CTM10430JUN05(ENGLISH)
Forcompleteserviceinformationalsosee:
POWERTECH DieselEngines—Mechanical FuelSystems ......................... CTM207
POWERTECH DieselEngines—Level4
ElectronicFuelSystemswithBoschVP44 Pump CTM170
POWERTECH DieselEngines—Level12
ElectronicFuelSystemswithStanadyne DE10Pump .......................... CTM331
POWERTECHDieselEngines—Level1
ElectronicFuelSystemswithDelphi/Lucas DP201Pump ......................... CTM284
POWERTECH DieselEngines—Level11
ElectronicFuelSystemswithDenso HPCR CTM220
POWERTECH DieselEnginesand PowerTechPlus—Level14ElectronicFuel SystemswithDensoHPCR .............. CTM320 AlternatorsandStarterMotors ........... CTM77 OEMEngineAccessories ...... CTM67(EnglishOnly)
Introduction
Forward
Thismanualiswrittenforanexperiencedtechnician. Essentialtoolsrequiredinperformingcertainservice workareidentifiedinthismanualandare recommendedforuse.
Thismanual(CTM104)coversonlythebaseengine.It isoneofsevenvolumeson4.5Land6.8Lengines. Thefollowingsixcompanionmanualscoverfuel systemandelectronicsrepair,operationand diagnostics:
• CTM207—MechanicalFuelSystems
• CTM170—Level4ElectronicFuelSystemswith BoschVP44Pump
• CTM331—Level12ElectronicFuelSystemswith StanadyneDE10Pump
• CTM284—Level1ElectronicFuelSystemswith Delphi/LucasDP201Pump
• CTM220—Level11ElectronicFuelSystemswith DensoHighPressureCommonRail
• CTM320—Level14ElectronicFuelSystemswith DensoHighPressureCommonRail
Othermanualswillbeaddedinthefuturetoprovide additionalinformationonelectronicfuelsystemsas needed.
Livewithsafety:Readthesafetymessagesinthe introductionofthismanualandthecautionspresented throughoutthetextofthemanual.
Thisisthesafety-alertsymbol.Whenyouseethis symbolonthemachineorinthismanual,bealertto thepotentialforpersonalinjury.
Usethiscomponenttechnicalmanualinconjunction withthemachinetechnicalmanual.Anapplication listinginSection01,Group001identifies product-model/componenttype-modelrelationship.See
themachinetechnicalmanualforinformationon componentremovalandinstallation,andgaining accesstothecomponents.
Informationisorganizedinsectionsandgroupsforthe variouscomponentsrequiringserviceinstruction. Section05summarizesallapplicableessentialtools, serviceequipmentandtools,othermaterialsneededto dothejob,andservicepartskits.Section06 summarizesallspecifications,weartolerances,and torquevalues.
Beforebeginningrepaironanengine,cleantheengine andmountonarepairstand.(SeeSection02,Group 010.)
ThismanualcontainsSIMetricunitsofmeasure followedimmediatelybytheU.S.customaryunitsof measure.Mosthardwareontheseenginesismetric sized.
Somecomponentsofthisenginemaybeserviced withoutremovingtheenginefromthemachine.Refer tothespecificmachinetechnicalmanualfor informationoncomponentsthatcanbeserviced withoutremovingtheenginefromthemachineandfor engineremovalandinstallationprocedures.
Readeachblockofmaterialcompletelybefore performingservicetocheckfordifferencesin proceduresorspecifications.Followonlythe proceduresthatapplytotheenginemodelnumberyou areworkingon.Ifonlyoneprocedureisgiven,that procedureappliestoalltheenginesinthemanual.
CALIFORNIAPROPOSITION65WARNING
Dieselengineexhaustandsomeofitsconstituents areknowntotheStateofCaliforniatocause cancer,birthdefectsandotherreproductiveharm.
DOWNLOAD COMPLETE MANUAL
JohnDeereDealers
ThechangeslistedbelowmakeyourCTMobsolete. Repair,operationanddiagnosticson4.5Land6.8L dieselenginesisnowcoveredinsevenmanuals. DiscardCTM104dated01Apr05andreplacewith thisnewmanual.Alsorefertothefollowing manuals:
• CTM104—4.5Land6.8LDieselEngines—Base Engine
• CTM207—4.5Land6.8LDieselEngines— MechanicalFuelSystems
• CTM170—4.5Land6.8LDieselEngines—Level4 ElectronicFuelSystemswithBoschVP44Pump
• CTM331—4.5Land6.8LDieselEngines—Level12 ElectronicFuelSystemswithStanadyneDE10 Pump
• CTM284—4.5Land6.8LDieselEngines—Level1 ElectronicFuelSystemswithDelphi/LucasDP201 Pump
• CTM220—4.5Land6.8LDieselEngines—Level11 ElectronicFuelSystemswithDensoHighPressure CommonRail
• CTM320—4.5Land6.8LDieselEngines—Level14 ElectronicFuelSystemswithDensoHighPressure CommonRail
Also,copythispagelistingchangesandroutethrough yourServiceDepartment.
SECTION01—GROUP001(EngineIdentification)
• Updatedengineapplicationcharts.
SECTION01—GROUP002(Fuels,Lubricantsand Coolants)
• Reviseddieselengineoilguidelines.
• Revisedenginecoolantguidelines.
SECTION02—GROUP010(EngineRebuild)
• Revisedenginedisassembly/assemblyprocedure.
SECTION02—GROUP060(LubricationSystem)
• Addedillustrations.
SECTION02—GROUP070(CoolingSystem)
• Updatedillustrations.
