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Service Engine


Engine Warranty Maintenance Statement

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

Avoid Fumes

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

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

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

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

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

Engine Oil

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



The following John Deere oils are PREFERRED:

• TORQ-GARD SUPREME

• PLUS-50

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

• API Service Classification SH/CF or higher.

Raising and Lowering the Engine Cover

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

IMPORTANT: Avoid damage! Do not operate the machine with the engine cover in the raised position.



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2. Pull out on the bottom of engine cover latches (A) on left and right side of machine, behind operator’s seat.

3. Unhook tops of the engine cover latches from the hooks on engine cover.


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4. Raise engine cover using handle (B). Open engine cover completely until it comes to rest.

5. Carefully lower engine cover using handle (B).

6. Hook the tops of the engine cover latches onto engine cover, and press in on bottom of latches to lock closed.

Raising and Lowering Seat Platform

To raise the operator’s seat platform:

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

c CAUTION: Avoid injury! Fingers and hands can be pinched or crushed. Be aware of potential pinch points and keep hands away.

2. Stand on the operator’s platform facing the operator’s seat.


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3. Pull forward on the lift release knob (A), while pulling forward and upward on the backrest of the operator’s seat.

4. The seat platform will latch in the raised position.

To lower the operator’s seat platform:


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1. Push in on the orange lock lever (A) on the support rod.

2. Hold in the lock lever while pushing rearward on the backrest of the operator’s seat.

3. Release the lock lever while continuing to lower the operator’s seat platform until it latches in the fully lowered position.

Checking Engine Oil

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

IMPORTANT: Avoid damage! Failure to check the oil level regularly could lead to serious engine problems if oil level is low:

• Check oil level before operating.

• Check oil level when the engine is cold and not running.

• Keep level between operating range on dipstick.

• Shut off engine before adding oil.


2. Raise engine cover.

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



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3. Remove dipstick (A) located on the left side of the engine. Wipe dipstick with a clean cloth.

4. Install dipstick.


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

• If oil is low, add oil to bring oil level no higher than level (B) on the dipstick.

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

6. Install dipstick.

7. Lower engine cover.

Changing Engine Oil and Filter

1. Run engine to warm oil.

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

3. Raise engine cover.

4. Place a drain pan under the oil drain location.

IMPORTANT: Avoid damage! Dirt and debris in oil may cause damage to the engine. Clean area around opening before removing plug or dipstick.



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5. Remove drain plug (A) located under the engine.


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6. Remove oil filter (B) located under the left side of the engine. Turn filter counterclockwise to remove.

7. Clean filter mounting surface on engine with a clean cloth.

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

9. Install new filter.

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

10. Install oil drain plug. Do not overtighten.


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11. Remove oil fill cap (C) on top of engine.

IMPORTANT: Avoid damage! Do not overfill crankcase with oil. Oil capacities given are with engine and crankcase completely dry. Some oil will remain in engine after draining.


12. Add approximately 7.4 L (7.8 qt) of oil.

13. Install oil fill cap.

14. Start engine.

• Run engine at a slow throttle speed for approximately two minutes.

• Check area under engine for oil leaks.

15. Stop engine.

16. After approximately two minutes check engine oil level.

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


17. Remove dipstick. Wipe with a clean cloth.

18. Install dipstick.


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19. Remove dipstick. Check oil level. Oil should be between levels (D) and (E) on the dipstick.

• If oil is low, add oil to bring oil level no higher than level (D) on the dipstick.

• If oil is above level (D) on the dipstick, drain to proper level.

20. Install dipstick.

21. Lower engine cover.

Cleaning Hood Screens

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

• Clear work area of bystanders.

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

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

IMPORTANT: Avoid damage! An obstructed air intake screen can cause engine damage due to overheating. Keep air intake screen and other external surfaces of the engine, including cooling fins, clean at all times to allow adequate air intake.


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

2. Raise engine cover.


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3. Clean all five hood screens (A) with a brush, compressed air, or water.

4. Check for debris inside engine cover at (B).

5. Close engine cover and latch.

Cleaning Oil Cooler and Radiator

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

• Clear work area of bystanders.

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

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

IMPORTANT: Avoid damage! Oil cooler coils and radiator cooling fins must be clean to prevent the engine from overheating and to allow adequate air intake.


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

2. Allow engine to cool.

3. Open engine cover.

IMPORTANT: Avoid damage! When cleaning the oil cooler and radiator fins do not allow water and debris to enter air cleaner intake hose. Keep compressed air nozzle at least 150 mm (6 in.) away from fins while cleaning.



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4. Remove dirt and debris from oil cooler and radiator (B) by directing a stream of compressed air or water from the front side of radiator to the rear, being certain not to allow water or debris to enter air cleaner intake hose (A).

