John Deere POWERTECH 4.5L and 6.8L Tier2 Stage II Marine Engines OPERATOR’S MANUAL
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Models Covered :
POWERTECH
4045DFM70/TFM75,
6068SFM50/75,
6068TFM75/76
Marine Engines
CONTENTS :
Record Keeping John Deere Instrument (Gauge) Panel
PowerTech Medallion . . . . . . . . . . . . . . . . . . . . . 01-1 (Electronically Controlled Engines)
Engine Serial Number Plate . . . . . . . . . . . . . . . . 01-1 (Continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5
Record Engine Serial Number . . . . . . . . . . . . . . 01-1 Optional Electronic Displays to Monitor
Engine Option Codes . . . . . . . . . . . . . . . . . . . . . 01-2 Engine and Navigation . . . . . . . . . . . . . . . . . . 15-6
Engine Option Codes-Continued . . . . . . . . . . . . 01-3 Using Diagnostic Gauge to Access Engine
Record Fuel Injection Pump or Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-7
High-Pressure Fuel Pump Model Number. . . . 01-4 Main Menu Navigation . . . . . . . . . . . . . . . . . . . . 15-8
Record Engine Control Unit (ECU) Serial Engine Configuration Data . . . . . . . . . . . . . . . . . 15-9
Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-4 Accessing Stored Trouble Codes . . . . . . . . . . . 15-11
Accessing Active Trouble Codes . . . . . . . . . . . 15-13
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-1 Engine Shutdown Codes . . . . . . . . . . . . . . . . . 15-15
Adjusting Backlighting. . . . . . . . . . . . . . . . . . . . 15-17
Fuels, Lubricants, and Coolant Adjusting Contrast . . . . . . . . . . . . . . . . . . . . . . 15-19
Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 Selecting Units Of Measurement . . . . . . . . . . . 15-21
Lubricity of Diesel Fuel . . . . . . . . . . . . . . . . . . . . 10-1 Setup 1-Up Display . . . . . . . . . . . . . . . . . . . . . 15-23
Handling and Storing Diesel Fuel . . . . . . . . . . . . 10-2 Setup 4-Up Display . . . . . . . . . . . . . . . . . . . . . 15-30
Testing Diesel Fuel. . . . . . . . . . . . . . . . . . . . . . . 10-2 Normal Engine Operation . . . . . . . . . . . . . . . . . 15-35
Bio-Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 Break-In Service. . . . . . . . . . . . . . . . . . . . . . . . 15-35
Minimizing the Effect of Cold Weather on Auxiliary Gear Drive Limitations . . . . . . . . . . . . 15-39
Diesel Engines . . . . . . . . . . . . . . . . . . . . . . . . 10-4 Generator Set Power Units. . . . . . . . . . . . . . . . 15-40
Diesel Engine Break-In Oil . . . . . . . . . . . . . . . . . 10-5 Starting the Engine. . . . . . . . . . . . . . . . . . . . . . 15-41
Diesel Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . 10-6 Emergency Starting Of 6068SFM50 and
Extended Diesel Engine Oil Service Intervals . . . 10-7 6068SFM75 With Electronic Failure . . . . . . . 15-43
Mixing of Lubricants . . . . . . . . . . . . . . . . . . . . . . 10-7 Warming Engine. . . . . . . . . . . . . . . . . . . . . . . . 15-44
Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7 Idling Engine . . . . . . . . . . . . . . . . . . . . . . . . . . 15-45
OILSCAN™and COOLSCAN™ . . . . . . . . . . . . . . 10-8 Engaging And Disengaging Front PTO (If
Alternative and Synthetic Lubricants. . . . . . . . . . 10-8 Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-45
Lubricant Storage . . . . . . . . . . . . . . . . . . . . . . . . 10-9 Cold Weather Operation. . . . . . . . . . . . . . . . . . 15-46
Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9 Stopping the Engine . . . . . . . . . . . . . . . . . . . . . 15-47
Diesel Engine Coolant . . . . . . . . . . . . . . . . . . . 10-10 Using a Booster Battery or Charger . . . . . . . . . 15-49
Drain Intervals for Diesel Engine Coolant . . . . 10-11 Lubrication and Maintenance
