John Deere 6650, 6750, 6850, 6950 Harvesters Manual TM4631 - PDF DOWNLOAD

6650, 6750, 6850 and 6950 Self-Propelled Forage Harvesters (SN. from 504341-)

DIAGNOSIS AND TESTS MANUAL Self-Propelled Forage Harvesters models 6650, 6750, 6850, 6950 (SN: 504341-) TM4631 01 SEP 05 (ENGLISH)

For complete service information also see: 686 and 688 Rotary Harvesting Units

TM458

630, 630A, 645 and 645A Pickup Platforms and 664, 665R, 666 and 666R Row-Crop Headers

5

676 Rotary Harvesting Unit

TM453

PowerTech 8.1 L Diesel Engines Base Engine

0

Alternators and Starting Motors

TM452

Electronic Fuel Injection Systems Machine Connection Information

8

Cam Lobe Motors

CTM86

PowerTech 6.8L and 8.1L, 6068 and 6081 Diesel Engines (Level 3 Electronic Fuel Systems with Bosch In-Line Pump)

CTM77

PowerTech 10.5L and 12.5L, 6105 and 6125 Diesel Engines (With Lucas Engine Controllers, Level 6, Electronic Fuel System), Op & Test PowerTech 4.5L & 6.8L Diesel Engines Tier 1/Stage I, Tier 2/Stage II, Tier 3/Stage IIIA, Tier 3/Stage IIA Tier 3/Stage III, (Base Engine) PowerTech 10.5 L & 12.5 L Diesel Base Engine

CTM68 CTM44 1 CTM19 CTM13 4 CTM11

5 John Deere Agriculture

Pinted by Belgreen

CTM10 4 CTM10 0

tm4631-DIAGNOSIS AND TESTS MANUAL

(g) by Belgreen v2.5

Table of contents FOREWORD Section 05 - SAFETY Group 05 - Safety Information Section 10 - GENERAL INFORMATION Group 05 - Fuel, Lubricants and Coolant Group 10 - Torque Values Group 15 - Serial Numbers Group 20 - Dimensions Section 20 - ENGINE Group 05 - Engine Removal and Installation Section 30 - FUEL, AIR INTAKE AND COOLING SYSTEMS Group 05 - Fuel Tank Group 10 - Air Intake System Group 15 - Engine Cooling System Section 40 - ELECTRICAL SYSTEM Group 05 - Electrical Connectors Group 10 - Electrical System Components Section 50 - POWER TRAIN Group 05 - Main Drive Belt Replacement Group 10 - Bevel Gear Drive Group 15 - Transmission and Differential Group 20 - Final Drives Group 25 - Hydrostatic Drive, Variable Pump Group 30 - Hydrostatic Drive, Fixed-Displacement Motor Group 35 - Hydrostatic Drive, Oil Change Group 40 - Cam Lobe Motor Section 60 - BRAKES, STEERING AND REAR AXLE Group 05 - Brake Operation Group 10 - Brakes Group 15 - Hydrostatic Steering Group 16 - ROW-TRAK System Group 20 - Rear Axle Section 70 - HYDRAULIC SYSTEM Group 05 - Hydraulic Pressure Accumulator Group 10 - Triple Hydraulic Pump Group 15 - Electromagnetic Control Valve Group 20 - Reverser Motor Group 25 - Hydraulic Motor - Discharge Spout Section 80 - MISCELLANEOUS Group 05 - Fuel Tank Hood Group 10 - Central Lubrication System Section 90 - OPERATOR′S CAB, AIR CONDITIONING SYSTEM Group 05 - Control Levers Group 10 - Cab Ventilation Group 15 - Cab Window Replacement Group 20 - R134a Air Conditioning System Group 25 - Super Comfort Seat Section 100 - HARVESTING UNITS Group 05 - Harvesting Unit Cross Drive Group 10 - Harvesting Units Section 110 - FEEDING SYSTEM Group 05 - Length-of-Cut Transmission <- Go to Global Table of contents

