John Deree Powertech 4 5l & 6 8l Operator Manual by JustinWiseg

Dieselengineexhaustandsomeofitsconstituentsare

Theengineexhaustfromthisproductcontainschemicals knowntotheStateofCaliforniatocausecancer,birth defectsorotherreproductiveharm.

TheStateofCaliforniarequirestheabovetwowarnings.

PowerTech 4.5Land6.8L Non-Certifiedand Tier1Certified OEMDieselEngines OPERATOR’SMANUAL PowerTech 4.5Land6.8L Non-CertifiedandTier1Certified OEMDieselEngines

OMRG25204Issue02Nov06(ENGLISH) CALIFORNIA Proposition65Warning

knowntotheStateofCaliforniatocausecancer,birth defects,andotherreproductiveharm. Ifthisproductcontainsagasolineengine: WARNING

JohnDeerePowerSystems LITHOINU.S.A. John Deree Powertech 4 5l & 6 8l Operator Manual

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This is the cut pages sample. Download all 164 page(s) at: ManualPlace.com

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Foreword

Thismanualcontainsinformationtooperateand servicethefollowing4.5L&6.8Lnon-certifiedand Tier11 emissioncertifiedOEMenginesbuiltat DubuqueIowa(T0),SaranFrance(CD)andTorreon Mexico(PE)from1996on.Theseengineshave mechanically-controlledfuelsystems.

SARANBUILTNON-CERTIFIEDENGINES

• CD4045DF120

• CD4045TF120

• CD4045TF220

• CD4045HF120

• CD6068TF120

• CD6068TF220

• CD6068HF120

TORREONBUILTNON-CERTIFIEDENGINES

• PE4045TF120

• PE4045TF220

• PE4045HF120

• PE6068TF120

• PE6068TF220

• PE6068HF120

DUBUQUEBUILTNON-CERTIFIEDENGINES

• T04045DF120

• T04045TF120

• T04045TF220

• T04045HF120

SARANBUILTTIER1CERTIFIEDENGINES

• CD4045DF150

• CD4045DF151

• CD4045DF152

• CD4045DF153

• CD4045DF154

• CD4045DF157

• CD4045DF158

1EmissioncertifiedforUnitedStatesasEPATier1andEuropean UnionasStage1.

• CD4045TF150

• CD4045TF152

• CD4045TF154

• CD4045TF155

• CD4045TF157

• CD4045TF158

• CD4045TF161

• CD4045TF162

• CD4045TF250

• CD4045TF251

• CD4045TF252

• CD4045TF253

• CD4045TF257

• CD4045TF258

• CD4045HF150

• CD4045HF152

• CD4045HF157

• CD4045HF158

• CD4045HF252

• CD6068DF150

• CD6068TF150

• CD6068TF151

• CD6068TF152

• CD6068TF157

• CD6068TF158

• CD6068TF159

• CD6068TF250

• CD6068TF251

• CD6068TF257

• CD6068TF258

• CD6068HF150

• CD6068HF157

• CD6068HF158

• CD6068HF250

• CD6068HF252

• CD6068HF254

• CD6068HF258

TORREONBUILTTIER1CERTIFIEDENGINES

• PE4045DF150

• PE4045TF150

OURGP11,0000004–19–27OCT06–1/2

Introduction

110306 PN=2

• PE4045TF151

• PE4045HF150

• PE4045HF252

• PE6068DF150

• PE6068TF150

• PE6068TF151

• PE6068TF250

• PE6068HF150

• PE6068HF250

DUBUQUEBUILTTIER1CERTIFIEDENGINES

• T04045DF150

• T04045DF151

• T04045DF152

• T04045DF153

• T04045TF150

• T04045TF151

• T04045TF152

• T04045TF250

• T04045TF251

• T04045HF120

• T04045HF150

• T06068DF150

• T06068TF150

• T06068TF151

• T06068TF250

• T06068HF150

• T06068HF250

NOTE:Before2005,allNon-certifiedandTier1 CertifiedSaranbuiltenginesusedthefollowing serialnumbersequences:

• (CDxxxxD500000)-(CDxxxxD799999)

• (CDxxxxT500000)-(CDxxxxT799999)

• (CDxxxxH500000)-(CDxxxxH799999)

Since2005,non-certifiedengineshavethe seventhdigitoftheserialnumberas“B”while Tier1certifiedengineshavetheseventhdigit as“C”.

READTHISMANUALcarefullytolearnhowtooperate andserviceyourenginecorrectly.Failuretodoso couldresultinpersonalinjuryorequipmentdamage.

THISMANUALSHOULDBECONSIDEREDa permanentpartofyourengineandshouldremainwith theenginewhenyousellit.

