John Deere Power Systems
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This repair manual covers the 6068 PowerT ech engines for Final T ier 4/Stage
This manual written for experienced Essential tools required performing certain service work are identified this manual.
Live W ith Safety : Read the safety messages the introduction this manual and the cautions presented throughout the text the
CAUTION: This the safety - alert symbol. When you see this symbol the machine this manual, alert the potential for personal injury .
Information this manual organized sections and sub divided into groups.
Section lists all applicable service equipment and other materials needed the job.
Section details all wear torque values and contains the wiring
This manual contains Metric units measure followed immediately the U.S. customary units measure. Most hardware these engines metric sized.
Read each block material completely before performing service check for dif ferences procedures Follow only the procedures that apply the component you are working on.
Component T echnical Manuals are concise service guides for specific Component technical manuals are written stand - alone manuals covering multiple machine
Section covers the safety measures follow while repairing the engine; engine identification engine emission & application and information about the fuels, lubricants & coolants.
Section covers the Repair and Adjustment
Section explains Systems Theory
Section the diagnostics section that provides troubleshooting procedures find problems.
Fundamental service information available from other sources covering basic theory fundamentals general and basic type failures and their
Diesel engine exhaust and some its constituents are known the State California cause cancer , birth defects and other reproductive harm.
6068HFC09 Right Rear V iew
When working through the instructions this you may require the use special For a complete listing John Deere approved essential and dealer fabricated engine tools, please refer the JDPS Master T ool Manual T echnical Manual
6068HFC09 Left Rear V iew
For more information which engine manuals should referred for a specific machine please refer the Application List Manual Component T echnical Manual This manual provides a listing machine and engine and their appropriate base engine and fuel system manual numbers. For OEM applications, the operators manual number for the engine also included.
John Deere University fers the following related training for the engine covered this More
Diesel Engine Systems I
Diesel Engine Basics
Diesel Fuel Fundamentals
Biodiesel Fundamentals
Electrical Methods and T echniques
Electrical Systems I
Electrical Systems
Engine - Aftertreatment System Fundamentals
Engine - Aftertreatment System Overview
Engine - Introduction Interim T ier 4/Stage III B
Engine - Introduction Final T ier 4/Stage T echnologies
Engine - Final T ier
4/Stage Advanced Engine Diagnostics
Engine - Integrated Emissions Control System Overview
information each these courses can found online the John Deere University website (example:
Engine - Integrated Emissions Control System Basic Diagnostics
Engine - Final T ier
4/Stage Sales and Marketing Overview
Engine - 6068/6090 Final T ier 4/Stage Engine Overview
Hydraulic Methods & T echniques
Hydraulic Systems I
Hydraulic Systems
John Deere Custom Performance
John Deere Plus 50™ & COOLGARD™
Service ADVISOR Methods & T echniques
Service ADVISOR Overview
JDPS - Service ADVISOR - Systems Overview
Actuator A device controlled the ECU perform a certain
Analog Signal which has a continuous range possible usually 0 V (low) V
Application Either a movable stationary piece equipment that the engine placed Applications T Irrigation Generator and
BAP Barometric Air Pressure the atmosphere (atmospheric
Boost Pressurized air the intake
CAC Charge Air Cooler Cools the compressed air from the turbine before enters the intake
CAN Controller Area The network applications that allows communication between the engine control unit and some
Circuit Power Power supplied a device for use its internal component
Crankshaft Position Sensor Used determine the angular position and velocity the crankshaft the 360° field
DEF Diesel Exhaust A urea water solution that injected into the exhaust stream before the SCR reduce
Digital A signal which consists only two levels voltage usually 0 V (low) V
DOC Diesel Oxidation Part the exhaust filter aftertreatment Used help reduce
DPF Diesel Particulate Filter Part the exhaust filter aftertreatment Used help reduce
DTC
Diagnostic T rouble A code that stored ECU memory when detects a problem the electronic control There are two types codes: Active and These codes are displayed monitor panels and can recalled the service
ECT Engine Coolant T The temperature the engine
ECU Engine Control Computer that controls the air , and ignition systems the
EGR Exhaust Gas Used help reduce
Electronic Injector that regulated the ECU control the proper amount fuel High - Pressure Common rail fuel
EOL This the abbreviation for End Line which where the ECU gets programmed the factory
EUI
Electronic Unit Injector that regulated the ECU control the proper amount fuel non - High - Pressure Common rail fuel
FMI Failure Mode Identifier The second part a two - part code that identifies control system fault codes according the J1939 This two - digit code identifies the type failure that has The first half the code the Suspect Parameter Number
H - Bridge Circuits the ECU set H - This allows for current reversed drive motors forward and
HPCR High - Pressure Common - A device that distributes high - pressure fuel the
Input This identifies a signal input a device control
J1939 The Society Automotive Engineers (SAE) standard for communication between the electronic control units heavy - duty both - and f - highway
JDCP John Deere Custom Performance Program allows the customer select software features and feature combinations prior loading the software into the also one way which embedded software managed and updated control units without removal the control unit from the
JDPS John Deere Power
MAP Manifold Air The pressure the air the intake sometimes referred
T Manifold Air T The temperature the air the intake
Meter Zero This the value the multimeter reads the ohm when the meter lead tips are held together
Mis - pin incorrect placement male pins female sockets within electrical connector Also known incorrect swapping wires and NOx Nitrogen A gas that produced a product especially higher combustion OOR Out - - The signal received the ECU out the expected range the
OORH Out - - Range Signal sensed the ECU higher than the component can produce (outside acceptable For some circuit this could caused open input open ground input wire shorted a voltage higher than the ECU expects
OORL Out - - Range Low Signal sensed the ECU lower than the component can produce (outside acceptable For some circuit this could caused input wire circuit power wire shorted
Output This identifies a signal output from a device control
Pin A style terminal that makes the electrical connection a connector Also called a male
Pressure Relief
The portion the
memory within the ECU that used when the ECU All data this memory lost when the ECU ”OFF”.
TWV T - W V A component the Electronic Injector
VGT V ariable Geometry T Used reduce
WIF W ater - - The WIF sensor sends a signal the ECU when water detected the
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Section Information
Group 000
Group 001 Identification
Group 002 —Fuels, and Coolant
Section and Adjustments
Group 010 Rebuild
Group 020 Head and V alve Repair and Adjustment
Group 030 and Rods Repair and Adjustment
Group 040 Main Flywheel Repair , and Adjustment
Group 050 and T iming Gear T rain Repair and Adjustment
Group 165 SPN -
Group 166 SPN -
Group 167 SPN -
Section ools and Other Materials
Group 170 T ools
Group 180 —Lubricants, and Other Materials
Section 06—Specifications
Group 200 and General OEM Specifications
Group 210 Specifications
Group 060 System Repair and Adjustment
Group 070 System Repair and Adjustment
Group 080 Intake and Exhaust System Repair and Adjustment - Dual T urbocharger
Group 085 Intake and Exhaust System Repair and Adjustment - Single T urbocharger
Group 090 Fuel System Repair and Adjustment
Group 100 Starting and Charging Systems Repair and Adjustment
Group 1 Engine Control Repair and Adjustment
Group 1 Repair and Adjustment
Group 1 Dosing Aftertreatment Devices Repair and Adjustment
Group 1 Dosing Aftertreatment Devices Repair and Adjustment
Section 03—Theory Operation
Group 120 ech PSS Base Engine Operation
Group 123 System
Group 126 System
Group 130 Fuel System
Group 135 Intake and Exhaust System
Group 137 System
Group 140 Control System
Section 04—Diagnostics
Group 150 Diagnostics
Group 155 T ests, and Procedures
Group 160 Instructions and Information
Group 161 SPN -
Group 162 SPN -
Group 163 SPN -
Group 164 SPN -
Original All illustrations and specifications this manual are based the latest information available the time publication. The right reserved make changes any time without notice.
Group 000 —Safety
Understand Signal W ords - 000 - 1
Recognize Safety Information - 000 - 1
Replace Safety Signs - 000 - 1
Follow Safety Instructions - 000 - 2 California Proposition W arning
. - 000 - 2
Exhaust Filter Cleaning - 000 - 2 A void Hot Exhaust - 000 - 2 W ork V entilated Area - 000 - 3
Decommissioning Proper
Recycling and Disposal Fluids and Components
- 000 - 3 Prevent Machine Runaway - 000 - 4 Practice Safe Maintenance - 000 - 4 W ork Clean Area - 000 - 5 W ear Protective Clothing - 000 - 5
Service Machines Safely - 000 - 5
Use Proper T ools
Construct Dealer - Made T ools Safely - 000 - 6
Support Machine Properly - 000 - 6 Use Proper Lifting Equipment - 000 - 7 Protect Against Noise - 000 - 7 Illuminate W ork Area Safely
Install All Guards
- 000 - 7
. - 000 - 8
Stay Clear Rotating Drivelines - 000 - 8
Protect Against High Pressure Spray - 000 - 8
Service Cooling System Safely - 000 - 9
Remove Paint Before W elding Heating
Precautions for W elding - 000W ait Before Opening High - Pressure Fuel System - 000 -
A void High - Pressure Fluids - 000 - 1 1
A void Heating Near Pressurized Fluid Lines
A void Static Electricity Risk When Refueling - 000Handle Fluids void Fires - 000 -
Prepare for Emergencies
Handling Batteries Safely
000 -
- 000Prevent Acid Burns - 000Prevent Battery Explosions - 000Live With Safety - 000 -
Group 001
ier Final T ier Stage and Stage OEM Applications .
- 002Diesel Engine Oil and Filter Service Intervals - 002Mixing Lubricants -
002 - 1 1 Diesel Engine Coolant (engine with wet sleeve cylinder liners) - 002W ater Quality for Mixing with Coolant Concentrate - 002Operating W arm T emperature Climates
DANGER ; The signal word DANGER indicates a hazardous situation not will result death serious injury
W ARNING ; The signal word W ARNING indicates a hazardous situation which, not avoided, could result death serious injury
CAUTION ; The signal word CAUTION indicates a hazardous situation not could result minor moderate injury . CAUTION may also used alert against unsafe practices associated with events which could lead personal injury
A signal word—DANGER, W used with the safety - alert
DANGER identifies the most serious hazards. DANGER W ARNING safety signs are located near specific hazards. General
This a safety - alert When you see this symbol your machine this manual, alert the potential for personal injury .
Follow recommended precautions and safe operating
precautions are listed CAUTION safety CAUTION also calls attention safety messages this
Replace missing damaged safety See the machine operator ’ s manual for correct safety sign
Carefully read all safety messages this manual and your machine safety Keep safety signs good Replace missing damaged safety sure new equipment components and repair parts include the current safety signs. Replacement safety signs are available from your John Deere dealer .
There can additional safety information contained parts and components sourced from suppliers that not reproduced this
Learn how operate the machine and how use controls properly not let anyone operate without
Keep your machine proper working
Unauthorized modifications the machine may impair the function and/or safety and fect machine life.
you not understand any part this manual and need contact your John Deere dealer
Diesel engine some its along with certain machine components contain emit chemicals known the State California cause cancer and birth
defects other reproductive certain fluids contained the machine and certain products component wear contain emit chemicals known the State California cause cancer and birth defects other reproductive harm.
Servicing machine attachments during exhaust filter cleaning can result serious personal injury A void exposure and skin contact with hot exhaust gases and components.
During auto manual/stationary exhaust filter cleaning the engine will run elevated idle and hot temperatures for extended period Exhaust gases and exhaust filter components reach temperatures hot enough burn people, ignite, melt common
Servicing machine attachments with engine running can result serious personal injury . A void exposure and skin contact with hot exhaust gases and components.
Exhaust parts and streams become very hot during Exhaust gases and components reach temperatures hot enough burn melt common materials.
Engine exhaust fumes can cause sickness necessary run engine enclosed remove the exhaust fumes from the area with exhaust pipe
you not have exhaust pipe extension, open the doors and get outside air into the
Safety and environmental stewardship measures must taken into account when decommissioning a machine and/or component. These measures include the following:
• Use appropriate tools and personal protective equipment such face shields during the removal handling objects and
• Follow instructions for specialized components.
• Release stored energy lowering suspended machine relaxing disconnecting the battery other electrical power , and releasing pressure hydraulic and other similar
• Minimize exposure components which may have residue from agricultural chemicals, such fertilizers and Handle and dispose these components appropriately
• Carefully drain fuel hydraulic and lines before recycling Use leak - proof containers when draining fluids. not use food beverage containers.
• not pour waste fluids onto the down a into any water
• Observe all and local ordinances governing the handling disposal waste fluids (example: brake fluid);
filters; batteries; and, other substances parts. Burning flammable fluids components other than specially designed incinerators may prohibited law and could result exposure harmful fumes
• Service and dispose air conditioning systems appropriately Government regulations may require a certified service center recover and recycle air conditioning refrigerants which could damage the atmosphere allowed
• Evaluate recycling options for rubber , and electronic components which may part completely
• Contact your local environmental recycling center , your John Deere dealer for information the proper way recycle dispose
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A void possible injury death from machinery runaway not start engine shorting across starter Machine will start gear normal circuitry
NEVER start engine while standing ground. Start engine only from operator ’ s with transmission neutral
Understand service procedure before doing work. Keep area clean and dry .
Never adjust machine while Keep feet , and clothing from power - driven Disengage all power and operate controls relieve pressure. Lower equipment the ground. Stop the engine. Remove the key . Allow machine cool.