tm4631-DIAGNOSIS AND TESTS MANUAL

tm4631-DIAGNOSIS AND TESTS MANUAL

(g) by Belgreen v2.5

Group 10 - Reverser Motor and Clutch Group 15 - Electric Clutch Group 20 - Feed Roll Channel Group 25 - Feed Roll Assembly Group 30 - Locking Pawl Section 120 - CUTTERHEAD ASSEMBLY Group 05 - Knife Sharpening Device Group 10 - Cutterhead Group 15 - Bottom and Outlet Bands Group 20 - Stationary Knife Removal and Installation Group 25 - Kernel Processor Group 30 - Power Chute Section 130 - DISCHARGE COMPONENTS Group 05 - Discharge Fan Group 10 - Blower Rotor and Rotor Bearings Group 15 - Discharge Spout Section 210 - GENERAL INFORMATION Group 05 - Specifications Group 10 - Drive Diagrams Group 15 - Ballast Charts Group 20 - Tread Widths Section 211 - SERVICE CODES Group Cont - Control Unit Group ECU - Diagnostic Trouble Codes for Powertech Engine 6081 Group ECU - Diagnostic Trouble Codes for Powertech Engine 6125 Group ECU - ECU Service Codes (Cummins Engine) Section 220 - ENGINE Group 05 - Engine Specifications Group 10 - Engine Tests Section 230 - FUEL, AIR INTAKE AND COOLING SYSTEMS Group 05 - Fuel, Air Intake and Cooling Systems Section 240 - ELECTRICAL SYSTEM (UP TO SERIAL NO. 504991) Group 05 - Preliminary Checks Group 06 - General Information Group 07 - Test Equipment Group 10 - Electrical System Diagrams Group 15A - Batteries, Starting Motor, Alternator Group 15B - Safety Switches, Basic Relays Group 15C - Engine Shut-Off Device Group 15D - Gauges Group 15E - Electronic INFO-TRAK Monitor Group 15H - Turn Discharge Spout Group 15I - Raise/Lower Discharge Spout Group 15K - Central Lubrication System Group 15L - Horizontal Reel Adjustment Group 15M - Raise Reel Group 15N - Reel Speed Adjustment Group 15O - 676 Rotary Harvesting Unit (North America) Group 15P - Attach Trailer Group 15Q - Header Raise/Lower Group 15R - Pressure Valves, Trailer Dump Group 15S - Main Clutch, Reverser Group 15T - Four-Wheel Drive

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tm4631-DIAGNOSIS AND TESTS MANUAL

tm4631-DIAGNOSIS AND TESTS MANUAL

(g) by Belgreen v2.5

Group 15U - Lighting System Group 15V - Work Lights Group 15WA - Stop Lights, Horn, Electrical Outlet (Europe Only) Group 15WB - Stop Lights, Horn, Electrical Outlet (USA Only) Group 15X - Beacon Light Group 15Y - Fan, Air Conditioning System Group 15Z - Windshield Wiper-/Washer System Group 15AA - Radio, Interior Lighting Group 15AB - Rotary Radiator Screen, Reverse Travel Alarm Group 15AC - Cigarette Lighter, Seat Compressor Group 15AD - Discharge Spout Rinsing System Group 15AE - Discharge Spout Flap Adjustment Group 15AF - Main Electronic System Group 15AG - Metal Detector Group 15AH - Electronic Control Unit Group 15AJ - ROW-TRAK System Group 15AK - POWR-SAVR Group 15AL - 676 Rotary Harvesting Unit (North America) Section 241 - ELECTRICAL SYSTEM (FROM SERIAL NO. 504992) Group 05 - Preliminary Checks Group 06 - General Information Group 07 - Test Equipment Group 10 - Electrical System Diagrams Group 15A - Batteries, Starting Motor, Alternator Group 15B - Safety Switches, Basic Relays Group 15C - Engine Shut-Off Device Group 15D - Instruments Group 15E - Electronic INFOTRAK Monitor Group 15H - Turning Discharge Spout Group 15I - Raising/Lowering Discharge Spout Group 15K - Central Lubrication System Group 15L - Reel Horizontal Adjustment Group 15M - Raising Reel Group 15N - Reel Speed Adjustment Group 15O - 676 Rotary Harvesting Unit (North America) Group 15P - Attaching Trailer Group 15Q - Raising/Lowering Harvesting Unit Group 15R - Pressure Valves, Trailer Dump Group 15S - Main Clutch, Reverser Group 15T - Four-Wheel Drive Group 15U - Lighting System Group 15V - Work Lights Group 15WA - Stop Lights, Horn, Electrical Outlet (Europe Only) Group 15WB - Stop Lights, Horn, Electrical Outlet (USA Only) Group 15X - Beacon Light Group 15Y - Fan, Air Conditioning System Group 15Z - Windshield Wiper/Washer System Group 15AA - Radio, Interior Lighting Group 15AB - Rotary Radiator Screen, Reverse Travel Alarm Group 15AC - Cigarette Lighter, Seat Compressor Group 15AD - Discharge Spout Rinsing System Group 15AE - Discharge Spout Flap Adjustment Group 15AF - Main Electronic System

