Utility Vehicle (SN. 010001-)
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TECHNICAL MANUAL
HPX815E Gator™ Utility Vehicle (SN. 010001-)
TM151019 01DEC18 (ENGLISH)
John Deere Horicon Works
Introduction
Foreword
Operation and tests sections help you identify the majority of routine failures quickly
This manual is written for an experienced technician. Essential Information is organized in groups for the various components tools required in performing certain service work are identified in requiring service instruction. At the beginning of each group are this manual and are recommended for use summarylistingsofallapplicableessentialtools,service equipment and tools, other materials needed to do the job, Live with safety: Read the safety messages in the introduction of service parts kits, specifications, wear tolerances, and torque this manual and the cautions presented throughout the text of the values. manual
CAUTION:needed for diagnosis, analysis, testing, and repair.
Technical Manuals are concise guides for specific machines They are on-the-job guides containing only the vital information
This is the safety-alert symbol When you see this symbol on the Fundamental service information is available from other sources machine or in this manual, be alert to the potential for personal covering basic theory of operation, fundamentals of injury. troubleshooting, general maintenance, and basic type of failures and their causes.
Technical manuals are divided in two parts: repair and operation
DX,TMIFC-19-20140415 and tests. Repair sections tell how to repair the components.
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Section 10 - General Information
Group 10 - Safety
Group 20 - General Specifications
Group 30 - Fuel, Lubricants, and Coolant
Group 40 - Machine Specifications
Section 20 - Engine Repair
Group 10 - Repair
Section 30 - Electrical Repair
Group 10 - General Information
Group 20 - Main Wire Harness
Group 30 - Wiring Harnesses, Kits
Group 40 - Repair
Section 40 - Power Train Repair
Group 10 - Repair
Section 50 - Steering Repair
Group 10 - Repair
Section 60 - Brake Repair
Group 10 - Brake Repair
Section 70 - Miscellaneous Repair
Group 10 - Component Location
Group 20 - Repair
Section 220 - Engine Operation, Tests, and Adjustments
Group 10 - Component Location
Group 20 - Theory of Operation
Group 30 - Diagnosis
Group 40 - Tests and Adjustments
Section 230 - Electrical Operation, Tests, and Adjustments
Group 10 - Component Location
Group 20 - Theory of Operation (Non - EEC)
Group 25 - Theory of Operation (EEC)
Group 30 - Diagnostics (Non - EEC)
Group 40 - Schematics
Group 50 - Schematics, Kits
Group 60 - Connector Information
Group 65 - Connector Information (EEC)
Group 70 - Tests and Adjustments
Section 240 - Control Unit Operation, Tests and Adjustments
Group 10 - Theory of Operation
Group 20 - Diagnostic Trouble Codes, ICC
Group 30 - Service ADVISOR Readings
Group 40 - Tests and Adjustments
Section 250 - Power Train Operation, Tests, and Adjustments
Group 10 - Component Location
Group 20 - Theory of Operation
Group 30 - Diagnostics
Group 40 - Tests and Adjustments
Section 260 - Steering and Brake Operation, Tests, and Adjustments
Group 10 - Component Location
Group 20 - Theory of Operation
Group 30 - Diagnostics
Group 40 - Tests and Adjustments
Group 10 - Service Tools and Kits
Section 299 - Service Tools
Group 10 - Safety
Recognize Safety Information...............................10-10-1
Understand Signal Words......................................10-10-1
Practice Safe Maintenance....................................10-10-2
Use Proper Tools...................................................10-10-2
Handle Fluids Safely - Avoid Fires........................10-10-2
Prevent Acid Burns................................................10-10-3
Prevent Battery Explosions...................................10-10-3
Handling Batteries Safely......................................10-10-3
Prepare for Emergencies.......................................10-10-4
Park Machine Safely..............................................10-10-4
Support Machine Properly.....................................10-10-5
Wear Protective Clothing.......................................10-10-5
Work in Clean Area...............................................10-10-5
Service Machines Safely.......................................10-10-5
Work In Ventilated Area.........................................10-10-6
Illuminate Work Area Safely..................................10-10-6
Replace Safety Signs............................................10-10-6
Use Proper Lifting Equipment................................10-10-6
Follow Tire Recommendations 10-10-7
Protect Against High Pressure Spray 10-10-7
Decommissioning - Proper Recycling and Disposal 10-10-
7 of Fluids and Components.............................
Live With Safety.....................................................10-10-8
Group 20 - General Specifications
Service Recommendations for O - Ring Boss 10-20-1 Fittings
Service Recommendations For Flat Face O - Ring 10-20-2 Seal Fittings....................................................
Metric Cap Screw Torque Values - Grade 7..........10-20-2
Metric Bolt and Screw Torque Values....................10-20-3
Unified Inch Bolt and Screw Torque Values..........10-20-4
Group 30 - Fuel, Lubricants, and Coolant
Diesel Fuel - North America 10-30-1
Diesel Fuel - Europe 10-30-1
Diesel Fuel Storage...............................................10-30-2
4 - Cycle Diesel Engine Oil - North America 10-30-2
Diesel Engine Oil - Europe....................................10-30-2
Biodegradable Oil..................................................10-30-3
Transaxle and MFWD Differential Oil....................10-30-3
Converting From HY - GARD to BIO HY - GARD.10-30-4
Grease - North America........................................10-30-4
Grease - Europe....................................................10-30-4 Alternative Lubricants............................................10-30-4
Synthetic Lubricants..............................................10-30-4
Lubricant Storage 10-30-5
Mixing of Lubricants..............................................10-30-5
Oil Filters 10-30-5
Operating in Warm Temperature Climates 10-30-5
Diesel Engine Coolant (engine without wet sleeve 10-30- 6 cylinder liners)
John Deere COOL - GARD™ II Coolant 10-30-6
Extender.........................................................
Testing Diesel Engine Coolant..............................10-30-7
Group 40 - Machine Specifications
Machine Specifications..........................................10-40-1
Product Serial Number..........................................10-40-1
Engine Serial Number Location.............................10-40-2
Group 10 Safety
Recognize Safety Information
Understand Signal Words
TS187-19: Signal Words
T81389-UN: Safety-alert symbol
This is a safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury.
Follow recommended precautions and safe operating practices.
DX,ALERT-19-19980929
DANGER; The signal word DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.
WARNING; The signal word WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION; The signal word CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. CAUTION may also be used to alert against unsafe practices associated with events which could lead to personal injury.
A signal word DANGER, WARNING, or CAUTION is used withthesafety-alertsymbol DANGERidentifiesthemostserious hazards. DANGER or WARNING safety signs are located near specific hazards General precautions are listed on CAUTION safetysigns.CAUTIONalsocallsattentiontosafetymessagesin this manual
DX,SIGNAL-19-20161005
Practice Safe Maintenance
Use Proper Tools
Handle Fluids Safely—Avoid Fires
Safety
TS218-UN: Keep Area Clean
Understand service procedure before doing work. Keep area clean and dry
Never lubricate, service, or adjust machine while it is moving
Keep hands, feet, and clothing away from power-driven parts
Disengage all power and operate controls to relieve pressure
Lower equipment to the ground Stop the engine Remove the key Allow machine to cool
Securely support any machine elements that must be raised for service work
Keep all parts in good condition and properly installed Fix damage immediately Replace worn or broken parts Remove any buildup of grease, oil, or debris.
On self-propelled equipment, disconnect battery ground cable () before making adjustments on electrical systems or welding on machine.
On towed implements, disconnect wiring harnesses from tractor before servicing electrical system components or welding on machine
Falling while cleaning or working at height can cause serious injury. Use a ladder or platform to easily reach each location. Use sturdy and secure footholds and handholds
DX SERV-19-20170228
TS779-UN: Proper Tools
Use tools appropriate to the work Makeshift tools and procedures can create safety hazards.