Supplemental Coolant Additives . . . . . . . . . . . . 10-12 Observe Service Intervals. . . . . . . . . . . . . . . . . . 20-1
Testing Diesel Engine Coolant . . . . . . . . . . . . . 10-12 Use Correct Fuels, Lubricants, and Coolant . . . . 20-2
Operating in Warm Temperature Climates . . . . 10-13 Lubrication and Maintenance Service
Disposing of Coolant . . . . . . . . . . . . . . . . . . . . 10-13 Interval Chart—Propulsion Power Units . . . . . 20-3
Lubrication and Maintenance Service
Engine Operating Guidelines Interval Chart—Generator Sets . . . . . . . . . . . . 20-5
John Deere Instrument (Gauge) Panel
(Mechanically Controlled 4045DFM70 Engines Lubrication & Maintenance/Daily
Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1 Daily Prestarting Checks . . . . . . . . . . . . . . . . . . 25-1
John Deere Instrument (Gauge) Panel
(Electronically Controlled Engines) . . . . . . . . . 15-3
Lubrication & Maintenance/250 Hour/6 Month Replacing Dry Air Cleaner Element
Changing Engine Oil and Replacing Oil Filter . . . 30-1 (Enclosed Element Installations) . . . . . . . . . . . 45-3
Servicing Fire Extinguisher . . . . . . . . . . . . . . . . . 30-3 Servicing Air Cleaner Filter Element . . . . . . . . . . 45-4
Servicing Battery . . . . . . . . . . . . . . . . . . . . . . . . 30-4 Replacing Air Cleaner Filter Element . . . . . . . . . 45-8
Inspect and Replacing Zinc Plugs. . . . . . . . . . . . 30-6 Replacing Alternator Belt (With Automatic
Checking Belt Wear (Manual Tensioner) . . . . . . 30-7 Tensioner). . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-9
Checking Engine Mounts . . . . . . . . . . . . . . . . . . 30-8 Replacing Alternator Belt (With Manual
Tensioner). . . . . . . . . . . . . . . . . . . . . . . . . . . 45-10
Lubrication & Maintenance/500 Hour/12 Month Check Front Power Take-Off (PTO) . . . . . . . . . 45-11
Replace Crankcase Vent Filter (If Equipped) . . . 35-1 Bleeding the Fuel System—Engines
Checking Crankcase Vent System . . . . . . . . . . . 35-1 With Mechanical Fuel Supply Pump . . . . . . . 45-12
Checking Air Intake System . . . . . . . . . . . . . . . . 35-3 Bleeding Fuel System—Engines With
Replacing Final Fuel Filter/Water Separator . . . . 35-4 Electric Fuel Supply Pump . . . . . . . . . . . . . . 45-14
Replacing Primary Fuel Filter Element . . . . . . . . 35-6 Bleeding Fuel System—6068SFM75 . . . . . . . . 45-16
Checking Belt Tensioner Spring Tension Remove and Install Auxiliary Gear
and Belt Wear (Automatic Tensioner) . . . . . . . 35-8 Driven Sea Water Pump (Except
Checking Cooling System. . . . . . . . . . . . . . . . . 35-10 6068SFM50) . . . . . . . . . . . . . . . . . . . . . . . . . 45-18
Replenishing Supplemental Coolant Remove And Install Sea Water Pump
Additives (SCAs) Between Coolant (6068SFM50) . . . . . . . . . . . . . . . . . . . . . . . . 45-19
Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-11
Testing Diesel Engine Coolant . . . . . . . . . . . . . 35-13 Troubleshooting
Remove, Inspect and Clean Engine Heat General Troubleshooting Information . . . . . . . . . 50-1
Exchanger Core . . . . . . . . . . . . . . . . . . . . . . 35-14 Precautions For Welding On Engines
Install Heat Exchanger Core. . . . . . . . . . . . . . . 35-16 Equipped With Electronic Engine Control Unit
Remove, Inspect and Clean Engine (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-2
Aftercooler Core (6068SFM50) . . . . . . . . . . . 35-18 Propulsion Engine Wiring Harness -
Install Aftercooler Core (6068SFM50). . . . . . . . 35-19 Mechanically Controlled Engine
Pressure Testing Cooling System. . . . . . . . . . . 35-20 (4045DFM70) . . . . . . . . . . . . . . . . . . . . . . . . . 50-4
Checking and Adjusting Engine Speeds . . . . . . 35-21 Propulsion Engine Instrument Panel -
Checking Engine Electrical Ground Mechanically Controlled Engine
