PowerTech Plus 4045 and 6068 Diesel Engines Operators Manual

POWERTECH E 4.5 and 6.8 L 4045 and 6068 Tier 3 / Stage IIIA OEM Diesel Engines OPERATOR’S MANUAL PowerTech E 4045TF285/HF285 and 6068HF285 OEM Diesel Engines OMRG37407 Issue 30Apr08 (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 California to cause cancer, birth defects or other reproductive harm. The State of California requires the above two warnings. John Deere Power Systems LITHO IN U.S.A.

Introduction OURGP12,00001E9 –19–23APR08–1/1 Foreword THIS MANUAL CONTAINS INFORMATION to operate and service the following Tier 3 / Stage IIIA emission-certified 1 engines: Saran-built (France) Tier 3 Electronically Controlled Engines: • CD4045TF285 (HPCR System; 2-Valve Head) • CD4045HF285 (HPCR System; 2-Valve Head) • CD6068HF285 (HPCR System; 2-Valve Head) Torreon-built (Mexico) Tier 3 Electronically Controlled Engines: • PE4045TF285 (HPCR System; 2-Valve Head) • PE4045HF285 (HPCR System; 2-Valve Head) • PE6068HF285 (HPCR System; 2-Valve Head) READ THIS MANUAL carefully to learn how to operate and service your engine correctly. Failure to do so could result in personal injury or equipment damage. THIS MANUAL SHOULD BE CONSIDERED a permanent part of your engine and should remain with the engine when you sell it. MEASUREMENTS IN THIS MANUAL are given in both metric and customary U.S. unit equivalents. Use only correct replacement parts and fasteners. Metric and inch fasteners may require a specific metric or inch wrench. WRITE ENGINE SERIAL NUMBERS and option codes in the spaces indicated in the Record Keeping Section. Accurately record all the numbers. Your dealer also needs these numbers when you order parts. File the identification numbers in a secure place off the engine. SETTING FUEL DELIVERY beyond published factory specifications or otherwise overpowering will result in loss of warranty protection for this engine. CERTAIN ENGINE ACCESSORIES such as radiator, air cleaner, and instruments are optional equipment on John Deere OEM Engines. These accessories may be provided by the equipment manufacturer instead of John Deere. This operator’s manual applies only to the engine and those options available through the John Deere distribution network. IMPORTANT: This manual covers only POWERTECH E Tier 3/ Stage IIIA emission certified 4.5 and 6.8 L OEM engines listed. (This is for both the U.S. EPA and European Union Council (EU) emission standards.) NOTE: This manual covers engines provided to OEM (Original Equipment Manufacturers). For engines in Deere machines, refer to the machine operator’s manual. POWERTECH is a trademark of Deere & Company 1 Emission certified for United States as EPA Tier 3 and for European Union as Stage IIIA. 050608 PN=2

Introduction OURGP11,0000251 –19–08OCT07–1/1 Engine Owner John Deere Engine Owner: Don’t wait until you need warranty or other service to meet your local John Deere Engine Distributor or Service Dealer. To register your engine for warranty via the Internet, use the following URL: http://www.johndeere.com/enginewarranty Learn who your dealer is and where he is. At your first convenience, go meet him. He’ll want to get to know you and to learn what your needs might be. Aux Utilisateurs De Moteurs John Deere: N’attendez pas d’e ˆ tre oblige ´ d’avoir recours a ` votre concessionnaire John Deere ou au point de service le plus proche pour vous adresser a ` lui. Pour enregistrer votre moteur pour la garantie via Internet, utilisez l’adresse suivante: http://www.johndeere.com/enginewarranty Renseignez-vous de ` s que possible pour l’identifier et le localiser. A la premie ` re occasion, prenez contact avec lui et faites-vous connaı ˆtre. Il sera lui aussi heureux de faire votre connaissance et de vous proposer ses services le moment venu. An Den Besitzer Des John Deere Motors: Warten Sie nicht auf einen evt. Reparaturfall, um den na ¨ chstgelegenen John Deere Ha ¨ndler kennen zu lernen. Zur Registrierung Ihres Motors fu ¨r die Garantie dient folgende Internet-Adresse: http://www.johndeere.com/enginewarranty Machen Sie sich bei ihm bekannt und nutzen Sie sein “Service Angebot”. Proprietario del motore John Deere: Non aspetti fino al momento di far valere la garanzia o di chiedere assistenza per fare la conoscenza del distributore dei motori John Deere o del concessionario che fornisce l’assistenza tecnica. Per registrare via Internet la garanzia del suo motore, si collegi al seguente sito URL: http://www.johndeere.com/enginewarranty Lo identifichi e si informi sulla sua ubicazione. Alla prima occasione utile lo contatti. Egli desidera fare la sua conoscenza e capire quali potrebbero essere le sue necessita `. Propietario De Equipo John Deere: No espere hasta necesitar servicio de garantı á o de otro tipo para conocer a su Distribuidor de Motores John Deere o al Concesionario de Servicio. Registre su motor para la garantı á en la siguiente direccio ń de internet: http://www.johndeere.com/enginewarranty Aprenda quie ń es su distribuidor y donde e ´l esta ´ situado. Cuando tenga un momento, vaya a visitarlo. A e ´l le gustara ´ conocerlo, y saber cua ´les podrı án ser sus necesidades. Till a ¨gare av John Deere motorer: Ta reda pa ˚ vem din a ˚ terfo ¨rsa ¨ljare a ¨r och beso ¨k honom sa ˚ snart tillfa ¨lle ges. Va ¨nta inte tills det a ¨r dags fo ¨r service eller eventuellt garantiarbete. Din motor garantiregistrerar Du via Internet pa ˚ http://www.johndeere.com/enginewarranty Din a ˚ terfo ¨rsa ¨ljare vill mycket ga ¨rna tra ¨ffa dig fo ¨r att la ¨ra ka ¨nna dina behov och hur ba ¨st han kan hja ¨lpa dig. 050608 PN=3