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tm4631-DIAGNOSIS AND TESTS MANUAL

tm4631-DIAGNOSIS AND TESTS MANUAL

(g) by Belgreen v2.5

Group 15AG - Metal Detector Group 15AH - Electronic Control Unit Group 15AJ - ROW-TRAK System Group 15AK - POWR-SAVR Group 15AL - 676 Rotary Harvesting Unit (North America) Group 15AM - Cutterhead Alarm Section 250 - POWER TRAIN Group 05 - Angled Drive Group 10 - Hydrostatic Drive Group 15 - Three-Speed Transmission Group 20 - Testing Hydrostatic System Section 260 - BRAKES, STEERING, REAR AXLE Group 05 - Brake Operating System Group 10 - Drum Brakes Group 15 - ROW-TRAK ROW-TRAK is a trademark of Deere & Company. System Group 20 - ROW-TRAK ROW-TRAK is a trademark of Deere & Company. Steering Function Group 25 - ROW-TRAK ROW-TRAK is a trademark of Deere & Company. Calibration Section 270 - HYDRAULIC SYSTEM Group 05 - General Information Group 10 - Electromagnetic Control Valve Group 15 - Testing Hydraulic System Group 20 - Header Float System Section 290 - OPERATOR′S CAB Group 05 - System Operational Checks Group 10 - System Diagnosis - Air Conditioning System, Operator′s Seat Group 20 - Theory of Operation

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tm4631-DIAGNOSIS AND TESTS MANUAL

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tm4631-DIAGNOSIS AND TESTS MANUAL

SAFETY

(g) by Belgreen v2.0

Foreword This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use.

Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.

This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury.

Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components.

Operation and tests sections help you identify the majority of routine failures quickly.

Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values.

Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair.

"Right-hand" and "left-hand" refer to the machine as seen in forward travel.

Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.

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Section 05 page 1

tm4631-DIAGNOSIS AND TESTS MANUAL

tm4631-DIAGNOSIS AND TESTS MANUAL

(g) by Belgreen v2.5

Section 05 - SAFETY Table of contents Group 05 - Safety Information ............................................................................................................... 1 Live With Safety ................................................................................................................................... 1 Support Machine Properly .................................................................................................................... 1 Wear Protective Clothing ...................................................................................................................... 2 Prepare for Emergencies ...................................................................................................................... 2 Work in Clean Area ............................................................................................................................... 2 Parking and Leaving the Forage Harvester ........................................................................................... 3 Remove Paint Before Welding or Heating ............................................................................................. 4 Handle Fluids Safely-Avoid Fires ........................................................................................................... 4 Prevent Acid Burns ............................................................................................................................... 6 Prevent Battery Explosions ................................................................................................................... 6 Avoid Heating Near Pressurized Fluid Lines .......................................................................................... 8 Illuminate Work Area Safely ................................................................................................................. 8 Replace Safety Signs ............................................................................................................................ 8 Use Proper Lifting Equipment ............................................................................................................... 9 Service Tires Safely ............................................................................................................................ 10 Practice Safe Maintenance ................................................................................................................. 11 Avoid High-Pressure Fluids ................................................................................................................. 11 Use Proper Tools ................................................................................................................................. 12 Service Machines Safely ..................................................................................................................... 12 Dispose of Waste Properly .................................................................................................................. 13

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tm4631-DIAGNOSIS AND TESTS MANUAL

Section 05 - SAFETY

Group 05: Safety Information

Group 05 - Safety Information Live With Safety

Safety Systems Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields.