MEASUREMENTSINTHISMANUALaregiveninboth metricandcustomaryU.S.unitequivalents.Useonly correctreplacementpartsandfasteners.Metricand inchfastenersmayrequireaspecificmetricorinch wrench.

RIGHT-HANDANDLEFT-HANDsidesaredetermined bystandingatthedriveorflywheelend(rear)ofthe engineandfacingtowardthefrontoftheengine.

WRITEENGINESERIALNUMBERSandoptioncodes inthespacesindicatedintheRecordKeepingSection. Accuratelyrecordallthenumbers.Yourdealeralso needsthesenumberswhenyouorderparts.Filethe identificationnumbersinasecureplaceofftheengine.

SETTINGFUELDELIVERYbeyondpublishedfactory specificationsorotherwiseoverpoweringwillresultin lossofwarrantyprotectionforthisengine.

CERTAINENGINEACCESSORIESsuchasradiator, aircleaner,andinstrumentsareoptionalequipmenton JohnDeereOEMEngines.Theseaccessoriesmaybe providedbytheequipmentmanufacturerinsteadof JohnDeere.Thisoperator’smanualappliesonlytothe engineandthoseoptionsavailablethroughtheJohn Deeredistributionnetwork.

NOTE:Thisoperatorsmanualcoversonlyengines providedtoOEM(OutsideEquipment Manufacturers).ForenginesinDeere machines,refertothemachineoperators manual.

Introduction

OURGP11,0000004–19–27OCT06–2/2

110306 PN=3

EngineOwner

JohnDeereEngineOwner:

Don’twaituntilyouneedwarrantyorotherserviceto meetyourlocalJohnDeereEngineDistributoror ServiceDealer.Toregisteryourengineforwarranty viatheInternet,usethefollowingURL: http://www.johndeere.com/enginewarranty

Learnwhoyourdealerisandwhereheis.Atyourfirst convenience,gomeethim.He’llwanttogettoknow youandtolearnwhatyourneedsmightbe.

AuxUtilisateursDeMoteursJohnDeere:

N’attendezpasd’e ˆ treoblige ´ d’avoirrecoursa ` votre concessionnaireJohnDeereouaupointdeservicele plusprochepourvousadressera ` lui.Pourenregistrer votremoteurpourlagarantieviaInternet,utilisez l’adressesuivante: http://www.johndeere.com/enginewarranty

Renseignez-vousdesquepossiblepourl’identifieret lelocaliser.Alapremie ` reoccasion,prenezcontact avecluietfaites-vousconnaıˆtre.Ilseraluiaussi heureuxdefairevotreconnaissanceetdevous proposersesserviceslemomentvenu.

AnDenBesitzerDesJohnDeereMotors:

WartenSienichtaufeinenevt.Reparaturfall,umden nachstgelegenenJohnDeereHandlerkennenzu lernen.ZurRegistrierungIhresMotorsfurdieGarantie dientfolgendeInternet-Adresse: http://www.johndeere.com/enginewarranty

MachenSiesichbeiihmbekanntundnutzenSiesein “ServiceAngebot”.

ProprietariodelmotoreJohnDeere:

Nonaspettifinoalmomentodifarvalerelagaranziao dichiedereassistenzaperfarelaconoscenzadel

distributoredeimotoriJohnDeereodel concessionariocheforniscel’assistenzatecnica.Per registrareviaInternetlagaranziadelsuomotore,si collegialseguentesitoURL: http://www.johndeere.com/enginewarranty

Loidentifichiesiinformisullasuaubicazione.Alla primaoccasioneutilelocontatti.Eglidesiderafarela suaconoscenzaecapirequalipotrebberoesserele suenecessita.

PropietarioDeEquipoJohnDeere:

Noesperehastanecesitarserviciodegarantı´aode otrotipoparaconocerasuDistribuidordeMotores JohnDeereoalConcesionariodeServicio.Registre sumotorparalagarantı´aenlasiguientedireccio ´ nde internet:http://www.johndeere.com/enginewarranty

Enteresedequienes,ydondeesta situado.Cuando tengaunmomento,vayaavisitarlo.Aellegustara conocerlo,ysabercualespodrı ´ ansersus necesidades.

TillagareavJohnDeeremotorer:

Taredapa ˚ vemdina ˚ terfo ¨ rsa ¨ ljarea ¨ rochbeso ¨ khonom sa ˚ snarttillfa ¨ lleges.Va ¨ ntaintetillsdeta ¨ rdagsfo ¨ r serviceellereventuelltgarantiarbete.Dinmotor garantiregistrerarDuviaInternetpa ˚ http://www.johndeere.com/enginewarranty

Dina ˚ terforsaljarevillmycketgarnatraffadigforattlara kannadinabehovochhurbasthankanhjalpadig.