Introduction OURGP12,00001EA –19–29NOV07–1/1 PowerTech E 4.5 L Engine With Electronic Fuel Systems (HPCR Fuel System) (Two-Valve Cylinder Head) RG14632 –UN–13APR06 4045HF285 Engine RG14633 –UN–13APR06 4045HF285 Engine PowerTech is a trademark of Deere & Company 050608 PN=4

Introduction OURGP12,00001EB –19–22APR08–1/1 PowerTech E 6.8 L Engine With Electronic Fuel Systems (HPCR Fuel System) (Two-Valve Cylinder Head) RG14634 –UN–13APR06 6068HF285 Engine PowerTech E is a trademark of Deere & Company 050608 PN=5

Introduction 050608 PN=6

Contents Page Page Record Keeping Accessing Active Trouble Codes ........... 15-10 Engine Serial Number Plate ................ 01-1 Engine Shutdown Codes ................. 15-12 Record Engine Serial Number .............. 01-1 Adjusting Backlighting.................... 15-13 Engine Option Codes ..................... 01-2 Adjusting Contrast ...................... 15-15 Record Engine Control Unit (ECU) Serial Selecting Units Of Measurement ........... 15-17 Number .............................. 01-4 Setup 1-Up Display ..................... 15-20 Record High-Pressure Fuel Pump Model Setup 4-Up Display ..................... 15-26 Number .............................. 01-4 Engine Operation Engine Break-In Service ................... 20-1 Safety ................................ 05-1 Starting the Engine ....................... 20-4 Normal Engine Operation .................. 20-7 Fuels, Lubricants, and Coolant Warming Engine ......................... 20-8 Diesel Fuel ............................. 10-1 Cold Weather Operation ................... 20-9 Lubricity of Diesel Fuel .................... 10-2 Using a Booster Battery or Charger ......... 20-11 Handling and Storing Diesel Fuel ............ 10-2 Avoid Excessive Engine Idling ............. 20-12 Testing Diesel Fuel ....................... 10-3 Changing Engine Speed .................. 20-13 Bio-Diesel Fuel .......................... 10-4 Stopping The Engine .................... 20-16 Minimizing the Effect of Cold Weather on Auxiliary Gear Drive Limitations ............ 20-17 Diesel Engines ........................ 10-6 Generator Set (Standby) Applications ........ 20-17 Diesel Engine Break-In Oil ................. 10-7 Diesel Engine Oil ........................ 10-8 Lubrication and Maintenance Diesel Engine Oil and Filter Service Intervals . . . 10-9 Observe Service Intervals.................. 25-1 Mixing of Lubricants ..................... 10-11 Use Correct Fuels, Lubricants, and Coolant .... 25-1 OILSCAN and COOLSCAN ............ 10-12 Lubrication and Maintenance Service Alternative and Synthetic Lubricants ......... 10-12 Interval Chart—Standard Industrial Engines . . 25-2 Lubricant Storage ....................... 10-13 Lubrication and Maintenance Service Oil Filters ............................. 10-13 Interval Chart—Generator (Standby) Diesel Engine Coolant ................... 10-14 Applications .......................... 25-4 Drain Intervals for Diesel Engine Coolant .... 10-15 Additional Information About Diesel Engine Coolants and Supplemental Coolant Lubrication & Maintenance/Daily Additives ............................ 10-16 Daily Prestarting Checks .................. 30-1 Testing Diesel Engine Coolant ............. 10-17 Operating in Warm Temperature Climates .... 10-18 Lubrication & Maintenance/500 Hour/12 Month Disposing of Coolant .................... 10-18 Servicing Fire Extinguisher ................. 35-1 Checking Engine Mounts .................. 35-1 Servicing Battery ........................ 35-2 Instrument Panels Instrument Panels........................ 15-1 Changing Engine Oil and Replacing Filter ..... 35-4 Checking Crankcase Vent System ........... 35-7 Using Diagnostic Gauge to Access Engine Information ........................... 15-4 Checking Air Intake System ................ 35-8 Replacing Fuel Filter Elements .............. 35-9 Main Menu Navigation .................... 15-5 Engine Configuration Data ................. 15-6 Continued on next page Accessing Stored Trouble Codes ............ 15-8 All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice. COPYRIGHT  2008 DEERE & COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION  Manual Previous Editions Copyright  2006 i 050608 PN=1

