.

MX9039

3. Remove clips (A).

MX9040

4. Carefully remove grille (B) from mounting studs (C). Move top of grille forward.

5. Disconnect wire harness (D) from each headlight assembly.

6. Remove grille.

Installing

MX9041

1. Install tabs (E) at bottom of grille into slots (F).

2. Connect wire harness to each headlight assembly.

3. Carefully move top of grille rearward and onto studs (C).

4. Install clips (A).

5. Lower hood.

Checking Engine Oil Level


IMPORTANT: Avoid damage! Failure to check the oil level regularly could lead to serious engine problems if oil level is low: · Check oil level before operating. · Check oil level when the engine is cold and not running. · Keep level between the FULL and the ADD marks. · Shut off engine before adding oil.

NOTE: Check oil twice a day if you run engine over 4 hours in a day.

Make sure engine is cold when checking engine oil level.

1. Park the vehicle safely. (See Parking Safely in the SAFETY section.)

2. Raise hood.


IMPORTANT: Avoid damage! Dirt and contamination can enter engine when checking oil level. Clean area around dipstick before removing.

MX9045

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

4. Install dipstick.

5. Remove dipstick.

6. Check oil level on dipstick; oil level should be between FULL and ADD levels on dipstick.

MX9044

7. If oil level is low:

a. Remove side panel on right side of engine.

b. Remove oil fill cap (B).

c. Add proper engine oil until oil level is within operating range on dipstick. Do not overfill.

8. If oil is above FULL level on the dipstick, drain to proper level.

9. Install dipstick.

10. Install side panel.

11. Lower hood.

Changing Engine Oil and Filter


IMPORTANT: Avoid damage! Change the oil more often if the vehicle is used in extreme conditions: · Extremely dusty conditions. · Frequent slow or low-speed operation. · Frequent short trips.

1. Run engine to warm the oil.

2. Park machine safely. (See Parking Safely in the SAFETY section.)

3. Raise hood.

4. Place container under oil drain located on right side of engine.

5. Remove side panel on right side of engine.

MX9053

6. Remove drain plug (A).

7. Wipe dirt from around oil filter (B).

8. Turn filter counter-clockwise to remove.

9. Put a light coat of clean engine oil on the gasket of new filter.

10. Install replacement oil filter by turning filter clockwise until gasket contacts filter base. Tighten additional one half turn.

11. Install drain plug. Do not overtighten.

MX9044

12. Remove oil fill cap (C).

13. Add engine oil:

· Engine oil capacity is 2.2 L (2.3 qt).

14. Install oil fill cap.

15. Start and run engine at idle to check for leaks.

16. Stop engine. Fix any leaks before operating.

17. Check engine oil level, add oil if necessary.

18. Install side panel.

19. Lower hood.

Cleaning Air Filter Dust Unloading Valve


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

1. Park machine safely. (See Parking Safely in the SAFETY section.)

2. Raise hood.

MX9046

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

4. Install valve.

5. Lower hood.

Checking Air Restriction Indicator

1. Park machine safely. (See Parking Safely in the SAFETY section.)

2. Raise hood.

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

MX9051a, MX9050a

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

· If red plunger inside air restriction indicator window (B) is visible, air cleaner requires immediate service.

4. Service air cleaner elements if needed.

5. Push reset button (C) on air restriction indicator.

6. Lower hood.

Servicing Air Filter Elements

c CAUTION: Avoid injury! Touching hot surfaces can burn skin. The engine and components will be hot if the engine has been running. Allow the engine to cool before servicing.


IMPORTANT: Avoid damage! Dirt and debris can enter the engine through a damaged filter element: · Do not wash paper element. · Do not attempt to clean paper element by tapping against another object. · Do not use pressurized air to clean element. · Replace element only if it is very dirty, damaged or the seal is cracked.

Servicing Primary Air Filter Element

1. Park the vehicle safely. (See Park Safely in the SAFETY section.)

2. Allow engine to cool.

3. Raise hood.

MX9046

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

MX9047

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

6. Install air cleaner canister cover (B) with rubber dust unloading valve pointing downward.

7. Check instruction molded into canister cover for proper installation.

8. Hook latches (A) onto cover.

MX9051

9. Push reset button (D) on air restriction indicator.

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

11. Stop engine.

12. Check air restriction indicator:

· If red plunger inside air restriction indicator is visible, air cleaner requires immediate service.