Securely support any machine elements that must raised for service
Keep all parts good condition and properly installed. Fix damage immediately . Replace worn broken parts. Remove any buildup
self - propelled disconnect battery ground cable ( before making adjustments electrical systems welding machine.
towed disconnect wiring harnesses from tractor before servicing electrical system components welding
Before starting a job:
• Clean work area and
• Make sure you have all necessary tools your
• Have the right parts hand.
• Read all instructions thoroughly; not attempt
W ear close fitting clothing and safety equipment appropriate the job.
Prolonged exposure loud noise can cause impairment loss
W ear a suitable hearing protective device such earmuf earplugs protect against objectionable uncomfortable loud
Operating equipment safely requires the full attention the operator not wear radio music headphones while operating machine.
T long hair behind your not wear a loose necklace when you work near machine tools moving parts. these items were get caught, severe injury could result.
Remove rings and other jewelry prevent electrical shorts and entanglement moving
Use tools appropriate the Makeshift tools and procedures can create safety
Use power tools only loosen threaded parts and fasteners.
For loosening and tightening use the correct size NOT use measurement tools metric A void bodily injury caused slipping
Use only service parts meeting John Deere specifications.
Faulty broken tools can result serious injury . When constructing tools, use proper , quality materials, and good
not weld tools unless you have the proper equipment and experience perform the
Always lower the attachment implement the ground before you work the machine. the work requires that the machine attachment provide secure support for left a raised hydraulically supported devices can settle leak
not support the machine cinder blocks, hollow tiles, props that may crumble under continuous load. not work under a machine that supported solely a Follow recommended procedures this
When implements attachments are used with a machine, always follow safety precautions listed the implement attachment manual.
Lifting heavy components incorrectly can cause severe injury machine
Follow recommended procedure for removal and installation components the manual.
Prolonged exposure loud noise can cause impairment loss hearing.
W ear a suitable hearing protective device such earmuf earplugs protect against objectionable uncomfortable loud
Illuminate your work area adequately but safely Use a portable safety light for working inside under the machine. Make sure the bulb enclosed a wire cage.
The hot filament accidentally broken bulb can ignite spilled fuel
Rotating cooling system and drives can cause serious injury
Keep all guards place all times during engine operation.
W ear close - fitting Stop the engine and sure and drives are stopped before making cleaning near fans and their drive
Entanglement rotating driveline can cause serious injury death.
Keep all shields place all Make sure rotating shields turn freely
W ear close - fitting clothing. Stop the engine and sure that all rotating parts and drivelines are stopped before making performing any type service engine machine driven
Spray from high pressure nozzles can penetrate the skin and cause serious injury Keep spray from contacting hands body . accident see a doctor immediately Any high pressure spray injected into the skin must surgically removed within a few hours gangrene may Doctors unfamiliar with this type injury should reference a knowledgeable medical source. Such information available from Deere & Company Medical Department
Explosive release fluids from pressurized cooling system can cause serious
Shut f Only remove filler cap when cool enough touch with bare hands. Slowly loosen cap first stop relieve pressure before removing completely .
A void potentially toxic fumes and dust.
Hazardous fumes can generated when paint heated using a
Remove paint before heating:
• Remove paint a minimum 100 from area fected paint cannot wear approved respirator before heating
• you sand grind avoid breathing the W ear approved respirator
• you use solvent paint stripper , remove stripper with soap and water before welding. Remove solvent paint stripper containers and other flammable material from Allow fumes disperse least minutes before welding
not use a chlorinated solvent areas where welding will take
all work area that well ventilated carry toxic fumes and dust away .
Dispose paint and solvent properly
Remove paint before welding heating (see Safety Section this manual for more information paint removal and high - pressure
CAUTION: A void potentially toxic fumes and dust. Hazardous fumes can generated when paint heated using a all work outside a well ventilated Dispose paint and solvent properly . you sand grind paint, avoid breathing the dust wearing approved respirator . you use solvent paint stripper , remove with soap and water before Remove solvent paint stripper containers and other flammable material from area before welding. Allow fumes disperse least minutes before welding heating.
IMPORT ANT : W elding the engine NOT welding must performed the follow these
Disconnect the positive (+) battery cable(s) open battery (+) switch
Clear move any wiring harness sections away from the welding area.
W elding engine components not
IMPORT ANT : High currents electrostatic discharge into electronic components from welding may cause permanent damage.
Remove paint from the area welded and ground cable clamp
Disconnect the negative ( battery cable(s) open battery ( switch equipped.
Never connect the welder ground any engine component engine driven components that may connected the engine.
After reverse steps
High - pressure fluid remaining fuel lines can cause serious injury Only technicians familiar with this type system should perform Before disconnecting fuel any other components between the high - pressure fuel pump and nozzles engines with High - Pressure Common Rail (HPCR) fuel system, confirm that the fuel pressure
Inspect hydraulic hoses periodically – least once per year – for exposed wire braid any other signs wear
Replace worn damaged hose assemblies immediately with John Deere approved replacement
Escaping fluid under pressure can penetrate the skin causing serious injury
A void the hazard relieving pressure before disconnecting hydraulic other T ighten all connections before applying
Search for leaks with a piece Protect hands and body from high - pressure fluids.
with this type injury should reference a knowledgeable medical Such information available English from Deere & Company Medical Department Moline, Illinois, U.S.A., calling 1 - 800 - 822 - 8262
accident see a doctor immediately Any fluid injected into the skin must surgically removed within a few hours gangrene may Doctors unfamiliar
309 - 748 -
Flammable spray can generated heating near pressurized fluid resulting severe burns yourself and not heat using a torch near pressurized fluid lines other flammable materials. Pressurized lines can accidentally burst when heat goes beyond the immediate flame area.
The removal sulfur and other compounds Ultra - Low Sulfur Diesel (ULSD) fuel decreases its conductivity and increases its ability store a static
Refineries may have treated the fuel with a static dissipating additive. However , there are many factors that can reduce the fectiveness the additive over
Static charges can build ULSD fuel while flowing through fuel delivery Static electricity discharge when combustible vapors are present could result a fire explosion.
important ensure that the entire system used refuel your machine (fuel supply transfer transfer and others) properly grounded and bonded. Consult with your fuel fuel system supplier ensure that the delivery system compliance with fueling standards for proper grounding and bonding
When you work around not smoke work near heaters other fire hazards.
Store flammable fluids away from fire not incinerate puncture pressurized
Make sure machine clean and not store oily rags; they can ignite and burn spontaneously
prepared a fire
Keep a first aid kit and fire extinguisher handy
Keep emergency numbers for ambulance and fire department near your
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Battery gas can Keep sparks and flames away from Use a flashlight check battery electrolyte
Never check battery charge placing a metal object across the posts. Use a voltmeter hydrometer .
Always remove grounded ( battery clamp first and replace grounded clamp
Sulfuric acid battery electrolyte poisonous and strong enough burn skin, eat holes clothing, and cause blindness splashed into
A void hazards by:
• Filling batteries a well - ventilated area
• W earing eye protection and rubber gloves
• A voiding use air pressure clean batteries
• A voiding breathing fumes when electrolyte added
• A voiding spilling dripping electrolyte
• Using correct battery booster charger
acid spilled skin eyes:
Flush skin with water
Apply baking soda lime help neutralize the Flush eyes with water for Get medical attention immediately .
acid swallowed: not induce
Drink large amounts water milk, but not exceed 2 L qt.). Get medical attention immediately
W ARNING: Battery and related accessories contain lead and lead chemicals known the State California cause cancer and reproductive harm. W ash hands after handling.
Sulfuric acid battery electrolyte strong enough burn eat holes and cause blindness splashed into
A void the hazard by:
Filling batteries a well - ventilated
W earing eye protection and rubber
A voiding breathing fumes when electrolyte
A voiding spilling dripping
Use proper jump start procedure.
you spill acid yourself:
Flush your skin with water
Apply baking soda lime help neutralize the Flush your eyes with water for minutes. Get medical attention immediately .
acid swallowed:
not induce
Drink large amounts water milk, but not exceed 2 L
Get medical attention immediately
Keep lighted and open flame away from the top battery Battery gas can
Never check battery charge placing a metal object across the Use a volt - meter hydrometer
not charge a frozen battery; may W arm battery 16°C (60°F).
Before returning machine customer , make sure machine functioning properly , especially the safety
Install all guards and
Engine Serial Number Plate Information
The engine serial number plate located the left - hand side engine block next the oil cooler
IMPORT ANT : The engine serial number plate can easily destroyed. Remove the plate record the information elsewhere, before cleaning the
Engine Serial Number (A)
Each engine has a - digit John Deere engine serial number identifying the producing factory , engine model designation, and a six digit sequential number . The following example:
CD6068U123456
PE6068U123456
Factory Code Producing Engine
France
Factory Code Producing Engine
• T Mexico 6068 Number Cylinders and T otal Displacement
• 6068 6 liters
U Emission Certification
• U V
6068HFC09
• D Naturally aspirated
• T T urbocharged • A
T urbocharged and aftercooled, air - - coolant
• H T urbocharged and air - - air
• S T urbocharged and air - - sea water
F User T ype
• F OEM (John Deere Power Systems)
•
Other letters are used identify John Deere equipment manufacturing locations
C Industrial
• C Industrial • G
Gen
Engine Configuration
• PSS (Series T urbocharger , DOC/DPF and SCR)
JOHN DEERE
addition the serial number plate, engines have engine option code label fixed the rocker arm cover . These codes indicate which the engine options were
installed your engine the factory . When need parts service, furnish your authorized servicing dealer engine distributor with these
Depending the final engines can meet the emissions regulations according the Environmental Protection Agency (EP California Air Resources Board (CARB) and for the Directive 97/68/EC relating the measures against emissions particles and gaseous pollutant from internal combustion engines. Such engines are called “CER TIFIED” and receive emission label fixed the
Emissions regulations prohibit tampering with the emission - related components listed below which would render that component inoperative make any adjustment the engine beyond published illegal install any part component where the principle fect that component render inoperative any engine component device which would fect the conformance the emission regulations.
IMPORT ANT : T o summarize, illegal anything except return the engine its original published specifications.
List emission - related components:
NOTE: Not all applications will equipped with all the below emissions
• Charge air cooling system
• Crankcase ventilation system
• DOC and DPF
• Fuel dosing system
• Fuel injection system
• and associated wiring
• EGR system
• Exhaust system
• Intake manifold
• SCR system
• T urbochargers
Emissions Control System Certification Label
CAUTION: Statutes providing severe penalties for tampering with emissions controls may apply the user dealer
The A and/or CARB emissions warranties not apply the
The emissions warranty applies those engines marketed John Deere that have been certified the United States Environmental Protection Agency (EP and/or California Air Resources Board (CARB); and used the United States and Canada Non - road The presence emissions label like the one shown signifies that the engine has been certified with the A and/or The EP A and CARB warranties only apply new engines having the certification label fixed the engine and sold stated above the geographic The presence number the third line the label signifies that the engine has been certified with the European Union countries per Directive
Emission Control System(s) Laws
The U.S. A and California ARB prohibit the removal rendering inoperative any device element design installed engines/equipment compliance with applicable emission regulations prior after the sale and delivery the engines/equipment the ultimate purchaser
NOTE: The hp/kW rating the engine emissions certification label specifies the gross engine hp/kW , which flywheel power without most applications this will not the same rating the advertised vehicle hp/kW
Diesel exhaust fluid (DEF) a high purity liquid that injected into the exhaust system engines equipped with selective catalytic reduction (SCR) systems. Maintaining the purity DEF important avoid malfunctions the SCR Engines requiring DEF shall use a product that meets the requirements for aqueous urea solution (AUS 32) according ISO 22241 -
The use John Deere Diesel Exhaust Fluid John Deere Diesel Exhaust Fluid available your John Deere dealer a variety package sizes suit your operational
(API) Diesel Exhaust Fluid Certification Program the AdBlue ™ Diesel Exhaust Fluid Certification Look for the API certification symbol the AdBlue™ name the container
some DEF referred one more these names:
• Urea
• Aqueous Urea Solution
• AUS
• AdBlue™
• NOx Reduction Agent
• Catalyst Solution
John Deere Diesel Exhaust Fluid not available, use DEF that certified the American Petroleum Institute
AdBlue a trademark the German Association the Automotive Industry
CAUTION: A void contact with case contact, immediately flush eyes with large amounts water for a minimum minutes. Reference the Materials Safety Data Sheet (MSDS) for additional information.
not ingest DEF the event DEF contact a physician immediately . Reference the Materials Safety Data Sheet (MSDS) for additional information.
preferred store DEF out extreme ambient temperatures. DEF freezes 1 (12 °F). Exposure temperatures greater than (86 °F) can degrade DEF over
Dedicated DEF storage containers must sealed between uses prevent evaporation and Containers made polyethylene, polypropylene, stainless steel are recommended transport and store DEF
Ideal conditions for storage DEF are:
IMPORT ANT : unlawful tamper with remove any component the aftertreatment not use DEF that does not meet the required specifications operate the engine with DEF .
• Store temperatures between and (23 and °F)
• Store dedicated containers sealed avoid contamination and evaporation
Never attempt create DEF mixing agricultural grade urea with water . Agricultural grade urea does not meet the necessary specifications and can damage the aftertreatment system.
not add any chemicals additives DEF effort prevent freezing. Any chemicals additives added DEF can damage the aftertreatment system.
Never add water any other fluid place of, addition DEF . Operating with a modified DEF using unapproved DEF can damage the aftertreatment
Under these DEF expected remain useable for a minimum Storing DEF higher temperatures can reduce its useful life approximately 6 months for every 5 °F) temperature above (86 °F).
unsure how long under what conditions DEF has been test DEF See T esting Diesel Exhaust Fluid
Long - term storage the DEF tank (over months) not long - term storage necessary , test DEF prior operating See T esting Diesel Exhaust Fluid
recommended purchase DEF quantities that will consumed within
The following storage information provided for reference and used a guideline only
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CAUTION: A void contact with case contact, immediately flush eyes with large amounts water for a minimum minutes. Reference the Materials Safety Data Sheet (MSDS) for additional information.
not ingest DEF the event DEF contact a physician immediately . Reference the Materials Safety Data Sheet (MSDS) for additional information.