Use power tools only to loosen threaded parts and fasteners. For loosening and tightening hardware, use the correct size tools DO NOT use U S measurement tools on metric fasteners Avoid bodily injury caused by slipping wrenches
Use only service parts meeting John Deere specifications
DX REPAIR-19-19990217
TS227-UN: Avoid Fires
When you work around fuel, do not smoke or work near heaters or other fire hazards
Store flammable fluids away from fire hazards Do not incinerate or puncture pressurized containers
Make sure machine is clean of trash, grease, and debris
Do not store oily rags; they can ignite and burn spontaneously.
DX FLAME-19-19980929
Prevent Acid Burns
Prevent Battery Explosions
Handling Batteries Safely
TS203-UN: Acid Burns
Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes
Avoid the hazard by:
Filling batteries in a well-ventilated area
Wearing eye protection and rubber gloves. Avoiding breathing fumes when electrolyte is added. Avoiding spilling or dripping electrolyte
Use proper jump start procedure.
If you spill acid on yourself:
Flush your skin with water.
Apply baking soda or lime to help neutralize the acid
Flush your eyes with water for 15 30 minutes. Get medical attention immediately
If acid is swallowed:
Do not induce vomiting.
Drink large amounts of water or milk, but do not exceed 2 L (2 quarts)
Get medical attention immediately.
DX,POISON-19-19930421
TS204-UN: Battery Explosions
Keepsparks,lightedmatches,andopenflameawayfromthetop of battery. Battery gas can explode.
Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer.
Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).
DX,SPARKS-19-19930303
TS204-UN: Caution
TS203-UN: Caution
Always remove grounded (-) battery clamp first and replace grounded clamp last.
Sulfuric acid in battery electrolyte is poisonous and strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.
Avoid hazards by:
Filling batteries in a well-ventilated area
Wearing eye protection and rubber gloves
Avoiding use of air pressure to clean batteries
Avoiding breathing fumes when electrolyte is added
Avoiding spilling or dripping electrolyte
Using correct battery booster or charger procedure
If acid is spilled on skin or in eyes:
Flush skin with water
Apply baking soda or lime to help neutralize the acid
Flush eyes with water for 15 30 minutes. Get medical attention immediately.
If acid is swallowed:
Do not induce vomiting.
Drink large amounts of water or milk, but do not exceed 2 L (2 qt.).
Get medical attention immediately
WARNING:Battery posts, terminals, and related accessories
Battery gas can explode Keep sparks and flames away from contain lead and lead compounds, chemicals known to the State batteries Use a flashlight to check battery electrolyte level ofCaliforniatocausecancerandreproductiveharm Wash hands after handling
Never check battery charge by placing a metal object across the
DX WW BATTERIES-19-20101202 posts. Use a voltmeter or hydrometer.
Prepare for EmergenciesTS291-UN: First Aid Kit
Be prepared if a fire starts
Keep a first aid kit and fire extinguisher handy
Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.
DX,FIRE2-19-19930303
TS230-UN: Remove the Key
Before working on the machine:
Lower all equipment to the ground. Stop the engine and remove the key
Disconnect the battery ground strap
Hang a "DO NOT OPERATE" tag station in operator
DX,PARK-19-19900604
Support Machine Properly
Wear Protective Clothing
Work in Clean Area
Service Machines Safely
Safety
TS229-UN: Support Properly
Always lower the attachment or implement to the ground before youworkonthemachine Iftheworkrequiresthatthemachineor attachment be lifted, provide secure support for them If left in a raised position, hydraulically supported devices can settle or leak down
Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack Follow recommended procedures in this manual.
When implements or attachments are used with a machine, always follow safety precautions listed in the implement or attachment operator′s manual
DX,LOWER-19-20000224
TS206-UN: Protective Clothing
Wear close fitting clothing and safety equipment appropriate to the job.
Prolonged exposure to loud noise can cause impairment or loss of hearing.
Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises
Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine
DX WEAR-19-19900910
T6642EJ-UN: Clean Work Area
Before starting a job:
Clean work area and machine.
Make sure you have all necessary tools to do your job.
Have the right parts on hand
Read all instructions thoroughly; do not attempt shortcuts.
DX,CLEAN-19-19900604
TS228-UN: Moving Parts
Tie long hair behind your head Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts If these items were to get caught, severe injury could result.
Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.
DX LOOSE-19-19900604
Work In Ventilated Area
Illuminate Work Area Safely
Replace Safety Signs
Use Proper Lifting Equipment
TS220-UN: Engine exhaust fumes
Engine exhaust fumes can cause sickness or death If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension Ifyoudonothaveanexhaustpipeextension,openthedoorsand get outside air into the area.
DX,AIR-19-19990217
TS223-UN: Work Area Safely
Illuminate your work area adequately but safely Use a portable safety light for working inside or under the machine Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil
DX,LIGHT-19-19900604
TS201-UN: Safety Signs
Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement
DX,SIGNS1-19-19900604
TS226-UN: Proper Lifting Equipment
Lifting heavy components incorrectly can cause severe injury or machine damage.
Follow recommended procedure for removal and installation of components in the manual.
DX LIFT-19-19900604
Protect Against High Pressure Spray
Decommissioning—Proper Recycling and Disposal of Fluids and Components
TS1133-UN: Recycle Waste
Safety and environmental stewardship measures must be taken into account when decommissioning a machine and/or component. These measures include the following:
Use appropriate tools and personal protective equipment such as clothing, gloves, face shields or glasses, during the removal or handling of objects and materials
Follow instructions for specialized components. Release stored energy by lowering suspended machine elements, relaxing springs, disconnecting the battery or other electrical power, and releasing pressure in hydraulic components, accumulators, and other similar systems
H111235-UN: Read OM
Keep your machine in proper working order
Use only prescribed tire sizes with correct ratings and inflate to the pressure specified in this manual
Use of other than prescribed tires may decrease stability, affect steering, result in premature tire failure, or cause other durability or safety issues.
DX,TIRE,INFO-19-20140519
TS1343-UN: High Pressure Spray
Spray from high pressure nozzles can penetrate the skin and cause serious injury Keep spray from contacting hands or body
If an accident occurs, see a doctor immediately Any high pressure spray injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar withthistypeofinjuryshouldreferenceaknowledgeablemedical source Such information is available from Deere & Company Medical Department in Moline, Illinois, U S A
DX,SPRAY-19-19920416
Minimize exposure to components which may have residue from agricultural chemicals, such as fertilizers and pesticides Handle and dispose of these components appropriately.
Carefully drain engines, fuel tanks, radiators, hydraulic cylinders, reservoirs, and lines before recycling components. Use leak-proof containers when draining fluids. Do not use food or beverage containers
Do not pour waste fluids onto the ground, down a drain, or into any water source
Observe all national, state, and local laws, regulations, or ordinances governing the handling or disposal of waste fluids (example: oil, fuel, coolant, brake fluid); filters; batteries; and, other substances or parts. Burning of flammable fluids or components inotherthanspeciallydesignedincineratorsmaybe prohibited by law and could result in exposure to harmful fumes or ashes.
Service and dispose of air conditioning systems appropriately. Government regulations may require a certified service center to recover and recycle air conditioning refrigerants which could damage the atmosphere if allowed to escape.
Evaluate recycling options for tires, metal, plastic, glass, rubber, and electronic components which may be recyclable, in part or completely.
Contact your local environmental or recycling center, or your John Deere dealer for information on the proper way to recycle or dispose of waste.