SECTION02—GROUP080(AirIntakeandExhaust System)
• Addedvariablegeometryturbochargeractuator linkageprocedures.
SECTION02—GROUP090(FuelSystem)
NOTE:Repairproceduresforfuelsystemshavebeen movedtoSection02,Group090insixother technicalmanuals:CTM207—MechanicalFuel Systems,CTM170—Level4ElectronicFuel SystemswithBoschVP44Pump,CTM331— Level12ElectronicFuelSystemswith StanadyneDE10Pump,CTM284—Level1 ElectronicFuelSystemswithDelphi/Lucas DP201Pump,CTM220—Level11Electronic FuelSystemswithDensoHighPressure CommonRailandCTM320—Level14 ElectronicFuelSystemswithDensoHigh PressureCommonRail.
SECTION02—GROUP100(StartingandCharging Systems)
• Startingandchargingsystemsarecoveredinthis section/group.
SECTION03—GROUP120(BaseEngineOperation)
• AddedEGRsystemoperation.
SECTION04—GROUP150(ObservableDiagnostics andTests)
Introduction
NOTE:Fuelsystemtestinganddiagnosticshasbeen movedtoSection04,Group150infiveother technicalmanuals:CTM207—MechanicalFuel Systems,CTM170—Level4ElectronicFuel SystemswithBoschVP44Pump,CTM331— Level12ElectronicFuelSystemswith StanadyneDE10Pump,CTM284—Level1 ElectronicFuelSystemswithDelphi/Lucas DP201Pump,CTM220—Level11Electronic FuelSystemswithDensoHighPressure CommonRailandCTM320—Level14 ElectronicFuelSystemswithDensoHigh PressureCommonRail.
SECTION5(ToolsandOtherMaterials)
• Allessentialtools,servicetools,dealerfabricated toolsandothermaterialslistedthroughoutthis manualareconsolidatedinthissectionforeaseof reference.
SECTION6(Specifications)
• Allrepair,testanddiagnosticspecificationslisted throughoutthismanualareconsolidatedinthis sectionforeaseofreference.
OUO1080,000023A–19–12JUN02–2/2
3/4RightFrontView—Two-ValveHeadEngine
3/4RightFrontView—Four-ValveHeadEngine
3/4LeftRearView—Two-ValveHeadEngine
3/4LeftRearView—Four-ValveHeadEngine POWERTECH isaregisteredtrademarkofDeere&Company
OUO1080,0000238–19–03JUN04–1/1
3/4RightFrontView—Two-ValveHeadEngine
3/4LeftRearView—Two-ValveHeadEngine
POWERTECH isaregisteredtrademarkofDeere&Company
OUO1080,0000239–19–06JUN02–1/1
POWERTECH 6.8LEngineWithElectronicFuelSystem—Tier2/StageII
6068HF475Four-ValveEngine(Level11ElectronicFuelSystem withDensoHighPressureCommonRail)
POWERTECH isaregisteredtrademarkofDeere&Company
6068HF475Four-ValveEngine
OUO1083,00005FC–19–17DEC03–1/1
POWERTECH 6.8LEngineWithElectronicFuelSystem—Tier3/StageIIIA
6068HF485EngineShown(ElectronicFuelSystemWithDenso HighPressureCommonRail)
POWERTECH isaregisteredtrademarkofDeere&Company
6068HF485Shown
OUO1083,00005FC–19–17DEC03–1/1
SECTION01—GeneralInformation Group000—Safety Group001—EngineIdentificationandApplication Charts Group002—Fuels,LubricantsandCoolants
SECTION02—RepairandAdjustments Group010—EngineRebuild Group020—CylinderHeadandValves(Two-Valve HeadEngines) Group021—CylinderHeadandValves(Four-Valve HeadEngines)
Group030—CylinderBlock,Liners,Pistonsand Rods
Group040—Crankshaft,MainBearingsand Flywheel
Group050—Camshaft,BalancerShaftsandTiming GearTrain Group060—LubricationSystem Group070—CoolingSystem Group080—AirIntakeandExhaustSystem Group090—FuelSystem Group100—StartingandChargingSystems
SECTION03—TheoryofOperation Group120—BaseEngineOperation
SECTION04—Diagnostics Group150—ObservableDiagnosticsandTests
SECTION05—ToolsandOtherMaterials Group170—RepairToolsandOtherMaterials Group180—DiagnosticServiceTools Group190—DealerFabricatedServiceTools
SECTION06—Specifications Group200—RepairandGeneralOEM Specifications
Group210—DiagnosticSpecifications
Allinformation,illustrationsandspecificationsinthismanualarebasedon thelatestinformationavailableatthetimeofpublication.Therightis reservedtomakechangesatanytimewithoutnotice.
COPYRIGHT 2005 DEERE&COMPANY Moline,Illinois Allrightsreserved AJohnDeereILLUSTRUCTION Manual PreviousEditions Copyright 1996,1998,2000,2002,2004
Group000—Safety .................... 01-000-1
Group001—EngineIdentificationandApplication Charts
EngineModelDesignation 01-001-1
EngineSerialNumberPlateInformation 01-001-2
OEMEngineOptionCodeLabel 01-001-3
InformationRelativetoEmissions
Regulations
01-001-4
EngineApplicationCharts 01-001-5
Group002—Fuels,LubricantsandCoolants
DieselFuel-Non-Certified,TierIandTier 2/StageIIEngines ....................
