John Deere 4.5L 6.8L Marine Diesel Engine (PowerTech) Operator Manual OMRG39400

Contents:
Record Keeping
Engine Serial Number Plate
Record Engine Serial Number
Engine Option Codes
Record High-Pressure Fuel Pump Model Number
Record Engine Control Unit (ECU) Serial Number
Safety
Recognize Safety Information
Understand Signal Words
Follow Safety Instructions
Replace Safety Signs
California Proposition 65 Warning
Illuminate Work Area Safely
Work in Clean Area
Use Proper Tools
Live With Safety
Prevent Machine Runaway
Handle Fuel Safely-Avoid Fires
Prepare for Emergencies
Handle Starting Fluid Safely
In Case of Fire
Handle Fluids Safely-Avoid Fires
Avoid Static Electricity Risk When Refueling
Service Machines Safely
Wear Protective Clothing
Protect Against Noise
Handling Batteries Safely
Prevent Acid Burns
Stay Clear of Rotating Drivelines
Install All Guards
Practice Safe Maintenance
Remove Paint Before Welding or Heating
Avoid Heating Near Pressurized Fluid Lines
Avoid High-Pressure Fluids
Do Not Open High-Pressure Fuel System
Protect Against High Pressure Spray
Prevent Battery Explosions
Avoid Hot Exhaust
Work In Ventilated Area
Service Cooling System Safely
Decommissioning – Proper Recycling and Disposal of Fluids and Components
Fuels, Lubricants, and Coolant
Diesel Fuel
Supplemental Diesel Fuel Additives
Lubricity of Diesel Fuel
Handling and Storing Diesel Fuel
Biodiesel Fuel
Testing Diesel Fuel
Fuel Filters
Minimizing the Effect of Cold Weather on Diesel Engines
Diesel Engine Break-In Oil – Non-Emissions Certified and Certified Tier 1, Tier 2, Tier 3, Stage I, Stage II, and Stage III
Diesel Engine Oil – Marine Engines
Engine Oil and Filter Service Intervals – Tier 3 and Stage IIIA – Marine Engines
Mixing of Lubricants
Alternative and Synthetic Lubricants
Lubricant Storage
Oil Filters
Diesel Engine Coolant (engine with wet sleeve cylinder liners)
Water Quality for Mixing with Coolant Concentrate
Operating in Warm Temperature Climates
Testing Coolant Freeze Point
Disposing of Coolant
Instrument Panels
Sea Trials for Performance and Warranty
John Deere Instrument (Gauge) Panel (Electronically Controlled Engines)
John Deere Instrument (Gauge) Panel (Electronically Controlled Engines) (Continued)
PV101 Instrument Panels
PV101 Diagnostic Gauge – Using
PV101 Diagnostic Gauge – Main Menu
PV101 Diagnostic Gauge – Essential Menus
DG14 Diagnostic Gauge – Using
DG14 Diagnostic Gauge – Main Menu
DG14 Diagnostic Gauge – Essential Menus
PV480 Instrument Panel
PV480 Diagnostic Gauge – Using
PV480 Diagnostic Gauge – Main Menu
PV480 Diagnostic Gauge – Essential Menus
Main Menu Navigation
Engine Configuration Data
Accessing Stored Diagnostic Trouble Codes
Accessing Active Diagnostic Trouble Codes
Engine Shutdown Diagnostic Trouble Codes
Adjusting Backlighting
Adjusting Contrast
Selecting Units Of Measurement
Setup 1-Up Display
Setup 4-Up Display
John Deere PowerSight
Engine Operation
Normal Engine Operation
Marine Break-In Service
Auxiliary Gear Drive Limitations
Generator Set Power Units
Starting the Engine
Warming Engine
Idling Engine
Cold Weather Operation
Stopping the Engine
Using a Booster Battery or Charger
Welding Near Electronic Control Units
Keep Electronic Control Unit Connectors Clean
Lubrication and Maintenance
Required Emission-Related Information
Observe Service Intervals
Use Correct Fuels, Lubricants, and Coolant
Lubrication and Maintenance Service Interval Chart
Lubrication & Maintenance – Daily