5. Check oil cooler coils and radiator fins for damage.

6. Lower engine cover.

Checking Air Filter Restriction Indicator

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

2. Raise engine cover.

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


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3. Check air restriction indicator (A).

• When the line (B) on the yellow plunger inside the indicator is within range (C), no air cleaner service is required.

• When line on the yellow plunger inside the indicator is within range (D), air cleaner needs replacement.

4. Lower engine cover.

Servicing Air Cleaner Elements

Primary Air Filter Element

IMPORTANT: Avoid damage! Dirt and debris can enter engine when air cleaner canister is opened. Do not open canister unless required for scheduled service. This will keep contamination of the intake system to a minimum.

Check filter element more frequently if operating in dusty conditions.


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

2. Allow engine to cool.

3. Raise engine cover.


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4. Release the three latches (A) (one not shown) and remove air cleaner canister cover (B).


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

6. Install air cleaner canister cover with rubber dust unloading valve pointing downward. (Check direction molded into canister cover for proper installation.)


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7. Push reset button (D) on the air restriction indicator.

8. Start engine. Allow engine to run approximately one minute at maximum throttle speed. Return to idle speed and run for another minute.

9. Stop engine.

10. Check air restriction indicator.

• If yellow plunger inside the indicator is visible inside the red zone, replace secondary air filter element.

Secondary Air Filter Element

1. Remove air cleaner canister cover.

2. Remove primary air filter element.


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

4. Install primary air filter element.

5. Install air cleaner canister cover.

6. Lower engine cover.

Cleaning Rubber Dust Unloading Valve

IMPORTANT: Avoid damage! Do not operate engine without air cleaner element and rubber dust unloading valve installed.


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

2. Allow engine to cool.

3. Raise engine cover.


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4. Locate dust unloading valve (A) attached to the front of the air cleaner canister.

5. Visually check dust unloading valve. Replace with new valve if worn, damaged, or missing.

6. Pinch corners (B) to allow any dirt or debris to fall out of the valve.

7. Lower engine cover.

Checking Radiator Hoses, Air Intake Hoses and Clamps

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

2. Allow engine to cool.

3. Raise engine cover.


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4. Check air intake hoses (A).

• Tighten hose clamps (B).

• Check hoses for cracks or damage. Replace if necessary.


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5. Check upper radiator hose (C) and lower radiator hose (Not Shown).

• Tighten hose clamps (D).

• Check hoses for cracks or damage. Replace if necessary.

6. Lower engine cover.

Service Cooling System Safely


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

• Shut off the engine and allow to cool.

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

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

Recommended Engine Coolant

The following John Deere coolants are preferred:

• COOL-GARD™ PRE-DILUTED SUMMER COOLANT (TY16036).

• COOL-GARD™ CONCENTRATED SUMMER COOLANT (TY16034).

If neither of the recommended coolants is available, use a glycol base coolant that meets the following specification:

• ASTM D4985 (JDM H24A2).

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

If using concentrate, mix approximately 50 percent antifreeze with 50 percent distilled or deionized water before adding to cooling system. This mixture will provide freeze protection to -37 degrees C (-34 degrees F).

Certain geographical areas may require lower temperature protection. See the label on your antifreeze container or consult your John Deere dealer to obtain the latest information and recommendations. Never exceed the maximum dilution rate for the coolant you are using. Exceeding the maximum rate will greatly reduce the coolant effectiveness.

Checking Coolant Level

IMPORTANT: Avoid damage! Using incorrect coolant mixture can damage the radiator:

• Do not operate engine without coolant or with plain water.

• Use antifreeze approved for use in aluminum engines.

• Do not exceed a 50% antifreeze mixture for the coolant.

• Do not pour coolant or water into radiator when engine is hot.


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

2. Allow engine to cool. Raise engine cover.


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3. Remove radiator cap (A) and check coolant level is up to filler neck.

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

5. Install radiator cap.

NOTE: Coolant recovery tank is used to catch overflow from radiator, and will be about half full during full power operation. Coolant will flow back into radiator as system cools.

6. Check coolant recovery tank. Make sure the overflow hose (B) is not touching the bottom of the recovery tank.

7. Coolant recovery tank should be half full at engine operating temperature.

8. If necessary, clean debris from the engine cover screen, oil cooler coils and radiator cooling fins.

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

Servicing the Cooling System

Draining Cooling System

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

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

IMPORTANT: Avoid damage!

• Do not operate engine without coolant.

• Do not pour coolant into the radiator when the engine is hot.