01-002-1
DieselFuel-Tier3/StageIIIAEngines 01-002-2
Bio-DieselFuel 01-002-3
LubricityofDieselFuel 01-002-4
DieselscanFuelAnalysis 01-002-4
DieselEngineBreak-InOil 01-002-5
DieselEngineOil—Non-CertifiedandTier1 CertifiedEngines
01-002-6
DieselEngineOil—Tier2/StageII CertifiedEngines ..................... 01-002-7
DieselEngineOil—Tier3/StageIIIACertified Engines............................ 01-002-8
OILSCAN,OILSCANPlus , COOLSCAN andCOOLSCANPLUS ...01-002-9
OilFilters 01-002-9
Grease 01-002-10
DieselEngineCoolant 01-002-11
AdditionalInformationAboutDiesel EngineCoolantsandSupplementalCoolant Additives .......................... 01-002-13
TestingDieselEngineCoolant ........... 01-002-14
SupplementalCoolantAdditives 01-002-15
OperatinginWarmTemperatureClimates..01-002-15
FlushandServiceCoolingSystem 01-002-16
DisposingofCoolant 01-002-17
HandleFluidsSafely—AvoidFires
Whenyouworkaroundfuel,donotsmokeorworknear heatersorotherfirehazards.
Storeflammablefluidsawayfromfirehazards.Donot incinerateorpuncturepressurizedcontainers.
Makesuremachineiscleanoftrash,grease,anddebris.
Donotstoreoilyrags;theycanigniteandburn spontaneously.
HandleStartingFluidSafely
CAUTION:Onlaterenginesequippedwithglow plugs,DONOTUSEETHERSTARTINGFLUID. Useofstartingfluidscouldcauseexplosion andpossibilityofpersonalinjury.
Startingfluidishighlyflammable.
Keepallsparksandflameawaywhenusingit.Keep startingfluidawayfrombatteriesandcables.
Topreventaccidentaldischargewhenstoringthe pressurizedcan,keepthecaponthecontainer,andstore inacool,protectedlocation.
Donotincinerateorpunctureastartingfluidcontainer.
ServiceCoolingSystemSafely
Explosivereleaseoffluidsfrompressurizedcooling systemcancauseseriousburns.
Shutoffengine.Onlyremovefillercapwhencoolenough totouchwithbarehands.Slowlyloosencaptofirststop torelievepressurebeforeremovingcompletely.
InstallFanGuards
Rotatingcoolingsystemfanscancauseseriousinjury.
Keepfanguardsinplaceatalltimesduringengine operation.Wearclosefittingclothes.Stopengineandbe surefanisstoppedbeforemakingadjustmentsor connections,orcleaningnearthefrontoftheengine.
OUO1083,00005FE–19–17DEC03–1/1
AvoidHotParts
Avoidskincontactwithexhaustmanifolds,turbochargers andmufflers.Keepflammablematerialsclearofthe turbocharger.
Externaldryexhaustpartsbecomeveryhotduring operation.Turbochargersmayreachtemperaturesashigh as500°C(932°F)underfullload,andnaturallyaspired exhaustmanifoldsmayreach600°C(1112°F)underfull load.Thismayignitepaper,clothorwoodenmaterials. Partsonenginesthathavebeenatfullloadandreduced tonoloadidlewillmaintainapproximately150°C(302°F).
OUO1083,00005FF–19–17DEC03–1/1
RotatingFan
HotSurface
PreventBatteryExplosions
Keepsparks,lightedmatches,andopenflameawayfrom thetopofbattery.Batterygascanexplode.
Nevercheckbatterychargebyplacingametalobject acrosstheposts.Useavoltmeterorhydrometer.
Donotchargeafrozenbattery;itmayexplode.Warm batteryto16°C(60°F).
PrepareforEmergencies
Bepreparedifafirestarts.
Keepafirstaidkitandfireextinguisherhandy.
Keepemergencynumbersfordoctors,ambulanceservice, hospital,andfiredepartmentnearyourtelephone.
HandlingBatteriesSafely
CAUTION:Batterygascanexplode.Keep sparksandflamesawayfrombatteries.Usea flashlighttocheckbatteryelectrolytelevel.
Nevercheckbatterychargebyplacingametal objectacrosstheposts.Useavoltmeteror hydrometer.
Alwaysremovegrounded(-)batteryclampfirst andreplaceitlast.
CAUTION:Sulfuricacidinbatteryelectrolyteis poisonous.Itisstrongenoughtoburnskin,eat holesinclothing,andcauseblindnessif splashedintoeyes.
Avoidthehazardby:
1.Fillingbatteriesinawell-ventilatedarea.
2.Wearingeyeprotectionandrubbergloves.
3.Avoidingbreathingfumeswhenelectrolyteis added.
4.Avoidingspillingordrippingelectrolyte.
5.Useproperjumpstartprocedure.
Ifyouspillacidonyourself:
1.Flushyourskinwithwater.
2.Applybakingsodaorlimetohelpneutralize theacid.
3.Flushyoureyeswithwaterfor15—30 minutes.Getmedicalattentionimmediately.
Ifacidisswallowed:
1.Donotinducevomiting.
2.Drinklargeamountsofwaterormilk,butdo notexceed2L(2 quarts).
3.Getmedicalattentionimmediately.
WARNING: Batteryposts,terminals,andrelated accessoriescontainleadandleadcompounds,chemicals knowntotheStateofCaliforniatocausecancerand reproductiveharm. Washhandsafterhandling.
AvoidHigh-PressureFluids
Escapingfluidunderpressurecanpenetratetheskin causingseriousinjury.
