John Deere POWERTECH Service Manual

OWERTECH



4.5L & 6.8L

Diesel Engines

Level 12 Electronic

Fuel System With

Stanadyne DE10 Pump

TECHNICAL MANUAL

OWERTECH

Engines—Level 12 Electronic Fuel

System with DE10 Pump



4.5 L & 6.8 L Diesel

03OCT05 (ENGLISH)

For complete service information also see:

OWERTECH

Engines—Base Engine ................. CTM104

Alternators and Starter Motors........... CTM77

OEM Engine Accessories ......CTM67 (English Only)



4.5 L and 6.8 L Diesel

John Deere Power Systems

LITHO IN U.S.A.

Forward

Introduction

This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use.

This manual (CTM331) covers only Level 12 Electronic Fuel System with the Stanadyne DE10 injection pump. It is one of five volumes on 4.5 L and 6.8 L engines. The following four companion manuals cover the base engine, mechanical fuel system, level 4 electronic fuel system and level 1 electronic fuel system repair, operation and diagnostics:

• CTM104—Base Engine

• CTM170—Level 4 Electronic Fuel System with

Bosch VP44 Pump

• CTM207—Mechanical Fuel Systems

• CTM284—Level 1 Electronic Fuel Systems with

Delphi (Lucas) DP201 Pump

Other manuals will be added in the future to provide additional information on electronic fuel systems as needed.

Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.

This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury.

component removal and installation, and gaining access to the components.

Information is organized in sections and groups for the various components requiring service instruction. Section 05 summarizes all applicable essential tools, service equipment and tools, other materials needed to do the job, and service parts kits. Section 06 summarizes all specifications, wear tolerances, and torque values.

Before beginning diagnosis or repair on an engine, clean the engine.

This manual contains SI Metric units of measure followed immediately by the U.S. customary units of measure. Most hardware on these engines is metric sized.

Some components of this engine may be serviced without removing the engine from the machine. Refer to the specific machine technical manual for information on components that can be serviced without removing the engine from the machine and for engine removal and installation procedures.

Read each block of material completely before performing service to check for differences in procedures or specifications. Follow only the procedures that apply to the engine model number you are working on. If only one procedure is given, that procedure applies to all the engines in the manual.

Use this component technical manual in conjunction with the machine technical manual. An application listing in Section 01, Group 001 identifies product-model/component type-model relationship. See the machine technical manual for information on

CTM331 (03OCT05) 4.5 L & 6.8 L Level 12 Electronic Fuel System

CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm.

OUO1080,00001FE –19–16NOV01–1/1

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Introduction

POWERTECH4.5 L Engine with Level 12 Electronic Fuel System and Stanadyne DE10

Pump

OWERTECH

Right Side of Engine

is a registered trademark of Deere & Company

Left Side of Engine

RG11932 –UN–06NOV01

RG11931 –UN–06NOV01

DPSG,OUO1004,129 –19–15MAY98–1/1

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Introduction

CTM331 (03OCT05) 4.5 L & 6.8 L Level 12 Electronic Fuel System

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SECTION 01—General Information

Group 000—Safety Group 001—Engine Identification Group 002—Fuels

SECTION 02—Repair and Adjustments

Group 090—Electronic Fuel System Repair and

Adjustments

Group 110—Electrical Engine Control Repair and

Adjustment

SECTION 03—Theory of Operation

Group 130—Electronic Fuel System Operation Group 140—Electronic Control System Operation

SECTION 04—Diagnostics

Group 150—Observable Diagnostics and Tests Group 160—Trouble Code Diagnostics and Tests

SECTION 05—Tools and Other Materials

Group 170—Electronic Fuel/Control System Repair

Tools and Other Materials

Group 180—Diagnostic Service Tools

SECTION 06—Specifications

Group 200—Repair Specifications Group 210—Diagnostic Specifications

CTM331 (03OCT05)

All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice.