DX,DRAIN-19-20150601
Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields
DX,LIVE-19-19920925
General Specifications
Service Recommendations for O-Ring Boss Fittings
Straight Fitting
T6243AE-UN: Straight Fitting
T6520AB-UN: Angle Fitting LEGEND: A-Lock Nut
B-Backup Washer
C-Head End
Group 20 General Specifications
1. Back off lock nut (A) and backup washer (B) completely to head end (C) of fitting.
2. Turn fitting into threaded boss until backup washer contacts face of boss.
3. Turn fitting head end counterclockwise to proper index (maximum of one turn).
4 NOTE:
Do not allow hoses to twist when tightening fittings
Hold fitting head end with a wrench and tighten locknut and backup washer to proper torque value
1 2 3 . Inspect O-ring boss seat for dirt or defects.
Lubricate O-ring with petroleum jelly Place electrical tape over threads to protect O-ring Slide O-ring over tape and into O-ring groove of fitting. Remove tape.
Tighten fitting to torque value shown on chart
Angle Fitting
3/8-24 UNF 7/16-20 UNF 1/2-20 UNF 9/16-18 UNF 3/4-16 UNF
7/8-14 UNF 1-1/16-12 UN 1-3/16-12 UN 1-5/16-12 UN 1-5/8-12 UN 1-7/8-12
General Specifications
Inspect the fitting sealing surfaces and O-ring. They must be free of dirt or defects
Lubricate O-rings and install into grove using petroleum jelly to hold in place.
Index angle fittings and tighten by hand pressing joint together to insure O-ring remains in place. 4
Tighten fitting or nut to torque value shown on the chart Do not allow hoses to twist when tightening fittings, use backup wrench on straight hose couplings.
IMPORTANT:
Tighten fittings to 150% of listed torque value if indexing is necessary or if fitting is attached to an actuating device.
Tighten fittings to 50% of listed torque value if used in aluminum housing FLAT FACE O-RING SEAL FITTING TORQUE*
050 7501 3/16-1210275 22 220 8751 3/16-1210275 25 401 0001 7/16-12142105 31 751 2501 11/16-12190140
10 1 500 2-12 217 160 *Torque tolerance is +15 -20% unless otherwise specified 3/8-24 5/8 9/16
Stud End O-ring Seal Torque for Straight and Adjustable Fittings* ThreadStraight HexLocknut HexStraight Fitting or Locknut
1/16-121 1/41 3/8176
3/16-121 3/81 1/2230
OUO6092,00010A4-19-20110531
NOTE: When bolting aluminum parts, specified in table tighten to 80% of torque
CED,OUO1085,12-19-20000731
General Specifications
Metric Bolt and Screw Torque Values
TS1670-UN: Metric Bolt and Screw
Class 4 8Class 8 8 or 9 8Class 10 9Class 12 9
Lubricated Dry Lubricated Dry Lubricated Dry Lubricated Dry [‘Lubricated”means [‘Dry”means [‘Lubricated”means [‘Dry”means [‘Lubricated”means [‘Dry”means [‘Lubricated”means [‘Dry”means Boltcoated with a lubricantplain or zinccoated with a lubricantplain or zinccoated with a lubricantplain or zinccoated with a lubricantplain or zinc orsuch as engine oil,plated withoutsuch as engine oil,plated withoutsuch as engine oil,plated withoutsuch as engine oil,plated without
Screwfasteners withanyfasteners withanyfasteners withanyfasteners withany Sizephosphate and oillubrication, orphosphate and oillubrication, orphosphate and oillubrication, orphosphate and oillubrication, or coatings, or M20 andM6 to M18coatings, or M20 andM6 to M18coatings, or M20 andM6 to M18coatings, or M20 andM6 to M18 larger fasteners withfasteners withlarger fasteners withfasteners withlarger fasteners withfasteners withlarger fasteners withfasteners with JDM F13C, F13F or F13JJDM F13B,JDM F13C, F13F or F13JJDM F13B,JDM F13C, F13F or F13JJDM F13B,JDM F13C, F13F or F13JJDM F13B, zinc flake coating ]F13E or F13Hzinc flake coating ]F13E or F13Hzinc flake coating ]F13E or F13Hzinc flake coating ]F13E or F13H zinc flakezinc flakezinc flakezinc flake coating ] coating ] coating ] coating ]
Torque values listed are for general use only, based on the strength of the bolt or Shear
screw DO NOT use these values if a different torque value or tightening
procedure is given for a specific application For stainless steel fasteners or for property class fasteners are used, tighten these to the strength of the original Make sure nuts on U-bolts, see the tightening instructions for the specific application Tighten fastener threads are clean and that you properly start thread engagement When possible, plastic insert or crimped steel type lock nuts by turning the nut to the dry torque lubricate plain or zinc plated fasteners other than lock nuts, wheel bolts or wheel nuts, shown in the chart, unless different instructions are given for the specific unless different instructions are given for the specific application application
DX TORQ2-19-20110112
General Specifications
Unified Inch Bolt and Screw Torque Values
TS1671-UN: Unified Inch Bolt and Screw
SAE Grade 2 [Grade 2 applies for hex cap screws (not hex bolts) up to 6 in (152 mm) long Grade 1 applies for SAE Grade 1SAE Grade 5, 5 1 or 5 2SAE Grade 8 or 8 2 hex cap screws over 6 in (152 mm) long, and for all other types of bolts and screws of any length ]
Bolt Lubricated Dry Lubricated Dry Lubricated Dry Lubricated Dry or [‘Lubricated”means [‘Dry”means [‘Lubricated”means [‘Dry”means [ Lubricated”means [‘Dry”means [‘Lubricated”means [‘Dry”means
Screwcoated with a lubricantplain or zinccoated with aplain or zinccoated with aplain or zinccoated with a lubricantplain or zinc
Sizesuch as engine oil,plated withoutlubricant such asplated withoutlubricant such asplated withoutsuch as engine oil,plated without fasteners withanyengine oil, fastenersanyengine oil, fastenersanyfasteners withany phosphate and oillubrication, orwith phosphate andlubrication, orwith phosphate andlubrication, orphosphate and oillubrication, or coatings, or 7/8 in and1/4 to 3/4 in oil coatings, or 7/8 in 1/4 to 3/4 in oil coatings, or 7/8 in 1/4 to 3/4 in coatings, or 7/8 in and1/4 to 3/4 in larger fasteners withfasteners withand larger fastenersfasteners withand larger fastenersfasteners withlarger fasteners withfasteners with JDM F13C, F13F or F13JJDM F13B,with JDM F13C, F13FJDM F13B,with JDM F13C, F13FJDM F13B,JDM F13C, F13F or F13JJDM F13B, zinc flake coating ]F13E or F13Hor F13J zinc flakeF13E or F13Hor F13J zinc flakeF13E or F13Hzinc flake coating ]F13E or F13H zinc flakecoating ]zinc flakecoating ]zinc flakezinc flake coating ] coating ] coating ] coating ]
725 535 1280 945
1200 2050 1500 2600 1920
1-3/8 750 550 950 700 750 550 950 700 1700 1250 2140 1580 2700 2000 3400 2500
1-1/2 990 730 1250 930 990 730 1250 930 2250 1650 2850 2100 3600 2650 4550 3350
Torque values listed are for general use only, based on the strength of the bolt or screw Replace fasteners with the same or higher grade If higher grade fasteners are DO NOT use these values if a different torque value or tightening procedure is given for a used, tighten these to the strength of the original Make sure fastener threads are specific application For plastic insert or crimped steel type lock nuts, for stainless steel clean and that you properly start thread engagement When possible, lubricate plain fasteners, or for nuts on U-bolts, see the tightening instructions for the specific application or zinc plated fasteners other than lock nuts, wheel bolts or wheel nuts, unless Shear bolts are designed to fail under predetermined loads Always replace shear bolts different instructions are given for the specific application with identical grade
DX,TORQ1-19-20110112
Fuel, Lubricants, and Coolant
Diesel Fuel North America
Use the proper diesel fuel to help prevent decreased engine performance and increased exhaust emissions. Failure to follow the fuel requirements listed below can void your engine warranty
Contact your local fuel distributor for properties of the diesel fuel in your area
In general, diesel fuels are blended to satisfy the low temperature requirements of the geographical area in which they are marketed.
