John Deere PowerTech 4.5 L & 6.8 L Non-Certified & Tier 1 Certified OEM Diesel Engines Operator’s Manual – PDF DOWNLOAD

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John Deere PowerTech 4.5 L & 6.8 L Non-Certified & Tier 1 Certified OEM Diesel Engines Operator’s Manual – PDF DOWNLOAD

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John Deere PowerTech 4.5 L & 6.8 L Non-Certified & Tier 1 Certified OEM Diesel Engines Operator’s Manual – PDF DOWNLOAD

Language : English
Pages : 164
Downloadable : Yes
File Type : PDF
Size: 2.17 MB

TABLE OF CONTENTS:

John Deere PowerTech 4.5 L & 6.8 L Non-Certified & Tier 1 Certified OEM Diesel Engines Operator’s Manual – PDF DOWNLOAD

Contents……………………………………………………………………………………………………. 7
Record Keeping…………………………………………………………………………………………… 9
PowerTech Medallion…………………………………………………………………………………… 9
Engine Serial Number Plate…………………………………………………………………………….. 9
Record Engine Serial Number……………………………………………………………………………. 10
Engine Option Codes…………………………………………………………………………………… 11
Record Fuel Injection Pump Model Number…………………………………………………………………. 13
Safety………………………………………………………………………………………………….. 14
Recognize Safety Information…………………………………………………………………………… 14
Understand Signal Words……………………………………………………………………………….. 14
Follow Safety Instructions…………………………………………………………………………….. 14
Replace Safety Signs………………………………………………………………………………….. 15
Prevent Machine Runaway……………………………………………………………………………….. 15
Handle Fuel Safely—Avoid Fires…………………………………………………………………………. 15
Prepare for Emergencies……………………………………………………………………………….. 16
Handle Starting Fluid Safely…………………………………………………………………………… 16
Handle Fluids Safely—Avoid Fires……………………………………………………………………….. 16
Service Machines Safely……………………………………………………………………………….. 17
Wear Protective Clothing………………………………………………………………………………. 17
Protect Against Noise…………………………………………………………………………………. 17
Handle Chemical Products Safely………………………………………………………………………… 18
Stay Clear of Rotating Drivelines………………………………………………………………………. 18
Practice Safe Maintenance……………………………………………………………………………… 19
Work In Ventilated Area……………………………………………………………………………….. 19
Avoid High-Pressure Fluids…………………………………………………………………………….. 20
Avoid Heating Near Pressurized Fluid Lines………………………………………………………………. 20
Remove Paint Before Welding or Heating………………………………………………………………….. 21
Service Cooling System Safely………………………………………………………………………….. 21
Install Fan Guards……………………………………………………………………………………. 22
Avoid Hot Parts………………………………………………………………………………………. 22
Avoid Harmful Asbestos Dust……………………………………………………………………………. 23
Prevent Battery Explosions…………………………………………………………………………….. 23
Handling Batteries Safely……………………………………………………………………………… 24
Protect Against High Pressure Spray…………………………………………………………………….. 25
Use Proper Lifting Equipment…………………………………………………………………………… 25
Use Proper Tools……………………………………………………………………………………… 25
Dispose of Waste Properly……………………………………………………………………………… 26
Fuels, Lubricants, and Coolant…………………………………………………………………………….. 27
Diesel Fuel………………………………………………………………………………………….. 27
Lubricity of Diesel Fuel………………………………………………………………………………. 27
Handling and Storing Diesel Fuel……………………………………………………………………….. 28
Testing Diesel Fuel…………………………………………………………………………………… 28
Bio-Diesel Fuel………………………………………………………………………………………. 29
Aviation (Jet) Fuels………………………………………………………………………………….. 30
Burner Fuels…………………………………………………………………………………………. 30
Minimizing the Effect of Cold Weather on Diesel Engines…………………………………………………… 31
Diesel Engine Break-In Oil…………………………………………………………………………….. 32
Diesel Engine Oil…………………………………………………………………………………….. 33
Extended Diesel Engine Oil Service Intervals…………………………………………………………….. 34
Mixing of Lubricants………………………………………………………………………………….. 34
OILSCAN™and COOLSCAN™…………………………………………………………………………………. 35
Alternative and Synthetic Lubricants……………………………………………………………………. 35
Lubricant Storage…………………………………………………………………………………….. 36
Oil Filters………………………………………………………………………………………….. 36
Grease………………………………………………………………………………………………. 37
Diesel Engine Coolant…………………………………………………………………………………. 38
Drain Intervals for Diesel Engine Coolant ………………………………………………………………. 39
Additional Information About Diesel Engine Coolants and Supplemental Coolant Additives……………………….. 40
Supplemental Coolant Additives…………………………………………………………………………. 41
Additional Information About Diesel Engine Coolants and Supplemental Coolant Additives……………………….. 42
Testing Diesel Engine Coolant………………………………………………………………………….. 43
Operating in Warm Temperature Climates………………………………………………………………….. 44
Disposing of Coolant………………………………………………………………………………….. 44
Engine Operating Guidelines……………………………………………………………………………….. 45
Instrument (Gauge) Panels……………………………………………………………………………… 45
Instrument (Gauge) Panel (North America)………………………………………………………………… 46
VDO Instrument (Gauge) Panel (Except North America)………………………………………………………. 48
Engine Break-In Service……………………………………………………………………………….. 50
Auxiliary Gear Drive Limitations……………………………………………………………………….. 53
Generator Set (Standby) Applications……………………………………………………………………. 53
Starting the Engine…………………………………………………………………………………… 54
Warming Engine……………………………………………………………………………………….. 56
Normal Engine Operation……………………………………………………………………………….. 57
Cold Weather Operation………………………………………………………………………………… 58
Changing Engine Speed…………………………………………………………………………………. 59
Avoid Excessive Engine Idling………………………………………………………………………….. 59