DEERE & COMPANY

Moline, Illinois

A John Deere ILLUSTRUCTIONManual

4.5 L & 6.8 L Level 12 Electronic Fuel System

INDX

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Contents

INDX

CTM331 (03OCT05)

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Page

Group 000—Safety ....................01-000-1

Group 001—Engine Identification

Engine Model Designation................01-001-1

Engine Serial Number Plate Information .....01-001-2

OEM Engine Option Code Label...........01-001-3

Information Relative to Emissions

Regulations .........................01-001-3

Engine Application Charts................01-001-4

Group 002—Fuels

Lubricants and Coolant ..................01-002-1

Diesel Fuel ...........................01-002-1

Bio-Diesel Fuel ........................01-002-2

Testing Diesel Fuel .....................01-002-2

Lubricity of Diesel Fuel ..................01-002-3

Section 01 General Information

Contents

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Contents

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Handle Fluids Safely—Avoid Fires

When you work around fuel, do not smoke or work near heaters or other fire hazards.

Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers.

Make sure machine is clean of trash, grease, and debris. Do not store oily rags; they can ignite and burn

spontaneously.

Group 000

Safety

01 000 1

TS227 –UN–23AUG88

DX,FLAME –19–29SEP98–1/1

Handle Starting Fluid Safely

Starting fluid is highly flammable. Keep all sparks and flame away when using it. Keep

starting fluid away from batteries and cables. To prevent accidental discharge when storing the

pressurized can, keep the cap on the container, and store in a cool, protected location.

Do not incinerate or puncture a starting fluid container.

Prepare for Emergencies

Be prepared if a fire starts.

TS1356 –UN–18MAR92

DX,FIRE3 –19–16APR92–1/1

Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance service,

hospital, and fire department near your telephone.

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TS291 –UN–23AUG88

000

Avoid High-Pressure Fluids

Escaping fluid under pressure can penetrate the skin causing serious injury.

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids.

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A.

Safety

X9811 –UN–23AUG88

Wear Protective Clothing

Wear close fitting clothing and safety equipment appropriate to the job.

Prolonged exposure to loud noise can cause impairment or loss of hearing.

Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.

Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine.

DX,FLUID –19–03MAR93–1/1

TS206 –UN–23AUG88

DX,WEAR –19–10SEP90–1/1

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Safety

Service Machines Safely

Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result.

Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.

01 000 3

Work In Ventilated Area

Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension.

If you do not have an exhaust pipe extension, open the doors and get outside air into the area

Work in Clean Area

Before starting a job:

• Clean work area and machine.

• Make sure you have all necessary tools to do your job.

• Have the right parts on hand.

• Read all instructions thoroughly; do not attempt

shortcuts.

DX,LOOSE –19–04JUN90–1/1

TS228 –UN–23AUG88

TS220 –UN–23AUG88

DX,AIR –19–17FEB99–1/1

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T6642EJ –UN–18OCT88

000

Remove Paint Before Welding or Heating

Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated

by welding, soldering, or using a torch. Remove paint before heating:

• Remove paint a minimum of 100 mm (4 in.) from area

to be affected by heating. If paint cannot be removed, wear an approved respirator before heating or welding.

• If you sand or grind paint, avoid breathing the dust.

Wear an approved respirator.

• If you use solvent or paint stripper, remove stripper with

soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

Do not use a chlorinated solvent in areas where welding will take place.

Safety

TS220 –UN–23AUG88

Do all work in an area that is well ventilated to carry toxic fumes and dust away.

Dispose of paint and solvent properly.

Avoid Heating Near Pressurized Fluid Lines

Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can accidentally burst when heat goes beyond the immediate flame area.

DX,PAINT –19–24JUL02–1/1

TS953 –UN–15MAY90

DX,TORCH –19–10DEC04–1/1

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Safety

Illuminate Work Area Safely

Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.

01 000 5

Construct Dealer-Made Tools Safely

Faulty or broken tools can result in serious injury. When constructing tools, use proper, quality materials, and good workmanship.

Do not weld tools unless you have the proper equipment and experience to perform the job.

DX,LIGHT –19–04JUN90–1/1

TS223 –UN–23AUG88

LX1016749 –UN–01JUL97

DX,SAFE,TOOLS –19–10OCT97–1/1

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000

Practice Safe Maintenance

Understand service procedure before doing work. Keep area clean and dry.