Diesel fuels specified to EN 590 or ASTM D975 are recommended
Required fuel properties
In all cases, the fuel shall meet the following properties: Cetanenumberof45minimum Cetanenumbergreaterthan50 is preferred, especially when temperatures are below-20°C (-4°F) or elevations above 1500 m (5000 ft)
Cold Filter Plugging Point(CFPP) below the expected low temperature ORCloud Pointat least 5°C (9°F) below the expected low temperature.
Fuel, Lubricants, and Coolant
IMPORTANT:
Avoid Damage! Do not mix diesel engine oil or any other type of lubricating oil with diesel fuel.
Handling and Storing Diesel Fuel
CAUTION:
Avoid Injury! Handle fuel carefully. Do not fill the fuel tank when engine is running Do not smoke while you fill the fuel tank or service the fuel system.
IMPORTANT:
Avoid Damage! Do not use galvanized containers diesel fuel stored in galvanized containers reacts with zinc coating in the container to form zinc flakes If fuel contains water, a zinc gel will also form. The gel and flakes will quickly plug fuel filters and damage fuel injectors and fuel pumps
Fill fuel tank at end of each day’s operation to prevent water condensation and freezing during cold weather
IMPORTANT:
Avoid Damage! The fuel tank is vented through the filler cap. If a new cap is required, always replace it with an original vented cap
Sulfur content
Fuel lubricityshould pass a minimum load level of 3100 grams as measured by ASTM D6078 or maximum scar diameter of 0 45 mm as measured by ASTM D6079 or ISO 12156-1.
If a fuel of low or unknown lubricity is used, addition of John Deere PREMIUM DIESEL FUEL CONDITIONER at the specified concentration is recommended
Diesel fuel quality and fuel sulfur content must comply with all existing emissions regulations for the area in which the engine operates Sulfur content less that 0.05% (500 ppm) is recommended for best performance. Diesel fuel sulfur content greater than 0 5% (5000 ppm) should not be used.
Diesel Fuel—Europe
When fuel is stored for an extended period or if there is a slow turnover of fuel, add a fuel conditioner to stabilize the fuel and to prevent water condensation Contact your fuel supplier for recommendations.
OUO1086 1000401-19-20120615
A cetane number greater than 50 is preferred, especially for air temperatures below-20°C (-4°F) or elevations above 1500 m (5000 ft).
In general, diesel fuels are blended to satisfy the low air temperaturerequirementsofthegeographicalareainwhichtheyCold Filter Plugging Point (CFPP) are sold
InEurope,dieselfuelisusuallyspecifiedtoEN590andsoldinfive The temperature at which diesel fuel begins to cloud or jell Use different classes or six different grades dieselfuelswithaCFPPwhichisatleast5°C(9°F)belowthe expected low air temperature If diesel fuels being supplied in your area DO NOT meet any of the above specifications, use diesel fuels with the following Sulfur Content of 0.05% (Max) equivalent properties:
If diesel fuel being used has a sulfur content greater than 0 05%, Cetane Number 40 (Min) reduce the service interval for engine oil and filter by 50%.
Consult your local diesel fuel distributor for properties of the diesel fuel available in your area. OUO1086,1000402-19-20120615
Diesel Fuel Storage
IMPORTANT: IMPORTANT:
Fuel, Lubricants, and Coolant
prevent possible igniting of fumes by an open flame or spark; this includes any appliance with a pilot light.
Avoid Damage! DO NOT USE GALVANIZED Avoid Damage! Keep all dirt, scale, water, or other foreign CONTAINERS dieselfuelstoredingalvanizedcontainersmaterial out of fuel. reacts with zinc coating in the container to form zinc flakes If fuel contains water, a zinc gel will also form. The gel and flakes will quickly plug fuel filters and damage fuel injectors and fuel pumps
Keep fuel in a safe, protected area and in a clean, properly marked (‘DIESEL FUEL”)container. DO NOT use deicers to attempt to remove water from fuel DO NOT depend on fuel filters to remove water from fuel. It is recommended that a water It is recommended that diesel fuel be stored ONLY in a clean, separator be installed in the storage tank outlet. BE SURE to approved POLYETHYLENE PLASTIC container WITHOUT any properly discard unstable or contaminated diesel fuel and/or their metalscreenorfilter.Thiswillhelppreventanyaccidentalsparkscontainers when necessary. from occurring Store fuel in an area that is well ventilated to OUO1086,1000403-19-20120615
4-CycleDieselEngineOil—NorthTORQ-GARD SUPREMETorq-Gard Supreme™
America OtheroilsmaybeusedifaboveJohnDeereoilsarenotavailable, provided they meet one of the following specifications: Use the appropriate oil viscosity based on the expected air temperaturerangeduringtheperiodbetweenrecommendedoilAPI Service Classifications CF or higher changes Operating outside of these recommended oil air temperature ranges may cause premature engine failure.OtheroilsmaybeusedifaboveJohnDeereoilsarenotavailable, provided they meet one of the following specifications: The following John Deere oils are PREFERRED:
PLUS-50Plus-50™
Diesel Engine Oil Europe
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®-SAE 15W-40
SAE 15W-40 API Service Classification CF-4 or higher.
SAE 5W-30 API Service Classification CC or higher. SAE 10W-30 API Service Classification CF or higher.
SAE 30 API Service Classification CF or higher.
Plus-50 is a trademark of Deere & Company Torq-Gard Supreme is a trademark of Deere & Company
UNI-GARD® SAE 15W-40
TORQ-GARD SUPREME SAE 5W-30.
TORQ-GARD SUPREME SAE 5W-30.
UNI-GARD SAE 5W-30
The following John Deere oils are also recommended, based on their specified temperature range:
TORQ-GARD SUPREME- SAE 10W-30.
UNI-GARD SAE 10W-30.
TORQ-GARD SUPREME SAE 30
UNI-GARD SAE 30.
OtheroilsmaybeusedifaboveJohnDeereoilsarenotavailable, provided they meet the following specification:
CCMC Specification D4 or Mercedes Benz MB228.1 or higher.
Fuel, Lubricants, and Coolant
Biodegradable Oil
Application
IMPORTANT:
Avoid Damage! Biodegradable oils, other than BIO HYGARD Hy-Gard™ , are not recommended.
Mixing of biodegradable oil and mineral oil will reduce the biodegradability of the lubricant in the machine. Mixing of HY-GARD and BIO HY-GARD will not result in performance deterioration
Cold Weather Operation
Precautions should be taken if BIO HY-GARD containers or equipment are stored for long periods of time in extremely cold temperatures. Freezing should be expected if BIO HY-GARD is Whenuseofabiodegradablelubricantisdesiredorrequired,BIOsubjected to the following temperatures: HY-GARD is recommended. BIO HY-GARD may be used under normal mowing conditions
DO NOT USE biodegradable lubricants in machines for the following operations:
Any machine used for scalping procedure.
