John Deere PowerTech 4.5 L and 6.8 L Non-Certified and Tier 1 Certified OEM Diesel Engines Official Operators Manual
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OMRG25204 Issue 02Nov06 (ENGLISH)
CONTENTS :
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 . .....01-5
Generator Set (Standby) Applications. ...............15-9
Starting the Engine. .........................................15-10
Warming Engine . .............................................15-12
Safety . .............................................................05-1
Normal Engine Operation . ...............................15-13
Cold Weather Operation . .................................15-14
Fuels, Lubricants, and Coolant
Changing Engine Speed. .................................15-15
Diesel Fuel . .......................................................10-1
Avoid Excessive Engine Idling . .......................15-15
Lubricity of Diesel Fuel . .....................................10-1
Stopping the Engine . .......................................15-16
Handling and Storing Diesel Fuel . .....................10-2
Using a Booster Battery or Charger . ...............15-17
Testing Diesel Fuel. ...........................................10-2
Bio-Diesel Fuel . .................................................10-3
Lubrication and Maintenance
Aviation (Jet) Fuels. ...........................................10-4
Burner Fuels. .....................................................10-4
Observe Service Intervals. .................................20-1
Minimizing the Effect of Cold Weather on
Lubrication and Maintenance Service
Diesel Engines . .............................................10-5
Interval Chart—Standard Industrial Engines . . 20-2
Diesel Engine Break-In Oil . ...............................10-6
Lubrication and Maintenance Service
Diesel Engine Oil . .............................................10-7
Interval Chart—Generator (Standby)
Extended Diesel Engine Oil Service Intervals . . . 10-8
Applications . .................................................20-4
Mixing of Lubricants . .........................................10-8
Use Correct Fuels, Lubricants, and Coolant . .....20-1
OILSCANand COOLSCAN . .........................10-9
Lubrication & Maintenance/Daily
Alternative and Synthetic Lubricants . .................10-9
Daily Prestarting Checks . .................................25-1
Lubricant Storage . ...........................................10-10
Oil Filters . .......................................................10-10
Grease . ...........................................................10-11
Lubrication & Maintenance/250 Hour/6 Month
Diesel Engine Coolant . ...................................10-12
Servicing Fire Extinguisher . ...............................30-1
Drain Intervals for Diesel Engine Coolant . .....10-13
Changing Engine Oil and Replacing Filter . .......30-2
Additional Information About Diesel
Checking Engine Mounts . .................................30-4
Engine Coolants and Supplemental Coolant
Servicing Battery . .............................................30-5
Additives . .....................................................10-14
Manual Belt Tensioner Adjustment . ...................30-7
Supplemental Coolant Additives . .....................10-15
Manual Belt Tensioner Adjustment Using
Additional Information About Diesel
Belt Tension Tool (Alternate Method
Engine Coolants and Supplemental Coolant
For Engines Without Auxiliary Drive) . .............30-8
Additives . .....................................................10-16
Testing Diesel Engine Coolant . .......................10-17
Lubrication & Maintenance/500 Hour/12 Month
Operating in Warm Temperature Climates . .....10-18
Cleaning Crankcase Vent Tube . .......................35-1
Disposing of Coolant . .....................................10-18
Checking Air Intake System . .............................35-2
Replacing Fuel Filter Element (Single Filter). .....35-3
Engine Operating Guidelines
Instrument (Gauge) Panels. ...............................15-1
Replacing Fuel Filter Elements (Dual Filters) . . . 35-5
Specifications
General OEM Engine Specifications—4.5 L
Checking Belt Tensioner Spring Tension
and Belt Wear (Automatic Tensioner) . ...........35-6
Engines. .........................................................60-1
Checking Engine Speeds . .................................35-9
Checking Engine Electrical Ground
General OEM Engine Specifications—6.8 L
Engines. .........................................................60-2
Connections . .................................................35-9
Engine Power Ratings And Fuel Injection
Checking Cooling System. ...............................35-10
Pump Specifications . .....................................60-3
Replenishing Supplemental Coolant
Additives (SCAs) Between Coolant
Engine Crankcase Oil Fill Quantities . .............60-11
Unified Inch Bolt and Screw Torque Values . . . 60-15
Metric Bolt and Screw Torque Values. .............60-16
Changes . .....................................................35-11
Testing Diesel Engine Coolant . .......................35-12
Pressure Testing Cooling System. ...................35-13
Lubrication and Maintenance Records
Using Lubrication and Maintenance Records . . . 65-1
Daily (Prestarting) Service . ...............................65-1
Lubrication & Maint./2000 Hour/24 Month
250 Hour/6 Month Service . ...............................65-2
Adjusting Variable Speed (Droop) on
500 Hour/12 Month Service . .............................65-3
Generator Set Engines . .................................40-1
Checking Crankshaft Vibration Damper
2000 Hour/24 Month Service . ...........................65-4
(6-Cylinder Engine Only) . ...............................40-3
Service as Required . .........................................65-5
Flushing and Refilling Cooling System . .............40-4
Emission System Warranty
Testing Thermostats Opening Temperature . .....40-7
U.S. EPA Emissions Control Warranty
Check and Adjust Valve Clearance . ...............40-10
Statement . .....................................................70-1
Emissions Control System Certification Label . . . 70-1
Service as Required
Additional Service Information . .........................45-1
Do Not Modify Fuel System . .............................45-1
Adding Coolant. .................................................45-2
Replacing Single Stage Air Cleaner . .................45-3
Replacing Axial Seal Air Cleaner Filter
Element . .......................................................45-4
Replacing Radial Seal Air Cleaner Filter
Element . .......................................................45-6
Replacing Fan and Alternator Belts . .................45-8
Checking Fuses In Instrument Panels . .............45-9
Checking Air Compressors . .............................45-10
Bleeding the Fuel System. ...............................45-11
Troubleshooting
General Troubleshooting Information . ...............50-1
Engine Wiring Diagram Legend
(Standard Instrument Panel For North
America) . .......................................................50-3
Wiring Diagram (Standard Instrument
Panel For North America) . .............................50-4
Engine Wiring Diagram—VDO
Instrument Panel (Except North America) . .....50-5
Engine Wiring Diagram Legend—VDO
Instrument Panel (Except North America) . .....50-6
Engine Troubleshooting . ...................................50-7
Storage
Engine Storage Guidelines . ...............................55-1
Preparing Engine for Long Term Storage . .........55-2
Removing Engine from Long Term Storage . .....55-3