Avoidthehazardbyrelievingpressurebefore disconnectinghydraulicorotherlines.Tightenall connectionsbeforeapplyingpressure.
Searchforleakswithapieceofcardboard.Protecthands andbodyfromhighpressurefluids.
Ifanaccidentoccurs,seeadoctorimmediately.Anyfluid injectedintotheskinmustbesurgicallyremovedwithina fewhoursorgangrenemayresult.Doctorsunfamiliarwith thistypeofinjuryshouldreferenceaknowledgeable medicalsource.SuchinformationisavailablefromDeere &CompanyMedicalDepartmentinMoline,Illinois,U.S.A.
WearProtectiveClothing
Wearclosefittingclothingandsafetyequipment appropriatetothejob.
Prolongedexposuretoloudnoisecancauseimpairment orlossofhearing.
Wearasuitablehearingprotectivedevicesuchas earmuffsorearplugstoprotectagainstobjectionableor uncomfortableloudnoises.
Operatingequipmentsafelyrequiresthefullattentionof theoperator.Donotwearradioormusicheadphones whileoperatingmachine.
ServiceMachinesSafely
Tielonghairbehindyourhead.Donotwearanecktie, scarf,looseclothing,ornecklacewhenyouworknear machinetoolsormovingparts.Iftheseitemsweretoget caught,severeinjurycouldresult.
Removeringsandotherjewelrytopreventelectrical shortsandentanglementinmovingparts.
WorkInVentilatedArea
Engineexhaustfumescancausesicknessordeath.Ifitis necessarytorunanengineinanenclosedarea,remove theexhaustfumesfromtheareawithanexhaustpipe extension.
Ifyoudonothaveanexhaustpipeextension,openthe doorsandgetoutsideairintothearea
WorkinCleanArea
Beforestartingajob:
• Cleanworkareaandmachine.
• Makesureyouhaveallnecessarytoolstodoyourjob.
• Havetherightpartsonhand.
• Readallinstructionsthoroughly;donotattempt shortcuts.
RemovePaintBeforeWeldingorHeating
Avoidpotentiallytoxicfumesanddust.
Hazardousfumescanbegeneratedwhenpaintisheated bywelding,soldering,orusingatorch.
Removepaintbeforeheating:
• Removepaintaminimumof100mm(4in.)fromarea tobeaffectedbyheating.Ifpaintcannotberemoved, wearanapprovedrespiratorbeforeheatingorwelding.
• Ifyousandorgrindpaint,avoidbreathingthedust. Wearanapprovedrespirator.
• Ifyouusesolventorpaintstripper,removestripperwith soapandwaterbeforewelding.Removesolventor paintstrippercontainersandotherflammablematerial fromarea.Allowfumestodisperseatleast15minutes beforeweldingorheating.
Donotuseachlorinatedsolventinareaswherewelding willtakeplace.
Doallworkinanareathatiswellventilatedtocarrytoxic fumesanddustaway.
Disposeofpaintandsolventproperly.
AvoidHeatingNearPressurizedFluidLines
Flammablespraycanbegeneratedbyheatingnear pressurizedfluidlines,resultinginsevereburnsto yourselfandbystanders.Donotheatbywelding, soldering,orusingatorchnearpressurizedfluidlinesor otherflammablematerials.Pressurizedlinescanbe accidentallycutwhenheatgoesbeyondtheimmediate flamearea.
IlluminateWorkAreaSafely
Illuminateyourworkareaadequatelybutsafely.Usea portablesafetylightforworkinginsideorunderthe machine.Makesurethebulbisenclosedbyawirecage. Thehotfilamentofanaccidentallybrokenbulbcanignite spilledfueloroil.
UseProperLiftingEquipment
Liftingheavycomponentsincorrectlycancausesevere injuryormachinedamage.
Followrecommendedprocedureforremovaland installationofcomponentsinthemanual.
ConstructDealer-MadeToolsSafely
Faultyorbrokentoolscanresultinseriousinjury.When constructingtools,useproper,qualitymaterialsandgood workmanship.
Donotweldtoolsunlessyouhavetheproperequipment andexperiencetoperformthejob.
DPSG,OUO1004,899–19–19MAY99–1/1
ConstructDealer-MadeToolsSafely
PracticeSafeMaintenance
Understandserviceprocedurebeforedoingwork.Keep areacleananddry.
Neverlubricate,service,oradjustmachinewhileitis moving.Keephands,feet,andclothingfrom power-drivenparts.Disengageallpowerandoperate controlstorelievepressure.Lowerequipmenttothe ground.Stoptheengine.Removethekey.Allowmachine tocool.
Securelysupportanymachineelementsthatmustbe raisedforservicework.
Keepallpartsingoodconditionandproperlyinstalled.Fix damageimmediately.Replacewornorbrokenparts. Removeanybuildupofgrease,oil,ordebris.
Onself-propelledequipment,disconnectbatteryground cable(-)beforemakingadjustmentsonelectricalsystems orweldingonmachine.
Ontowedimplements,disconnectwiringharnessesfrom tractorbeforeservicingelectricalsystemcomponentsor weldingonmachine.
UseProperTools
Usetoolsappropriatetothework.Makeshifttoolsand procedurescancreatesafetyhazards.
Usepowertoolsonlytoloosenthreadedpartsand fasteners.
Forlooseningandtighteninghardware,usethecorrect sizetools.DONOTuseU.S.measurementtoolson metricfasteners.Avoidbodilyinjurycausedbyslipping wrenches.
UseonlyservicepartsmeetingJohnDeerespecifications.