Support Machine Properly

Support Properly Always lower the attachment or implement to the ground before you work on the machine. If the work requires that the machine or 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.

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Section 05 page 1

tm4631-DIAGNOSIS AND TESTS MANUAL

Section 05 - SAFETY

Group 05: Safety Information

Wear Protective Clothing

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.

Prepare for Emergencies

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. <- Go to Section TOC

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Section 05 - SAFETY

Group 05: Safety Information

Work in Clean Area

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.

Parking and Leaving the Forage Harvester

Parking and Leaving the Forage Harvester

Remove Key Lower harvesting unit to the ground. <- Go to Section TOC

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Section 05 - SAFETY

Group 05: Safety Information

Before leaving the forage harvester, disengage main clutch and shut off engine. Move gear shift lever to neutral, apply parking brake, remove key and lock the operator′s cab. Position chock blocks. →NOTE: Use only chock blocks provided with the machine.

Never leave forage harvester unattended as long as engine is running.

Never leave the operator′s cab when driving.

Remove Paint Before Welding or Heating

Toxic Fumes Avoid potentially toxic fumes and dust.

Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch.

Remove paint before heating: Remove paint a minimum of 76 mm (3 in.) from area to be affected by heating.

If you sand or grind paint, avoid breathing the dust. Wear an approved respirator.

If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

Do all work in an area that is ventilated to carry toxic fumes and dust away.

Dispose of paint and solvent properly.

Handle Fluids Safely-Avoid Fires

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. <- Go to Section TOC

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Section 05 - SAFETY

Group 05: Safety Information

Make sure machine is clean of trash, grease, and debris.

Do not store oily rags; they can ignite and burn spontaneously.

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Section 05 - SAFETY

Group 05: Safety Information

Prevent Acid Burns

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: 1.Filling batteries in a well-ventilated area.

2.Wearing eye protection and rubber gloves.

3.Avoiding breathing fumes when electrolyte is added.

4.Avoiding spilling or dripping electrolyte.

5.Use proper jump start procedure.

If you spill acid on yourself: 1.Flush your skin with water.

2.Apply baking soda or lime to help neutralize the acid.

3.Flush your eyes with water for 15-30 minutes. Get medical attention immediately.

If acid is swallowed: 1.Do not induce vomiting.

2.Drink large amounts of water or milk, but do not exceed 2 L (2 quarts).

3.Get medical attention immediately.

Prevent Battery Explosions

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Section 05 - SAFETY

Group 05: Safety Information

Battery Explosions Keep sparks, lighted matches, and open flame away from the top 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).

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Section 05 - SAFETY

Group 05: Safety Information

Avoid Heating Near Pressurized Fluid Lines

Flammable Spray Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials.

Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area.

Illuminate Work Area Safely

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.

Replace Safety Signs

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Section 05 - SAFETY

Group 05: Safety Information

Safety Signs Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement.

Use Proper Lifting Equipment

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.

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Section 05 - SAFETY

Group 05: Safety Information

Service Tires Safely

Explosive Tire and Rim Parts Explosive separation of a tire and rim parts can cause serious injury or death.

Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job.

Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a wheel and tire assembly. The heat can cause an increase in air pressure resulting in a tire explosion. Welding can structurally weaken or deform the wheel.

When inflating tires, use a clip-on chuck and extension hose long enough to allow you to stand to one side and NOT in front of or over the tire assembly. Use a safety cage if available.

Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.