IMPORT ANT : Use only distilled water rinse components that are used deliver DEF T water can contaminate DEF . distilled water not available, rinse with clean tap water , then thoroughly rinse with ample amounts DEF .
DEF spilled contacts any surface other than the storage immediately clean the surface with clear water . DEF corrosive painted and unpainted metallic surfaces and can distort some plastic and rubber components.
and Use suitable containers transport and store DEF Containers made stainless steel are
A void prolonged contact with skin. case accidental wash skin immediately with soap and water
Keep anything used store dispense DEF clean dirt and W ash and rinse containers funnels thoroughly with distilled water remove contaminants.
DEF filled into engine fuel tank other fluid not operate engine until system properly purged DEF . Contact your John Deere dealer immediately determine how clean and purge the system.
Reasonable care should taken when refilling the DEF Ensure that the DEF tank cap area free debris before removing the Seal containers DEF between use prevent contamination and
A void splashing DEF and not allow DEF come into contact with skin, eyes, mouth.
unapproved such diesel fuel coolant added the DEF contact your John Deere dealer immediately determine how clean and purge the
water has been added the DEF tank, a tank cleaning necessary See Cleaning DEF T ank this After refilling the check the DEF See T esting Diesel Exhaust Fluid
The operator must maintain appropriate DEF levels all times. Check the DEF level daily and refill the tank The filling port identified a blue colored cap embossed with the DEF
DEF not harmful but DEF can corrosive materials such copper ,
IMPORT ANT : Using DEF with the correct concentration critical engine and aftertreatment system performance. Extended storage and other conditions can adversely alter the DEF
DEF quality draw a sample out the DEF tank storage tank into a clear container DEF must crystal clear with a light ammonia smell. DEF appears cloudy , has a colored has a profound ammonia likely not within DEF this condition should not Drain flush with distilled water and refill with new good DEF After refilling the check the DEF
suspicion the engine packaged DEF fluid has been contaminated with water
T approved tools are available through your John Deere dealer:
• JDG1 1594 Digital DEF digital tool providing easy read concentration measurement
• JDG1 1684 DEF - cost alternative tool providing analog reading
Follow instructions included with either tool obtain the
The correct DEF concentration urea. the DEF concentration not within specification, drain the DEF flush with distilled water and fill with new good DEF packaged DEF not within dispose DEF packages and replace with new good DEF
the DEF passes the visual and smell test, check the DEF concentration with a handheld refractometer calibrated measure DEF
DEF concentration should checked when the engine has been stored for extended periods, there
Although there little issue with minor spillage DEF the large amounts DEF should large spills occur , contact local environmental authorities for assistance with clean -
not dump substantial quantities DEF onto the ground send DEF wastewater treatment
a substantial quantity DEF not within specification, contact the DEF supplier for assistance with disposal.
Consult your local fuel distributor for properties the diesel fuel available your diesel fuels are blended satisfy the low temperature requirements the geographical area which they are
Sulfur content for Interim T ier Final T ier Stage III and Stage Engines
• Use ONL Y ultra low sulfur diesel (ULSD) fuel with a maximum mg/kg (15 ppm) sulfur
Sulfur Content for T ier 3 and Stage III A Engines
Diesel fuels specified 590 ASTM D975 are recommended. Renewable diesel fuel produced hydrotreating animal fats and vegetable oils basically identical petroleum diesel Renewable diesel that meets EN ASTM 15940 acceptable for use all percentage mixture
• Use diesel fuel with sulfur content less than 1000 mg/kg (1000 ppm) RECOMMENDED.
• Use diesel fuel with sulfur content mg/kg ppm) REDUCES the oil and filter change
all cases, the fuel shall meet the following properties:
• BEFORE using diesel fuel with sulfur content greater than 2000 mg/kg (2000 ppm), contact your John Deere dealer
Cetane number Cetane number greater than especially for temperatures below °F) elevations above 1675 m (5500
Cold Filter Plugging Point (CFPP) should least 5 °F) below the expected lowest temperature Cloud Point below the expected lowest ambient
Fuel lubricity should pass a maximum scar diameter measured ASTM D6079 ISO 12156A maximum scar diameter 0.45 preferred.
Diesel fuel quality and sulfur content must comply with all existing emissions regulations for the area which the engine NOT use diesel fuel with sulfur content greater than 000 mg/kg (10 000
NOT use E - Diesel (Diesel fuel and ethanol blend).
Use E - Diesel fuel any John Deere machine may void the machine warranty
CAUTION: A void severe injury death due the fire and explosion risk from using E - Diesel fuel.
Diesel fuel can the source performance other operational problems for many reasons. Some causes include poor lubricity , low cetane number , and a variety properties that cause fuel system These and others are referenced other sections this
T o optimize engine performance and reliability , closely follow recommendations fuel quality , and which are found elsewhere this
Sulfur Content for T ier 2 and Stage Engines
• Use diesel fuel with sulfur content less than 2000 mg/kg (2000 ppm)
• Use diesel fuel with sulfur content mg/kg ppm) REDUCES the oil and filter change interval.
• BEFORE using diesel fuel with sulfur content greater than 5000 mg/kg (5000 contact your John Deere dealer
Sulfur Content for Other Engines
• Use diesel fuel with sulfur content less than 5000 mg/kg (5000 ppm)
RECOMMENDED.
• Use diesel fuel with sulfur content greater than 5000 mg/kg (5000 ppm) REDUCES the oil and filter change
IMPORT ANT : not mix used diesel engine oil any other type lubricating oil with diesel fuel.
Improper fuel additive usage may cause damage fuel injection equipment diesel engines.
T o further aid maintaining performance and reliability the fuel John Deere has developed a family fuel additive products for most global
The primary products include Fuel - Protect Diesel Fuel
Conditioner (full feature conditioner winter and summer formulas) and Fuel - Protect Keep Clean (fuel injector deposit removal and A vailability these and other products varies See your local John Deere dealer for availability and additional information about fuel additives that might right for your
Most diesel fuels manufactured the United and the European Union have adequate lubricity ensure proper operation and durability fuel injection system However , diesel fuels manufactured some areas the world may lack the necessary lubricity
IMPORT ANT : Make sure the diesel fuel used your machine demonstrates good lubricity characteristics.
Fuel lubricity should pass a maximum scar diameter measured ASTM D6079 ISO 12156A maximum scar diameter
CAUTION: Reduce the risk Handle fuel carefully . NOT fill the fuel tank when engine running. NOT smoke while you fill the fuel tank service the fuel system.
Fill the fuel tank the end each operation prevent water condensation and freezing during cold weather
Keep all storage tanks full practical minimize condensation.
Ensure that all fuel tank caps and covers are installed properly prevent moisture from Monitor water content the fuel regularly
fuel low unknown lubricity add John Deere Fuel - Protect Diesel Fuel Conditioner (or equivalent) the specified Lubricity BioDiesel Fuel
Fuel lubricity can improve significantly with BioDiesel blends B20 (20% Further increase lubricity limited for BioDiesel blends greater than
When using biodiesel the fuel filter may require more frequent replacement due premature plugging.
Check engine oil level daily prior starting A rising oil level may indicate fuel dilution the engine
IMPORT ANT : The fuel tank vented through the filler cap. a new filler cap required, always replace with original vented
When fuel stored for extended period there a slow turnover add a fuel conditioner stabilize the fuel and prevent water condensation. Contact your fuel supplier John Deere dealer for recommendations.
BioDiesel fuel comprised mono - alkyl esters long chain fatty acids derived from vegetable oils animal fats. BioDiesel blends are BioDiesel mixed with petroleum diesel fuel a volume
The petroleum diesel portion all BioDiesel blends must meet the requirements ASTM D975 (US) 590 (EU) commercial
Before using fuel containing review the BioDiesel Use Requirements and Recommendations this Operator ’ s
Environmental laws and regulations can encourage prohibit the use Operators should consult with appropriate governmental authorities prior using
All John Deere Engines with Exhaust Filter (Released 201 1 and After)
While blends (B5) are preferred, BioDiesel concentrations a 20% blend (B20) petroleum diesel fuel can BioDiesel blends B20 can used ONL Y the BioDiesel (100% BioDiesel B100) meets ASTM equivalent specification. Expect a reduction power and a reduction fuel economy when using B20.
BioDiesel users the U.S. are strongly encouraged purchase BioDiesel blends from a - 9000 Certified Marketer and sourced from a - 9000 Accredited Producer (as certified the National BioDiesel Certified Marketers and Accredited Producers can found the following website: http://www
BioDiesel contains residual Ash levels exceeding the maximums allowed either ASTM D6751 EN14214 can result more rapid ash loading and require more frequent cleaning the Exhaust Filter (if
The fuel filter can require more frequent replacement, when using BioDiesel particularly switching from Check engine oil level daily prior starting
A rising oil level can indicate fuel dilution the engine BioDiesel blends B20 must used within days the date BioDiesel manufacture. BioDiesel blends above B20 must used within days from the date BioDiesel
BioDiesel concentrations above B20 can harm the s emission control systems and should not Risks but are not limited more frequent stationary regeneration, soot accumulation, and increased intervals for ash removal.
John Deere approved fuel which contain detergent and dispersant are required when using BioDiesel blends from B10—B20, and are recommended when using lower BioDiesel blends.
All John Deere Engines Excluding Exhaust Filter (Primarily Released Prior 2012)
When using BioDiesel blends the following must considered:
• Cold - weather flow degradation
• Stability and storage issues (moisture microbial growth)
• Possible filter restriction and plugging (usually a problem when first switching BioDiesel used engines)
• Possible fuel leakage through seals and hoses (primarily issue with older engines)
• Possible reduction service life engine components
While blends (B5) are BioDiesel concentrations a 20% blend (B20) petroleum diesel fuel can BioDiesel blends B20 can used ONL Y the BioDiesel (100% BioDiesel B100) meets ASTM D6751, 14214, equivalent specification. Expect a reduction power and a reduction fuel economy when using
These John Deere engines can operate BioDiesel blends above B20 (up 100% Operate levels above B20 ONL Y the BioDiesel permitted law and meets the 14214 specification (primarily available Engines operating BioDiesel blends above B20 might not fully comply with permitted all applicable emissions Expect a 12% reduction power and 18% reduction fuel economy when using 100% BioDiesel.
John Deere approved fuel which contain detergent and dispersant are required when using BioDiesel blends from B10—B20, and are recommended when using lower BioDiesel
Request a certificate analysis from your fuel distributor ensure that the fuel compliant with the specifications provided this Operator ’ s Manual.
Consult your John Deere dealer for approved fuel conditioners improve storage and performance with BioDiesel
The following must also considered using BioDiesel blends above B20:
• Possible coking blocked injector resulting power loss and engine misfire John Deere approved fuel conditioners are not used
• Possible crankcase oil dilution (requiring more frequent oil changes)
• Possible lacquering seizure internal components
• Possible formation sludge and sediments
• Possible thermal oxidation fuel elevated temperatures
• Possible compatibility issues with other materials (including copper , lead, zinc, tin, brass, and bronze) used fuel handling equipment
• Possible reduction water separator ficiency
• Possible damage paint exposed BioDiesel
• Possible corrosion fuel injection equipment
• Possible elastomeric seal and gasket material degradation (primarily issue with older engines)
• Possible high acid levels within fuel system
• Because BioDiesel blends above B20 contain more using blends above B20 can result more rapid
A fuel analysis program can help monitor the quality diesel The fuel analysis can provide critical data such cetane number , fuel sulfur water suitability for cold weather
ash loading and require more frequent cleaning the Exhaust Filter (if present)
IMPORT ANT : Raw pressed vegetable oils are NOT acceptable for use fuel any concentration John Deere Their use could cause engine failure.
cloud acid number , particulate contamination, and whether the fuel meets specification.
Contact your John Deere dealer for more information diesel fuel
manufacturing tolerances have significantly reduced capacities for debris and water .
The importance fuel filtration cannot overemphasized with modern fuel The combination increasingly restrictive emission regulations and more ficient engines requires fuel system operate much higher Higher pressures can only achieved using fuel injection components with very close tolerances. These close
John Deere brand fuel filters have been designed and produced specifically for John Deere
T o protect the engine from debris and water , always change engine fuel filters specified this
John Deere diesel engines are designed operate fectively cold weather
However , for fective starting and cold - weather a little extra care necessary The following information outlines steps that can minimize the fect that cold weather may have starting and operation your See your John Deere dealer for additional information and local availability cold - weather aids.
When temperatures fall below 0 (32 °F), winter grade fuel 1 - D North America) best suited for cold - weather Winter grade fuel has a lower cloud point and a lower pour
Cloud point the temperature which wax begins form the This wax causes fuel filters Pour point the lowest temperature which movement the fuel
Diesel Fuel Flow Additive
Use John Deere Fuel - Protect Diesel Fuel Conditioner (winter which contains anti - gel chemistry , equivalent fuel conditioner treat non - winter grade fuel 2 - D North America) during the cold - weather season. This generally extends operability about (18 °F) below the fuel cloud For operability even lower use winter grade
IMPORT ANT : T reat fuel when outside temperature drops below 0 (32 °F). For best results, use with untreated fuel. Follow all recommended instructions
When operating with BioDiesel wax formation can occur warmer Begin using John Deere Fuel - Protect Diesel Fuel Conditioner (winter formula) 5 (41 °F) treat BioDiesel fuels during the cold - weather Use lower blends temperatures below 0 (32 °F). Use only winter grade petroleum diesel fuel temperatures below - (14 °F).