Any verticut operation in temperatures exceeding 32°C (90°F)
BIO HY-GARD should be used only in cases where the benefits of its use offset the extra initial cost, the increased oil change cost and the potential increasing maintenance costs for hydraulic systems with high temperatures and heavy loads
If the natural color of the fluid has become black, it is possible an overheating problem exists. Change the fluid
Stored for six months at-18° to-23°C (-1° to-10°F)
Stored for seven days at-23° to-26°C (-10° to-15°F)
Stored for three days at-26° to-29°C (-15° to-20°F)
Stored for two days at-29° to-34°C (-20° to-30°F)
Stored for one day at-34°C (-30°F) and below.
IMPORTANT:
Avoid Damage! Equipment should not be started or any operation attempted until BIO HY-GARD has reached a safe operating viscosity.
If freezing of BIO HY-GARD is suspected, the container or equipment MUST be warmed to at least 0°C (32°F) and maintainedfor24-48hourstoensurethefluidhasreachedasafe operating viscosity
Hy-Gard is a trademark of Deere & Company
If the fluid becomes milky, water contamination may be a problem. Investigate the source of the contamination
Take fluid level reading when system is cold.
Transaxle and MFWD Differential Oil
Use the appropriate oil viscosity based on these air temperature ranges Operating outside of these recommended oil air temperature ranges may cause premature hydrostatic transmission or hydraulic system failures
IMPORTANT:
Avoid Danger! Mixing of LOW VISCOSITY Hy-Gard™ and HyGard™ transmission oils is permitted. DO NOT mix any other oils in this transmission DO NOT use engine oils or‘Type F”(Red) Automatic Transmission Fluid in this transmission
OUO1086,1000407-19-20120615
TS1660-UN: Transaxle Oil Ranges
John Deere J20C Hy-Gard™ transmission and hydraulic oil is recommended. John Deere J20D Low Viscosity Hy-Gard™ transmission and hydraulic oil may be used, if within the specified temperature range
Fuel, Lubricants, and Coolant
OtheroilsmaybeusedifaboverecommendedJohnDeereJohn Deere Standard JDM J20D. oils are not available, provided they meet one of the following specifications:Hy-Gard is a trademark of Deere & Company
John Deere Standard JDM J20C;
Converting From HY-GARD to BIO HYGARD
Systems being converted from HY-GARD to BIO HY-GARD should follow the procedure listed below to obtain maximum lubricant biodegradability.
Park machine on a level surface.
Lower cutting units, stop engine, set park brake and remove key from ignition
Drain hydraulic reservoir.
Replace hydraulic filter.
Grease - North America
IMPORTANT:
Avoid Damage! ONLY use a quality grease application DO NOT mix any other greases application DO NOT use any BIOGREASE application
Fill reservoir with BIO HY-GARD to appropriate level
Start engine and bring to medium idle.
Turn steering wheel full stroke several times and cycle cutting units several times
Stop engine and check hydraulic oil level. Add BIO HY-GARD to appropriate level
Operate machine under normal operating conditions for a minimum of two hours.
Repeat steps 1-8
Follow recommended maintenance schedules
OUO1086
The following John Deere greases are preferred for the cutting units and unit attachments:
John Deere Golf and Turf Cutting Unit Grease
John Deere Cornhead Grease
John Deere Cotton Picker Spindle Grease
Other greases may be used if above preferred John Deere greases are not available, provided they meet the following specifications:
The following John Deere greases are preferred for the machine and lift arms:
John Deere Special Purpose HD Water Resistant Grease
John Deere Multi-Purpose HD Lithium Complex Grease
Grease - Europe
Use the following grease based on the air temperature range
Polyurea Grease - NLGI Grade 2
Calcium Complex Grease - NLGI Grade 2.
JohnDeereStandardJDMJ13E4-NLGIGrade2
OUO1086,1000409-19-20120615
Reel Support Grease - JDM J13E6, NLGI Grade 0
Other greases may be used if above preferred John Deere Operating outside of the recommended grease air temperature greases are not available, provided they meet the following range may cause premature failures. specifications:
Reel Support Grease Applications:
IMPORTANT:
Avoid Damage! ONLY use a quality grease application DO NOT mix any other greases application. DO NOT use any BIOGREASE application in in in in in in this this this this this this
The following John Deere greases are PREFERRED:
GREASE-GARD™-JDM J13E4, NLGI Grade 2
Alternative Lubricants
Polyurea Grease - NLGI Grade 2
Calcium Complex Grease - Grade 2
Lithium Complex Grease - NLGI Grade 0.
John Deere Standard JDM J13E4 - NLGI Grade 2
OUO1086 100040A-19-20120615
If alternative lubricants are to be used, it is recommended that the factory fill be thoroughly removed before switching to any alternative lubricant.
Use of alternative lubricants could cause reduced life of the OUO1086,100040B-19-20120615 component
Synthetic Lubricants
The recommended air temperature limits and service or lubricant changeintervalsshouldbemaintainedasshownintheoperator’s manual, unless otherwise stated on lubricant label.
Synthetic lubricants may be used in John Deere equipment if they meet the applicable performance requirements (industry Avoid mixing different brands, grades, or types of oil. Oil classification and/or military specification) as shown in this manufacturers blend additives in their oils to meet certain manual. specifications and performance requirements. Mixing different
Fuel, Lubricants, and Coolant
oils can interfere with the proper functioning of these additives
OUO1086,100040C-19-20120615 and degrade lubricant performance
Lubricant Storagecontamination.Storedrumsontheirsides.Makesureall
containers are properly marked as to their contents. Dispose of all old, used containers and their contents properly
All machines operate at top efficiency only when clean lubricants
OUO1086,100040D-19-20120615 are used Use clean storage containers to handle all lubricants
Store them in an area protected from dust, moisture, and other
Mixing of Lubricantslubricantscaninterferewiththeproperfunctioningofthese
additives and lubricant properties which will downgrade their intended specified performance
In general, avoid mixing different brands or types of lubricants.
Manufacturers blend additives in their lubricants to meet certain specifications and performance requirements Mixing different
Oil FiltersMostJohnDeerefilterscontainpressurereliefandanti-drainback
IMPORTANT:
valves for better engine protection.
Avoid Damage! Filtration of oils is critical to proper lubrication performance. Always change filters regularly.
OUO1086,100040E-19-20120615
ASTB Tested In Accordance With SAE J806
Other oil filters may be used if above recommended John Deere oil filters are not available, provided they meet the following specification:
OUO1086 100040F-19-20120615
The following John Deere oil filters are PREFERRED:
Automotive and light truck engine oil filters
Operatin g Climates in Warm Temperature
John Deere engines are designed to operate using recommended engine coolants.
Always use a recommended engine coolant, even when operating in geographical areas where freeze protection is not required
IMPORTANT:
Water may be used as coolantin emergency situations only
Foaming, hot surface aluminum and iron corrosion, scaling, andcavitationoccurwhenwaterisusedasthecoolant,even when coolant conditioners are added.
Drain cooling system and refill with recommended engine coolant as soon as possible
DX,COOL6-19-20130515
Fuel, Lubricants, and Coolant
Diesel Engine Coolant (engine without wet sleeve cylinder liners)
Preferred Coolants
The following pre-mix engine coolants are preferred:
John Deere COOL-GARD™II
John Deere COOL-GARD II PG
COOL-GARD II pre-mix coolant is available in several concentrations with different freeze protection limits as shown in the following table.
COOL-GARD II pre-mix Freeze Protection Limit
COOL-GARD II Water-Base
COOL-GARD II 20/80
COOL-GARD II 30/70
COOL-GARD II 50/50
COOL-GARD II 55/45
COOL-GARD II PG 60/40
Coolant concentrate meeting ASTM D6210 requirements in a 40 60% mixture of concentrate with quality water
Pre-mix coolant meeting ASTM D3306 requirements
Coolant concentrate meeting ASTM D3306 requirements in a 40 60% mixture of concentrate with quality water
If coolant meeting one of these specifications is unavailable, use a coolant concentrate or pre-mix coolant that has a minimum of the following chemical and physical properties:
Is formulated with a nitrite-free additive package
Protects the cooling system metals (cast iron, aluminum alloys, and copper alloys such as brass) from corrosion
Water Quality
Water quality is important to the performance of the cooling system. Distilled, deionized, or demineralized water is recommended for mixing with ethylene glycol and propylene glycol base engine coolant concentrate.