Introduction

OURGP11,0000251–19–11OCT06–1/1

110306 PN=4

Introduction RG,RG34710,5501–19–04JAN02–1/1 POWERTECH 4.5LEnginesWithMechanicalControls(Tier1EmissionCertified) RG7999–UN–19JUN00 4045DEngine RG7998–UN–19JUN00 4045DEngine RG7996–UN–19JUN00 4045TEngine RG7997–UN–19JUN00 4045TEngine POWERTECH isatrademarkofDeere&Company 110306 PN=5

Introduction RG,RG34710,5503–19–04JAN02–1/1 POWERTECH 6.8LEnginesWithMechanicalControls(Tier1EmissionCertified) RG8003–UN–19JUN00 6068DEngine RG8002–UN–19JUN00 6068DEngine RG8001–UN–19JUN00 6068TEngine RG8000–UN–19JUN00 6068TEngine POWERTECH isatrademarkofDeere&Company 110306 PN=6

RecordKeeping

Instrument(Gauge)Panel(NorthAmerica) ..... 15-2

PowerTechMedallion 01-1 VDOInstrument(Gauge)Panel(Except EngineSerialNumberPlate 01-1 NorthAmerica) 15-4 RecordEngineSerialNumber 01-2 EngineBreak-InService 15-6 EngineOptionCodes 01-3 AuxiliaryGearDriveLimitations 15-9 RecordFuelInjectionPumpModelNumber 01-5 GeneratorSet(Standby)Applications 15-9 StartingtheEngine 15-10 WarmingEngine 15-12 Safety 05-1 NormalEngineOperation ................. 15-13 ColdWeatherOperation .................. 15-14 Fuels,Lubricants,andCoolant ChangingEngineSpeed .................. 15-15 DieselFuel 10-1 AvoidExcessiveEngineIdling 15-15 LubricityofDieselFuel 10-1 StoppingtheEngine 15-16 HandlingandStoringDieselFuel 10-2 UsingaBoosterBatteryorCharger 15-17 TestingDieselFuel 10-2 Bio-DieselFuel 10-3

LubricationandMaintenance Aviation(Jet)Fuels 10-4 ObserveServiceIntervals 20-1 BurnerFuels ............................ 10-4 UseCorrectFuels,Lubricants,andCoolant 20-1 MinimizingtheEffectofColdWeatheron LubricationandMaintenanceService DieselEngines 10-5 IntervalChart—StandardIndustrialEngines..20-2 DieselEngineBreak-InOil 10-6 LubricationandMaintenanceService DieselEngineOil 10-7 IntervalChart—Generator(Standby) ExtendedDieselEngineOilServiceIntervals...10-8 Applications 20-4 MixingofLubricants 10-8 OILSCANandCOOLSCAN 10-9

Lubrication&Maintenance/Daily AlternativeandSyntheticLubricants 10-9 DailyPrestartingChecks 25-1 LubricantStorage 10-10 OilFilters ............................. 10-10 Grease ............................... 10-11 Lubrication&Maintenance/250Hour/6Month DieselEngineCoolant 10-12 ServicingFireExtinguisher 30-1 DrainIntervalsforDieselEngineCoolant 10-13 ChangingEngineOilandReplacingFilter 30-2 AdditionalInformationAboutDiesel CheckingEngineMounts 30-4 EngineCoolantsandSupplementalCoolant ServicingBattery 30-5 Additives 10-14 ManualBeltTensionerAdjustment 30-7 SupplementalCoolantAdditives 10-15 ManualBeltTensionerAdjustmentUsing AdditionalInformationAboutDiesel BeltTensionTool(AlternateMethod EngineCoolantsandSupplementalCoolant ForEnginesWithoutAuxiliaryDrive) ........ 30-8 Additives ............................ 10-16 TestingDieselEngineCoolant ............. 10-17 Lubrication&Maintenance/500Hour/12Month OperatinginWarmTemperatureClimates .... 10-18 CleaningCrankcaseVentTube ............. 35-1 DisposingofCoolant 10-18 CheckingAirIntakeSystem ................ 35-2 ReplacingFuelFilterElement(SingleFilter) .... 35-3 EngineOperatingGuidelines Instrument(Gauge)Panels 15-1 Continuedonnextpage

Contents PagePage

Allinformation,illustrationsandspecificationsinthismanualarebasedon thelatestinformationavailableatthetimeofpublication.Therightis reservedtomakechangesatanytimewithoutnotice. COPYRIGHT  2006 DEERE&COMPANY Moline,Illinois Allrightsreserved AJohnDeereILLUSTRUCTION Manual PreviousEditions Copyright  1996,2000,2002,2004 i 110306 PN=1

ReplacingFuelFilterElements(DualFilters)...35-5 Specifications

GeneralOEMEngineSpecifications—4.5L

CheckingBeltTensionerSpringTension andBeltWear(AutomaticTensioner) 35-6Engines 60-1 GeneralOEMEngineSpecifications—6.8L CheckingEngineSpeeds 35-9