NOTE: average, winter grade diesel fuel has a lower Btu (heat content) rating. Using winter grade fuel may reduce power and fuel efficiency , but should not cause any other engine performance Check the grade fuel being used before troubleshooting for low - power complaints cold - weather
Air Intake Heater
air intake heater available option for some engines aid cold weather
Use solid winterfronts not recommended with any John Deere engine. Their use can result excessive engine coolant, oil, and charge air This can lead reduced engine loss power and poor fuel economy Winterfronts may also put abnormal stress fan and fan drive components potentially causing premature
Ether ether port the intake available aid cold weather
CAUTION: Ether highly flammable. not use ether when starting engine equipped with glow plugs air intake heater
Coolant Heater
engine block heater (coolant heater) available option aid cold weather starting.
Seasonal V iscosity Oil and Proper Coolant Concentration
winterfronts are used, they should never totally close f the grill frontal Approximately 25% area the center the grill should remain open all time should the air blockage device applied directly the radiator
equipped with a thermostatically controlled radiator shutter this system should regulated such a way that the shutters are completely open the time the coolant reaches (200 °F) prevent excessive intake manifold Manually controlled systems are not
Use seasonal grade viscosity engine oil based the expected air temperature range between oil changes and a proper concentration low silicate antifreeze (See DIESEL ENGINE OIL and ENGINE COOLANT requirements this section.)
air - - air aftercooling used, the shutters must completely open the time the intake manifold air temperature reaches the maximum allowable temperature out the charge air cooler
For more information, see your John Deere dealer .
New engines are filled the factory with John Deere
Break - Plus ™ Engine During the breakadd John Deere BreakPlus™ Engine Oil, needed maintain the specified oil
• API Service Category - 4
• API Service Category - 4
• ACEA Oil Sequence
• ACEA Oil Sequence
Operate the engine under various particularly heavy loads with minimal help seat engine components properly
During the initial operation a new rebuilt change the oil and filter between a minimum 100 hours and maximum equal the interval specified for John Deere Plus50™
After engine overhaul, fill the engine with John Deere BreakPlus™ Engine
John Deere BreakPlus™ Engine Oil not use SAE 10W - viscosity grade diesel engine oil meeting one the following:
Break - Plus a trademark Deere & Company Plus - a trademark Deere & Company
one these oils used during the initial operation a new rebuilt change the oil and filter between a minimum 100 hours and a maximum 250
IMPORT ANT : not use any other engine oils during the initial break - a new rebuilt
John Deere BreakPlus™ Engine Oil can used for all John Deere diesel engines all emission certification
After the break - use John Deere Plus™ other diesel engine oil recommended this
Use oil viscosity based the expected air temperature range during the period between oil
John Deere ™ the recommended engine oil.
Extended service intervals may apply when John Deere Plus50™ engine oil Refer the engine oil drain interval table and consult your John Deere dealer for more
John Deere Plus50™ engine oil not available, engine oil meeting one more the following may used:
• API Service Category - 4
• API Service Category - 4
• ACEA Oil Sequence
• ACEA Oil Sequence
NOT use engine oil containing more than sulfated sulfur
Multi - viscosity diesel engine oils are preferred.
Diesel fuel quality and fuel sulfur content must comply with all existing emissions regulations for the area which the engine
IMPORT ANT : Use only ultra low sulfur diesel (ULSD) fuel with a maximum sulfur content mg/kg (15
Plus - a trademark Deere & Company
Recommended oil and filter service intervals are based a combination oil pan capacity , type engine oil and filter and sulfur content the diesel Actual service intervals also depend operation and maintenance practices.
Approved Oil T ypes
• John Deere Plus™
• include API - API - ACEA and ACEA
Use oil analysis evaluate the condition the oil and aid selection the proper oil and filter service Contact your John Deere dealer for more information engine oil
Change the oil and oil filter least once every months even the hours operation are fewer than the otherwise recommended service
Diesel fuel sulfur content fects engine oil and filter service intervals. Higher fuel sulfur levels reduce oil and filter service
Use diesel fuel with sulfur content less than mg/kg (15 ppm)
Engine operation high altitude decreases oil change
See Diesel Engine Oil Service Interval for Operation High Altitude for additional
IMPORT ANT : T o avoid engine damage:
NOTE: The 500 hour extended oil and filter change interval only allowed all the following conditions are met:
• Engine equipped with extended drain interval oil pan
• Use diesel fuel with sulfur content less than mg/kg (15 ppm)
• Use John Deere Plus50™ oil
• Use approved John Deere oil filter
Engine Oil and Filter Service Intervals
Oil Pan Size (L/kW)
Greater than equal 0.10
Greater than equal 0.12
John Deere Plus50™ 375 hours 500 hours
Other Oils 250 hours 250 hours
Oil analysis may extend the service interval a maximum not exceed the interval Plus50™ Oil analysis means taking a series oil samples hour increments beyond the normal service interval until either the data indicates the end useful oil life the maximum service interval John Deere Plus - oils
• Reduce oil and filter service intervals 50% when using biodiesel blends greater than Oil analysis may allow longer service interval.
• Use only approved oil types.
See applicable operator ’ s manual for service intervals.
avoid mixing dif ferent brands types
Oil manufacturers blend additives their oils meet certain specifications and performance
Mixing dif ferent oils can interfere with the proper functioning these additives and degrade lubricant
Consult your John Deere dealer obtain specific information and recommendations.
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Conditions certain geographical areas may require lubricant recommendations dif ferent from those printed this manual.
Some John Deere brand coolants and lubricants may not available your
Consult your John Deere dealer obtain information and recommendations.
Synthetic lubricants may used they meet the performance requirements shown this
Y our equipment can operate top ficiency only when clean lubricants are
Use clean containers handle all
The temperature limits and service intervals shown this manual apply both conventional and synthetic
- refined base stock products may used the finished lubricant meets the performance
Make certain that all containers are properly marked identify their
Store lubricants and containers area protected from and other Store containers their side avoid water and dirt accumulation.
Properly dispose all old containers and any residual lubricant they may
Filtration oils critically important for proper operation and John Deere brand oil filters have been designed and produced specifically for John Deere applications.
the bond between the filter media and the element end fatigue life the canister (if and pressure capability the filter Non - John Deere branded oil filters might not meet these key John Deere
Always change oil filters regularly specified this
John Deere filters adhere engineering specifications for quality the filter filter ficiency strength
The following pre - mix engine coolants are preferred:
• John Deere COOL - GARD ™
• John Deere COOL - GARD
COOL - GARD pre - mix coolant available several concentrations with dif ferent freeze protection limits shown the following table.
COOL - GARD pre - mix Freeze Protection Limit
COOL - GARD 20/80 - 9 (16 °F)
COOL - GARD 30/70°F)
COOL - GARD 50/50 - (°F)
COOL - GARD 55/45 - (°F)
COOL - GARD 60/40 - (°F)
COOL - GARD 60/40 - (°F)
Not all COOL - GARD pre - mix products are available all
Use COOL - GARD when a non - toxic coolant formulation
• Coolant concentrate meeting ASTM D6210 requirements a mixture concentrate with quality water
coolant meeting one these specifications use a coolant concentrate pre - mix coolant that has a minimum the following chemical and physical properties:
• Provides cylinder liner cavitation protection according either the John Deere Cavitation T est Method a fleet study run above 60% load capacity
• formulated with a nitrite - free additive package
• Protects the cooling system metals (cast iron, aluminum alloys, and copper alloys such brass) from corrosion
W ater quality important the performance the cooling demineralized water recommended for mixing with ethylene glycol and propylene glycol base engine coolant
Drain and flush the cooling system and refill with fresh coolant the indicated interval, which varies with the coolant
The following engine coolant also recommended:
• John Deere COOL - GARD Concentrate a mixture concentrate with quality water .
IMPORT ANT : When mixing coolant concentrate with water , not use less than 40% greater than 60% concentration coolant. Less than 40% gives inadequate additives for corrosion protection. Greater than 60% can result coolant gelation and cooling system problems.
When COOL - GARD COOL - GARD the drain interval 6 years 6000 hours a coolant other than COOL - GARD COOL - GARD reduce the drain interval 2 years 2000 hours
IMPORT ANT : not use cooling system sealing additives antifreeze that contains sealing additives.
Other ethylene glycol propylene glycol base coolants may used they meet the following specification:
• Pre - mix coolant meeting ASTM D6210 requirements
not mix ethylene glycol and propylene glycol base coolants. not use coolants that contain nitrites.
Engine coolants are a combination three chemical components: ethylene glycol (EG) propylene glycol (PG) antifreeze, inhibiting coolant additives, and quality water
Freeze Protection
The relative concentrations glycol and water the engine coolant determine its freeze protection limit.
W ater quality important the performance the cooling demineralized water recommended for mixing with ethylene glycol and propylene glycol base engine coolant concentrate.
All water used the cooling system should meet the following minimum specifications for quality:
Chlorides
Sulfates
<40 mg/L
<100 mg/L
T otal solids <340 mg/L
T otal dissolved I hardness <170 mg/L 5.5—9.0
NOT use a coolant - water mixture greater than 60% ethylene glycol 60% propylene
IMPORT ANT : not use bottled drinking water because often contains higher concentrations total dissolved solids.
John Deere engines are designed operate using recommended engine coolants.
Always use a recommended engine even when operating geographical areas where freeze protection not
IMPORT ANT : W ater may used coolant emergency situations only
Foaming, hot surface aluminum and iron corrosion, scaling, and cavitation occur when water used the coolant, even when coolant conditioners are
Drain cooling system and refill with recommended engine coolant soon possible.
The use a handheld coolant refractometer the and most accurate method determine coolant freeze This method more accurate than a test strip a float - type hydrometer which can produce poor results.
A coolant refractometer available through your John Deere dealer under the SER VICEGARD ™ tool Part number 75240 provides economical solution accurate freeze point determination the
T o use this tool:
Allow cooling system cool ambient
Open radiator cap expose
With the included dropper , collect a small coolant
Open the lid the refractometer , place one drop coolant the window and close the
Look through the eyepiece and focus necessary
Record the listed freeze point for the type coolant (ethylene glycol coolant propylene glycol) being tested.
SER VICEGARD a trademark Deere & Company
Improperly disposing engine coolant can threaten the environment and ecology
Use leakproof containers when draining not use food beverage containers that may mislead someone into drinking from them.
not pour waste onto the down a into any water
Inquire the proper way recycle dispose waste from your local environmental recycling center , from your John Deere engine distributor servicing dealer
Group 010 —Engine Rebuild
Check and Service Cooling
System - 010 - 1
Check Air Intake System - 010 - 1
Check Electrical System - 010 - 2
Check Exhaust System .
. - 010 - 2
Clean Engine - 010 - 3
Disconnect T urbocharger Oil
Supply Line - 010 - 4
Engine Assembly Sequence - 010 - 5
Engine Break - Guidelines - 010 - 6
Engine Disassembly Sequence . . . .
General T une -
- 010 - 8
tions - 010 - 9
Engine Repair Stand - 010 - 9
Install JT07268 Engine Mounting Adapter D05223ST Repair Stand .
- 010 -
Install JDG1 1853 Engine Mounting Adapter D05223ST Repair Stand - 010 -
Install Lift Straps - 010 - 1 1
Lifting Procedure - 010 -
Mount Engine Repair Stand Using JT07268
- 010 -
Mount Engine Repair Stand Using JDG1 1853 - 010Engine Overhaul Guidelines - 010 -
Safety Precautions - 010 -
Sealant Application Guidelines
- 010 -
Group 020 —Cylinder Head and V alve Repair and Adjustment
Cylinder Block T Deck Cleaning and Inspection - 020 - 1
Cylinder Head Cleaning and Inspection
. - 020 - 1
Cylinder Head Flatness Check - 020 - 1
Cylinder Head Installation - 020 - 2
Cylinder Head Removal - 020 - 5
Cylinder Head Thickness Measurement
. - 020 - 6
Cylinder Head Gasket Inspection - 020 - 7
Fuel Injector Sleeves
Installation - 020 - 8
Fuel Injector Sleeves Removal - 020 - 9
Glow Plug Installation - 020Glow Plug Removal
- 020 - 1 1
Glow Plug Bore Cleaning and Inspection - 020 - 1 1
Glow Plug Heat Shield Installation - 020Glow Plug Heat Shield Removal - 020 -
Glow Plug Wiring Harness
- 020 -
Glow Plug Wiring Harness Removal - 020Crankcase Pressure Relief V alve Maintenance - 020Push Rod Cleaning and Inspection - 020 -
Rocker Arm Carrier Inspection - 020 -
Rocker Arm Cover Inspection - 020Rocker Arm Cover Installation - 020Rocker Arm Cover Removal - 020Rocker Arm Cover V ent T ube Inspection
- 020 -
Rocker Arm Shaft Assembly Assemble - 020Rocker Arm Shaft Assembly
- 020Rocker Arm Shaft Carrier Assembly Installation
- 020Rocker Arm Shaft Carrier Assembly Removal - 020 -
Rocker Arm Shaft Assembly T ear Down - 020V alve Cleaning and Inspection .
- 020 -
. - 020V alve Clearance Adjustment
alve Grinding - 020 -
alve Measurement - 020 -
alve Recess Measurement - 020 -
alve Assembly Installation - 020V alve Assembly Removal
- 020V alve Bridges, V alve Retainer , and V alve Retainer Locks Inspection - 020V alve Guide Cleaning and Measurement - 020V alve Guide Installation .