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Section 05 - SAFETY

Group 05: Safety Information

Practice Safe Maintenance

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 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.

Avoid High-Pressure Fluids

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Section 05 - SAFETY

Group 05: Safety Information

High-Pressure Fluids Escaping fluid under pressure can penetrate the skin causing serious injury.

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids.

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A.

Use Proper Tools

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.

Service Machines Safely

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tm4631-DIAGNOSIS AND TESTS MANUAL

GENERAL INFORMATION

(g) by Belgreen v2.0

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.

Dispose of Waste Properly

Recycle Waste Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with John Deere equipment include such items as oil, fuel, coolant, brake fluid, filters, and batteries.

Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

Do not pour waste onto the ground, down a drain, or into any water source.

Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants.

Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your John Deere dealer.

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Section 10 page 13

tm4631-DIAGNOSIS AND TESTS MANUAL

tm4631-DIAGNOSIS AND TESTS MANUAL

(g) by Belgreen v2.5

Section 10 - GENERAL INFORMATION Table of contents Group 05 - Fuel, Lubricants and Coolant ............................................................................................. 1 Fuel ....................................................................................................................................................... 1 Handle Fuel Safely-Avoid Fires ............................................................................................................. 1 Fill the Fuel Tank .................................................................................................................................. 1 Fill Extra Fuel Tank ............................................................................................................................... 2 Diesel Engine Oil .................................................................................................................................. 3 Engine Break-In Oil ............................................................................................................................... 3 Diesel Engine Coolant ........................................................................................................................... 4 Transmission Oil ................................................................................................................................... 5 Transmission and Hydraulic Oil ............................................................................................................ 6 Grease .................................................................................................................................................. 7 Alternative and Synthetic Lubricants .................................................................................................... 7 Mixing of Lubricants ............................................................................................................................. 7 Lubricant Storage ................................................................................................................................. 8 Use Genuine John Deere Parts .............................................................................................................. 8 Group 10 - Torque Values ....................................................................................................................... 9 Metric Bolt and Cap Screw Torque Values ............................................................................................ 9 Unified Inch Bolt and Cap Screw Torque Values ................................................................................. 10 Group 15 - Serial Numbers ................................................................................................................... 11 Serial Number Plates .......................................................................................................................... 11 Forage Harvester (Product Identification) Type Plate ......................................................................... 11 Product Identification Number ............................................................................................................ 12 Engine Serial Number - Cummins Engine ........................................................................................... 12 Engine Serial Number - Engine Type 6081 ......................................................................................... 13 Engine Serial Number - Engine Type 6125 ......................................................................................... 13 Operator′s Cab Serial Number ............................................................................................................ 13 Four Wheel Drive Motor Serial Number .............................................................................................. 14 Kernel Processor Serial Number ......................................................................................................... 14 Power Chute Serial Number ................................................................................................................ 14 Three-Speed Transmission Serial Number .......................................................................................... 15 Final Drive Serial Number ................................................................................................................... 15 Angled Drive (Main Gearcase) Serial Number .................................................................................... 15 Length-of-Cut Transmission Serial Number ........................................................................................ 16 Group 20 - Dimensions .......................................................................................................................... 17 Dimensions ......................................................................................................................................... 17

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tm4631-DIAGNOSIS AND TESTS MANUAL

Section 10 - GENERAL INFORMATION

Group 05: Fuel, Lubricants and Coolant

Group 05 - Fuel, Lubricants and Coolant Fuel CAUTION: Never fill tank when engine is running. During filling of tank, smoking is strictly prohibited!

The quality and cleanliness of the fuel is an important factor in obtaining dependable performance and satisfactory engine life.

Use commercial diesel fuel with low sulfur content.

Engine oil and oil filter change interval must be reduced by 50% if diesel fuel with a sulfur content greater than 0.5% is used.

Bio Diesel (Rape Methyl Ester - RME) may also be used as an alternative to mineral oil-based diesel fuel.

Fill the fuel tank at the end of each day′s operation to prevent condensation and freezing during cold weather.