DisposeofWasteProperly
Improperlydisposingofwastecanthreatenthe environmentandecology.Potentiallyharmfulwasteused withJohnDeereequipmentincludesuchitemsasoil,fuel, coolant,brakefluid,filters,andbatteries.
Useleakproofcontainerswhendrainingfluids.Donotuse foodorbeveragecontainersthatmaymisleadsomeone intodrinkingfromthem.
Donotpourwasteontotheground,downadrain,orinto anywatersource.
Airconditioningrefrigerantsescapingintotheaircan damagetheEarth’satmosphere.Governmentregulations mayrequireacertifiedairconditioningservicecenterto recoverandrecycleusedairconditioningrefrigerants.
LiveWithSafety
Beforereturningmachinetocustomer,makesure machineisfunctioningproperly,especiallythesafety systems.Installallguardsandshields.
Inquireontheproperwaytorecycleordisposeofwaste fromyourlocalenvironmentalorrecyclingcenter,orfrom yourJohnDeeredealer. DX,LIVE–19–25SEP92–1/1
DX,DRAIN–19–03MAR93–1/1
EngineModelDesignation
JohnDeereEngineModel—4045and6068Engines
JohnDeereenginemodeldesignationincludesnumberof cylinders,displacementinliters,aspiration,usercode,and applicationcode.Forexample:
4045TF275Engine
4................................................................Numberofcylinders
4.5.............................................................Literdisplacement
T................................................................Aspirationcodeoremissiontierlevel(seefollowing) F................................................................Usercode(seebelow)
275............................................................ POWERTECH applicationcode
AspirationCode(EarlierEngines)
D...............................................................Naturallyaspirated T................................................................Turbocharged,noaftercooling
A...............................................................Turbochargedandair-to-coolantaftercooled H...............................................................Turbochargedandair-to-airaftercooled S...............................................................Turbochargedandair-to-seawateraftercooled
EmissionTierLevel(LaterEngines)
BNon-certifiedengines
C,EorF...................................................Tier1/StageIemissioncertifiedengine G,JorK...................................................Tier2/StageIIemissioncertifiedengine L,M,NorP..............................................Tier3/StageIIIAemissioncertifiedengine UserCode
AP.............................................................IndustriesJohnDeereMexicoS.AdeC.V.(Saltillo/Monterrey,Mexico)
AT.............................................................Agritaliasrl(Vittoria,Sicily,Italy)
BE.............................................................BellEquipmentCo.(RichardsBay,SouthAfrica)
CQ............................................................JohnDeereBrazil(Horizontina,Brazil)
DW............................................................JohnDeereDavenportWorks(Davenport,Iowa) E...............................................................JohnDeereOttumwaWorks(Ottumwa,Iowa)
F................................................................OEM(OutsideEquipmentManufacturers) FF.............................................................Deere-Hitachi(Kernersville,NorthCarolina)
FG.............................................................GoldoniS.P.A.(Modena,Italy)
FM.............................................................MarineEngines
H...............................................................JohnDeereHarvesterWorks(EastMoline,Illinois) KV.............................................................JohnDeereCommercialWorksiteProducts(Knoxville,Tennessee/Dubuque, Iowa) L................................................................JohnDeereWerkeMannheim(Germany)
LA.............................................................JohnDeereWerkeMannheim(Germany)(EngineswithBoschVP44InjectionPump) LV.............................................................JohnDeereCommercialProducts(Augusta,Georgia) N...............................................................JohnDeereDesMoinesWorks(DesMoines,Iowa) P...............................................................IndustriasJohnDeereMexicoS.A.deC.V.(Saltillo/Monterrey,Mexico)
PY.............................................................Larson&ToubroLtd.(Pune,India)
RW............................................................JohnDeereWaterlooTractorWorks(Waterloo,Iowa)
T................................................................JohnDeereDubuqueWorks(Dubuque,Iowa)
T8..............................................................CamecoIndustries(Thibodaux,Louisiana)
TJ..............................................................JohnDeereForestry(Timberjack)(Sweden/Finland/Canada) YC.............................................................JohnDeereJialianHarvesterCo.Limited(China) Z................................................................JohnDeereWERKEZweibrucken(Germany) ApplicationCode 001,etc.....................................................SeeEngineApplicationCharts,laterinthisGroup
IMPORTANT:Theengineserialnumberplate(A)can beeasilydestroyed.Before“hottank” cleaningtheblock,removetheplate.
NOTE:Four-valveheadengineshave“16V”or“24V” printedonaplatelocatedontherockerarm cover.The4045HF475modelhas“16V”todenote 16valvestotalwhile6068HF475has“24V”to denote24valvestotal.
EngineSerialNumber(B)
Eachenginehasa13-digitJohnDeereengineserial numberidentifyingtheproducingfactory,enginemodel designation,anda6-digitsequentialnumber.The followingisanexample:
T04045T000000
T0...........................Factoryproducingengine 4045T.....................Enginemodeldesignation 000000...................Sequentialserialnumber FactoryCode(EngineManufacturer) T0...........................Dubuque,Iowa CD..........................Saran,France
PE..........................Torreon,Mexico
J0...........................Rosario,Argentina EngineModelDesignation
4045T.....................Definitionexplainedpreviously.(SeeENGINE MODELDESIGNATIONearlierinthisgroup.
SequentialNumber
000000...................6-digitsequentialserialnumber.Onlater engines,thissequencenumberisprecededby aletterlistedintheEmissionTierLevelearlier inthisgroup.
EngineApplicationData(C)
Thesecondlineofinformationontheserialnumberplate identifiestheengine/machineorOEMrelationship.See ENGINEAPPLICATIONCHARTSlaterinthisgroup.
