John Deere POWERTECH 4.5L & 6.8L 4045 & 6068 OEM Diesel Engines Use & Maintenance Manual – PDF DOWNLOAD

Description

John Deere POWERTECH 4.5L & 6.8L 4045 & 6068 OEM Diesel Engines Use & Maintenance Manual – PDF DOWNLOAD

DESCRIPTION:

John Deere POWERTECH 4.5L & 6.8L 4045 & 6068 OEM Diesel Engines Use & Maintenance Manual – PDF DOWNLOAD

Foreword :

READ THIS MANUAL carefully to learn how to operate and service your engine correctly. Failure to do so could result in personal injury or equipment damage. THIS MANUAL SHOULD BE CONSIDERED a permanent part of your engine and should remain with the engine when you sell it.

• MEASUREMENTS IN THIS MANUAL are given in both metric and customary U.S. unit equivalents. Use only correct replacement parts and fasteners. Metric and inch fasteners may require a specific metric or inch wrench. RIGHT-HAND AND LEFT-HAND sides are determined by standing at the drive or flywheel end (rear) of the engine and facing toward the front of the engine.
• WRITE ENGINE SERIAL NUMBERS and option codes in the spaces indicated in the Record Keeping Section. Accurately record all the numbers. Your dealer also needs these numbers when you order parts. File the identification numbers in a secure place off the engine.
• SETTING FUEL DELIVERY beyond published factory specifications or otherwise overpowering will result in loss of warranty protection for this engine. CERTAIN ENGINE ACCESSORIES such as radiator, air cleaner, and instruments are optional equipment on John Deere OEM Engines.
• These accessories may be provided by the equipment manufacturer instead of John Deere. This operator’s manual applies only to the engine and those options available through the John Deere distribution network.

TABLE OF CONTENTS:

John Deere POWERTECH 4.5L & 6.8L 4045 & 6068 OEM Diesel Engines Use & Maintenance Manual – PDF DOWNLOAD