In winter use special winter fuel or add an anti-gelling compound to the fuel to maintain its proper viscosity.

IMPORTANT: The fuel tank is vented through the filler cap. If new filler cap is required, always replace it with an original vented cap.

Handle Fuel Safely-Avoid Fires

Avoid Fires Handle fuel with care: it is highly flammable. Do not refuel the machine while smoking or when near open flame or sparks.

Always stop engine before refueling machine. Fill fuel tank outdoors.

Prevent fires by keeping machine clean of accumulated trash, grease, and debris. Always clean up spilled fuel.

Fill the Fuel Tank

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Section 10 page 1

tm4631-DIAGNOSIS AND TESTS MANUAL

Section 10 - GENERAL INFORMATION

Group 05: Fuel, Lubricants and Coolant

Filling the fuel tank CAUTION: Handle fuel with care. Never fill tank when engine is running. During filling of tank smoking is strictly prohibited!

Fill the fuel tank at the end of each day′s operation to prevent condensation or freezing during cold weather periods.

Fuel tank capacity: 700 L (185 U.S. gal) Item

Measurement

Specification

Fuel tank

Capacity

700 L (185 U.S. gal)

Fill Extra Fuel Tank

Fill extra fuel tank →NOTE: The extra fuel tank is not standard equipment. It is available as field installation kit.

An extra fuel tank with a capacity of 300 liters (79.25 U.S. gal) can be fitted on the right-hand side of the operator′s platform.

Item

Measurement

Specification

Extra fuel tank

Capacity

300 L (79.25 U.S. gal)

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Section 10 - GENERAL INFORMATION

Group 05: Fuel, Lubricants and Coolant

Diesel Engine Oil

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

The following oil is preferred: John Deere PLUS-50 ™ The following oil is also recommended: John Deere TORQ-GARD SUPREME ™ Other oils may be used if they meet one or more of the following: API Service Classification CH-4 API Service Classification CG-4 API Service Classification CF-4 ACEA Specification E3 ACEA Specification E2 Multi-viscosity diesel engine oils are preferred.

If diesel fuel with sulfur content greater than 0.5% is used, reduce the service interval by 50%.

Extended service intervals may apply when John Deere preferred engine oils are used. Consult your John Deere dealer for more information.

Engine Break-In Oil New engines are filled at the factory with John Deere ENGINE BREAK-IN OIL. During the break-in period, add John Deere ENGINE BREAK-IN OIL as needed to maintain the specified oil level.

Change the oil and filter after the first 100 hours of operation of a new or rebuilt engine.

After engine overhaul, fill the engine with John Deere ENGINE BREAK-IN OIL. If John Deere ENGINE BREAK-IN OIL is not available, use a diesel engine oil meeting one of the following during the first 100 hours of operation: API Service Classification CE ACEA Specification E1

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Section 10 - GENERAL INFORMATION

Group 05: Fuel, Lubricants and Coolant

After the break-in period, use John Deere PLUS-50 ™ or other diesel engine oil as recommended in this manual.

IMPORTANT: Do not use PLUS-50 ™ oil or engine oils meeting API CG4, API CF4, ACEA E3, or ACEA E2 performance levels during the first 100 hours of operation of a new or rebuilt engine. These oils will not allow the engine to break-in properly.

Diesel Engine Coolant The engine cooling system is filled to provide year-round protection against corrosion and cylinder liner pitting, and winter freeze protection to -37°C (-34°F).

John Deere COOL-GARD is preferred for service.

If John Deere COOL-GARD is not available, use a low silicate ethylene glycol base coolant concentrate in a 50% mixture of concentrate with quality water.

The coolant concentrate shall be of a quality that provides cavitation protection to cast iron and aluminum parts in the cooling system. John Deere COOL-GARD meets this requirement.

A 50% mixture of ethylene glycol engine coolant in water provides freeze protection to -37°C (-34°F). If protection at lower temperatures is required, consult your John Deere dealer for recommendations.

Water quality is important to the performance of the cooling system. Distilled, deionized, or demineralized water is recommended for mixing with ethylene glycol base engine coolant concentrate.