COOL-GARD II 60/40
Not all COOL-GARD II pre-mix products are available in all Coolant Drain Intervals countries
Use COOL-GARD II PG when a non-toxic coolant formulation is required Drain and flush the cooling system and refill with fresh coolant at the indicated interval, which varies with the coolant used
When COOL-GARD II or COOL-GARD II PG is used, the drain
Additional Recommended Coolantsinterval is 6 years or 6000 hours of operation.
If a coolant other than COOL-GARD II or COOL-GARD II PG
The following engine coolant is also recommended:isused,reducethedrainintervalto2yearsor2000hoursof operation.
IMPORTANT:
John Deere COOL-GARD II Concentrate in a 40 60% mixture of concentrate with quality water
Do not use cooling system sealing additives or antifreeze that contains sealing additives
IMPORTANT:
When mixing coolant concentrate with water, do not use Do not mix ethylene glycol and propylene glycol base less than 40% or greater than 60% concentration of coolant coolants Less than 40% gives inadequate additives for corrosion protection Greaterthan60%canresultincoolantgelationDo not use coolants that contain nitrites and cooling system problems
COOL-GARD is a trademark of Deere & Company
DX,COOL18-19-20130515
Other Coolants
Other ethylene glycol or propylene glycol base coolants may be used if they meet one of the following specifications:
Pre-mix coolant requirements meeting ASTM D6210
John Deere COOL-GARD™ II Coolant Extender
Some coolant additives gradually deplete during engine operation For COOL-GARD™ II pre-mix and COOL-GARD II
Concentrate, replenish coolant additives between drain intervals by adding COOL-GARD II Coolant Extender.
COOL-GARD II Coolant Extender should not be added unless indicated by COOL-GARD II Test Strips. These test strips provide
a simple, effective method to check the freeze point, additive levels, and pH of your engine coolant
Test the coolant solution at intervals of 12 months and whenever excessive coolant is lost through leaks or overheating
IMPORTANT:
Do not use COOL-GARD II Test Strips with COOL-GARD II PG.
Fuel, Lubricants, and Coolant
COOL-GARD II Coolant Extender is a chemically matched The use of non-recommended supplemental coolant additives additive system for use with all COOL-GARD II coolants. COOL- can result in additive drop-out, gelation of the coolant, or GARDIICoolantExtenderisnotintendedforusewithnitrite-corrosion of cooling system components containing coolants
Add the recommended concentration of COOL-GARD II Coolant Extender DO NOT add more than the recommended amount
IMPORTANT:
COOL-GARD is a trademark of Deere & Company
Do not add a supplemental coolant additive when the cooling system is drained and refilled with any of the following:
John Deere COOL-GARD II
John Deere COOL-GARD II PG
Testing Diesel Engine Coolant
DX,COOL16-19-20130515
Add only the recommended concentration of John Deere COOLGARD II Coolant Extender. DO NOT add more than the recommended amount
Maintaining adequate concentrations of glycol and inhibiting additives in the coolant is critical to protect the engine and cooling systemagainstfreezing,corrosion,andcylinderlinererosionandWhen Using Nitrite-Containing Coolants pitting
Test the coolant solution at intervals of 12 months or less and Compare the test strip results to the supplemental coolant whenever excessive coolant is lost through leaks or overheating.additive(SCA)charttodeterminetheamountofinhibiting additives in your coolant and whether more John Deere Liquid Coolant Conditioner should be added Coolant Test Strips
Add only the recommended concentration of John Deere Liquid Coolant Conditioner DO NOT add more than the recommended Coolant test strips are available from your John Deere dealer. amount. These test strips provide a simple, effective method to check the freeze point and additive levels of your engine coolant Coolant Analysis
When Using John Deere COOL-GARD II
Foramorethoroughevaluationofyourcoolant,performacoolant analysis. The coolant analysis can provide critical data such John Deere COOL-GARD II Premix™ , COOL-GARD II PG as freezing point, antifreeze level, pH, alkalinity, nitrite content Premix and COOL-GARD II Concentrate are maintenance free (cavitation control additive), molybdate content (rust inhibitor coolants for up to six years or 6000 hours of operation, provided additive), silicate content, corrosion metals, and visual that the cooling system is topped off using only John Deere assessment. COOL-GARD II Premix or COOL-GARD II PG premix Test the coolant condition annually with coolant test strips designed for Contact your John Deere dealer for more information on coolant use with John Deere COOL-GARD II coolants If the test strip analysis chartindicatesthatadditiveisrequired,addJohnDeereCOOL-COOL-GARD is a trademark of Deere & Company GARD II Coolant Extender as directed DX,COOL9-19-20110411
Machine Specifications
Machine Specifications
NOTE:
Specifications and design subject to change without notice
Group 40 Machine Specifications
HPX 815EHPX815E (EEC)
Ground Speed:
Reverse Engine:
Make
Engine Power Information
Type
Model
Steering: Brakes:
Cylinders
Displacement
Bore
Stroke Injection
Cooling
Air Cleaner
Engine Shut Off
Product Serial Number
Dimensions:
Overall Length with Bumper2 87 m (113 in) Overall Width1.52 m (60.0 in)
MX52301,00018E2-19-20180122
MXT022127-UN: Product S N Location
LEGEND:
A-Product Identification Number
The13-digitproductidentificationnumber(A)isontheright-hand side frame.
MX52301,00018E3-19-20180122
Machine Specifications
Engine Serial Number Location
MXT010283-UN: Diesel Engine S N Location
Engine serial number (A) is on valve cover. The model number designates the engine type
BS62576,00020AD-19-20180122
Group 10 - Repair
Summary of References........................................
Essential or Recommended Tools.........................
Service Equipment and Tools................................
Other Material........................................................
Specifications........................................................
Remove and Install Engine....................................
Remove and Install Muffler
Remove and Install Rocker Arm Cover
Remove and Install Rocker Arm and Push Rods
Remove and Install Cylinder Head
Recondition Cylinder Head
Remove and Install Exhaust Manifold
Remove and Install Rear Crankshaft Oil Seal
Remove and Install Front Crankshaft Oil Seal
Remove and Install Timing Gear Cover
Check Camshaft End Play
Check Timing Gear Backlash
Remove and Install Idler Gear
Remove and Install Cam Followers
Remove and Install Camshaft
Remove and Install Oil Pan and Strainer
Check Connecting Rod Side Play
Check Crankshaft End Play
Remove and Install Crankshaft and Main 20-10-47 Bearings
Remove and Install Flywheel 20-10-50 Remove and Install Flywheel Plate 20-10-51 Remove and Install Timing Gear Housing 20-10-52 Remove and Install Oil Pump 20-10-53 Oil Pressure Regulating Valve 20-10-55 Coolant Temperature Switch 20-10-55 Remove and Install Thermostat 20-10-56
Remove and Install Water Pump 20-10-57
Remove and Install Fuel Filter 20-10-57
Remove and Install Fuel Filter Assembly 20-10-58
Remove and Install Fuel Transfer Pump 20-10-60
Remove and Install Fuel Injection Nozzle.............20-10-61
Remove and Install Fuel Injection Pump...............20-10-64
Remove and Install Fuel Control and Governor 20-10-67 Linkage
Remove and Install Fuel Shutoff Solenoid 20-10-68 Repair Starting Motor 20-10-69 40 Amp Alternator 20-10-72
Repair
Summary of References
Remove and Install Engine
Remove and Install Muffler
Remove and Install Rocker Arm Cover
Remove and Install Cylinder Head
Recondition Cylinder Head
Remove and Install Exhaust Manifold
Remove and Install Rear Crankshaft Oil Seal
Remove and Install Front Crankshaft Oil Seal
Remove and Install Timing Gear Cover
Check Camshaft End Play
Check Timing Gear Backlash
Remove and Install Idler Gear
Remove and Install Cam Followers
Remove and Install Camshaft
Remove and Install Oil Pan and Strainer
Check Connecting Rod Side Play
Check Crankshaft End Play
Check Connecting Rod Bearing Clearance
Check Crankshaft Main Bearing Clearance
Remove, Inspect, and Install Connecting Rod
Essential or Recommended Tools
NOTE:
Order tools from the SERVICEGARD™ Catalog.