Never lubricate, service, or adjust machine while it is moving. Keep hands, feet , and clothing from power-driven parts. Disengage all power and operate controls to relieve pressure. Lower equipment to the ground. Stop the engine. Remove the key. Allow machine to cool.

Securely support any machine elements that must be raised for service work.

Keep all parts in good condition and properly installed. Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or debris.

On self-propelled equipment, disconnect battery ground cable (-) before making adjustments on electrical systems or welding on machine.

Safety

On towed implements, disconnect wiring harnesses from tractor before servicing electrical system components or welding on machine.

Use Proper Tools

Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards.

Use power tools only to loosen threaded parts and fasteners.

For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches.

TS218 –UN–23AUG88

DX,SERV –19–17FEB99–1/1

TS779 –UN–08NOV89

Use only service parts meeting John Deere specifications.

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Safety

Dispose of Waste Properly

Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with John Deere equipment include such items as oil, fuel, coolant, brake fluid, filters, and batteries.

Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

01 000 7

Do not pour waste onto the ground, down a drain, or into any water source.

Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants.

Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your John Deere dealer.

Live With Safety

Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields.

TS1133 –UN–26NOV90

DX,DRAIN –19–03MAR93–1/1

CTM331 (03OCT05)

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TS231 –19–07OCT88

000

Safety

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Group 001

Engine Identification

Engine Model Designation

John Deere Engine Model—4045 and 6068 Engines John Deere engine model designation includes number of

cylinders, displacement in liters, aspiration, user code, and application code. For example:

4045TF275 Engine

4 ................................................................ Number of cylinders

4.5 ............................................................. Liter displacement

T ............................................................... Aspiration code

F ............................................................... User code

275 ............................................................ P

Aspiration Code

D ............................................................... Naturally aspirated

T ............................................................... Turbocharged, no aftercooling

A ............................................................... Turbocharged and Air-to-Coolant Aftercooled

H ............................................................... Turbocharged and Air-to-Air Aftercooled

User Factory Code

AP Industries John Deere Mexica S. A de C. V. (Saltillo/Monterrey, Mexico

AT ............................................................. Agritalia srl (Vittoria, Sicily, Italy)

BE Bell Equipment Co. (Richards Bay, South Africa)

CQ ............................................................ John Deere Brazil (Horizontina, Brazil)

DW ............................................................ John Deere Davenport Works (Davenport, Iowa)

E ............................................................... John Deere Ottumwa Works (Ottumwa, Iowa)

F ............................................................... OEM (Outside Equipment Manufacturers)

FF ............................................................. Deere-Hitachi (Kernersville, North Carolina)

FG ............................................................. Goldoni S.P.A. (Modena, Italy)

FM ............................................................ Marine Engines

H ............................................................... John Deere Harvester Works (East Moline, Illinois)

KV ............................................................. John Deere Commercial Worksite Products (Knoxville, Tennessee)

L ................................................................ John Deere Werke Mannheim (Germany)

LA ............................................................. John Deere Werke Mannheim (Germany) (Engines with Bosch VP44 Injection Pump)

LV ............................................................. John Deere Commercial Products (Augusta, Georgia)

N ............................................................... John Deere Des Moines Works (Des Moines, Iowa)

P ............................................................... Industrias John Deere Mexico S.A. de C.V. (Saltillo/Monterrey, Mexico)

PY ............................................................. Larson & Toubro Ltd. (Pune, India)

RW ............................................................ John Deere Waterloo Tractor Works (Waterloo, Iowa)

T ............................................................... John Deere Dubuque Works (Dubuque, Iowa)

T8 ............................................................. Cameco Industries (Thibodaux, Louisiana)

TJ .............................................................. John Deere Forestry (Timberjack) (Sweden/Finland/Canada)

YC ............................................................. John Deere Jialian Harvester Co. Limited (China)

Z ............................................................... John Deere WERKE Zweibrucken (Germany)

Application Code

001, etc. .................................................... See ENGINE APPLICATION CHARTS, later in this Group

OWERTECH



application code

01 001 1

OWERTECH

is a registered trademark of Deere & Company

CTM331 (03OCT05)

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001

Engine Serial Number Plate Information

IMPORTANT: The engine serial number plate (A) can

be easily destroyed. Before “hot tank” cleaning the block, remove the plate.