IMPORTANT: Do not use cooling system sealing additives or antifreeze that contains sealing additives.

Coolant Drain Intervals Drain the factory fill engine coolant, flush the cooling system, and refill with new coolant after the first 3 years or 3000 hours of operation. Subsequent drain intervals are determined by the coolant used for service. At each interval, drain the coolant, flush the cooling system, and refill with new coolant.

When John Deere COOL-GARD is used, the coolant drain interval is 3 years or 3000 hours of operation.

If COOL-GARD is not used, the drain interval is reduced to 2 years or 2000 hours of operation.

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Section 10 - GENERAL INFORMATION

Group 05: Fuel, Lubricants and Coolant

Transmission Oil

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

The following oils are preferred: John Deere EXTREME-GARD ™ John Deere GL-5 GEAR LUBRICANT Other oils may be used if they meet the following: API Service Classification GL-5

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Section 10 - GENERAL INFORMATION

Group 05: Fuel, Lubricants and Coolant

Transmission and Hydraulic Oil

Transmission and Hydraulic Oil Use oil viscosity based on the expected air temperature range during the period between oil changes.

The following oils are preferred: John Deere HY-GARD ™ John Deere Low Viscosity HY-GARD ™ Other oils may be used if they meet one of the following: John Deere Standard JDM J20C John Deere Standard JDM J20D Use the following oil when a biodegradable fluid is required: John Deere [ BIO-HY-GARD meets or exceeds the minimum biodegradability of 80% within 21 days according to CEC-L-33-T-82 test method. BIO-HY-GARD should not be mixed with mineral oils because

BIO-HY-GARD this reduces the™biodegradability and makes proper oil recycling impossible. ]

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Section 10 - GENERAL INFORMATION

Group 05: Fuel, Lubricants and Coolant

Grease

Grease Use grease based on NLGI consistency numbers and the expected air temperature range during the service interval.

The following greases are preferred: John Deere SD POLYUREA GREASE The following greases are also recommended: John Deere HD MOLY GREASE John Deere HD LITHIUM COMPLEX GREASE John Deere HD WATER RESISTANT GREASE John Deere GREASE-GARD Other greases may be used if they meet the following: NLGI Performance Classification GC-LB IMPORTANT: Some types of grease thickener are not compatible with others. Consult your grease supplier before mixing different types of grease.

Alternative and Synthetic Lubricants Conditions in certain geographical areas may require lubricant recommendations different from those printed in this manual.

Some John Deere brand coolants and lubricants may not be available in your location.

Consult your John Deere dealer to obtain information and recommendations.

Synthetic lubricants may be used if they meet the performance requirements as shown in this manual.

The temperature limits and service intervals shown in this manual apply to both conventional and synthetic oils.

Re-refined base stock products may be used if the finished lubricant meets the performance requirements.

Mixing of Lubricants In general, avoid mixing different brands or types of oil. Oil manufacturers blend additives in their oils to meet certain specifications and performance requirements. <- Go to Section TOC

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Section 10 - GENERAL INFORMATION

Group 10: Torque Values

Mixing different oils can interfere with the proper functioning of these additives and degrade lubricant performance.

Consult your John Deere dealer to obtain specific information and recommendations.

Lubricant Storage Your equipment can operate at top efficiency only when clean lubricants are used.

Use clean containers to handle all lubricants.

Whenever possible, store lubricants and containers in an area protected from dust, moisture, and other contamination. Store containers on their side to avoid water and dirt accumulation.

Make certain that all containers are properly marked to identify their contents.

Properly dispose of all old containers and any residual lubricant they may contain.

Use Genuine John Deere Parts

Use Genuine John Deere Parts Genuine John Deere parts have been specifically designed for John Deere machines.

Other parts are neither examined nor released by John Deere. Installation and use of such products could have negative effects upon the design characteristics of the machine and thereby affect its safety.

Avoid this risk by using only genuine John Deere parts.

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tm4631-DIAGNOSIS AND TESTS MANUAL

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