Servicing Secondary Air Filter Element

1. Remove air cleaner canister cover.

2. Remove primary air filter element.

MX9048

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

4. Install primary air filter element.

5. Replace air cleaner canister cover.

6. Push reset button on air restriction indicator.

7. Lower hood.

Checking Air Filter Intake Hoses and Clamps

1. Park machine safely. (See Parking Safely in the SAFETY section.)

2. Raise hood.

3. Remove side panel from right side of engine.

MX9055

4. Tighten upper air intake hose clamp (B) and lower air intake hose clamps (C).

5. Install side panel.

6. Lower hood.

Service Cooling System Safely

c CAUTION: Avoid injury! Explosive release of fluids from pressurized cooling system can cause serious burns. Built-up pressure may cause explosive release of coolant when the radiator cap is removed:

· Shut off engine and allow to cool.

· Do not remove the cap unless the radiator and the engine are cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

Recommended Engine Coolant

The following John Deere coolants are preferred:

· COOL-GARD® PRE-DILUTED SUMMER COOLANT (TY16036).

· COOL-GARD® CONCENTRATED SUMMER COOLANT (TY16034).

If neither of the recommended coolants is available, use a 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.

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.

Servicing Cooling System

c CAUTION: Avoid injury! The radiator will be hot and can burn skin. Built-up pressure may cause explosive release of coolant when the radiator cap is removed:

· Shut off the engine and allow to cool.

· Do not remove the cap unless the radiator and the engine are cool enough to touch with bare hands.

· Slowly loosen the cap to the first stop to release all pressure. Then remove the cap.

Checking Cooling System

1. Park machine safely. (See Parking Safely in the SAFETY section.)

2. Allow engine to cool.

3. Raise hood.

4. Remove side panel from right side of engine.

MX9056

5. Check recovery tank (A) coolant level:

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

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

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

7. Add pre-diluted coolant or specified ratio of antifreeze and water.

8. Install recovery tank cap.

9. Lower hood.

Draining Cooling System

1. Park machine safely. (See Parking Safely in the SAFETY section.)

2. Allow engine to cool.

3. Raise hood.

4. Remove side panel from right side of engine.

MX9059

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

6. Close radiator cap tightly.

M93065

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

MX9057

8. Position drain pan under engine block drain plug (C) at right side of engine. Remove drain plug and allow all coolant to drain.

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

10. Close radiator petcock and install engine block drain plug.

11. Flush cooling system.

Flushing Cooling System

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.

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

c CAUTION: Avoid injury! Engine and coolant will be hot. Avoid contact with skin to prevent serious burns.

4. Stop engine.

5. Open radiator petcock and remove engine block drain plug.

6. Drain cooling system immediately before rust and dirt settle.

7. Close radiator petcock and install engine block drain plug.

Filling Cooling System


IMPORTANT: Avoid damage! Using incorrect coolant mixture can damage the radiator: · Do not operate engine with plain water. · Use antifreeze approved for use in aluminum engines. · Do not exceed a 50% antifreeze mixture for the coolant. · Do not pour coolant or water into the radiator when the engine is hot.

NOTE: John Deere COOL-GARD coolant is recommended when adding coolant to the cooling system.

Follow the directions on the container for correct mixture ratio.

1. Allow radiator to cool.

2. Fill cooling system.

· Cooling system capacity is 2.4 L (2.5 qt).

3. Install and tighten radiator cap.

4. Run engine until it reaches operating temperature.

5. Stop engine.

MX9056

6. Check recovery tank (A) coolant level:

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

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

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

8. Install side panel.

9. Lower hood.

Checking Radiator Hoses and Clamps

1. Park machine safely. (See Parking Safely in the SAFETY section.)

2. Raise hood.

NOTE: Visually inspect hoses for cracks and wear. Squeeze hoses to check for deterioration. Hoses should not be hard and brittle, nor soft or swollen.

MX9052

3. Check upper radiator hose (A) for damage or cracking. Replace if necessary.

4. Tighten hose clamps (B) as needed.

5. Remove side panel from right side of engine.

MX9054

6. Check lower radiator hose (C) for damage or cracking. Replace if necessary.

7. Tighten hose clamps (D) as needed.

8. Install side panels.

9. Lower hood.

Checking and Cleaning Fuel Filter Sediment Bowl and Replacing Filter

c CAUTION: Avoid injury! Fuel vapors are explosive and flammable:

· Do not smoke while handling fuel.