Daily Prestarting Checks
Lubrication & Maintenance – 250 Hours/6 Months
Changing Engine Oil and Replacing Oil Filter
Servicing Air Cleaner Filter Element (4045SFM85)
Servicing Fire Extinguisher
Servicing Battery
Checking Engine Mounts
Inspecting and Replacing Zinc Plugs (If Equipped)
Lubrication & Maintenance – 500 Hours/12 Months
Replacing Crankcase Vent Filter
Checking Air Intake System
Replacing Fuel Filters/Cleaning Water Separator
Checking Belt Tensioner Spring Tension and Belt Wear
Checking Cooling System
Pressure Testing Cooling System
Servicing Heat Exchanger Core (4045TFM85 / 4045AFM85)
Installing Heat Exchanger Core (4045TFM85 / 4045AFM85)
Servicing Heat Exchanger Core (4045SFM85)
Installing Heat Exchanger Core (4045SFM85)
Servicing Heat Exchanger Core (6.8 L)
Installing Heat Exchanger Core (6.8 L)
Servicing Aftercooler Core (4045SFM85)
Installing Aftercooler Core (4045SFM85)
Servicing Aftercooler Core (6068SFM85)
Installing Aftercooler Core (6068SFM85)
Checking and Adjusting Engine Speeds
Checking Engine Electrical Ground Connections
Replacing Sea Water Pump Impeller (4045TFM85)
Replacing Sea Water Pump Impeller (4045AFM85 / 4045SFM85 / 6068AFM85)
Replacing Sea Water Pump Impeller (6068SFM85)
Lubrication & Maintenance – 1500 Hours
Checking Crankshaft Vibration Damper (If Equipped)
Lubrication & Maintenance – 2000 Hours/24 Months
Checking and Adjusting Engine Valve Clearance
Overhauling Sea Water Pump (4045TFM85)
Overhauling Sea Water Pump (4045AFM85 / 4045SFM85 / 6068AFM85)
Overhauling Sea Water Pump (6068SFM85)
Lubrication & Maintenance – 3000 Hours
Checking Crankshaft Vibration Damper (If Equipped)
Lubrication & Maintenance – 4500 Hours/36 Months
Replace Crankshaft Vibration Damper
Lubrication & Maintenance – 6000 Hours/72 Months
Flushing And Refilling Cooling System
Removing and Installing Thermostats
Testing Thermostats
Service As Required
Do Not Modify Fuel System
Draining Water From Fuel Filters
Adding Coolant
Pre-Start Cleaning Guide
Servicing Air Cleaner Filter Element (4045TFM85)
Replacing Air Cleaner Filter Element (4045AFM85 and All 6068)
Replacing Alternator Belt
Bleeding Fuel System
Troubleshooting
General Troubleshooting Information
Precautions for Welding
Precautions For Welding On Vessels Equipped With Electronic Engine Control Unit (ECU)
Engine Troubleshooting
Instrument Panel Method for Retrieving Diagnostic Trouble Codes
Checking Fuses
Diagnostic Trouble Codes (DTCs) – Operation
Diagnostic Trouble Codes (DTCs) – Listing
Intermittent DTC Diagnostics
Storage
Engine Storage Guidelines
Preparing Engine for Long-Term Storage
Removing Engine from Long-Term Storage
Specifications
General Marine Engine Specifications – 4.5L
General Marine Engine Specifications – 6.8L
Engine Power And Speed Ratings
Engine Crankcase Oil Fill Quantities
Unified Inch Bolt and Screw Torque Values
Metric Bolt and Screw Torque Values
Lubrication and Maintenance Records
Using Lubrication and Maintenance Records
Daily (Prestarting) Service
250 Hours/6 Months Service
500 Hours/12 Months Service
1500 Hour Service
2000 Hours/24 Months Service
3000 Hour Service
4500 Hours/60 Months Service
6000 Hours/72 Months Service
Service As Required
Warranty
John Deere Warranty in OEM Applications
Emissions Control System Certification Label
European Union (EU) Declaration of Emissions Conformity
Carbon Dioxide Emissions (COâ‚‚)
U.S. Marine Compression-Ignition Engine Emission Control Warranty Statement