ESSENTIAL TOOLS listed are required to perform the job
Disassemble and Assemble Pistons
Cylinder Bore
Remove and Install Crankshaft and Main Bearings
Remove and Install Flywheel
Remove and Install Flywheel Plate
Remove and Install Timing Gear Housing
Remove and Install Oil Pump
Oil Pressure Regulating Valve
Coolant Temperature Switch
Remove and Install Thermostat
Remove and Install Water Pump
Remove and Install Fuel Filter
Remove and Install Fuel Filter Assembly
Remove and Install Fuel Transfer Pump
Remove and Install Fuel Injection Nozzle
Remove and Install Fuel Injection Pump
Remove and Install Fuel Control and Governor Linkage
Remove and Install Fuel Shutoff Solenoid
Repair Starting Motor 40 Amp Alternator
MX52301 0001669-19-20171218
RECOMMENDED TOOLS, as noted, are suggested to perform the job correctly Some tools may be available from local suppliers or may be fabricated.
Center Distance Gauge JDG1749
Setting Center Distance Between Engine and Transaxle
Magnetic Follower Holder Kit.......D15001NU
Used to hold followers away from camshaft during removal Clutch Removal Tool JDG1641
Used to remove clutch Nozzle Cleaning Kit JDF13
Used to clean fuel injector nozzles
SERVICEGARD is a trademark of Deere & Company correctly and are obtainable only from the SERVICEGARD™ Catalog
MX52301,00018F8-19-20171218
Service Equipment and Tools
NOTE:
Order tools according to information given in the SERVICEGARD™ Catalog Some tools may be available from a local supplier.
Clutch Center Distance Gauge JDG10358
Establish engine position and shims
Valve Spring Compressor JDE138
Used to remove and install valve components. Valve Guide Driver.......JDG504 Used to install valve guides
SERVICEGARD is a trademark of Deere & Company
MX52301 00018F9-19-20171218
Other Material
N/A (U S )
Form-In-Place Gasket
to mating surfaces of rear
N/A (U S ) PM37465 (U.S.)
Name Use
Thread Lock (MediumApply to threads of timing gear housing Strength)cap screws
John Deere™ Form-In-Place
Apply to timing gear cover mating surfaces Gasket
MX52301,00018FA-19-20180108
Item Measurement Specification
50 N m
Four Main Mounting Cap ScrewTorque (37 lb ft) 37 N·m Clutch Cap ScrewTorque (26 lb ft) 30 44 N m Fifth Isolator Mounting Cap Screw and NutTorque (22 32 lb ft)
2 2 L Engine Oil With FilterCapacity (2 3 qt)
28 N m Muffler Mount NutsTorque (248 lb in)
11 N m
Rocker Arm Cover BoltTorque (97 lb in) 11 97–11 98 mm Rocker Arm Shaft–StandardOD (0 471–0 472 in)
11 95 mmRocker Arm Shaft–Wear LimitOD (0 470 in) 12 00–12 02 mm Rocker Arm Shaft/Support–StandardID (0 472–0 473 in)
12 09 mmRocker Arm Shaft/Support–Wear LimitID (0.476 in)
0 02–0 05 mm
Rocker Arm Shaft/SupportClearance(0 001–0 002 in)
0 13 mmRocker Arm Shaft/Support–Wear LimitClearance (0 005 in) 0–0 03 mm
Rod BendDistance (0 0–0 001 in) 26 N m Rocker Arm Support BoltTorque (230 lb in) 27 N·m Cylinder Head Bolt–First PassTorque (20 lb ft)
54–58 N m
Cylinder Head Bolt–Final PassTorque (40–43 lb ft)
Cylinder Head Distortion–StandardOut-of-Flat(0 002inor less)
0 15 mm
Cylinder Head Distortion–Wear LimitOut-of-Flat (0 006 in)
1 028 1 202
mm Intake Valve SeatWidth (0 041 0 047 in)
1 308 1 52 mm
Exhaust Valve SeatWidth (0 051 0 060 in)
0 9 1 1 mm
Valve Face Margin–IntakeDistance(0 035 0 043 in)
1 0 1 2 mm
Valve Face Margin–ExhaustDistance(0 039 0 047 in)
0 51 mm
Valve Face Margin–Wear Limit (Intake and Exhaust)Distance (0 020 in)
Valve Face Angle–IntakeAngle30°
Valve Face Angle–ExhaustAngle45°
Valve Stem–IntakeDiameter(0 235 0 235 in)
Valve Stem–ExhaustDiameter(0.234 0.235 in)
5 90 mm
Item Measurement Specification
ValveGuide-to-ValveStem(Intakeand0 17 mm
Clearance Exhaust)–Wear Limit(0 007 in)
9 8 10 mm
Valve Guide HeightHeight(0 386 0 394 in)
37.8 mm
Valve Spring Free Length (C)Length (1 488 in)
1 3 mm
Maximum Spring Inclination (B)Distance (0 051 in)
Lower Valve Seat SurfaceAngle70°
Upper Valve Seat SurfaceAngle15° 11 N m
Cylinder Head Cap ScrewsTorque (97 lb in)
Muffler Support Bracket Cap ScrewsTorque (17–21 lb ft)
11 N m
Seal Case-to-Block Cap ScrewsTorque (97 lb in)
9 N m
Seal Case to Oil Pan Spacer Cap ScrewsTorque (80 lb in)
83 N m
Flywheel BoltsTorque (61 lb ft)
59 N m
Stub Shaft-to-Flywheel Cap ScrewsTorque (44 lb·ft)
37 N m
Clutch Mounting Cap ScrewTorque (27 lb ft) 113–123 N·m
Crankshaft Pulley Cap ScrewTorque (83–90 lb ft)
9 N m
Timing Cover Cap ScrewsTorque (80 lb in)
CamshaftEnd Play(0 002 0 006 in)
Timing GearBacklash(0 002 0 005 in)
0 14 mm
Timing Gear (All)–Wear LimitBacklash (0 006 in)
36.95–36.98
0 05 mm or less
Valve Stem (Intake and Exhaust)–Wear LimitDiameter (0 232 in) 0 40 0 60 mm
Valve Recession (Intake and Exhaust)Distance(0 016 0 024 in)
0 9 mm
Valve Recession (Intake)–Wear LimitDistance (0 035 in)
0 8 mm
Valve Recession (Exhaust)–Wear LimitDistance (0 03 in)
6 0 6 01 mm
Valve Guide ID–StandardID(0 236 0 237 in)
6 08 mm
Valve Guide ID–Wear LimitID (0 239 in)
Valve Guide-to-Valve Stem (Intake and Clearance (0 006 0 007 Exhaust)–Knurling Range in)
15 0 17 mm
Valve Guide-to-Valve Stem Oil Clearance: 0 03 0 05 mm Intake (0 001 0 002 in)
mm Idler Gear Shaft–StandardDiameter(1.455–1.456 in)
36 90 mm