Engine Serial Number (B)

Each engine has a 13-digit John Deere engine serial number identifying the producing factory, engine model designation, and a 6-digit sequential number. The following is an example:

CD4045T000000

CD .......................... Factory producing engine

4045T ..................... Engine model designation

000000 ................... Sequential serial number

Factory Code (Engine Manufacturer)

T0 ........................... Dubuque, Iowa

CD .......................... Saran, France

PE .......................... Torreon, Mexico

J0 ........................... Rosario, Argentina

Engine Model Designation

4045T ..................... Definition explained previously. See ENGINE

Sequential Number

000000 ................... 6-digit sequential serial number

MODEL DESIGNATION earlier in this group.

Engine Application Data (C)

Engine Identification

RG11816 –UN–15NOV01

Engine Serial Number Plate

RG9060 –UN–16MAR98

Dubuque Engine Serial Number Plate

The second line of information on the serial number plate identifies the engine/machine or OEM relationship. See ENGINE APPLICATION CHARTS later in this group.

Coefficient of Absorption (D) — (Saran-Built Engines Only)

The second line of information on the Saran serial number plate also contains the coefficient of absorption value for smoke emissions.

A—Engine Serial Number Plate B—Engine Serial Number C—Engine Application Data D—Coefficient of Absorption (Saran Engines Only)

Saran Engine Serial Number Plate

RG11949 –UN–07NOV01

RG11948 –UN–06NOV01

Torreon Engine Serial Number Plate

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Engine Identification

OEM Engine Option Code Label

An option code label is secured to the top of the valve cover and identifies the factory installed options on each OEM engine to ensure correct parts acquisition.

Always provide option code information and engine base code when ordering repair parts. A listing of option codes is given in parts catalogs and operator’s manuals.

NOTE: Before “hot tank” cleaning, ensure that option

codes are recorded elsewhere.

Information Relative to Emissions Regulations

01 001 3

RG12027 –UN–03DEC01

OUO1080,000020E –19–26NOV01–1/1

Depending on the final destination, engines can meet the emissions regulations according to the US Environmental Protection Agency (EPA), California Air Resources Board (CARB) and for Europe, the Directive 97/68/EC relating the measures against the emissions of particles and gaseous pollutant from internal combustion engines. Such engines are called “CERTIFIED” and receive an emission label stuck on the engine.

The regulations prohibit tampering with the emission-related components listed below which would render that component inoperative or to make any adjustment on the engine beyond published specifications. It is also illegal to install a part or

component where the principle effect of that component is to bypass, defeat, or render inoperative any engine component or device which would affect the engine’s conformance to the emission regulations.

To summarize, it is illegal to do anything except return the engine to its original published specifications.

List of emission-related components:

• Fuel injection system

• Intake manifold

• Turbocharger

• Charge air cooling system

• Piston

OUO1080,0000035 –19–29AUG01–1/1

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Engine Identification

001

Engine Application Charts

Machine Model Engine Model Waterloo - Tractors

5425 Tractor PE4045TLV53 5525 Tractor PE4045TLV54 7220 Tractor PE6068HRW59 7320 Tractor PE6068HRW59 7420 Tractor PE6068HRW60 7520 Tractor PE6068HRW60 7815 Tractor PE6068HRW63

Mannheim, Germany

6020SE Tractor (R2) CD4045TL270 6120, 6120SE Tractor (R2) CD4045TL271 6215 Advantage Tractor (NA) CD4045TL272 6215 Classic Tractor (R2) CD4045TL272 6220, 6220SE Tractor (R2) CD4045TL272 6320SE Tractor (R2) CD4045HL270 6415 Advantage Tractor (NA) CD4045HL272 6420SE Tractor (R2) CD4045HL271 6515 Classic Tractor (R2) CD6068HL270 6520L Tractor (NA) CD4045HL273 6520SE Tractor (R2) CD6068TL270 6615 Advantage Tractor (NA) CD6068TL271, CD6068HL271 6620SE Tractor 6068HL272 6715 Advantage Tractor (NA) CD6068TL273, CD6068HL273