Contents……………………………………………………………………………. 7
Record Keeping…………………………………………………………………… 9
® Medallion………………………………………………………………….. 9
Engine Serial Number Plate ……………………………………………………. 9
Record Engine Serial Number……………………………………………………. 10
Engine Option Codes ………………………………………………………….. 11
Record PTO Serial Number ……………………………………………………… 13
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 Bypass Starting……………………………………………………….. 15
Handle Fuel Safely—Avoid Fires…………………………………………………. 15
Prepare for Emergencies……………………………………………………….. 16
Handle Starting Fluid Safely…………………………………………………… 16
Handle Fluids Safely—Avoid Fires……………………………………………….. 16
Service Engines 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
Avoid Harmful Asbestos Dust……………………………………………………. 22
Prevent Battery Explosions…………………………………………………….. 22
Prevent Acid Burns……………………………………………………………. 23
Protect Against High Pressure Spray…………………………………………….. 23
Dispose of Waste Properly……………………………………………………… 24
Fuels, Lubricants, and Coolant…………………………………………………….. 25
Diesel Fuel …………………………………………………………………. 25
Lubricity of Diesel Fuel………………………………………………………. 25
Diesel Fuel Storage ………………………………………………………….. 26
Filling Fuel Tank…………………………………………………………….. 26
Minimizing the Effect of Cold Weather on Diesel Engines ………………………….. 27
Diesel Engine Break-In Oil…………………………………………………….. 28
Diesel Engine Oil ……………………………………………………………. 29
Extended Diesel Engine Oil Service Intervals…………………………………….. 29
Mixing of Lubricants …………………………………………………………. 30
OILSCAN®and COOLSCAN™…………………………………………………………. 30
Alternative and Synthetic Lubricants……………………………………………. 31
Lubricant Storage ……………………………………………………………. 31
Grease………………………………………………………………………. 32
Diesel Engine Coolant…………………………………………………………. 33
Diesel Engine Coolants, Supplemental Additive Information…………………………. 34
Testing Diesel Engine Coolant………………………………………………….. 35
Replenishing Supplemental Coolant Additives (SCAs) Between Coolant Changes …………. 36
Operating in Warm Temperature Climates………………………………………….. 37
Disposing of Coolant …………………………………………………………. 37
Engine Operating Guidelines……………………………………………………….. 38
Instrument (Gauge) Panels……………………………………………………… 38
Instrument (Gauge) Panel (North America) ……………………………………….. 39
VDO Instrument (Gauge) Panel (Except North America) ……………………………… 41
Normal Engine Operation ………………………………………………………. 43
Break-In Service …………………………………………………………….. 43
Auxiliary Gear Drive Limitations……………………………………………….. 46
Generator Set (Standby) Applications……………………………………………. 46
Starting the Engine ………………………………………………………….. 47
Cold Weather Operation ……………………………………………………….. 49
Warming Engine ………………………………………………………………. 50
Changing Engine SpeedłStandard (Mechanical) Governor……………………………… 51
Avoid Excessive Engine Idling …………………………………………………. 51
Stopping the Engine ………………………………………………………….. 52
Using a Booster Battery or Charger……………………………………………… 53
Lubrication and Maintenance……………………………………………………….. 55
Observe Service Intervals……………………………………………………… 55
Use Correct Fuels, Lubricants, and Coolant………………………………………. 56
Lubrication and Maintenance Service Interval Chart—Standard ………………………. 57
Lubrication and Maintenance Service Interval Chart—Generator (Standby) Applications …. 59
Lubrication & Maintenance/Daily……………………………………………………. 60
Daily Prestarting Checks ……………………………………………………… 60
Lubrication & Maintenance/250 Hour/6 Month………………………………………….. 64
Servicing Fire Extinguisher …………………………………………………… 64
Lubricating PTO Clutch Shaft Bearings…………………………………………… 64
Changing Engine Oil and Replacing Oil Filter ……………………………………. 65
Checking PTO Clutch Adjustment…………………………………………………. 68
Checking Engine Mounts ……………………………………………………….. 69
Servicing Battery ……………………………………………………………. 70
Manual Belt Tensioner Adjustment ………………………………………………. 72
Lubrication & Maintenance/600 Hour/12 Month…………………………………………. 74
Lubricating PTO Clutch Internal Levers and Linkage……………………………….. 74
Cleaning Crankcase Vent Tube…………………………………………………… 74
Checking Air Intake System…………………………………………………….. 75
Replacing Fuel Filter Element …………………………………………………. 76
Checking Belt Tensioner Spring Tension and Belt Wear (Automatic Tensioner) …………. 77
Checking Cooling System……………………………………………………….. 79
Checking Effectiveness of Coolant Solution………………………………………. 80
Adding Supplemental Coolant Additives (SCA’s) …………………………………… 81
Pressure Testing Cooling System ……………………………………………….. 82
Lubrication & Maint./2000 Hour/24 Month…………………………………………….. 83
Adjusting Variable Speed (Droop) on Generator Set Engines…………………………. 83
Checking Crankshaft Vibration Damper (6-Cylinder Engine Only) …………………….. 85
Flushing Cooling System……………………………………………………….. 86
Testing Thermostats Opening Temperature ………………………………………… 88
Check and Adjust Valve Clearance……………………………………………….. 92
Service as Required………………………………………………………………. 95
Additional Service Information…………………………………………………. 95
Do Not Modify Fuel System……………………………………………………… 95
Adding Coolant ………………………………………………………………. 96
Replacing Single Stage Air Cleaner……………………………………………… 98
Replacing Axial Seal Air Cleaner Filter Element………………………………….. 99
Replacing Radial Seal Air Cleaner Filter Element………………………………….101
Replacing Fan and Alternator Belts ……………………………………………..103
Power Take-Off (PTO) Clutch…………………………………………………….104
Checking Fuses………………………………………………………………..105
Bleeding the Fuel System ………………………………………………………106
Troubleshooting…………………………………………………………………..110
General Troubleshooting Information……………………………………………..110
Engine Wiring Diagram Legend (North America)……………………………………..111
Wiring Diagram (North America) …………………………………………………112
Engine Wiring Diagram Legend—VDO Instrument Panel (Except North America)…………….113
Engine Wiring Diagram—VDO Instrument Panel (Except North America)…………………..114
Engine Troubleshooting ………………………………………………………..115
Storage………………………………………………………………………….121
Engine Storage Guidelines………………………………………………………121
Use AR41785 Engine Storage Kit …………………………………………………121
Preparing Engine for Long Term Storage…………………………………………..122
Removing Engine from Long Term Storage…………………………………………..124
Specifications……………………………………………………………………125
General OEM Engine Specifications……………………………………………….125
Fuel Injection Pump Specifications1 …………………………………………….127
Engine Crankcase Oil Fill Quantities ……………………………………………131
Unified Inch Bolt and Cap Screw Torque Values ……………………………………135
Metric Bolt and Cap Screw Torque Values …………………………………………136
Lubrication and Maintenance Records…………………………………………………137
Using Lubrication and Maintenance Records………………………………………..137
Daily (Prestarting) Service…………………………………………………….137
250 Hour/6 Month Service……………………………………………………….138
600 Hour/12 Month Service………………………………………………………139
2000 Hour/24 Month Service……………………………………………………..140
Service as Required……………………………………………………………141
Emission System Warranty…………………………………………………………..142
U.S. EPA Emissions Control Warranty Statement…………………………………….142
Emissions Control System Certification Label……………………………………..143
John Deere Service Literature Available……………………………………………..144
Technical Information………………………………………………………….144
Publications for this Engine……………………………………………………145
John Deere Service Keeps You On the Job…………………………………………….. 0
John Deere Parts……………………………………………………………… 0
The Right Tools………………………………………………………………. 0
Well-Trained Technicians………………………………………………………. 0
Prompt Service……………………………………………………………….. 0

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JOHN DEERE POWERTECH 4.5L & 6.8L 4045 & 6068 OEM DIESEL ENGINES USE & MAINTENANCE MANUAL – PDF DOWNLOAD:

PLEASE NOTE:

• This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
• The manual can be all yours – Once payment is complete, you will be taken to the download page from where you can download the manual. All in 2-5 minutes time!!
• Need any other service / repair / parts manual, please feel free to contact us at [email protected] . We may surprise you with a nice offer

S.V