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

2. Allow engine to cool.

3. Raise engine cover.


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


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5. Open petcock (B) located on the right side of the radiator. Drain coolant into a pan.

6. Close petcock after all coolant has drained from the radiator.

7. Flush the cooling system.

Flushing Cooling System

IMPORTANT: Avoid damage!

• Do not flush the cooling system when the engine is hot.

• Do not operate engine without coolant.


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

2. Install and tighten radiator cap.

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

4. Stop engine.

c CAUTION: Avoid injury! Touching hot surfaces can burn skin. The engine, components, and fluids will be hot if the engine has been running. Keep hands and body away from hot surfaces when servicing or working near the engine and components.

5. Open radiator petcock.

• Drain cooling system immediately before rust and dirt settle.

6. Close radiator petcock.

7. Fill cooling system with clean water and repeat flushing until system is clean.

8. Drain system and fill with coolant.

Filling Cooling System

IMPORTANT: Avoid damage! Using incorrect coolant mixture can damage the radiator:

• Do not operate engine without coolant or with plain water.

• Use antifreeze approved for use in aluminum engines.

• Do not exceed a 50% antifreeze mixture for the coolant.

• Do not pour coolant or water into radiator when engine is hot.


1. With engine and cooling system cool, open radiator cap to the first stop to release all pressure. Press down on cap slightly and turn counterclockwise to remove.

NOTE: Cooling system capacity is 7.5 L (8 qt).

2. Fill cooling system.

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

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

3. Start engine and watch coolant level in radiator. Add coolant if necessary to bring coolant level up to filler neck.

4. Install and tighten radiator cap. Run engine until at operating temperature.

5. Stop engine and allow to cool down.

6. Add coolant if necessary.

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

Servicing Fuel Water Separator Sediment Bowl

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

• Shut engine off before filling fuel tank.

• Do not smoke while handling fuel.

• Keep fuel away from flames or sparks.

• Fill fuel tank outdoors or in well ventilated area.

• Clean up spilled fuel immediately.

• Use clean approved non-metal container to prevent static electric discharge.

• Use clean approved plastic funnel without screen or filter to prevent static electric discharge.

Checking

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

2. Allow engine to cool.

3. Raise engine cover.

4. Locate the fuel filter sediment bowl on the left side of the engine.


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

Cleaning and Replacing

1. Close fuel shut-off valve (B) by turning to the horizontal position as shown.

2. Turn collar (C) to remove bowl and filter. Discard filter.

3. Clean bowl and install new filter.

4. Install bowl and collar. Tighten collar hand tight.

5. Open fuel shut-off valve by turning lever to vertical position.

6. Prime fuel system.

7. Start engine and check for leaks.

Priming Diesel Fuel System

NOTE: It may be necessary to prime the fuel system after running out of fuel or changing the fuel filter.

1. Make sure the machine is on a level surface, not a slope.

2. Turn off PTO switch.

3. Lower attachments to the ground.

4. Lock the park brake.


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5. Turn key switch to RUN position for 2 minutes prior to starting engine. The fuel pump (A) will pressurize the fuel and remove any air in the system

6. Start engine. If engine will not start, repeat previous step.

Checking and Adjusting Alternator Belt

c CAUTION: Avoid injury! Rotating parts can catch fingers, loose clothing, or long hair. Wait for engine and all moving parts to stop before leaving operator’s station to adjust or service machine.

Check Belt Tension

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

2. Allow engine to cool.

3. Raise engine cover.


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4. Check alternator belt (A).

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

• Apply thumb pressure to the belt approximately halfway between the sheaves. Belt should deflect inward approximately 10 - 15 mm (3/8 - 1/2 in.).

Adjusting Belt Tension


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Picture Note: Alternator located on right side of engine.

1. Loosen adjustment bolt (B).

2. Loosen alternator mounting bolt (C).

3. Apply outward pressure to the alternator housing.

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

5. Check belt tension:

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

6. Lower engine cover.

Replacing Alternator Belt

c CAUTION: Avoid injury! Rotating parts can catch fingers, loose clothing, or long hair. Wait for engine and all moving parts to stop before leaving operator’s station to adjust or service machine.

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

2. Allow engine to cool.

3. Raise engine cover.


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Picture Note: Alternator located on right side of engine.

4. Loosen alternator mounting bolt (A).

5. Loosen and remove adjustment bolt (B).

6. Apply inward pressure to the alternator housing.

7. Remove worn belt from the alternator sheave and both engine sheaves.

NOTE: It may be necessary to loosen hex nuts holding radiator fan shroud to radiator, and to raise or lower shroud until enough clearance can be gained to pull belt between fan blades and shroud.

8. Install new belt over fan blades and engine sheaves, and over alternator pulley.