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PowerTech
4.5 L and 6.8 L
Non-Certified and
Tier 1 Certified
OEM Diesel Engines
OPERATOR’S MANUAL
PowerTech 4.5 L and 6.8 L
Non-Certified and Tier 1 Certified
OEM Diesel Engines
OMRG25204 Issue 02Nov06 (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 chemi
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Introduction Foreword This manual contains information to operate and • CD4045TF150 service the following 4.5 L & 6.8 L non-certified and • CD4045TF152 1 Tier 1 emission certified OEM engines built at • CD4045TF154 Dubuque Iowa (T0), Saran France (CD) and Torreon • CD4045TF155 Mexico (PE) from 1996 on. These engines have • CD4045TF157 mechanically-controlled fuel systems. • CD4045TF158 • CD4045TF161 SARAN BUILT NON-CERTIFIED ENGINES • CD4045TF162 • CD4045TF250 • CD4045DF120 • CD4045TF251 • CD404
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Introduction • PE4045TF151 READ THIS MANUAL carefully to learn how to operate • PE4045HF150 and service your engine correctly. Failure to do so • PE4045HF252 could result in personal injury or equipment damage. • PE6068DF150 • PE6068TF150 THIS MANUAL SHOULD BE CONSIDERED a • PE6068TF151 permanent part of your engine and should remain with • PE6068TF250 the engine when you sell it. • PE6068HF150 • PE6068HF250 MEASUREMENTS IN THIS MANUAL are given in both metric and customary U.S. unit equivalents
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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 Mechanical Controls (Tier 1 Emission Certified) 4045D Engine 4045D Engine 4045T Engine 4045T Engine POWERTECH is a trademark of Deere & Company RG,RG34710,5501 –19–04JAN02–1/1 110306 PN=5 RG7996 –UN–19JUN00 RG7999 –UN–19JUN00 RG7997 –UN–19JUN00 RG7998 –UN–19JUN00
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Introduction POWERTECH 6.8 L Engines With Mechanical Controls (Tier 1 Emission Certified) 6068D Engine 6068D Engine 6068T Engine 6068T Engine POWERTECH is a trademark of Deere & Company RG,RG34710,5503 –19–04JAN02–1/1 110306 PN=6 RG8001 –UN–19JUN00 RG8003 –UN–19JUN00 RG8000 –UN–19JUN00 RG8002 –UN–19JUN00
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Contents Page Page Record Keeping Instrument (Gauge) Panel (North America)..... 15-2 PowerTech Medallion..................... 01-1 VDO Instrument (Gauge) Panel (Except Engine Serial Number Plate................ 01-1 North America) ........................ 15-4 Record Engine Serial Number .............. 01-2 Engine Break-In Service................... 15-6 Engine Option Codes..................... 01-3 Auxiliary Gear Drive Limitations ............. 15-9 Record Fuel Injection Pump Model Number.... 0
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Contents Page Page Replacing Fuel Filter Elements (Dual Filters) . . . 35-5 Specifications Checking Belt Tensioner Spring Tension General OEM Engine Specifications—4.5 L and Belt Wear (Automatic Tensioner)....... 35-6 Engines.............................. 60-1 Checking Engine Speeds.................. 35-9 General OEM Engine Specifications—6.8 L Checking Engine Electrical Ground Engines.............................. 60-2 Connections .......................... 35-9 Engine Power Ratings And Fuel In
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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. POWERTECH is a trademark of Deere & Company. RG,RG34710,5505 –19–04JAN02–1/1 Engine Serial Number Plate Each engine has a 13-digit John Deere engine serial number. The first two digits identify the factory that produced the engine: • “T0” indicates the engine was built in Dubuque, Iowa • “CD” indicates the engine was built in Saran, France • “PE” in
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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) Dubuque Engine Serial Number Plate Engine Model Number (C) Coefficient of Absorption Value (D) (Saran Engines Only) Saran Engine Serial Number Plate Torreon Engine Serial Number Plate RG,RG34710,5507 –19–04JAN02–1/1 01-2 110306 PN=10 RG7935 –UN–1
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Record Keeping Engine Option Codes 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 recor
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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 Fuel Injection Pump Model Number Record the fuel injection pump model and serial information found on the serial number plate (A). Model No. RPM Manufacturer’s No. Serial No. A—Serial Number Plate Record Injection Pump Serial Number RG,RG34710,5511 –19–20MAY96–1/1 01-5 110306 PN=13 RG8008A –UN–13JUN00
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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 Machine Runaway Avoid possible injury or death from machinery runaway. Do not start engine by shorting across starter terminals. Machine will start in gear if normal circuitry is bypassed. NEVER start engine while standing on ground. Start engine only from operator’s seat, with transmission in neutral or park. DX,BYPAS1 –19–29
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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
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Safety Service Machines Safely Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result. Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts. DX,LOOSE –19–04JUN90–1/1 Wear Protective Clothing Wear close fitting clothing and safety equipment appropriate to the job. Prolonged exposure to loud noise can cause impair
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Safety Handle Chemical Products Safely Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere equipment include such items as lubricants, coolants, paints, and adhesives. A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques. Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly
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Safety Practice Safe Maintenance 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 in
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Safety Avoid 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
