John Deere PowerTech 4.5L 6.8L OEM Diesel Engine Operator Manual OMRG33324

Contents:
Record Keeping
Medallion
Engine Serial Number Plate
Record Engine Serial Number
Engine Option Codes
Record Engine Control Unit (ECU) Serial Number
Record Fuel Injection Pump Information
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 – Tier 2 and Stage II
Engine Oil and Filter Service Intervals – Tier 2 and Stage II – OEM Applications
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 Panel Identification
Instrument Panels – Identification
Instrument Panel – Elect. Cont. Earlier Engines
Instrument Panel
Using Diagnostic Gauge to Access Engine Information
Using Touch Switches to Display Information
Changing Units of Measure (English or Metric)
Viewing Engine Configuration Data
Viewing Active Engine Service Codes/Diagnostic Trouble Codes (DTCs)
Viewing Stored Service Codes/Diagnostic Trouble Codes (DTCs) in the Engine ECU
Instrument Panel – Elect. Cont. Later Engines
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 Trouble Codes
Accessing Active Trouble Codes
Engine Shutdown Codes
Adjusting Backlighting
Adjusting Contrast
Selecting Units Of Measurement
Setup 1-Up Display
Setup 4-Up Display
Instrument Panel – Mech. Cont. “270” Engines
Instrument Panel (Earlier 4.5 L “270” Engines)
Instrument Panel (Later 4.5 L “270” Engines)
Engine Operation – Except 4.5L “270” Engines
Engine Break-In Service
Starting the Engine
Normal Engine Operation
Warming Engine
Cold Weather Operation
Using a Booster Battery or Charger
Avoid Excessive Engine Idling
Changing Engine Speed
Stopping The Engine
Auxiliary Gear Drive Limitations
Generator Set (Standby) Applications
Engine Operation- 4.5 L “270” Engines
Normal Engine Operation
Break-In Service
Auxiliary Gear Drive Limitations
Generator Set (Standby) Power Units
Starting The Engine
Cold Weather Starting
Warming Engine
Avoid Excessive Engine Idling
Stopping the Engine
Using a Booster Battery or Charger
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 – 500 Hours/12 Months
Servicing Fire Extinguisher
Checking Engine Mounts
Servicing Battery
Manual Belt Tensioner Adjustment
Manual Belt Tensioner Adjustment Using Belt Tension Tool (Alternate Method For Engine Without Auxiliary Drive)
Changing Engine Oil and Replacing Filter
Checking Crankcase Vent System
Checking Air Intake System
Replacing Fuel Filter Elements
Checking Belt Tensioner Spring Tension and Belt Wear (Automatic Tensioner)
Checking Engine Electrical Ground Connections
Checking Cooling System
Replenishing Supplemental Coolant Additives (SCAs) Between Coolant Changes
Testing Diesel Engine Coolant
Pressure Testing Cooling System
Checking and Adjusting Engine Speeds
Lubrication & Maintenance – 1500 Hours
Checking Crankshaft Vibration Damper (If Equipped)
Lubrication & Maintenance – 2000 Hours/24 Months
Adjusting Variable Speed (Droop) – Generator Set Engine Only
Flushing and Refilling Cooling System
Testing Thermostats Opening Temperature
Check and Adjust Valve Clearance
Check and Adjust Valve Clearance (4045HF475 And 6068HF475 Engines)
Test Glow Plugs for Continuity
Lubrication & Maintenance – 3000 Hours
Checking Crankshaft Vibration Damper (If Equipped)
Lubrication & Maintenance – 4500 Hours/36 Months
Replace Crankshaft Vibration Damper
Service As Required
Additional Service Information
Do Not Modify Fuel System
Adding Coolant
Pre-Start Cleaning Guide
Replacing Single Stage Air Cleaner
Replacing Axial Seal Air Cleaner Filter Element
Replacing Radial Seal Air Cleaner Filter Element
Replacing Fan and Alternator Belts
Checking Fuses
Checking Air Compressors (If Equipped)
Bleeding the Fuel System (Engines With Electronic Fuel Systems And Bosch VP44 Pump)
Bleed the Fuel System (Engines with Electronic Fuel Systems and Stanadyne DE10 Pump)
Bleed the Fuel System (Engines with Electronic Fuel Systems and Denso High Pressure Common Rail) (4045HF475, 6068HF475)
Bleeding the Fuel System
Troubleshooting
General Troubleshooting Information
Precautions For Welding
Precautions for Electrical System When Steam Cleaning Engine
Engine Wiring Layout (Electronic Fuel System With Stanadyne DE10 Injection Pump)
Engine Wiring Layout (Electronic Fuel System With Bosch VP44 Injection Pump)
Engine Wiring Layout (Electronic Fuel System With Denso High Pressure Common Rail)(4045HF475,6068HF475)
Engine Wiring Diagram (With Earlier Electronic Instrument Panel)
Engine Wiring Diagram (With Earlier Electronic Instrument Panel)-Continued
Engine Wiring Diagram (With Later Full-Featured Electronic Instrument Panel)
Engine Wiring Diagram (With Later Full-Featured Electronic Instrument Panel)-Continued
Engine Troubleshooting
Blink Code Method for Retrieving Diagnostic Trouble Codes (All Except Early VP44 Pump Engines)
Blink Code Method for Retrieving Diagnostic Trouble Codes (Early VP44 Pump Engine Only)
Instrument Panel Method for Retrieving Diagnostic Trouble Codes
Displaying Of Diagnostic Trouble Codes (DTCs)
Listing of Diagnostic Trouble Codes (DTCs) (Engines With Electronic Fuel Systems And Stanadyne DE10 Pump)
Listing of Diagnostic Trouble Codes (DTCs) (Engines With Electronic Fuel Systems And Bosch VP44 Pump)
Listing of Diagnostic Trouble Codes (DTCs) (Engines With Electronic Fuel Systems And Denso High Pressure Common Rail) (“475” Engines)
Error Codes Displayed (With Early Electronic Panels)
Intermittent Fault Diagnostics (With Electronic Controls)
Displaying Diagnostic Gauge Software (Later Engines)
Storage
Engine Storage Guidelines
Preparing Engine for Long-Term Storage
Removing Engine from Long Term Storage
Specifications
General OEM Engine Specifications
Engine Power Ratings And Fuel System Specifications – 4045
Engine Power Ratings And Fuel System Specifications – 6068
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
500 Hour/12 Month Service
1500 Hour Service
2000 Hour/24 Month Service
3000 Hour Service
4500 Hours/60 Months Service
Service as Required
Warranty
John Deere Warranty in OEM Applications
Emissions Control System Certification Label
EPA Non-road Emissions Control Warranty Statement-Compression Ignition
CARB Non-road Emissions Control Warranty Statement-Compression Ignition
John Deere Service Literature Available
Technical Information