Connections . . . . . . . . . . . . . . . . . . . . . . . . . 35-21 (4045DFM70) . . . . . . . . . . . . . . . . . . . . . . . . . 50-7
Electronically Controlled Engine
Lubrication&Maintenance/2000 Hour/24 Month Electrical System Layout — 6068SFM50
Checking and Adjusting Engine Valve Shown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-8
Clearance (Except 6068SFM75) . . . . . . . . . . . 40-1 Wiring Diagram for John Deere Main
Checking and Adjusting Engine Valve Station (Wheel House) Instrument
Clearance (6068SFM75) . . . . . . . . . . . . . . . . . 40-4 Panel - Electronically Controlled Engine . . . . 50-10
Flushing And Refilling Cooling System . . . . . . . . 40-6 Wiring Diagram for John Deere Main
Inspecting Thermostats and Testing Station (Wheel House) Instrument
Opening Temperature . . . . . . . . . . . . . . . . . . . 40-9 Panel - Electronically Controlled Engine
Checking Crankshaft Vibration Damper (Continued) . . . . . . . . . . . . . . . . . . . . . . . . . . 50-11
(6-Cylinder Engine Only). . . . . . . . . . . . . . . . 40-10 Wiring Diagram for John Deere Optional Fly
Inspect and Repair Sea Water Pump Bridge Instrument Panel - Electronically Controlled
(Except 6068SFM50) . . . . . . . . . . . . . . . . . . 40-11 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-12
Inspect And Repair Sea Water Pump 6068SFM50 Marine Electronic Control
(6068SFM50) . . . . . . . . . . . . . . . . . . . . . . . . 40-14 System Wiring Diagram . . . . . . . . . . . . . . . . 50-14
Testing Glow Plugs for Continuity Engine Coolant and Sea Water Flow For
(6068SFM75) . . . . . . . . . . . . . . . . . . . . . . . . 40-16 Heat Exchanger Engines (Except
6068SFM50,75) . . . . . . . . . . . . . . . . . . . . . . 50-16
Service as Required Engine Coolant and Sea Water Flow
Additional Service Information . . . . . . . . . . . . . . 45-1 (6068SFM50, 6068SFM75). . . . . . . . . . . . . . 50-18
Do Not Modify Fuel System . . . . . . . . . . . . . . . . 45-1
Adding Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . 45-2
Engine Troubleshooting . . . . . . . . . . . . . . . . . . 50-19
Electrical Troubleshooting. . . . . . . . . . . . . . . . . 50-26
Blink Code Method for Retrieving
Diagnostic Trouble Codes. . . . . . . . . . . . . . . 50-28
Instrument Panel Method for Retrieving
Diagnostic Trouble Codes. . . . . . . . . . . . . . . 50-29
Listing Of Diagnostic Trouble Codes (DTC) . . . 50-30
Intermittent Fault Diagnostics . . . . . . . . . . . . . . 50-34
Displaying Diagnostic Gauge Software. . . . . . . 50-34
Storage
Engine Storage Guidelines . . . . . . . . . . . . . . . . . 55-1
Preparing Engine for Long Term Storage . . . . . . 55-2
Removing Engine from Long-Term Storage . . . . 55-3
Specifications
General Engine Specifications—4.5 L
Engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-1
General Engine Specifications—6.8 L
Engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-2
Fuel Injection Pump Specifications . . . . . . . . . . . 60-3
Engine Crankcase Oil Fill Quantities . . . . . . . . . 60-4
Unified Inch Bolt and Screw Torque Values . . . . 60-6
Metric Bolt and Screw Torque Values. . . . . . . . . 60-7
Lubrication and Maintenance Records
Using Lubrication and Maintenance Records . . . 65-1
Daily (Prestarting) Service . . . . . . . . . . . . . . . . . 65-1
250 Hour/6 Month Service . . . . . . . . . . . . . . . . . 65-2
500 Hour/12 Month Service . . . . . . . . . . . . . . . . 65-3
2000 Hour Service . . . . . . . . . . . . . . . . . . . . . . . 65-4
Service As Required. . . . . . . . . . . . . . . . . . . . . . 65-5
Emission System Warranty
Emissions Control System Certification Label. . . 70-1
U.S. EPA Emissions Control Warranty
Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-2
EU Declaration of Emissions Conformity . . . . . . 70-2