Idler Gear Shaft–Wear LimitDiameter (1 452 in)
37 0–37 025
mm Idler Gear Bushing–StandardID (1 4567–1 4577 in)
0 03–0 08 mm
Idler Gear Bushing OilClearance(0.001–0.003 in)
0 18 mm
Idler Gear Bushing Oil–Wear LimitClearance (0 007 in)
20 93–20 96
mm Cam Follower–StandardDiameter (0 824–0 825 in)
20 90 mm
Cam Follower–Wear LimitDiameter (0 823 in)
21 00–21 02
mm Cam Follower Bore–StandardDiameter (0 827–0 828 in)
21 04 mm
Cam Follower Bore–Wear LimitDiameter (0 828 in)
0 13 mm
Cam Follower-to-Bore–Wear LimitClearance (0 005 in)
0 04–0 09 mm
Cam Follower-to-Bore–StandardClearance(0 002–0 004 in)
11 N m
Camshaft Cap ScrewsTorque (97 lb in)
0 05–0 15 mm
Camshaft Side GapGap(0 002–0 006 in)
0 00–0 02 mm
Camshaft Bend–StandardDeflection
0 05 mm
Camshaft Bend–Wear LimitDeflection (0 002 in)
34 14–34 27
mm
Camshaft Lobe–StandardHeight (1 343–1 349 in)
33 89 mm
Camshaft Lobe–Wear LimitHeight (1 334 in)
39 94–35 96
Camshaft Gear Side and Flywheel End mm Diameter Journals–Standard (1 572–1 573 in)
CamshaftGearSideandFlywheelEndJournals–Wear39 91 mm
Diameter Limit(1 571 in)
(0 00–0 001 in)
Item
Camshaft Intermediate Journal OD–Standard
Camshaft Intermediate Journal OD–Wear Limit
Camshaft Bushing–Standard
Camshaft Bushing–Wear Limit
Camshaft Bushing-to-Camshaft
Camshaft Intermediate Bore ID’s: Standard
Wear Limit
Oil Clearance
Camshaft Flywheel-End Bore ID’s:
Standard
Wear Limit
Oil Clearance
Oil Strainer to-Block Cap Screws
Oil Pan-to-Engine Cap Screws
Oil Pan-to-Timing Gear Housing Cap Screws
Connecting Rod Side Play
Crankshaft
Connecting Rod Cap Screw
Connecting Rod-to-Crankshaft–Standard
Connecting Rod-to-Crankshaft–Wear Limit
Main Bearing Cap Screws (Oil Applied)
Crankshaft Main Bearing–Standard
Crankshaft Main Bearing–Wear Limit
Connecting Rod Cap Screw
Connecting Rod Bearing–Standard
Connecting Rod Bearing
Connecting Rod Bearing–Standard
Connecting Rod Bearing–Wear Limit
Connecting Rod Cap Screw
Piston Ring Groove Clearance:
Top Ring–Standard
Top Ring–Wear Limit
Second Ring–Standard
Second Ring–Wear Limit
Oil Ring–Standard
Standard Piston Ring End Gap:
First Compression Ring–Standard
Measurement Specification
39 91–39 94 mm
Diameter (1 571–1 572 in)
39 88 mmDiameter (1 569 in)
Item
First Compression Ring–Wear Limit
Second Compression Ring–Standard
Second Compression Ring–Wear Limit
40.0–40.08 mm
Diameter (1 575–1 578 in)
40 15 mm
Diameter (1 580 in)
0 04–0 14 mm
Clearance (0 002–0 005 in)
40.0–40.03 mm (1 575–1 576 in)
40 1 mm (1 579 in)
0 07–0 12 mm (0 003–0 005 in)
40 0–40 03 mm (1 575–1 576 in)
40 1 mm (1 579 in)
0 04–0 09 mm (0 002–0 003 in)
11 N m
Torque (97 lb in)
25 N m
Torque (221 lb·in)
20 N m
Torque (177 lb in)
0 20 0 40 mm
Clearance (0 008 0 016 in)
0.11 0.25 mm
End Play(0 004 0 010 in)
22 6 27 5 N m (16 6 20 2
Torque lb ft)
(200 243 lb in)
0 02 0 06 mm
Clearance (0 001 0 002 in)
0 11 mm
Clearance (0 004 in)
Torque (56 60 lb ft)
75.5 81.5 N m
0 02 0 05 mm
Clearance (0.001 0.002 in)
0 12 mm
Clearance (0 005 in)
22 6–27 5 N·m
Torque (16 6–20 2 lb ft)
37 982–38 10
mm
Diameter (1 495–1 496 in)
1 50–1 51 mm
Thickness (0.059 in)
0 02–0 06 mm
Clearance (0 001–0 002 in)
0 11 mm
Clearance (0 004 in)
22 6–27 5 N m
Torque (200–243 lb·in)
0 06 0 10 mm
Clearance (0.002 0.004 in)
0 20 mm
Clearance (0 0079 in)
0 05 0 09 mm
Clearance (0 002 0 0035 in)
0 20 mm
Clearance (0 008 in)
0 02 0 06 mm
Clearance (0 001 0 002 in)
0 15 0 30 mm
Gap (0 006 0 012 in)
Oil Ring–Standard
Oil Ring–Wear Limit
Piston Pin–Standard
Piston Pin–Wear Limit
Piston Pin Bore–Standard
Piston Pin Bore–Wear Limit
Piston Pin Bore–Standard
Piston Pin Bore–Wear Limit
Piston Pin Bushing–Standard
Piston Pin Bushing–Wear Limit
Piston Pin–Standard
Piston Pin–Wear Limit
Measuring Distance (A)
Standard-Sized Piston
Standard-Sized Piston–Wear Limit
Standard Size Cylinder Bore
Cylinder Bore–Wear Limit
Piston-to-Cylinder
Cylinder
Cylinder–Wear Limit
Cylinder
Cylinder–Wear Limit
Main Bearing Cap Screws
Crankshaft
Crankshaft Connecting Rod Journal–Standard
Crankshaft Connecting Rod Journal–Wear Limit
Crankshaft Main Bearing Journal–Standard
Crankshaft Main Bearing Journal–Wear Limit
Main Bearing–Standard
Main Bearing
Main Bearing Oil Clearance
Main Bearing Oil Clearance–Wear Limit
Flywheel Bolts
Measurement Specification
0 39 mm Gap (0 015 in) 0 18 0 33 mm
Gap (0 007 0 013 in)
Item
Clutch Bolt
Flywheel Plate Cap Screws
Timing Gear Housing Mounting Cap Screws
Oil Pump Outer Rotor-to-Timing Cover–Standard
Oil Pump Outer Rotor-to-Timing Cover–Wear
Limit Oil Pump Inner-to-Outer Rotor Clearance
Oil Pump Rotors-to-Timing Cover–Standard
Oil Pump Rotors-to-Timing Cover–Wear Limit
Oil Regulating Valve Spring
Released
Compressed Spring
Compressed Length Tension
Oil Pressure Regulating Valve Retaining Nut
Thermostat Housing Cap Screws
Measurement Specification
Water Pump Mounting Cap Screws
Fuel Injector
Fuel Injector Fuel Return Line Nuts
Fuel Injector Nozzle
Fuel Injector Separator Plate Wear–Maximum
Injector Pump Mounting Nuts
Injector Pump Drive Gear Nut
Injector Gear Cover Cap Screws
Fuel Injector Line Nuts
Starting Motor Cap Screw Torque
Slip Ring
Exposed Brush
Exposed Brush
Alternator Sheave Nut Measurement Specification