· Keep fuel away from flames or sparks.

· Shut off engine before servicing.

· Cool engine before servicing.

· Work in a well-ventilated area.

· Clean up spilled fuel immediately.

NOTE: Change filter when fuel is low.

Checking Sediment Bowl

1. Park machine safely. (See Parking Safely in the SAFETY section.) Allow engine to cool.

2. Raise hood.

3. Remove side panel from right side of engine.

4. Check fuel sediment bowl. If water and deposits are detected, removal of the sediment bowl and replacement of the fuel filter is required.

Cleaning Sediment Bowl and Replacing Fuel Filter

MX9058

1. Move the fuel shut-off valve (A) to the "C" (closed) position (B).

2. Position drain pan under fuel filter sediment bowl to catch fuel spillage.

3. Turn locking collar (C) counterclockwise to remove bowl (D).

4. Remove and discard the fuel filter.

5. Clean bowl.

6. Install new filter to filter head.

7. Install sediment bowl and locking collar.

8. Open fuel shut-off valve.

9. Install side panel.

10. Lower hood.

NOTE: Fuel system is self bleeding.

11. Crank engine to bleed fuel system.

Fuel Injection Pump


IMPORTANT: Avoid damage! Do not clean a warm or hot fuel injection pump with steam or water. Clean with compressed air if pump is not cooled.

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.

Servicing the Alternator Belt

c CAUTION: Avoid injury! Fingers or loose clothing can get caught in rotating parts. Stop engine and wait for all moving parts to stop before servicing.

Checking Belt Tension

1. Park machine safely. (See Parking Safely in the SAFETY section.) Allow engine to cool.

2. Raise hood.

3. Remove side panel from left side of engine.

MX9060

4. Apply moderate thumb pressure to belt (A) halfway between the pulleys. Belt should deflect inward approximately 9mm (3/8 in.).

5. Adjust belt tension if deflection is more or less than specified.

Adjusting Belt Tension

1. Loosen adjusting bolt (B).

2. Loosen mounting bolt (C).

3. Apply outward pressure to alternator housing until tension is correct.

4. Tighten bolts.

5. Check belt tension.

6. Install side panel.

7. Lower hood.

Replacing Belt

NOTE: Replace alternator belt if excessive wear, damage or stretching is detected.

1. Raise hood.

2. Remove front grille.

3. Disconnect black negative (-) cable from battery.

4. Remove both engine side panels.

5. Loosen adjusting bolt (B).

6. Loosen mounting bolt (C).

7. Apply inward pressure to alternator housing.

8. Remove belt from alternator sheave, fan sheave and crankshaft sheave.

9. Route defective belt over fan and remove.

10. Install new belt over fan and onto sheaves.

11. Apply outward pressure to alternator housing until tension is correct.

12. Tighten bolts (B) and (C).

13. Check belt tension. Adjust as necessary.

14. Connect black negative (-) cable to battery.

15. Install grille.

16. Install both engine side panels.

17. Lower hood.

Cleaning Grille and Side Screens


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

1. Check grille and both side panel screens for dirt, grass clippings and debris.

2. Clean grille and side screens with a brush or cloth.

Cleaning Radiator Cooling Screen, Cooling Fins and Oil Cooler Coils

c CAUTION: Avoid injury! Compressed air can cause debris to fly a long distance.

· Clear work area of bystanders.

· Wear eye protection when using compressed air for cleaning purposes.

· Reduce compressed air pressure to 210 kPa (30 psi).


IMPORTANT: Avoid damage! Cooling screen, fins and coils must be clean to prevent engine from overheating and to allow adequate air intake.

Cleaning Radiator Cooling Screen

1. Park vehicle safely. (See Parking Safely in the SAFETY section.) Allow engine to cool.

2. Raise hood.

MX9061

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

4. Lift and remove radiator screen (B).

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

Cleaning Radiator Cooling Fins

1. Remove both engine side panels.

2. Remove front grille.

MX9062

3. Remove all dirt and debris from fins (A) at front and rear of radiator including fan shroud using compressed air or water.

Cleaning Oil Cooler Coils (Hydrostatic Models Only)

MX9088

1. Remove all dirt and debris from oil cooler coils (A) using compressed air or water.

2. Install radiator cooling screen.

3. Install grille and both engine side panels.

4. Install air intake to position on top of radiator.

5. Lower hood.

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