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POWERTECH
4.5 and 6.8 L
4045 and 6068
Tier 2 / Stage II
OEM Diesel Engines
OPERATOR’S MANUAL
POWERTECH 4.5 and 6.8 L Tier 2 /
Stage II OEM Diesel Engines
OMRG33324 Issue 7Aug06 (ENGLISH)
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
If this product contains a gasoline engine:
WARNING
The engine exhaust from this product contains chemicals
known to the State of
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Introduction Foreword THIS MANUAL CONTAINS INFORMATION to operate • PE6068HF475 (HPCR System; 4-Valve Head) and service the following Tier 2 / Stage II 1 emission-certified engines: READ THIS MANUAL carefully to learn how to operate and service your engine correctly. Failure to do so Saran-built (France) Tier 2 Mechanically Controlled could result in personal injury or equipment damage. Engines: THIS MANUAL SHOULD BE CONSIDERED a • CD4045DF270 permanent part of your engine and should remain with
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Introduction IMPORTANT: This manual covers only non-emission certified or Tier 1 / POWERTECH Tier 2 / Stage II Stage I emission certified (U.S. and emission certified 4.5 and 6.8 L OEM EU) are covered in a separate engines listed. These engines meet operators manual, OMRG25204. Tier 2 emission certification 2 standards. (This is for both the U.S. NOTE: This manual covers engines provided to OEM EPA and European Union Council (Original Equipment Manufacturers). For (EU) standards.) Engines with
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Introduction 080706 PN=4
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Introduction Engine Owner John Deere Engine Owner: distributore dei motori John Deere o del concessionario che fornisce l’assistenza tecnica. Per Don’t wait until you need warranty or other service to registrare via Internet la garanzia del suo motore, si meet your local John Deere Engine Distributor or collegi al seguente sito URL: Service Dealer. To register your engine for warranty http://www.johndeere.com/enginewarranty via the Internet, use the following URL: http://www.johndeere.com/engine
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Introduction POWERTECH 4.5 L Engines With Electronic Fuel Systems (Tier 2 Emission Certified) (Two-Valve Cylinder Head Models) 4045 Engine 4045 Engine (Stanadyne DE10 Injection Pump Shown) POWERTECH is a trademark of Deere & Company. OUOD002,0000162 –19–04AUG06–1/1 080706 PN=6 RG11931 –UN–06NOV01 RG11932 –UN–06NOV01
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Introduction POWERTECH 6.8 L Engines With Electronic Fuel Systems (Tier 2 Emission Certified) (Two-Valve Cylinder Head Models) 6068 Engine (Bosch VP44 Injection Pump Shown) 6068 Engine POWERTECH is a trademark of Deere & Company. OUOD002,0000163 –19–04AUG06–1/1 080706 PN=7 RG11933 –UN–24OCT01 RG11934 –UN–24OCT01
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Introduction POWERTECH 4.5/6.8 L Engines With Electronic Fuel Systems (Tier 2 Emission Certified) (Four-Valve Cylinder Head “475” Models) 6068HF475 Engine Shown (Level 11 Electronic Fuel System With 6068HF475 Shown Denso High Pressure Common Rail) POWERTECH is a trademark of Deere & Company. OURGP11,000018B –19–04AUG06–1/1 080706 PN=8 RG12199 –UN–24MAY02 RG12200 –UN–24MAY02
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Contents Page Page Record Keeping Using Touch Switches to Display PowerTech Medallion..................... 01-1 Information .......................... 16-10 Engine Serial Number Plate................ 01-1 Changing Units of Measure (English or Record Engine Serial Number .............. 01-2 Metric).............................. 16-12 Engine Option Codes..................... 01-3 Viewing Engine Configuration Data ......... 16-14 Record Engine Control Unit (ECU) Serial Viewing Active Engine Service
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Contents Page Page Auxiliary Gear Drive Limitations ............ 19-17 Checking Crankshaft Vibration Damper Generator Set (Standby) Applications........ 19-17 (6-Cylinder Engine Only)................. 35-2 Flushing and Refilling Cooling System ........ 35-3 Engine Operation- 4.5 L “270” Engines Testing Thermostats Opening Temperature .... 35-6 Normal Engine Operation.................. 20-1 Check and Adjust Valve Clearance (All Break-In Service......................... 20-2 Engines Except 4045HF4