Stopping the Engine…………………………………………………………………………………… 60
Using a Booster Battery or Charger……………………………………………………………………… 61
Lubrication and Maintenance……………………………………………………………………………….. 63
Observe Service Intervals……………………………………………………………………………… 63
Use Correct Fuels, Lubricants, and Coolant………………………………………………………………. 63
Lubrication and Maintenance Service Interval Chart—Standard Industrial Engines………………………………. 64
Lubrication and Maintenance Service Interval Chart—Generator (Standby) Applications………………………….. 66
Lubrication & Maintenance/Daily……………………………………………………………………………. 68
Daily Prestarting Checks………………………………………………………………………………. 68
Lubrication & Maintenance/250 Hour/6 Month………………………………………………………………….. 72
Servicing Fire Extinguisher……………………………………………………………………………. 72
Changing Engine Oil and Replacing Filter………………………………………………………………… 73
Checking Engine Mounts………………………………………………………………………………… 75
Servicing Battery…………………………………………………………………………………….. 76
Manual Belt Tensioner Adjustment……………………………………………………………………….. 78
Manual Belt Tensioner Adjustment Using Belt Tension Tool (Alternate Method For Engines Without Auxiliary Drive)…. 79
Lubrication & Maintenance/500 Hour/12 Month…………………………………………………………………. 81
Cleaning Crankcase Vent Tube…………………………………………………………………………… 81
Checking Air Intake System…………………………………………………………………………….. 82
Replacing Fuel Filter Element (Single Filter)……………………………………………………………. 83
Replacing Fuel Filter Elements (Dual Filters)……………………………………………………………. 85
Checking Belt Tensioner Spring Tension and Belt Wear (Automatic Tensioner)………………………………….. 86
Checking Engine Speeds………………………………………………………………………………… 89
Checking Engine Electrical Ground Connections……………………………………………………………. 89
Checking Cooling System……………………………………………………………………………….. 90
Replenishing Supplemental Coolant Additives (SCAs) Between Coolant Changes………………………………….. 91
Testing Diesel Engine Coolant………………………………………………………………………….. 92
Pressure Testing Cooling System………………………………………………………………………… 93
Lubrication & Maint./2000 Hour/24 Month…………………………………………………………………….. 94
Adjusting Variable Speed (Droop) on Generator Set Engines…………………………………………………. 94
Checking Crankshaft Vibration Damper (6-Cylinder Engine Only)……………………………………………… 96
Flushing and Refilling Cooling System…………………………………………………………………… 97
Testing Thermostats Opening Temperature………………………………………………………………….100
Check and Adjust Valve Clearance………………………………………………………………………..103
Service as Required……………………………………………………………………………………….106
Additional Service Information………………………………………………………………………….106
Do Not Modify Fuel System………………………………………………………………………………106
Adding Coolant………………………………………………………………………………………..107
Replacing Single Stage Air Cleaner………………………………………………………………………108
Replacing Axial Seal Air Cleaner Filter Element…………………………………………………………..109
Replacing Radial Seal Air Cleaner Filter Element………………………………………………………….111
Replacing Fan and Alternator Belts………………………………………………………………………113
Checking Fuses In Instrument Panels……………………………………………………………………..114
Checking Air Compressors……………………………………………………………………………….115
Bleeding the Fuel System……………………………………………………………………………….116
Troubleshooting…………………………………………………………………………………………..120
General Troubleshooting Information……………………………………………………………………..120
Engine Wiring Diagram Legend (Standard Instrument Panel For North America)…………………………………..122
Wiring Diagram (Standard Instrument Panel For North America)……………………………………………….123
Engine Wiring Diagram—VDO Instrument Panel (Except North America)…………………………………………..124
Engine Wiring Diagram Legend—VDO Instrument Panel (Except North America)…………………………………….125
Engine Troubleshooting…………………………………………………………………………………126
Storage………………………………………………………………………………………………….133
Engine Storage Guidelines………………………………………………………………………………133
Preparing Engine for Long Term Storage…………………………………………………………………..134
Removing Engine from Long Term Storage…………………………………………………………………..135
Specifications……………………………………………………………………………………………136
General OEM Engine Specifications—4.5 L Engines…………………………………………………………..136
General OEM Engine Specifications—6.8 L Engines…………………………………………………………..137
Engine Power Ratings And Fuel Injection Pump Specifications……………………………………………….138
Engine Crankcase Oil Fill Quantities…………………………………………………………………….146
Unified Inch Bolt and Screw Torque Values………………………………………………………………..150
Metric Bolt and Screw Torque Values……………………………………………………………………..151
Lubrication and Maintenance Records…………………………………………………………………………152
Using Lubrication and Maintenance Records………………………………………………………………..152
Daily (Prestarting) Service…………………………………………………………………………….152
250 Hour/6 Month Service……………………………………………………………………………….153
500 Hour/12 Month Service………………………………………………………………………………154
2000 Hour/24 Month Service……………………………………………………………………………..155
Service as Required……………………………………………………………………………………156
Emission System Warranty…………………………………………………………………………………..157
U.S. EPA Emissions Control Warranty Statement…………………………………………………………….157
Emissions Control System Certification Label……………………………………………………………..157
John Deere Service Literature Available……………………………………………………………………..158
Technical Information………………………………………………………………………………….158

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JOHN DEERE POWERTECH 4.5 L & 6.8 L NON-CERTIFIED & TIER 1 CERTIFIED OEM DIESEL ENGINES OPERATOR’S MANUAL – PDF DOWNLOAD:

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