A—EngineSerialNumberPlate
B—EngineSerialNumber
C—EngineApplicationData
D—CoefficientofAbsorption(EarlySaranEngines)
CoefficientofAbsorption(D)—(EarlySaran-Built Engines-LaterEngines,InternalFactory Identification)
OEMEngineOptionCodeLabel
Anoptioncodelabelissecuredtothetopofthevalve coverandidentifiesthefactoryinstalledoptionsoneach OEMenginetoensurecorrectpartsacquisition.
Alwaysprovideoptioncodeinformationandenginebase codewhenorderingrepairparts.Alistingofoptioncodes isgiveninPartsCatalogsandOperator’sManuals.
NOTE:Before“hottank”cleaning,ensurethatoption codesarerecordedelsewhere.
ThesecondlineofinformationonSaranserialnumber platealsocontainsthecoefficientofabsorptionvaluefor smokeemissions. DPSG,OUO1004,482–19–07NOV98–1/1
RG19661,0000005–19–15JUN05–2/2
InformationRelativetoEmissionsRegulations
Dependingonthefinaldestination,enginescanmeet theemissionsregulationsaccordingtotheUS EnvironmentalProtectionAgency(EPA),CaliforniaAir ResourcesBoard(CARB)andforEurope,the Directive97/68/ECrelatingthemeasuresagainstthe emissionsofparticlesandgaseouspollutantfrom internalcombustionengines.Suchenginesarecalled “CERTIFIED”andreceiveanemissionlabelonthe engine.
Theregulationsprohibittamperingwiththe emission-relatedcomponentslistedbelowwhichwould renderthatcomponentinoperativeortomakeany adjustmentontheenginebeyondpublished specifications.Itisalsoillegaltoinstallapartor componentwheretheprincipleeffectofthat
componentistobypass,defeat,orrenderinoperative anyenginecomponentordevicewhichwouldaffect theengine’sconformancetotheemissionregulations. Tosummarize,itisillegaltodoanythingexcept returntheenginetoitsoriginalpublished specifications.
Listofemission-relatedcomponents:
• Fuelinjectionsystem
• Intakemanifold
• Turbocharger
• EGRcooler
• EGRvalve
• Chargeaircoolingsystem
• Piston
OUO1080,0000035–19–29AUG01–1/1
EngineApplicationCharts
JOHNDEEREAGRICULTURALEQUIPMENT
MachineModelEngineModel
BellEquipment,SouthAfrica
884CaneLoaderCD4045TBE50(Tier1)
904HaulTractorCD4045TBE51(Tier1)
1266HaulTractorCD6068TBE50(Tier1)
1866HaulTractorCD6068TBE51(Tier2) 2256HaulTractorCD6068HBE50(Tier1)
DesMoines,Iowa
4700Sprayer(138kW)T06068TN050,PE6068TN050,T06068TN053,PE6068TN053 4700Sprayer(149kW)PE6068TN052
4710SprayerPE6068TN052
4720SprayerPE6068HN051(Tier2)
6700SprayerT04045TN050,PE4045TN050 7455CottonStripperT06068TN051,PE6068TN051 7460CottonStripperPE6068TN054 9935CottonPickerT06068TN051,PE6068TN051
EastMoline,Illinois
9400CombineT06068HH050 9410CombineT06068HH051 9450CombineT06068HH052,PE6068HH052 9550Combine(LowPower)PE6068HH054(4-Valve)(Tier2) 9550/9550SHCombine(HighPower)PE6068HH055(4-Valve)(Tier2) 9560Combine(LowPower)PE6068HH054(4-Valve)(Tier2) 9560Combine(HighPower)PE6068HH055(4-Valve)(Tier2) 9965PeanutCombinePE6068HH057
Horizontina,Brazil
1165CombineJ06068TCQ11
1170CombineCD6068TCQ50
1175CombineJ06068TCQ12
1450CombineJ06068TCQ04
1450CWS/WTSCombineCD6068HCQ60,JO6068TCG04(Tier2) 1550CWS/WTSCombineCD6068HCQ61,JO6068ACQ04(Tier2)
3518CombineJ06068TYC51
9650CombineJ06068HCQ01
5403/5605TractorJ04045DCQ01 5705TractorJ04045TCQ02
6405TractorJ04045TCQ01
6415TractorJ04045TCQ03
JOHNDEEREAGRICULTURALEQUIPMENT
MachineModelEngineModel
6605TractorJ06068TCQ02
6615TractorJ06068TCQ15
7505TractorJ06068TCQ03
7515TractorJ06068TCQ14 Jiamusi,China
1075CombineCD6068TYC50,J06068TYC50 3518CombineCD6068TYC51,CD6068HYC50,J06068TYC51 Zweibrucken,Germany
2254CombineCD6068HZ050 3200/3400TelehandlerCD4045TZ250 3215/3415Telehandler(EuropeanVersion)CD4045HZ275,CD4045TZ270 3215/3415Telehandler(NorthAmericanVersion)CD4045HZ275,CD4045TZ270 3220/3420Telehandler(EuropeanVersion)CD4045HZ275 3220/3420Telehandler(NorthAmericanVersion)CD4045HZ275 3800Telehandler,ArticulatedCD4045HZ050,4045HZ060 9540/9540HillmasterCombineCD6068HZ060 CD6068HZ480(4-Valve)(Tier2) 9560/9560HMCombineCD6068HZ470(4-Valve)(Tier2)
CD6068HZ481(4-Valve)(Tier2) Ottumwa,Iowa
4890WindrowerT04045TE050,PE4045TE050
4895WindrowerT04045TE051,PE4045TE051 4990WindrowerT06068TE050,PE6068TE050 4995WindrowerPE6068TE051
Waterloo,Iowa
7210(SYNCROPLUS)TractorT06068TRW53
7210(POWRQUAD)TractorT06068TRW50,PE6068TRW50 7220TractorCD6068TRW01,PE6068TRW01,PE6068HRW59
7220IVTTractorPE6068HRW61
7320TractorCD6068HRW01,PE6068HRW01,PE6068HRW59