- 020V alve Guide Removal
- 020V alve Seat Cleaning and Inspection - 020V alve Seat Grinding and Measurement - 020V alve Seat Inserts Installation - 020V alve Seat Inserts Removal
- 020V alve Spring Inspection and Measurement - 020Continued next page
Group 030 Block, Liners, Pistons, and Rods Repair and Adjustment
Connecting Rod
Center - - Center Bore
Measurement - 030 - 1
Connecting Rod and Cap
Inspection - 030 - 1
Connecting Rod Bearing
Inspection and Measurement - 030 - 2
Connecting Rod Bearing
Inspection and Measurement (Rod and Crankshaft Engine) - 030 - 3
Connecting Rod Cap Screw T orque Procedure - 030 - 4
Connecting Rod Pin Bore
Cleaning and Inspection - 030 - 5
Connecting Rod Piston Pin Bushing
Installation - 030 - 5
Connecting Rod Piston Pin Bushing
Removal - 030 - 6
Cylinder Block Cleaning and Inspection
Cylinder Block Components
- 030 - 7
Measurement - 030 - 1 1
Cylinder Block O - ring
Installation - 030 -
Cylinder Block, Piston, and Rod T roubleshooting Guide
- 030 -
Cylinder Liner Cleaning - 030 -
Cylinder Liner Flange
Measurement - 030 -
Cylinder Liner Installation - 030 -
Cylinder Liner Removal .
Cylinder Liner Standout
030 -
Measurement - 030 -
Cylinder Liner V isual Inspection - 030 -
Cylinder Liner O - ring Bore Cleaning
Cylinder Liner Packing Installation
Piston Cleaning
Piston Inspection
Piston and Connecting Rod
Assembly Installation
Piston and Connecting Rod
030 -
030 -
030 -
030 -
030 -
Assembly Removal - 030 -
Piston and Connecting Rod
Assembly Assemble - 030 -
Piston and Connecting Rod
Assembly T ear Down
Piston Spray Jet Cleaning and Inspection
030 -
030 -
Piston Spray Jet Installation - 030 -
Piston Spray Jet Removal - 030 -
Piston Height Measurement - 030Page
- 030 -
Piston Pin and Piston Pin Bore Inspection - 030Piston Pin and Connecting Rod Bushing Inspection - 030Piston Protrusion Measurement
Piston Rings Installation - 030Piston Skirt Measurement - 030Piston Liner Clearance Check - 030 -
Group 040 Main Bearings, Flywheel Repair , and Adjustment
Crankshaft End Play Check - 040 - 1
Crankshaft Grinding Specs - 040 - 1
Crankshaft Inspection - 040 - 2
Crankshaft Installation - 040 - 2
Crankshaft Removal . . . . . .
. - 040 - 3
Crankshaft Gear Installation - 040 - 4
Crankshaft Gear Removal - 040 - 5
Crankshaft Grinding Guidelines - 040 - 5
Crankshaft Journals and Bearing Assembly Measurement
- 040 - 6
Crankshaft Main Bearing Oil Clearance Check - 040 - 7
Crankshaft Main Bearing Cap Line Bore Specs - 040 - 7
Crankshaft Main Bearing Caps Installation
- 040 - 8
Crankshaft Main Bearing Caps Removal - 040 -
Crankshaft Rear Oil Seal
Installation - 040 - 1 1
Crankshaft Rear Oil Seal Removal
Crankshaft Thrust Bearing
- 040 -
Inspection - 040 -
Crankshaft T iming Wheel
Installation - 040Crankshaft T iming Wheel
Removal
Crankshaft Unitized Front Oil Seal
- 040 -
Installation - 040 -
Crankshaft Unitized Front Oil Seal
Removal - 040 -
Crankshaft Unitized Rear Oil Seal
Installation
Crankshaft Unitized Rear Oil Seal
- 040 -
Removal - 040 -
Crankshaft V ibration Damper
Inspection - 040Crankshaft V ibration Damper
Installation
Crankshaft V ibration Damper
- 040 -
Removal - 040 -
Crankshaft V iscous Damper
Inspection - 040Continued next page
Crankshaft V iscous Damper
Installation - 040 -
Crankshaft V iscous Damper Removal - 040 -
Flywheel Inspection
Flywheel Installation
- 040 -
040 -
Flywheel Removal - 040 -
Flywheel Face Flatness Check - 040 -
Flywheel Housing Installation - 040 -
Flywheel Housing Removal - 040 -
Flywheel Pilot Bearing Bore Concentricity Check
Flywheel Ring Gear
040 -
Installation - 040 -
Flywheel Ring Gear Removal - 040 -
Open Crankcase V entilation
System Inspection - 040 -
Open Crankcase V entilation
System Installation (Standard System) - 040 -
Open Crankcase V entilation
System Removal (Standard System) - 040 -
Open Crankcase V entilation
System Installation (High Capacity System) - 040 -
Open Crankcase V entilation
System Removal (High Capacity System) - 040 -
Group 050 and T iming Gear T rain Repair and Adjustment
Camshaft Check End Play - 050 - 1
Camshaft Inspection - 050 - 1
Camshaft Installation - 050 - 2
Camshaft Removal
Camshaft Bushing Installation
- 050 - 3
- 050 - 4
Camshaft Bushing Journal Measurement - 050 - 4
Camshaft Bushing Removal - 050 - 5
Camshaft and Upper Idler Gear T iming .
- 050 - 6
Camshaft Follower Inspection and Measurement - 050 - 8
Camshaft Follower Installation - 050 - 9
Camshaft Follower Removal - 050 - 9
Camshaft Gear Inspection - 050 -
Camshaft Gear Installation
Camshaft Gear Removal
- 050 -
- 050 -
Camshaft Gear - Driven Auxiliary Drive Installation - 050 - 1 1
Camshaft Gear - Driven Auxiliary Drive Removal - 050 -
Camshaft Journal Measurement
- 050 -
Camshaft Lobe Lift Measurement - 050 -
Page
Camshaft Thrust Plate Measure Clearance and Thickness - 050Front Plate Installation - 050Front Plate Removal - 050Idler Gears Measure End Play .
Lower Idler Gear Inspection . .
- 050 -
. - 050 -
Lower Idler Gear Installation - 050Lower Idler Gear Removal - 050T iming Gear Cover Installation - 050T iming Gear Cover Removal - 050T iming Gears Check Backlash . . . . .
Upper Idler Gear Inspection . . .
. . - 050 -
- 050 -
Upper Idler Gear Installation - 050Upper Idler Gear Removal - 050 -
Group 060 System Repair and Adjustment
Dipstick T ube and Dipstick Inspection
- 060 - 1
Dipstick T ube and Dipstick Installation - 060 - 2 Dipstick T ube and Dipstick
Coolant Pump Assembly
Removal - 070 - 8
Coolant Pump Inlet Elbow
Installation - 070 - 9
Coolant Pump Inlet Elbow
Removal .
. - 070 - 9
Cooling System Air Bleeding - 070 -
Fan (Fixed Speed Fan)
Inspection and Installation - 070 - 1 1
Fan (Fixed Speed Fan)
Removal
Fan ariable Speed Fan)
- 070 - 1 1
Inspection and Installation - 070 -
Fan ariable Speed Fan)
Removal - 070 -
Fan Drive Adapter Installation - 070 -
Fan Drive Adapter Removal - 070 -
Fan Drive Assembly Assemble .
. . - 070 -
Fan Drive Assembly
Installation - 070 -
Fan Drive Assembly Removal - 070 -
Fan Drive Pulley Installation - 070 -
Fan Drive Pulley Removal - 070 -
Thermostat Installation
- 070 -
Thermostat Removal - 070 -
Thermostat Housing Assemble - 070 -
Thermostat Housing Removal - 070 -
Thermostat Housing T ear Down - 070 -
Group 080 Intake and Exhaust System
EGR Cooler Coolant Supply Line (Dual T urbocharger) Removal - 080 -
EGR Cooler Gas Inlet Pipe (Dual T urbocharger) Installation .
- 080 -
EGR Cooler Gas Inlet Pipe (Dual T urbocharger) Removal - 080 -
EGR Cooler Gas Outlet Pipe (Dual T urbocharger) Installation - 080 -
EGR Cooler Gas Outlet Pipe (Dual T urbocharger) Removal .
- 080 -
EGR Flow V enturi Assembly (Dual T urbocharger) Installation - 080 -
EGR Flow V enturi Assembly (Dual T urbocharger) Removal - 080 -
EGR Flow V enturi Coolant Return Line (Dual T urbocharger)
Installation
EGR Flow V enturi Coolant Return Line (Dual T urbocharger)
- 080 -
Removal - 080 -
EGR Flow V enturi Coolant Supply Line (Dual T urbocharger)
Installation
EGR Flow V enturi Coolant Supply Line (Dual T urbocharger)
- 080 -
Removal - 080 -
EGR Flow V enturi Inlet Pipe (Dual T urbocharger) Installation - 080 -
EGR Flow V enturi Inlet Pipe (Dual T urbocharger) Removal - 080 -
Repair and Adjustment - Dual T urbocharger
Air Inlet Installation (High Capacity OCV) - 080 - 1
Air Inlet Removal (High Capacity OCV)
- 080 - 3
EGR Cooler Straps (Dual T urbocharger) Installation - 080 - 3
EGR Cooler Straps (Dual T urbocharger) Removal - 080 - 4
EGR Cooler Assembly (Dual T urbocharger) Installation .
- 080 - 4
EGR Cooler Assembly (Dual T urbocharger) Removal - 080 - 4
EGR Cooler Bracket Installation - 080 - 5
EGR Cooler Bracket Removal - 080 - 9
EGR Cooler Coolant Return Line (Dual T urbocharger) Installation - 080 -
EGR Cooler Coolant Return Line (Dual T urbocharger)
Removal - 080 -
EGR Cooler Coolant Supply Line (Dual T urbocharger)
Installation - 080Page
EGR V alve Bracket (Dual T urbocharger) Installation - 080 -
EGR V alve Bracket (Dual T urbocharger) Removal - 080 -
Exhaust Gas Recirculation (Dual T urbocharger) Component V iew - 080 -
Exhaust Manifold (Dual T urbocharger) Installation - 080Exhaust Manifold (Dual T urbocharger) Removal and Inspection
Sliding Element Bracket
- 080 -
Installation - 080Sliding Element Bracket
Removal - 080 -
Extending T urbocharger Life (Dual T urbocharger)
Fixed T urbocharger Oil Drain Line (Dual T urbocharger)
- 080 -
Installation - 080 -
Fixed T urbocharger Oil Drain Line (Dual T urbocharger)
Removal
- 080 -
Intake Manifold (Dual T urbocharger) Installation - 080Continued next
Intake Manifold (Dual T urbocharger) Removal and Inspection - 080 -
T urbocharger (Dual T urbocharger)
Break -
- 080 -
T urbocharger (Dual T urbocharger)
Failure Analysis - 080 -
T urbocharger (Dual T urbocharger)
Inspection - 080 -
T urbocharger Compression
Housing (Dual T urbocharger)
Orientation .
T urbocharger Compressor
Interstage (Dual T urbocharger)
- 080 -
Installation - 080 -
T urbocharger Compressor
Interstage (Dual T urbocharger)
Removal
T urbocharger Coolant Supply
Line and Return Line (Dual
- 080 -
T urbocharger) Installation - 080 -
T urbocharger Coolant Supply
Line and Return Line (Dual
T urbocharger) Removal
- 080 -
T urbocharger , Fixed (Dual T urbocharger) Installation - 080 -
T urbocharger , Fixed (Dual T urbocharger) Removal - 080 -
T urbocharger Oil Supply Lines (Dual T urbocharger)
Installation - 080T urbocharger Oil Supply Lines (Dual T urbocharger)
Removal - 080 -
T urbocharger T urbine Interstage (Dual T urbocharger)
Installation
T urbocharger T urbine Interstage (Dual T urbocharger)
- 080 -
Removal - 080 -
T urbocharger VGT Adjustment
Ring Installation
T urbocharger VGT Adjustment
- 080 -
Ring Removal - 080 -
T urbocharger , VGT (Dual T urbocharger) Installation - 080 -
T urbocharger , VGT (Dual T urbocharger) Removal .
- 080 -
VGT Actuator (Dual T urbocharger) Installation - 080 -
VGT Actuator (Dual T urbocharger) Removal - 080 -
VGT Actuator Linkage (Dual T urbocharger) Installation
- 080VGT Actuator Linkage (Dual T urbocharger) Removal - 080 -
VGT Oil Drain Line (Dual T urbocharger) Installation - 080 -
VGT Oil Drain Line (Dual T urbocharger) Removal - 080VGT Speed Sensor (Dual T urbocharger) Installation - 080 -
VGT Speed Sensor (Dual T urbocharger) Removal . . .
- 080 -
Group 085 —Air Intake and Exhaust System
Repair and Adjustment - Single T urbocharger
Air Inlet Installation (Standard Capacity OCV) .
. - 085 - 1
Air Inlet Removal (Standard Capacity OCV) - 085 - 2
EGR Cooler Assembly (Single T urbocharger) Installation - 085 - 3
EGR Cooler Assembly (Single T urbocharger) Removal . .