Contents Page Page Checking Belt Tensioner Spring Tension Displaying Diagnostic Gauge Software ....... 50-10 Engine Troubleshooting .................. 50-12 and Belt Wear (Automatic Tensioner) ...... 35-11 Checking Engine Electrical Ground Connections ......................... 35-13 Storage Engine Storage Guidelines ................. 55-1 Checking Cooling System................. 35-13 Replenishing Supplemental Coolant Preparing Engine for Long Term Storage ...... 55-2 Removing Engine from Long Term Storage .... 55-3 Additives (SCAs) Between Coolant Changes ............................ 35-14 Testing Diesel Engine Coolant ............. 35-16 Specifications General OEM Engine Specifications .......... 60-1 Pressure Testing Cooling System........... 35-17 Checking and Adjusting Engine Speeds ...... 35-18 Engine Power Ratings And Fuel System Specifications ......................... 60-3 Engine Crankcase Oil Fill Quantities ......... 60-4 Lubrication & Maint./2000 Hour/24 Month Unified Inch Bolt and Screw Torque Values .... 60-5 Checking Crankshaft Vibration Damper Metric Bolt and Screw Torque Values......... 60-6 (6-Cylinder Engine Only) ................. 40-1 Flushing and Refilling Cooling System ........ 40-2 Lubrication and Maintenance Records Testing Thermostats Opening Temperature .... 40-5 Using Lubrication and Maintenance Records . . . 65-1 Check and Adjust Valve Clearance .......... 40-8 Daily (Prestarting) Service ................. 65-1 500 Hour/12 Month Service ................ 65-2 Service as Required 2000 Hour/24 Month Service ............... 65-3 Additional Service Information .............. 45-1 Service as Required ...................... 65-4 Do Not Modify Fuel System ................ 45-2 Adding Coolant .......................... 45-3 Emission System Warranty Replacing Single Stage Air Cleaner .......... 45-5 U.S. EPA Emmission Control Warranty Replacing Axial Seal Air Cleaner Filter Statement ............................ 70-1 Element ............................. 45-6 Emission Control System Certification Label.... 70-1 Replacing Radial Seal Air Cleaner Filter Element ............................. 45-8 Replacing Fan and Alternator Belts ......... 45-10 Checking Fuses ........................ 45-11 Checking Air Compressors ................ 45-11 Bleed the Fuel System ................... 45-12 Troubleshooting General Troubleshooting Information ......... 50-1 Precautions For Welding On Engines Equipped With Electronic Engine Control Unit (ECU) ............................... 50-1 Precautions for Electrical System When Steam Cleaning Engine ................. 50-2 Engine Wiring Layout ..................... 50-3 Engine Wiring Diagram (With Full-Featured Electronic Instrument Panel) . . . 50-4 Engine Wiring Diagram (With Full-Featured Electronic Instrument Panel)— Continued ............................ 50-5 Instrument Panel Method for Retrieving Diagnostic Trouble Codes ................ 50-6 Displaying Of Diagnostic Trouble Codes (DTCs) .............................. 50-7 Listing of Diagnostic Trouble Codes (DTCs) .... 50-8 Intermittent Fault Diagnostics (With Electronic Controls) .................... 50-10 ii 050608 PN=2

Record Keeping OURGP12,00001C3 –19–14MAR06–1/1 Engine Serial Number Plate RG8007 –UN–15JAN99 Engine Serial Number Plate A—Serial Number Plate Each engine has a John Deere engine serial number. The first two digits identify the factory that produced the engine: • “CD” = Saran, France • “PE” = Torreon, Mexico The engine’s serial number plate (A) is located on the right-hand side of cylinder block behind the fuel filter. OURGP12,00001C4 –19–14MAR06–1/1 Record Engine Serial Number RG14641 –UN–17MAY06 Saran Factory Engine Serial Number Plate RG14629 –UN–28AUG07 Torreon Factory Engine Serial Number Plate 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) Engine Model Number (C) NOTE: Engine serial numbers on the 7th digit indicates the Emission Level as follows: • “B” for non-certified engines • “C” for Tier 1 / Stage I engines • “G” for Tier 2 / Stage II engines • “L” for Tier 3 / Stage IIIA engines 01-1 050608 PN=9

Record Keeping OURGP12,00001C5 –19–14MAR06–1/2 Engine Option Codes RG14630 –UN–13APR06 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 option codes. The first two digits of each code identify a specific group, such as alternators. The last two digits of each code identify one specific option provided on your engine, such as a 12-volt, 55-amp alternator. NOTE: These option codes are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice. If an engine is ordered without a particular component, the last two digits of that functional group option code will be 99, 00, or XX. The list on the next page shows only the first two digits of the code numbers. For future reference such as ordering repair parts, it is important to have these code numbers available. To ensure this availability, enter the third and fourth digits shown on your engine option code label in the spaces provided on the following page. 01-2 050608 PN=10 Continued on next page

PowerTech Plus 4045 and 6068 Diesel Engines Operators Manual

You're Reading a Preview

Recently Viewed