7320IVTTractorPE6068HRW61
7410(SYNCROPLUS)TractorT06068TRW54,PE6068HRW54
7410(POWRQUAD)TractorT06068TRW51,PE6068TRW51
7420TractorCD6068HRW01,PE6068HRW01
7510(POWRQUAD)TractorT06068TRW70,PE6068TRW70 7520TractorCD6068HRW01,PE6068HRW01
7610Tractor(105kW)T06068TRW52,PE6068TRW52
7610Tractor(110kW)T06068TRW72,PE6068TRW72
Acceptableoilconsumption,guidelinefor...04-150-2
Aircleaneroperation 03-120-19
Airfilterrestrictionindicatortest ......... 04-150-36Thrustplateclearance,measure ....... 02-050-17
Airheater,removeandinstall ........... 02-080-38
Camshaftfollowers(four-valvehead)
AirintakeandexhaustsystemInspect,measureandassemble ....... 02-021-20
Theoryofoperation 03-120-16
Camshaftfollowers(two-valvehead)
Airintakepipe,removeandinstall 02-080-34Inspect,measureandassemble 02-020-17 Carrierassembly(four-valvehead)
Coolanttemperatureabovenormal 04-150-9
Coolanttemperaturebelownormal ....... 04-150-10
Coolingsystem
Check 04-150-27
Deaeration ....................... 02-070-19
Diagnostics
Coolantinoiloroilincoolant 04-150-10
Enginecoolanttemperatureabove
Cylinderhead
Checkforheadgasketfailures 04-150-24
Gasketconstructionanddiagnostics .... 03-120-14
Cylinderhead(four-valvehead)
Capscrews,torque-turn 02-021-50
Checkflatness 02-021-30
Finalassembly 02-021-58
Gasket,inspectandrepair ........... 02-021-28
Inspectandclean 02-021-30 normal 04-150-9
Enginecoolanttemperaturebelow
Install 02-021-47
Preliminarychecks 02-021-23 normal 04-150-10
Flushandservice 01-002-16
Pressuretest...................... 04-150-22
Theory 03-120-10
Remove .......................... 02-021-7
Thickness,measure ................ 02-021-31
Cylinderhead(two-valvehead)
Capscrews,cleanandinspect 02-020-40,
Crankcasepressure,check ............ 04-150-19
COOLSCANandOILSCAN 01-002-9 02-021-44
Crankingspeedtest 04-150-14
Crankshaft
Endplay,check ................... 02-040-19
Failureanalysis 02-040-1
Flange,cleanandinspect 02-040-32
Gear,removeandinstall ............. 02-040-43
Capscrews,torque-turn ............. 02-020-46
Checkflatness 02-020-28
Finalassembly 02-020-53
Gasket,inspectandrepair 02-020-25
Inspectandclean .................. 02-020-27
Install ........................... 02-020-43
Grindingguidelines 02-040-49 Remove 02-020-7
Grindingspecifications 02-040-50
Inspect .......................... 02-040-46
Preliminarychecks 02-020-20
Thickness,measure 02-020-29
Cylinderliners Install 02-040-54
Journals,measure 02-040-47
Mainandthrustbearinginserts,
Clean 02-030-12
Deglaze 02-030-20
Flangecounterboredepth 02-030-40 install 02-040-52
Mainbearingcaps,measure .......... 02-040-51
MainbearingID,measure 02-040-47
Mainbearings,checkclearance 02-040-42
Mainbearings,remove .............. 02-040-40
Pulley,install 02-040-6
Pulley,remove 02-040-3
Rearsealandsleeve,handling ........ 02-040-27
Rearsealandsleeve,install 02-040-32
Rearsealandsleeve,remove ........ 02-040-27
Removeandinstalltimingwheel 02-040-39
Removecrankshaft ................. 02-040-45
Replacefrontsealandwearsleeve 02-040-9
Thrustjournalandbearing,measure 02-040-48
Cylinderblock
Bores,measure 02-030-39
Flangethickness,measure ........... 02-030-40
Inspect .......................... 02-030-13
Install 02-030-47
InstallpackingandO-rings 02-030-45
Measure 02-030-39
O-ringbore,clean .................. 02-030-35
Preliminarychecks 02-030-8
Remove 02-030-5
Standout(heightaboveblock) 02-030-44
Cylinderliners(four-valvehead)
Standout,check 02-021-46
Cylinderliners(two-valvehead)
Standout,check 02-020-42
Completedisassembly 02-030-7 D
Inspectandclean 02-030-32
Mainbearingbore,measure 02-030-35
Topdeck,measureflatness 02-030-41 Damper,vibration
Cylinderblock(four-valvehead) Inspect 02-040-2
Topdeck,cleanandinspect 02-021-45 Install ............................ 02-040-6
Cylinderblock(two-valvehead) Remove 02-040-3
Topdeck,cleanandinspect 02-020-41
Dealerfabricatedtools 05-190-1
Fuelsupplypumppushrod(two-valvehead)Engineoilpressurelow
Glowplugbores(four-valvehead)
Idlergear
Bushingandshaft,measure
Springpins,install 02-050-35
Upper,install 02-050-35
Injectionnozzlebores(two-valvehead)
Clean 02-020-30
Injectionpumptimingmark,transfer 02-050-34
Injectorbores(four-valvehead)
Clean ........................... 02-021-32
Injectors,fuel(four-valvehead)