- 085 - 4
EGR Cooler Coolant Return Line (Single T urbocharger) Installation - 085 - 5
EGR Cooler Coolant Return Line (Single T urbocharger) Removal
EGR Cooler Coolant Supply Line (Single T urbocharger)
- 085 - 5
Installation - 085 - 5
EGR Cooler Coolant Supply Line (Single T urbocharger)
Removal
- 085 - 5
EGR Cooler Gas Inlet Pipe (Single T urbocharger) Installation - 085 - 6
EGR Cooler Gas Inlet Pipe (Single T urbocharger) Removal - 085 - 7
EGR Cooler Gas Outlet Pipe (Single T urbocharger)
Installation
EGR Cooler Gas Outlet Pipe (Single T urbocharger)
- 085 - 8
Removal - 085 - 9
EGR Flow V enturi Assembly (Single T urbocharger)
Installation
EGR Flow V enturi Assembly (Single T urbocharger)
- 085 - 9
Removal - 085 - 9
EGR Flow V enturi Coolant Return Line (Single T urbocharger)
Installation
EGR Flow V enturi Coolant Return Line (Single T urbocharger)
- 085 -
Removal - 085 - 1 1
EGR Flow V enturi Coolant Supply Line (Single T urbocharger)
Installation
EGR Flow V enturi Coolant Supply Line (Single T urbocharger)
- 085 - 1 1
Removal - 085 - 1 1
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EGR Flow V enturi Inlet Pipe (Single T urbocharger) Installation - 085 -
EGR Flow V enturi Inlet Pipe (Single T urbocharger) Removal - 085 -
Exhaust Gas Recirculation (Single T urbocharger) Component
V iew - 085 -
Exhaust Manifold (Single T urbocharger) Installation - 085 -
Exhaust Manifold (Single T urbocharger) Removal and Inspection .
Extending T urbocharger Life
VGT T urbocharger Oil Supply
Lines (Single T urbocharger)
Installation - 085 -
VGT T urbocharger Oil Supply Lines (Single T urbocharger)
Removal . .
- 085 -
Group 090 —Electronic Fuel System Repair and Adjustment
EGR Cooler Bracket Fuel Component Assembly .
- 085 -
(Single T urbocharger) - 085 -
Intake Manifold (Single T urbocharger) Installation - 085 -
Intake Manifold (Single T urbocharger) Removal and Inspection - 085 -
T urbocharger (Single T urbocharger) Break - - 085 -
T urbocharger (Single T urbocharger) Failure
Analysis
- 090 - 1
Electronic Injectors Cleaning (In Engine) - 090 - 2
Electronic Injectors Installation - 090 - 3 Electronic Injectors Removal - 090
085 -
T urbocharger (Single T urbocharger) Inspection - 085 -
T urbocharger Compression
Housing (Single T urbocharger)
Orientation - 085 -
VGT Actuator (Single T urbocharger) Installation - 085VGT Actuator (Single
T urbocharger) Removal - 085VGT Actuator Linkage (Single
T urbocharger) Installation - 085VGT Actuator Linkage (Single T urbocharger) Removal
VGT Coolant Supply Line and Return Line (Single
- 085 -
T urbocharger) Installation - 085VGT Coolant Supply Line and Return Line (Single T urbocharger) Removal
- 085 -
VGT Oil Drain Line (Single T urbocharger) Installation - 085 -
VGT Oil Drain Line (Single T urbocharger) Removal - 085 -
VGT Speed Sensor (Single T urbocharger) Installation
- 085 -
VGT Speed Sensor (Single T urbocharger) Removal - 085 -
VGT T urbocharger Assembly (Single T urbocharger)
Installation .
VGT T urbocharger Assembly (Single T urbocharger)
- 085 -
Removal - 085 -
Group 100 Starting and Charging Systems Repair and Adjustment
Alternator
Group 1 Engine Control Repair and Adjustment
EGR
EGR
Repair DEUTSCH Connectors
Repair MetriPack™ Connectors - 1 -
Repair T yco HDSCS Connectors - 1 -
WEA
Group 1 Dosing Aftertreatment Devices Repair and Adjustment
Diesel Particulate Filter Maintenance and Service - 1 - 1
Diesel Oxidation Catalyst (DOC) Cleaning
DPF Dif ferential Pressure Sensor Manifold Installation - 1 - 3
DPF
DEF T ank Heater Coolant Control
V alve Solenoid Removal - 1 -
Selective Catalyst Reduction (SCR)
Cleaning and Inspection - 1 -
Selective Catalyst Reduction (SCR) Handling
- 1 -
Selective Catalyst Reduction Brackets and Piping Installation - 1 -
Selective Catalyst Reduction (SCR), Brackets and Piping Removal
- 1 -
Remove debris that has accumulated near radiator
V isually inspect entire cooling system and all components for leaks Repair replace necessary
Drain coolant.
Remove and check See Thermostat T esting Section Group
Refill
Run engine until reaches operating temperature. Check entire cooling system for
After engine check coolant
Check system for holding pressure. See Cooling System Pressure T est Section Group
Replace air cleaner primary filter element. (See manual.) Replace secondary element primary element has holes
Check condition air intake hoses and The Final T ier 4 engine has extensive air intake and exhaust system with numerous joints. Replace hoses and/or pipes that are cracked, split, otherwise poor
Check hose clamps (A) for Replace clamps that cannot properly This will help prevent dust from entering the air intake system which could cause serious engine damage.
CAUTION: Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight check battery electrolyte level.
Never check battery charge placing a metal object across the posts. Use a voltmeter hydrometer . Always remove grounded ( battery clamp first and replace
W ARNING: Battery and related accessories contain lead and lead chemicals known the State California cause cancer and reproductive harm. W ash hands after handling.
Clean batteries and cables with damp corrosion remove and wash terminals with a solution ammonia baking soda water Then flush area with clean water
Coat battery terminals and connectors with petroleum jelly mixed with baking soda retard T est batteries are not near full try find out why .
low - maintenance check level electrolyte each cell each battery Level should bottom filler water use mineral - free water
Inspect exhaust system for leaks
Check exhaust manifold (A) for cracks and gasket Repair replace necessary
Check that turbocharger - - exhaust gas recirculation (EGR) cooler etc, clamps are securely tightened and not
Check exhaust system for evidence oil
Oil exhaust system may caused excessive valve stem - - guide clearance excessive light load engine
water must added batteries more often than every 250 alternator may
NOTE: W ater cannot added maintenancefree batteries appear either undercharged check alternator and charging
Check tension drive belts. See Belt T ensioner Spring T ension Check Section Group
Check operation starter motor and
Consumable:
• Plastic
• T ape
CAUTION: NOT power wash the exhaust filter assembly selective catalytic reduction (SCR) assembly when they are The clamps securing sections the filter may loosen, resulting exhaust gas leaks.
Cap plug all openings engine. electrical components (starter , alternator , etc.) are not removed prior cover with plastic and tape securely prevent moisture from
Steam - clean engine thoroughly
IMPORT ANT : Never steam clean pour cold water the high - pressure fuel pump while still warm. T o may cause seizure pump parts. Also, avoid electrical components, wiring, the ECU, and sensors.
CAUTION: not work exhaust filter assembly selective catalytic reduction (SCR) assembly when external temperature exceeds (120 °F).
Disconnect T urbocharger Oil Supply Line
Drain all engine oil and not previously
IMPORT ANT : When servicing turbocharged engines a rollover disconnect turbocharger oil inlet line (A) and (B) from oil filter housing turbocharger before rolling engine over . Failure may cause a hydraulic lock upon starting engine. Hydraulic lock may cause possible engine
Hydraulic lock occurs when trapped oil the oil filter housing drains through the turbocharger , the exhaust and intake manifolds, and then into the cylinder head.
After starting the engine, the trapped oil the manifold and head released into the cylinder(s), filling them with oil, causing hydraulic lock and possible engine
Disconnect turbocharger oil supply See T urbocharger Oil Supply Lines (Dual T urbocharger) Installation Section Group 080 VGT T urbocharger Oil Supply Lines (Single T urbocharger) Installation Section Group
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The following assembly sequence suggested when engine has been completely sure check runout clearance engine Refer the appropriate repair group when assembling engine components.
Install any sensors/gauges and cylinder block
NOTE: Refer appropriate group for inspection and repair engine
Install liners, Orings, and packings.
Install exhaust manifold assembly
Install EGR cooler bracket assembly
24. Install EGR cooler and EGR cooler inlet pipe.
Install fuel lines EGR cooler bracket assembly
Install engine oil filter base and cooler assembly
Install air intake manifold.
27.
Rotate Install piston cooling orifices cylinder
Install crankshaft. Install main bearing caps.
Install front high - pressure fuel and upper idler gear
Install flywheel rear oil and
Rotate Install pistons and connecting
Install oil pump assembly , lower idler gear , and front timing gear cover
Install front crankshaft oil seal.
Rotate engine repair stand and install engine oil 1
Rotate engine. Install camshaft followers.
Install cylinder head assembly with new head
Install coolant
14. Install fuel injectors and fuel feed tubes.
Install high - pressure common rail (HPCR) and high - pressure injection
16. Install rocker arm shaft carrier and valve bridges.
Install rocker arm shaft assembly and push
Install electronic injector wiring
19. Install rocker arm cover .
Install high - pressure fuel lines from high - pressure fuel
Install fuel filter header assembly and fuel
Install EGR flow and EGR valve assembly
Install EGR flow venturi coolant
Install EGR cooler coolant return
32. Install air inlet, mixer , and air throttle assemblies.
install fixed turbocharger Connect fixed turbocharger oil drain
Install VGT turbocharger and oil drain
install turbine and compressor interstage pipes
Connect all turbocharger oil supply
37. Install front crankshaft pulley and damper .
Install fan belt tensioner
Install thermostat housing and bypass tube assembly
40. Install coolant pump assembly .
Install fan pulley and fan
Install starter and alternator
Install engine wiring
Install OCV filter assembly
45. Install fan drive belt.
Remove engine from
Install ECU and ECU bracket and fuel
48. Fill engine with coolant and engine oil.
Install VGT coolant Install fixed turbocharger oil drain line.
Special T ools:
• None
Consumable Materials:
• John Deere Oil Filter
• John Deere Break - Plus Engine Oil
Engine break - should performed new engines when the following repairs have been performed:
• Main bearings, rod bearings, crankshaft, any combination these parts have been replaced.
• liners have been
Use a dynamometer perform the following preliminary break - necessary , preliminary engine break - can performed without a dynamometer under controlled operating conditions.
IMPORT ANT : NOT use John Deere Plusoil, engine oils meeting API CG4, API CF4, ACEA ACEA E2, performance levels during break - period engine that has had a major These oils will not allow overhauled engine properly wear during the breakperiod.
not add makeup oil until the oil level BELOW the add mark. John Deere BreakPlus Engine Oil should used make any oil consumed during break -
NOT fill above the crosshatch pattern FULL mark. Oil levels anywhere within the crosshatch are acceptable.
Fill engine crankcase proper level with John Deere Break - Plus Engine Oil during breakUse break - oil regardless ambient This oil specifically formulated enhance breakJohn Deere diesel engines.
IMPORT ANT : During preliminary break - periodically check engine oil pressure and coolant temperature. Also check for signs fuel, oil, coolant leaks.
Start run loads and speeds shown following chart for time limits
NOTE: For applications with constant speed just follow the time and load specifications below
T ime Load Engine Speed
1 minute load 850 rpm
2 minutes load Fast Idle minutes load 2000 rpm rated speed
Minutes Full load Rated speed
After preliminary break - run engine minutes 1500 rpm, with load before shutdown.
Check and readjust valve clearance necessary Cylinder head retorque not
NOTE: During the first avoid prolonged periods engine idling sustained maximum load engine will idle longer than 5 stop
Operate the engine heavy loads with minimal idling during the break -
Change the oil and filter between a minimum 100 hours and a maximum 500 hours during the initial operation a new rebuilt the engine has significant operating time constant speeds, and/or light load usage, additional 100 hour break - period recommended using a new change John Deere Break - Plus Engine Oil and new John Deere oil filter
• ACEA Oil Sequence
the engine has significant operating time constant speeds, and/or light load usage, make - oil required the first 100 hour period, a longer breakperiod may these there are two acceptable Drain the oil and replace with fresh John Deere Break - Plus Engine Oil and a new John Deere oil filter Y may choose continue running the engine with the same oil and filter for a maximum 500 hours.
John Deere Break - Plus Engine Oil not use a 10W - diesel engine oil meeting one the following during the initial 250 hours operation:
• API Service Category - 4
• ACEA Oil Sequence
IMPORT ANT : not use any other engine oils during the initial break - a new rebuilt engine.
John Deere Break - Plus Engine Oil can used for all John Deere diesel engines all emission certification
After the breakperiod, use John Deere Plusother diesel engine oil recommended this manual.
NOTE: Some increase oil consumption may expected when low viscosity oils are Check oil levels more frequently
1
The following sequence suggested when complete disassembly for overhaul Refer the appropriate repair group when removing individual engine
Drain all coolant and engine oil. Check engine oil for metal
Remove ECU and ECU bracket and fuel
Install engine stand.
Remove fan drive
Remove OCV filter assembly
Remove engine wiring harness.
Remove starter and alternator
Remove fan pulley and fan
Remove coolant pump assembly .
Remove thermostat cover , and bypass tube assembly
Remove fan belt tensioner .