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Contents Page Page Engine Wiring Layout (Electronic Fuel Lubrication and Maintenance Records System With Denso High Pressure Common Using Lubrication and Maintenance Records . . . 60-1 Rail)(4045HF475,6068HF475)............. 45-5 Daily (Prestarting) Service ................. 60-1 Engine Wiring Diagram (With Earlier 500 Hour/12 Month Service ................ 60-2 Electronic Instrument Panel).............. 45-6 2000 Hour/24 Month Service ............... 60-3 Engine Wiring Diagram (Engines With Ser
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Contents iv 080706 PN=4
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Record Keeping POWERTECH Medallion A medallion is located on the rocker arm cover which identifies each engine as a John Deere POWERTECH engine. NOTE: Four-valve head engines also have “16V” or “24V” printed on their medallions. The 4045HF475 has “16V” to denote 16 valves total while 6068HF475 has “24V” to denote 24 valves total. POWERTECH is a trademark of Deere & Company. OURGP11,0000274 –19–04AUG06–1/1 Engine Serial Number Plate Each engine has a 13-digit John Deere engine serial number. Th
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Record Keeping Record Engine Serial Number Record all of the numbers and letters found on your engine serial number plate in the spaces provided below. This information is very important for repair parts or warranty information. Engine Serial Number (B) Saran Engine Serial Number Plate Engine Model Number (C) Coefficient of Absorption Value (D) (Saran Engines Only) NOTE: Effective in April 2005, engine serial numbers were changed at the 7th digit to show the Emission Level. Previously this digit
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Record Keeping Engine Option Codes A—Engine Base Code In addition to the serial number plate, OEM engines have an engine option code label affixed to the rocker arm cover. These codes indicate which of the engine options were installed on your engine at the factory. When in need of parts or service, furnish your authorized servicing dealer or engine distributor with these numbers. The engine option code label includes an engine base code (A). This base code must also be recorded along with the o
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Record Keeping NOTE: Your engine option code label may not contain An additional option code label may also be all option codes if an option has been added delivered with the engine. Place this sticker or after the engine left the producing factory. tag, for reference, either on this page or in the engine owner’s warranty booklet under If option code label is lost or destroyed, OPTION CODES title. consult your servicing dealer or engine distributor selling the engine for a replacement. Option Co
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Record Keeping Record Engine Control Unit (ECU) Serial Number Record the part number and serial number information found on the serial number label (A) on the Engine Control Unit (ECU) mounted on or near the engine. Part No. Serial No. A—Serial Number Label Record Engine Control Unit (ECU) Serial Number OURGP12,00000AD –19–27JUL06–1/1 Record Fuel Injection Pump Model Number Record the fuel injection pump model and serial information found on the serial number plate (A). Model No. RPM Manufacture
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Safety Recognize Safety Information 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 –19–29SEP98–1/1 Understand Signal Words A signal word—DANGER, WARNING, or CAUTION—is used with the safety-alert symbol. DANGER identifies the most serious hazards. DANGER or WARNING safety signs are located near specific hazards. General precautions are li
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Safety Replace Safety Signs Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement. DX,SIGNS1 –19–04JUN90–1/1 Prevent Bypass Starting Avoid possible injury or death from engine runaway. Do not start engine by shorting across starter terminal. Engine will start with PTO engaged if normal circuitry is bypassed. Start engine only from operator’s station with PTO disengaged or in neutral. Prevent Bypass Starting RG,RG34710,7508 –19–27JUL06–1/1 Ha
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Safety Prepare for Emergencies 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 –19–03MAR93–1/1 Handle Starting Fluid Safely Starting fluid is highly flammable. Keep all sparks and flame away when using it. Keep starting fluid away from batteries and cables. To prevent accidental discharge when storing the pressurized can, keep the cap on the container