JOHN DEERE AGRICULTURAL EQUIPMENT

Zweibrucken, Germany

3215 TeleHandler CD4045HZ061, CD4045HZ275 3220 TeleHandler CD4045HZ060, CD4045HZ275 3415 TeleHandler CD4045HZ061, CD4045HZ275 3420 TeleHandler CD4045HZ060, CD4045HZ275 3700 TeleHandler CD4045TZ060 3800 TeleHandler CD4045HZ060

Continued on next page

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Engine Identification

JOHN DEERE CONSTRUCTION & FORESTRY EQUIPMENT Application Engine Model Dubuque

310G Backhoe Loader PE4045DT058, T04045DT058 310G Backhoe Loader (Alt Comp) PE4045TT088, T04045TT088 310SG Backhoe Loader PE4045TT089, T04045TT089 315SG Backhoe Loader PE4045TT089, T04045TT089 710G Backhoe PE6068TT057 450H Crawler Dozer (Alt Comp) PE4045TT084, T04045TT084 450H Crawler Dozer (Nat Asp) PE4045DT058, T04045DT058 450H LGP Crawler Dozer PE4045TT085, T04045TT085 550H Crawler Dozer PE4045TT087, T04045TT087 550H LGP Crawler Dozer PE4045TT086, T04045TT086 650H Crawler Dozer PE4045HT050 700H Crawler Dozer PE6068TT060 710G Backhoe Loader PE6068TT057

Saltillo, Mexico

120C Excavator PE4045HP050 160C LC Excavator PE4045HP051

Deere-Hitachi - Kernersville

200LC Excavator PE6068HT059

Forestry

810 Forwarder CD4045HTJ75 543 DTT Feller Buncher Harvester PE6068HDW62 640 DTT Feller Buncher Harvester PE6068HDW62 1010 Forwarder T04045HTJ76, CD4045HTJ76 1110 Forwarder CD6068HTJ75 1058 Forwarder T04045HTJ76 1410 Forwarder CD6068HTJ77 1458 Forwarder CD6068HTJ77 770 Harvester CD6068HTJ77 770D Wheel Harvester CD4045HTJ77 863 Harvester CD6068HTJ77 1070 Harvester CD6068HTJ76 1063 Harvester CD6068HTJ76 548 Skidder PE6068HDW59 648DD/648TC Skidder PE6068HDW60

01 001 5

JOHN DEERE OEM (OUTSIDE EQUIPMENT MANUFACTURERS)

CD4045TF275 CD4045TFM75 Marine Engine PE4045HF275 CD4045TF275 PE4045TF275 CD6068HF275 PE6068HF275 CD6068TF275 PE6068TF275

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001

Engine Identification

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Lubricants and Coolant

NOTE: Refer to Section 01, Group 002 of CTM104 Base

Engine Manual for information on lubricants and coolants.

Diesel Fuel

Group 002

Fuels

01 002 1

DPSG,OUO1004,2761 –19–16MAY00–1/1

Consult your local fuel distributor for properties of the diesel fuel available in your area.

In general, diesel fuels are blended to satisfy the low temperature requirements of the geographical area in which they are marketed.

Diesel fuels specified to EN 590 or ASTM D975 are recommended.

Required fuel properties

In all cases, the fuel must meet the following properties:

Cetane number of 45 minimum. Cetane number greater than 50 is preferred, especially for temperatures below -20°C (-4°F) or elevations above 1500 m (5000 ft).

Cold Filter Plugging Point (CFPP) below the expected low temperature OR Cloud Point at least 5°C(9°F) below the expected low temperature.

Fuel lubricity should pass a minimum load level of 3100 grams as measured by ASTM D6078 or, maximum scar diameter of 0.45 mm as measured by ASTM D6079.

Sulfur content:

• Diesel fuel quality and fuel sulfur content must comply with all existing regulations for the area in which the engine operates.