Remove front crankshaft pulley and damper
Disconnect all turbocharger oil supply
14. Remove coolant lines from VGT turbocharger .
Remove turbine and compressor interstage pipes
16. Remove VGT turbocharger and oil drain line.
disconnect fixed turbocharger oil drain Remove fixed turbocharger
Remove air mixer , and air throttle
Remove EGR cooler coolant return
Remove EGR flow venturi coolant
21. Remove EGR pipes, flow venturi, and EGR valve assembly .
Remove fuel filter header assembly and fuel
Remove air intake
24. Remove engine oil filter base and cooler assembly .
Remove high - pressure fuel
31. Remove high - pressure fuel line sets and high - pressure common rail. Discard lines.
Remove coolant
Remove rocker arm cover
NOTE: NOT damage option code label (if when removing rocker arm cover
Remove electronic injector wiring
35. Remove rocker arm shaft assembly and push rods. Identify push rods for reassembly
Remove rocker arm shaft carrier
37. Remove fuel inlet connectors and injectors.
Remove cylinder head assembly Remove and discard head
NOTE: W A bolt down liners when rotating engine flywheel with cylinder removed.
Remove camshaft followers and identify for reassembly
Rotate engine repair stand and remove engine oil pan.
Remove front crankshaft oil
Remove front timing gear cover , oil pump assembly , and lower idler gear
Rotate engine vertical Perform bearing - - journal wear checks with Remove pistons and connecting Identify for reassembly
44. Remove flywheel, rear oil seal, and flywheel housing.
Remove upper idler gear , and front
Remove main bearing Perform bearing - - journal wear checks with Plastigage. Remove crankshaft.
Remove piston cooling orifices from cylinder
Rotate engine horizontal remove Orings, and packings. Mark liners for reassembly same bore from which removed.
Remove fuel lines from EGR cooler bracket assembly
Remove EGR cooler and EGR cooler inlet
Remove EGR cooler bracket assembly
Remove exhaust manifold assembly
29. Remove high - pressure fuel lines from high - pressure fuel pump and discard lines.
Remove any sensors/gauges and cylinder block
NOTE: Refer appropriate group for inspection and repair engine components.
a general engine tune - not necessary
ALL recommended manual hourly service procedures are performed your engine performance not within the rated application the following service procedures are recommended help restore engine normal operating ficiency
IMPORT ANT : Engines are equipped with electronically - controlled fuel systems
that have a diagnostic feature that will display detailed codes alert operator specific performance Refer the DIAGNOSTICS Section this manual for diagnostic code troubleshooting procedures electronically controlled fuel systems.
Check fuel injection
Check engine oil Correct necessary
Check engine valve Adjust necessary
Check engine Correct necessary
Check fuel quality Manual
NOTE: Only the 2722 (6000 lb) heavy duty engine repair stand (A) No. D05223ST manufactured Owatonna T ool referenced this When any other repair stand consult the instructions for mounting the
Refer machine technical manual for steps remove engine from
D05223ST Engine Repair Stand
Install JT07268 Engine Mounting Adapter D05223ST Repair Stand
Special T ools:
• JT07268 Engine Mounting Adapter
• D05223ST Repair Stand
• D05226ST Adapter Plate
Attach D05226ST special adapter (B) D05223ST repair stand (A) using three ASTM A574 socket head cap screws T ighten
Specification
Repair Stand
Socket Head Cap orque 600 (443
Attach JT07268 engine adapter (C) D05226ST
special adapter , using four Class 10.9 cap screws (E). T ighten
Specification
JT07268 Engine
Adapter - - D05226ST
Special Adapter Cap orque 135 (100
D05223ST Repair Stand D05226ST Special Adapter JT07268 Engine Adapter
Socket Head Cap Screw used) Cap Screw used)
Install JDG1 1853 Engine Mounting Adapter D05223ST Repair Stand
Special T ools:
• JDG1 1853 Engine Mounting Adapter
• D05223ST Repair Stand
Attach JDG1 1853 engine mounting adapter (B) D05223ST repair stand using three socket head cap screws T ighten three socket head cap screws
Specification
Repair Stand
Socket Head Cap
D05223ST Repair Stand JDG1 1853 Engine Mounting Adapter
600 N·m (443 lb·ft)
Socket Head Cap Screw used)
Install Lift Straps
Special T ools:
• JDG1 1260 Lifting Bracket
Consumable Material:
• M12 X Cap Screws
Install Front Lift Strap
NOTE: Bracket should not make contact with any other surrounding
IMPORT ANT : Cap screws are one time use only .
Using one (M12 X 30) cap screw (B), install lift strap (A) the front exhaust manifold side cylinder
NOTE: install turbocharger oil line support bracket underneath lift
T orque cap screw (B) specification.
Install Rear Lift Strap
NOTE: Bracket should not make contact with any other surrounding
Orient the bracket angle 25° from parallel the
IMPORT ANT : Cap screws are one time use only .
Using one (M12 X 30) cap screw install lift strap (A) the rear intake manifold side cylinder head.
T orque cap screw (B)
Special T ools
• JDG23 Engine Lifting Sling
CAUTION: The only recommended method for lifting the engine with JDG23 Engine Lifting Sling and safety approved lifting straps that come with Use extreme caution when lifting and NEVER permit any part the body positioned under engine being lifted suspended.
NOTE: engine lifting straps are misplaced, they can procured through service
install lift See Install Lift Straps Section Group
IMPORT ANT : Lift engine with longitudinal loading lifting sling and lifting brackets only Angular loading greatly reduces lifting capacity sling and brackets.
Lift spacing sling adjustable. Position each lifting point that engine hangs level when
Attach the JDG23 Engine Lifting Sling (A) engine lifting straps (B) and overhead hoist floor
Lifting straps are designed lift the engine and small such hydraulic pumps and air compressors mounted the engine auxiliary gear belt - driven such
air conditioning compressors and larger such structural oil air are attached other locations the the lifting straps provided with the engine are not intended for this purpose. T echnician responsible for providing adequate lifting devices under these See machine technical manual for additional information removing engine from
NOTE: Use engine lifting sling the ONL Y APPROVED method for lifting engine.
Carefully lift engine and slowly lower desired
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Mount Engine Repair Stand
JT07268 Engine Mounting Adapter Front Mounting Holes Rear Mounting Hole Upper Mounting Hole
Special T ools:
• JT07268 Engine Mounting Adapter
• D05223ST Repair Stand
• D05226ST Adapter Plate
• DFRG15 Spacer Kit
CAUTION: NEVER remove the overhead lifting equipment until the engine securely mounted onto the repair stand and all mounting hardware tightened specified torque. Always release the overhead lifting equipment slowly .
Disconnect turbocharger oil supply line.
Mount the engine JT07268 engine mounting adapter (A) follows:
Front Mounting Holes (B):
• T M12 x x Class cap screws from DFRG15 spacer
• T 9 x spacers from DFRG15 spacer
Rear Mounting Hole (C):
• One M14 x x Class cap screw from DFRG15 spacer
NOTE: Remove appropriate components get clearance when installing engine onto repair These components can differ depending the
Perform Install JT07268 Engine Mounting Adapter
D05223ST Repair Stand Section 02, Group 010.
Drain all engine oil and
Upper Mounting Hole (D):
• One M14 x x Class cap screw from DFRG15 spacer
• One x spacer from DFRG15 spacer
IMPORT ANT : When servicing turbocharged engines a rollover stand, disconnect turbocharger oil supply line from oil filter housing turbocharger before rolling engine over Failure may cause a hydraulic lock upon starting engine. Hydraulic lock may cause possible engine failure.
T ighten cap screws specifications.
Specification
Engine Repair Stand M12 Cap orque
Engine Repair Stand M14
orque
Mount Engine Repair Stand
JDG1 1853 Engine Mounting Adapter M12 x x Cap Screws used) M14 x x Cap Screw M14 x x Cap Screw Spacer
Special T ools:
• D05223ST Engine Repair Stand
• JDG1 1853 Engine Mounting Adapter
CAUTION: NEVER remove the overhead lifting equipment until the engine securely mounted onto the repair stand and all mounting hardware tightened specified torque. Always release the overhead lifting equipment slowly .
NOTE: Remove appropriate components get clearance when installing engine onto repair These components can differ depending the
Perform Install JDG1 1853 Engine Mounting Adapter D05223ST Repair Stand Section 02, Group 010.
oil supply line from oil filter housing turbocharger before rolling engine over . Failure may cause a hydraulic lock upon starting engine. Hydraulic lock may cause possible engine failure.
Disconnect turbocharger oil supply
Install M14 x x cap screw (D) through spacer (E) into upper mounting hole
Install two M12 x x cap screws
Install M14 x x cap screw T ighten cap screws specifications.
Drain all engine oil and IMPORT ANT : When servicing turbocharged engines a rollover stand, disconnect turbocharger
• The engine hard start due low cranking compression.
Engine life and performance vary depending operating conditions and the level regular engine Engines can brought back original performance standards through proper overhaul procedure and replacement worn parts with genuine John Deere service parts. Overhauling the engine before a major failure can avoid costly repairs and Consider installing a John Deere overhaul kit when:
• The engine begins experience power loss and there are known engine component failures.
• The engine develops high crankcase pressure (Blow - by) and there are known engine component
• The engine begins use Refer Section for acceptable oil
• The engine has high usage hours and the owner wants take preventive measure avoid high - cost repairs and costly
Overhaul kits may available for John Deere engines your
Only qualified service familiar with this can use the engine repair
T o maintain shear strength alloy steel Class SAE Grade 8 higher cap screws must used mount adapters and engine repair stand.
T ighten cap screws specifications
For full thread certain that tapped holes adapters and engine blocks are clean and not A thread length engagement equal 1 - 1/2 screw diameters minimum required maintain strength requirements.
specified John contact for center balance
T o prevent possible personal injury due engine recheck make sure that engine solidly mounted before releasing support from engine lifting device. not position any part the body under a load being lifted Accidental slippage can result personal injury
Use the lifting jack when necessary lift the engine for When working the the jack must its lowest position keep the center gravity and the possibility tipping low
T o avoid structural personal injury , not exceed the maximum capacity rating 2722 (6000 Maximum capacity determined with the center the engine located not more than 330 (13 in.) from the mounting hub surface the engine stand.
The center balance engine must located within the engine stand rotating
IMPORT ANT : using a rollover stand engine mounting adapters different from the ones
T o prevent possible personal injury due sudden engine movement, lower the engine operating jack release valve slowly not unscrew release valve knob more than two turns from its closed
Listed below are sealants which have been tested and are used the John Deere factory control leakage and assure hardware W A use the following recommended sealants when assembling your John Deere Diesel Engine assure quality performance.
Fuel filter drain and bleed plugs
T emperature sending unit and switch
Connectors: turbo line and turbo drain
Adapter fitting for turbo oil inlet line
LOCTITE ® thread sealants are designed perform sealing standards with machine oil residue excessive machine oil poor cleanliness quality clean with Refer John Deere Merchandise and Parts Sales Manual for ordering information.
LOCTITE® 620 Retaining Compound, High T emperature Adhesive
• PM38652 bottle
T apered bore viscous damper
AR31790 SCOTCH-GRIP ® EC1099 Plastic Adhesive:
• AR31790 1 oz.)
LOCTITE® 242—Thread Lock and Sealer
(Medium Strength) (Blue):
• PM37418 6 tube
• PM37477 bottle
Injector sleeves cylinder
LOCTITE® 680 (Loctite # 37485) Retaining
Compound (Green):
• PM37485 (1.2 oz.) bottle
Plugs and fittings: fuel filter base, intake manifold, cylinder block (oil
Injection pump timing hole
Cap screws: injection pump access cover , electronic tachometer cover , oil filler inlet, oil filter adapter , rear oil seal
Oil pressure sending
Piston cooling orifice OD.
Oil Cooler threaded
LOCTITE® 592 Pipe Sealant with TEFLON ® (White):
• PM37398 6 tube
• PM37397 bottle
Pipe plugs: cylinder block.
Coolant pump and block coolant drain valves
LOCTITE a registered trademark Loctite SCOTCH - GRIP a registered trademark TEFLON a registered trademark Pont
Expansion (frost) plugs cylinder
Dipstick tube hole both sides cylinder
Cam timing sensor bushing cylinder block front
High T emperature Grease
Camshaft thrust washer - both Camshaft gear seat diameters.
First and last diameters - camshaft
Camshaft
PERMA TEX A viation (Form-A-Gasket No. 3):
• TY6299 227 g container
Rear camshaft bore steel cap plug
Oil pan gasket surfaces
Cylinder Block T Deck — Cleaning and Inspection
Special T ools:
• JDG680 T
Remove gasket and other foreign material from top Gasket surface must clean.
Clean threaded holes cylinder block using JDG680 T any 1/2 - UNC - tap about Use compressed air remove debris and fluids from the cap screw Replace block there evidence damage.
Use compressed air remove all loose foreign material from cylinders and top
Inspect top deck for see Cylinder Block Components Measurement Section 02, Group 020.
Cylinder Head — Cleaning and Inspection
Inspect combustion face for evidence physical oil coolant gasket failure prior cleaning the cylinder Repair replace cylinder head there evidence physical damage; such cracking, abrasion, distortion, valve seat “torching”.
Inspect all cylinder head passages for restrictions.
Scrape gasket and rust from Use a powered brass copper wire brush clean sealing
Cylinder Head Flatness Check
Special T ools:
• D05012ST - A Precision Straight Edge
Check cylinder head flatness using D05012ST - A Precision Straightedge and feeler Check and diagonally several
Specification
Cylinder Head
Acceptable Out - - Flat for Entire Length Width
Maximum Acceptable Out - - Flat for Every 150
out - - flat exceeds specifications, the cylinder head must reconditioned replaced. (See Cylinder Head Thickness Measurement Section Group
ANT : sure remove all plugs before cleaning parts can damaged destroyed hot tank
Clean cylinder head a chemical hot with solvent and a brush.