Install ........................... 02-021-51
Intakeairleaktest 04-150-34
Intakemanifoldpressure
Oilfilters 01-002-9
Oilincoolantorcoolantinoil 04-150-10
Oilpan,install 02-060-32
Oilpressurecheck 04-150-17
Oilpressurehigh 04-150-8
Oilpressurelow 04-150-6
Oilpressureregulatingvalve
Removeandinstall ................. 02-060-14
Oilpump
Assemble 02-060-29
Disassemble 02-060-28 Measure 04-150-30
Intakemanifoldpressure(turboboost)
Explodedview 02-060-24
Inspectandmeasureclearances 02-060-26 specifications 06-210-23 Install 02-060-30
Intakemanifoldpressure(turboboost)specifications Remove 02-060-25 (Continued) 06-210-34
Intakemanifoldpressure,measure ....... 04-150-30
Intakerestrictioncheck ................ 04-150-33
Lubricationsystem
Oilpumppick-uptube 02-060-24
OILSCANandCOOLSCAN ............. 01-002-9
Othermaterials
Airintakeandexhaustsystem ........ 05-170-54
Camshaft,balancershaftandtiminggear L train 05-170-42
Coolingsystem 05-170-53
DiagnosticsCrankshaft,mainbearingsand flywheel 05-170-34
Engineoilpressurehigh 04-150-8
Cylinderblock,liners,pistonsandRockerarmassembly(four-valvehead)
02-021-18 rods 05-170-26
Cylinderheadandvalves(four-valveDisassembleandinspect 02-021-17
02-021-53 head) 05-170-20
Cylinderheadandvalves(two-valveRockerarmassembly(two-valvehead)
Thermostat(four-valvehead)Radialbearingclearancetest 02-080-14
Removeandinstall 02-070-8
Recommendationsforuse 02-080-27
Thermostat(single)Remove 02-080-3 Repair 02-080-21
Install 02-070-2
Remove 02-070-1Theoryofoperation 03-120-20
Removeandinstall(highflowsingle thermostat) ...................... 02-070-4
Thermostats
Thermostats(dual),removeandinstall 02-070-7
Wastegatetest .................... 04-150-36
Openingtemperaturetest 04-150-21 V
Timinggearbacklash,measure 02-050-13
TiminggearcoverValve(four-valvehead) Bridges,inspectandmeasure 02-021-16
Cleanandinspect 02-050-49
Install 02-050-50Valveseats(four-valvehead) Grind 02-021-37
Remove 02-050-3
Timingmark,transfer ................. 02-050-34Valveseats(two-valvehead) Grind ............................ 02-020-33
Timingwheel,removeandinstall ........ 02-040-39
Timing,injectionpumpgear ............ 02-050-43Valves Lift,measure 02-050-1
Tools
Camshaft,balancershaftandtiminggearValves(four-valvehead) Clean 02-021-25 train 05-170-35
Coolingsystem 05-170-50Clearance,checkandadjust 02-021-1 Grind 02-021-27
Crankshaft,mainbearingsand flywheel 05-170-27Guides,clean 02-021-34 Guides,knurl 02-021-36
Cylinderblock,liners,pistonsand rods ........................... 05-170-20Guides,measure ................... 02-021-35 Inspectandmeasure ............... 02-021-26
Cylinderheadandvalves(four-valve head) .......................... 05-170-12Install ........................... 02-021-43 Lift,measure 02-021-5
Cylinderheadandvalves(two-valve head)
05-170-3Preliminarychecks 02-021-23
Dealerfabricated 05-190-1
Recess,measure 02-021-22
Diagnostic 05-180-1Remove 02-021-24
Enginerebuild 05-170-1
Seatbore,measure 02-021-41
Lubricationsystem 05-170-43Seatinserts,install 02-021-42
Startingandchargingsystems 05-170-55
Seatinserts,remove 02-021-37
TurboboostSeats,cleanandinspect ............. 02-021-36
Measure ......................... 04-150-30
Springs,inspectandmeasure ......... 02-021-25
TurbochargerValves(two-valvehead) Clean 02-020-22
Adjustwastegateactuator 02-080-16
Axialbearingendplaytest 02-080-13Clearance,checkandadjust 02-020-2 Grind 02-020-24
Boostpressurespecifications 06-210-23
BoostpressurespecificationsGuides,clean 02-020-30 Guides,knurl 02-020-32 (Continued) 06-210-34
Boostpressure,measure 04-150-30Guides,measure 02-020-31 Inspectandmeasure 02-020-23
Break-in 02-080-27
Extendinglife ...................... 02-080-1Install ........................... 02-020-39 Lift,measure ....................... 02-020-5
Failureanalysis ..................... 02-080-5 Inspection ......................... 02-080-7Preliminarychecks ................. 02-020-20 Recess,measure .................. 02-020-19
Install ........................... 02-080-23
Lubrication 03-120-21Remove 02-020-21
Oilinletline........................ 02-010-6
Rotators,inspect 02-020-22
Oilsealleaktest 04-150-20Seatbore,measure 02-020-38
Prelube 02-080-22
Seatinserts,install 02-020-39