• Sulfur content less than 0.05% (500 ppm) is preferred.

• If diesel fuel with sulfur content greater than 0.05% (500 ppm) is used, crankcase oil service intervals may be affected. (See recommendation for Diesel Engine Oil.)

• DO NOT use diesel fuel with sulfur content greater than 1.0%.

IMPORTANT: DO NOT mix used engine oil or any

other type of lubricating oil with diesel fuel.

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002

Bio-Diesel Fuel

Consult your local fuel distributor for properties of the bio-diesel fuel available in your area.

Bio-diesel fuels may be used ONLY if the bio-diesel fuel properties meet the latest edition of ASTM PS121, DIN 51606 or equivalent specification.

It has been found that bio-diesel fuels may improve lubricity in concentrations up to a 5% blend in petroleum diesel fuel.

When using a blend of bio-diesel fuel, the engine oil level must be checked daily when the air temperature is -10°C (14°F) or lower. If the oil becomes diluted with fuel, shorten oil change intervals accordingly.

IMPORTANT: Raw pressed vegetable oils are NOT

acceptable for use for fuel in any concentration in John Deere engines.

These oils do not burn completely, and will cause engine failure by leaving deposits on injectors and in the combustion chamber.

Fuels

A major environmental benefit of bio-diesel fuel is its ability to biodegrade. This makes proper storage and handling of bio-diesel fuel especially important. Areas of concern include:

• Quality of new fuel

• Water content of the fuel

• Problems due to aging of the fuel

Potential problems resulting from deficiencies in the above areas when using bio-diesel fuel in concentrations above 5% may lead to the following symptoms:

• Power loss and deterioration of performance

• Fuel leakage

• Corrosion of fuel injection equipment

• Coked and/or blocked injector nozzles, resulting in

engine misfire

• Filter plugging

• Lacquering and/or seizure of internal components

• Sludge and sediments

• Reduced service life of engine components

Testing Diesel Fuel

DIESELSCAN is a John Deere fuel analysis program that can be used to monitor the quality of your fuel. The DIESELSCAN analysis verifies fuel type, cleanliness, water content, suitability for cold weather operation, and whether the fuel meets specifications.

Check with your John Deere dealer for availability of DIESELSCAN kits.

DIESELSCAN is a trademark of Deere & Company

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Lubricity of Diesel Fuel

Diesel fuel must have adequate lubricity to ensure proper operation and durability of fuel injection system components.

Diesel fuels for highway use in the United States and Canada require sulfur content less than 0.05% (500 ppm).

Diesel fuel in the European Union requires sulfur content less than 0.05% (500 ppm).

Experience shows that some low sulfur diesel fuels may have inadequate lubricity and their use may reduce performance in fuel injection systems due to inadequate lubrication of injection pump components. The lower concentration of aromatic compounds in these fuels also adversely affects injection pump seals and may result in leaks.

Fuels

01 002 3

Use of low lubricity diesel fuels may also cause accelerated wear, injection nozzle erosion or corrosion, engine speed instability, hard starting, low power, and engine smoke.

Fuel lubricity should pass a minimum load level of 3100 gram as measured by the ASTM D6078 or maximum scar diameter of 0.45 mm as measured by ASTM D6079.

ASTM D975 and EN 590 specifications do not require fuels to pass a fuel lubricity test.

If fuel of low or unknown lubricity is used, add John Deere PREMIUM DIESEL FUEL CONDITIONER (or equivalent) at the specified concentration.