Dry with compressed air and blow out all
Special T ools:
• JDG1 1260 Lifting Bracket
• JDG1 1 184 W Injection Line Nut
Consumable Material:
• Anti Seize Compound
• C - Seal
• Coolant Manifold Cap Screws
• Engine Oil
• Exhaust Manifold Gasket
• Gasket
• Gasket Fixed T urbocharger - - Interstage Gas T ube
• Head Cap Screws
• Head Gasket
• High T emperature Grease
• Intake Manifold Gasket
• Loctite 242 Holymar 760
• Mounting Gasket
• O - rings
• Petroleum Jelly Soapy W ater
• 569 NEVER - SEEZ Compound
• Rocker Arm Cover Gasket
• Rocker Arm Shaft Carrier - - Head Gasket
• SAE30 Diesel Engine Oil
• VGT T urbocharger Gasket
Head Cap Screw (26 used) Cylinder Head
IMPORT ANT : W A thoroughly inspect new cylinder head gasket for possible manufacturing Return any gasket that does not pass inspection.
Using Lint free towel, wipe cylinder block combustion surface remove residual assembly fluids and other contaminants.
Install two dowels (C) into the cylinder block head (B) deck
Install a new head gasket (D) cylinder block. not use sealant gasket; install dry .
IMPORT ANT : cylinder head lowered onto cylinder block and the head not positioned correctly
Dowel used) Cylinder Head Gasket
locating dowels, remove cylinder head and install a new gasket. NOT try reposition cylinder head the same gasket again since the fire ring may possibly damaged.
NOTE: may beneficial use additional guide pins locate gasket cylinder block combustion surface.
Install cylinder head gasket (D) cylinder using locating dowels a Make sure that head positioned correctly over dowels and sits flat cylinder block top
IMPORT ANT : W A use NEW cap screws when installing cylinder head. Cap screws may used only one time.
NOT use multi - viscosity oils lubricate cap SAE30
Dip entire cap screw clean SAE30 diesel engine Allow excess oil drip f cap
NOTE: Excess oil will not allow cap screws reach proper clamp load using torque yield strategy
Install special cylinder head cap screws through head and gasket and into
NOTE: All head cap screw are the same
T ighten cap screw 1 the initial torque per given Follow the cap screw tightening sequence shown the figure
Specification
Cylinder Head Cap T orque 100 (74 -
After initial torque, apply final torque per below specification the same sequence
Specification
Cylinder Head Cap T orque 155 -
V erify all torques (Allow five minutes for bolt
Specification
Cylinder Head Cap erify T orque 155 N·m -
Using oil proof marker , draw a line parallel the crankshaft across the entire top each cap screw This line will used a reference mark.
1
Sequentially (start cap screw 1 and proceed through cap screw No. 26) turn each cap screw 90°. Line cap screw will perpendicular
Specification
Cylinder Head Cap orque T urn 90°
NOTE: Double check line position all cap
removed, perform Electronic Injectors Installation Section Group
Install push
13. Perform Rocker Arm Shaft Carrier Assembly
Installation Section 02, Group 020.
Perform Rocker Arm Cover Installation Section Group
15. Perform Thermostat Housing Assemble Section 02, Group 070.
Perform High - Pressure Injection Lines and Feed T ubes Installation Section Group
17. Perform Exhaust Manifold (Dual T urbocharger)
Installation Section Group 080 Exhaust Manifold (Single T urbocharger) Installation Section Group
Perform EGR Cooler Assembly (Dual T urbocharger)
Installation Section 02, Group 080 EGR Cooler
Assembly (Single T urbocharger) Installation Section Group
Perform Intake Manifold (Dual T urbocharger)
Installation Section 02, Group 080 Intake Manifold (Single T urbocharger) Installation Section 02, Group
Perform T urbocharger , VGT (Dual T urbocharger)
Installation Section Group 080 VGT T urbocharger Assembly (Single T urbocharger)
Installation Section Group
Perform EGR Cooler Assembly (Dual T urbocharger)
Installation Section Group 080 EGR Cooler
Perform EGR Flow V enturi Assembly (Dual T urbocharger) Installation Section Group 080 EGR Flow V enturi Assembly (Single T urbocharger)
Installation Section 02, Group 085.
Perform Open Crankcase V entilation System
Assembly (Single T urbocharger) Installation Section Group
25. removed, perform Alternator Installation Section Group
Installation (Standard System) Open Crankcase V entilation System Installation (High Capacity System) Section 02, Group 040.
Perform T urbocharger , Fixed (Dual T urbocharger)
Installation Section Group
Perform Fan Drive Assembly Installation Section Group
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Cylinder Head — Removal
Special T ools:
• JDG1 1 184 W Injection Line Nut
• JDG1 1260 Lifting Bracket
NOTE: not necessary remove engine from machine service cylinder head all Refer your Machine T echnical Manual for engine removal
Drain coolant.
Perform Fan Drive Assembly Removal Section Group 070
Perform Alternator Removal Section Group 100.
1
12.
Exhaust Manifold (Single T urbocharger) Removal and Inspection Section 02, Group 085.
Perform High - Pressure Injection Lines and Feed T ubes Removal Section Group
Perform Thermostat Housing Removal Section 02, Group 070.
Perform Rocker Arm Cover Removal Section Group
14.
Perform Glow Plug Removal Section 02, Group 020.
Lock flywheel
NOTE: not disassemble rocker arm shaft from the rocker arm shaft carrier .
Perform EGR Cooler Assembly (Dual T urbocharger)
Removal Section Group 080 EGR Cooler
Assembly (Single T urbocharger) Removal Section Group 085
Perform T urbocharger , VGT (Dual T urbocharger)
Removal Section Group 080 VGT T urbocharger Assembly (Single T urbocharger)
Removal Section Group 085
19.
Perform T urbocharger , Fixed (Dual T urbocharger)
Removal Section Group
Perform Open Crankcase V entilation System
Removal (Standard System) Open Crankcase V entilation System Removal (High Capacity System) Section 02, Group 040.
Perform Intake Manifold (Dual T urbocharger) Removal and Inspection Section Group 080
Intake Manifold (Single T urbocharger) Removal and Inspection Section 02, Group 085.
Remove rocker arm shaft carrier assembly with rocker arm shaft attached with the carrier See Rocker Arm Shaft Assembly T ear Down Section Group
Remove push
necessary , perform Electronic Injectors Removal Section Group
Remove all cylinder head cap screws (A). Discard cap
ANT : NOT use screwdrivers pry bars between cylinder block and cylinder head loosen head - - block gasket seal.
Lift cylinder head from block cylinder head use soft hammer tap the cylinder
Remove cylinder head gasket Inspect for possible oil, coolant, combustion chamber leaks. Also, check for evidence incorrect defective head gasket being Discard
Perform EGR Cooler Assembly (Dual T urbocharger) Removal Section Group 080 EGR Cooler
Assembly (Single T urbocharger) Removal Section Group
10. Perform Exhaust Manifold (Dual T urbocharger) Removal and Inspection Section Group 080
NOTE: not rotate crankshaft with cylinder head removed unless all cylinder liners are secured with cap screws and large flat washers. See Piston and Connecting Rod Assembly Removal Section Group
Cylinder Head Removal
Cylinder Head Gasket
Cylinder Head Cap Screw (26 used)
Cylinder Head
Measure head thickness from rocker arm shaft carrier gasket rail - - combustion
cylinder head thickness less than minimum allowable thickness, NOT attempt resurface. Install a new cylinder
When resurfacing cylinder remove ONL Y what necessary restore
Specification
New Cylinder
Minimum Acceptable
Thickness
Combustion Face
Surface Finish (Surface Grind Only) (AA)
Maximum W ave Depth
Maximum Material
Removal for Resurfacing
IMPORT ANT : After resurfacing cylinder head, check for see Cylinder Head — Flatness
Cylinder Head Thickness Check
Check Section Group Also check
surface finish combustion face head. Measure and record valve recess cylinder head. See V alve Recess Measurement Section 02, Group 020.
Cylinder Head Gasket — Inspection
Special T ools:
• JDG1 1260 Lifting Bracket
Fire Rings Gasket Body
Head Gasket Inspection
Rocker Arm Oil Port Elastomer Beading
Front Engine
The following inspection procedures are recommended whenever a head gasket joint failure when joint disassembly takes
Review historical data relating machine operation, and repair , along with diagnostic Note all areas requiring further inspection and
Perform Rocker Arm Cover
Removal Section 02, Group 020. Then check for presence coolant the
Record head cap screw torques prior Upon check cap screw length dif
Perform Cylinder Head Removal Section 02, Group
Observe surfaces removed head
Examine fire rings (A) for the following:
• Fire rings
• Adjacent body area burned
• Fire rings pattern eccentric contains voids.
• Discoloration fire rings and adjacent body areas.
• Fire rings surfaces
Examine gasket body (B) for the following:
• Combustion gas erosion paths soot deposits originating combustion seals.
• Extreme embrittlement localized
• O - ring seal missing damaged port area
• Elastomer (D) missing
• Oil coolant paths from port areas.
• Localized areas low compression.
Special T ools:
• JDG1649A Injector Sleeve Installer
Consumable Material:
• Combustion Sealing W asher
• Feed T ubes
• High - Pressure Injection Lines
• High T emperature Grease
• Loctite 680
• Loctite 242
• Loctite 620 High T emperature Adhesive
• Lubricant Soap
• Rocker Arm Cover Gasket
IMPORT ANT : installing a new fuel injector nozzle sleeve when cylinder head assembled make sure that piston NOT near top dead center (TDC). Rotate engine until piston bottom dead center (BDC) piston damage will result.
Support cylinder head that the lower surface the head approximately above work
Apply Loctite 620 high temperature adhesive the side walls the bottom the fuel injector sleeve bore.
Lubricate O - rings with liquid
IMPORT ANT : not remove mix sleeve Orings.
Service sleeve provided with O - rings installed it. The upper O - ring (A) diesel fuel compatible while the lower O - ring (B) coolant Both O - rings are identified a different color and are not available spare parts.
not use any petroleum based products lubricate fuel injector sleeve O - rings O - rings will
Position injector sleeve (C) over bore and place JDG1649A injector sleeve installer into
Upper Green O - ring Lower Y ellow O - ring Sleeve Installed sleeve
1
Using a hammer , carefully strike the sleeve installation tool drive the sleeve fully into the injector bore until sleeve bottoms out the correct depth
Perform Electronic Injectors
Installation Section Group
Perform High - Pressure Common - Rail (HPCR)
Installation Section Group
Perform High - Pressure Injection Lines and Feed T ubes Installation Section Group
Perform Injector Wiring Harness Installation Section Group
Perform Rocker Arm Cover
Installation Section Group
Perform T urbocharger , Fixed (Dual T urbocharger)
Installation Section Group 080 VGT T urbocharger Assembly (Single T urbocharger)
Installation Section Group
Injector Sleeves — Removal
Special T ools:
• JDG10631 Injector Sleeve Puller
• JDG1 1 186 Injector Puller
IMPORT ANT : removing the sleeve with cylinder head engine, insure area around the sleeve clean and free debris that could enter the fuel system cylinder Plug cap injector bores head when sleeve has been removed.
Perform Electronic Injectors Removal Section 02, Group 090.
Forcing Screw Spacer Flat W asher Hex Nut
Place forcing screw (A) into the injector Insure the expander portion the tool installed that the expander will locate securely the sleeve inner diameter Using a backup tighten the forcing screw
Forcing Screw
JDG10631 Injector Sleeve Puller
Install spacer (B) the forcing screw Position the spacer with the cut - out facing into the cylinder head.
Install flat washer (C) and hex nut T urn hex nut until sleeve
Remove tool with sleeve. Spacer Flat W asher Hex Nut
Glow Plug — Installation
Special T ools:
• None Consumable Materials:
• None
NOTE: some cylinder number 1 glow plug must installed before the thermostat
Install six glow plugs (A) into the cylinder head. T orque all plugs
Specification
orque (133 -
Plugs used)
Glow Plug — Removal
Special T ools:
• None
equipped, perform T urbocharger , Fixed (Dual T urbocharger) Removal Section 02, Group 080 VGT T urbocharger Assembly (Single T urbocharger) Removal Section Group
Perform Glow Plug Heat Shield Removal Section 02, Group 020.
Perform Glow Plug Wiring Harness Removal Section Group
NOTE: some the thermostat housing may need removed access the cylinder number 1 glow some removing only thermostat cover would sufficient access the cylinder number 1 glow plug
necessary , perform Thermostat Housing Removal Section 02, Group 070.
Loosen and remove all glow plugs (E) from cylinder
Glow Plug Bore — Cleaning and Inspection
Look for any burr foreign particles trapped inside the glow plug bore with the help
Clean glow plug bores with a plastic
NOTE: A few drops light oil kerosene will help clean the
Option A
NOTE: This option covers engines equipped with dual turbocharger , without provision sliding element bracket. These engines are equipped with two glow plug heat shields.
Install two heat shields
Install four nuts (B) and tighten
Specification
Install two nuts (C) and tighten
Specification
Option B
NOTE: This option covers engines equipped with single and dual turbocharger , with provision sliding element These engines are equipped with one glow plug heat
Install studs (A) and a stud (B) shown. T ighten
Install heat shield (C) Install nuts (D) and a nut (E) shown. T ighten specification.
Specification
and orque
Glow Plug Heat Shield — Removal
Option A
NOTE: This option covers engines equipped with dual turbocharger , without provision sliding element These engines are equipped with two glow plug heat shields.
remove wiring harness clamp cap
Remove four nuts (F) from the top heat shields
Loosen and remove two nuts (G) from heat shields
Remove the two rocker arm cover heat shield (E) from the rocker arm cover
Shield used) Nuts used)
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• Thank you very much for reading the preview of the manual.
• You can download the complete manual from: www.heydownloads.com by clicking the link below
• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.
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