CheckingEngineElectricalGroundEngines 60-2 EnginePowerRatingsAndFuelInjection Connections 35-9

CheckingCoolingSystem 35-10PumpSpecifications 60-3 EngineCrankcaseOilFillQuantities 60-11

ReplenishingSupplementalCoolant Additives(SCAs)BetweenCoolantUnifiedInchBoltandScrewTorqueValues...60-15 MetricBoltandScrewTorqueValues........ 60-16 Changes ............................ 35-11

TestingDieselEngineCoolant ............. 35-12

PressureTestingCoolingSystem 35-13

LubricationandMaintenanceRecords

UsingLubricationandMaintenanceRecords...65-1 Daily(Prestarting)Service 65-1

Lubrication&Maint./2000Hour/24Month 250Hour/6MonthService 65-2

AdjustingVariableSpeed(Droop)on 500Hour/12MonthService 65-3 GeneratorSetEngines 40-1 2000Hour/24MonthService 65-4

CheckingCrankshaftVibrationDamper

ServiceasRequired 65-5 (6-CylinderEngineOnly) ................. 40-3

FlushingandRefillingCoolingSystem ........ 40-4

TestingThermostatsOpeningTemperature 40-7 U.S.EPAEmissionsControlWarranty CheckandAdjustValveClearance 40-10 Statement 70-1

ServiceasRequired

AdditionalServiceInformation .............. 45-1

DoNotModifyFuelSystem ................ 45-1

AddingCoolant .......................... 45-2

ReplacingSingleStageAirCleaner 45-3

ReplacingAxialSealAirCleanerFilter Element 45-4

ReplacingRadialSealAirCleanerFilter Element 45-6

ReplacingFanandAlternatorBelts 45-8

CheckingFusesInInstrumentPanels 45-9 CheckingAirCompressors 45-10

BleedingtheFuelSystem ................. 45-11

Troubleshooting

GeneralTroubleshootingInformation 50-1

EngineWiringDiagramLegend (StandardInstrumentPanelForNorth America) 50-3

WiringDiagram(StandardInstrument PanelForNorthAmerica) ................ 50-4

EngineWiringDiagram—VDO InstrumentPanel(ExceptNorthAmerica) 50-5

EngineWiringDiagramLegend—VDO InstrumentPanel(ExceptNorthAmerica) 50-6

EngineTroubleshooting 50-7

Storage

EngineStorageGuidelines ................. 55-1

PreparingEngineforLongTermStorage 55-2

RemovingEnginefromLongTermStorage 55-3

EmissionSystemWarranty

EmissionsControlSystemCertificationLabel...70-1

Contents PagePage

110306 PN=2

Amedallionislocatedontherockerarmcoverwhich identifieseachengineasaJohnDeere POWERTECH engine.

POWERTECH Medallion RG11608–UN–17OCT01 RG11609–UN–17OCT01

POWERTECH isatrademarkofDeere&Company.

Eachenginehasa13-digitJohnDeereengineserial number.Thefirsttwodigitsidentifythefactorythat producedtheengine:

• “T0”indicatestheenginewasbuiltinDubuque,Iowa • “CD”indicatestheenginewasbuiltinSaran,France • “PE”indicatestheenginewasbuiltinTorreon,Mexico • “J0”indicatestheenginewasbuiltinRosario,Argentina

Yourengine’sserialnumberplate(A)islocatedonthe right-handsideofcylinderblockbehindthefuelfilter.

RG,RG34710,5505–19–04JAN02–1/1

RG,RG34710,5506–19–04JAN02–1/1

RecordKeeping

RG8007–UN–15JAN99 13-DigitEngineSerialNumberPlate

EngineSerialNumberPlate

01-1 110306 PN=9

RecordKeeping RG,RG34710,5507–19–04JAN02–1/1 RecordEngineSerialNumber RG7936–UN–13NOV97 DubuqueEngineSerialNumberPlate RG7935–UN–13NOV97 SaranEngineSerialNumberPlate RG9062–UN–16MAR98 TorreonEngineSerialNumberPlate Recordallofthenumbersandlettersfoundonyour engineserialnumberplateinthespacesprovidedbelow. Thisinformationisveryimportantforrepairpartsor warrantyinformation. EngineSerialNumber(B) EngineModelNumber(C) CoefficientofAbsorptionValue(D) (SaranEnginesOnly) 01-2 110306 PN=10 John Deree Powertech 4 5l & 6 8l Operator Manual Full download: http://manualplace.com/download/john-deree-powertech-4-5l-6-8l-operator-manual/ This is the cut pages sample. Download all 164 page(s) at: ManualPlace.com