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Fuels

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Section 02 Repair and Adjustments

Page Page

Group 090—Electronic Fuel System Repair and

Adjustments

Fuel System—General Information .........02-090-1

Relieve Fuel System Pressure ............02-090-1

Remove and Install Final Fuel Filter/Water

Bowl and/or Pre-Filter/Water Bowl Base . . .02-090-2

Fuel Pre-Filter/Water Bowl Assembly

(Optional)...........................02-090-5

Final Fuel Filter Assembly................02-090-6

Replace Final Fuel Filter/Water Bowl and

Pre-Filter/Water Bowl..................02-090-7

Remove Fuel Supply Pump...............02-090-9

Install Fuel Supply Pump................02-090-10

Injection Pump Static Timing.............02-090-10

Remove Injection Pump ................02-090-11

Inspect Injection Pump Drive Gear ID and

Shaft OD ..........................02-090-13

Install Injection Pump ..................02-090-13

Remove Fuel Injection Nozzles...........02-090-16

Clean Fuel Injection Nozzle Bore .........02-090-18

Clean Fuel Injection Nozzles.............02-090-18

Fuel Injection Nozzle Test...............02-090-19

Disassemble Fuel Injection Nozzles .......02-090-22

Adjust Fuel Injection Nozzle .............02-090-23

Install Seals on Fuel Injection Nozzle ......02-090-24

Install Fuel Injection Nozzles.............02-090-25

Bleed the Fuel System .................02-090-26

Contents

Remove Blade Terminals from Connector

Body .............................02-110-11

Repair (Pull Type) METRI-PACK

Connectors ........................02-110-12

Repair (Push Type) METRI-PACK

Connectors ........................02-110-14

Repair DEUTSCH Connectors ..........02-110-17

Repair AMP Connector .................02-110-20

Group 110—Electrical Engine Control Repair and

Adjustment

Engine Control Unit (ECU) ...............02-110-1

Remove and Install Engine Coolant

Temperature Sensor ..................02-110-2

Remove and Install Loss of Coolant

Temperature Sensor ..................02-110-2

Replace Crankshaft Position Sensor ........02-110-3

Remove and Install Oil Pressure Sensor.....02-110-3

Remove and Install Manifold Air Temperature

Sensor.............................02-110-4

Remove and Install Fuel Temperature

Sensor.............................02-110-4

Remove and Install Fuel Heater ...........02-110-5

Connectors ...........................02-110-6

Use Electrical Insulating Compound ........02-110-6

Using High-Pressure Washer .............02-110-7

Repair WEATHERPACK Connector .......02-110-8

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Contents

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Electronic Fuel System Repair and Adjustments

Fuel System—General Information

Group 090

Stanadyne DE10 pumps are static lock-pin timed during installation of the injection pump.

The fuel supply pump is a separate component mounted on upper right-hand side of engine block and is actuated by a pin in block that rides on engine camshaft lobe.

Engines may be equipped with an optional fuel pre-filter/water bowl.

Relieve Fuel System Pressure

CAUTION: Escaping diesel fuel under pressure can have sufficient force to penetrate the skin, causing serious injury. Before disconnecting lines, be sure to relieve pressure. Before applying pressure to the system, be sure ALL connections are tight and lines, pipes and hoses are not damaged. Keep hands and body away from pinholes and nozzles which eject fluid under pressure. Use a piece of cardboard or wood, rather than hands, to search for suspected leaks.

All engines are equipped with a round final fuel filter with water bowl. Hand primer on top of filter element is optional.

All engines use Stanadyne Rate Shaping Nozzles (RSN).

Field-installed options include fuel heater, water bowl and hand fuel primer.

OUO1089,00001F7 –19–06NOV01–1/1

High Pressure Fluids

02 090 1

X9811 –UN–23AUG88

If ANY fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result. Doctors unfamiliar with this type of injury may call the Deere & Company Medical Department in Moline, Illinois, or other knowledgeable medical source.

Any time the fuel system has been opened up for service (lines disconnected or filters removed), it will be necessary to bleed air from the system. See BLEED THE FUEL SYSTEM in this group.

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Electronic Fuel System Repair and Adjustments

Remove and Install Final Fuel Filter/Water Bowl and/or Pre-Filter/Water Bowl Base

Refer to operator’s manual for proper servicing and (hourly) replacement intervals.

090

Engines are equipped with a final fuel filter/water bowl (A) and may have an optional pre-filter/water bowl.

Final fuel filters/water bowls can be equipped with a transparent (see-through) water collection bowl and/or hand primer on machines equipped with only one filter.

A—Final Fuel Filter/Water Bowl

Continued on next page

Final Fuel Filter

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