Loading...POWERTECH 4.5L & 6.8L
Diesel Engines
Level 12 Electronic
Fuel System With
Stanadyne DE10 Pump
TECHNICAL MANUAL
POWERTECH 4.5 L & 6.8 L Diesel
Engines—Level 12 Electronic Fuel
System with DE10 Pump
03OCT05 (ENGLISH)
For complete service information also see:
POWERTECH 4.5 L and 6.8 L Diesel
Engines—Base Engine . . . . . . . . . . . . . . . . . CTM104
Alternators and Starter Motors . . . . . . . . . . . CTM77
OEM Engine Accessories . . . . . . CTM67 (English Only)
John Deere Power Systems
LITHO IN U.S.A.
Introduction
Forward
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.
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
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.
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
CTM331 (03OCT05) |
4.5 L & 6.8 L Level 12 Electronic Fuel System |
|
012506 |
PN=2
Introduction
POWERTECH 4.5 L Engine with Level 12 Electronic Fuel System and Stanadyne DE10
Pump
RG11931 –UN–06NOV01
Right Side of Engine
RG11932 –UN–06NOV01
Left Side of Engine
POWERTECH is a registered trademark of Deere & Company |
DPSG,OUO1004,129 –19–15MAY98–1/1 |
CTM331 (03OCT05) |
4.5 L & 6.8 L Level 12 Electronic Fuel System |
|
012506 |
PN=3
Introduction
CTM331 (03OCT05) |
4.5 L & 6.8 L Level 12 Electronic Fuel System |
|
012506 |
PN=4
Contents
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
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.
COPYRIGHT 2002
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION Manual
01
02
03
04
05
06
INDX
CTM331 (03OCT05) |
i |
4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=1
Contents
01
02
03
04
05
06
INDX
CTM331 (03OCT05) |
ii |
4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=2
01
Section 01
General Information
Contents
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
CTM331 (03OCT05) 01-1 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=1
Contents
01
CTM331 (03OCT05) 01-2 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=2
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.
TS1356 –UN–18MAR92
Prepare for Emergencies
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.
CTM331 (03OCT05) |
01-000-1 |
DX,FIRE3 –19–16APR92–1/1
–UN–23AUG88 TS291 DX,FIRE2 –19–03MAR93–1/1
4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=9
Safety
01
000 Avoid High-Pressure Fluids
2
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.
X9811 –UN–23AUG88
DX,FLUID –19–03MAR93–1/1
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.
CTM331 (03OCT05) |
01-000-2 |
TS206 –UN–23AUG88
DX,WEAR –19–10SEP90–1/1
4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=10
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.
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.
01
000
3
–UN–23AUG88 TS228 DX,LOOSE –19–04JUN90–1/1
–UN–23AUG88 TS220 DX,AIR –19–17FEB99–1/1
–UN–18OCT88 T6642EJ DX,CLEAN –19–04JUN90–1/1
CTM331 (03OCT05) 01-000-3 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=11
Safety
01
000 Remove Paint Before Welding or Heating
4
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.
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.
TS220 –UN–23AUG88
DX,PAINT –19–24JUL02–1/1
–UN–15MAY90 TS953 DX,TORCH –19–10DEC04–1/1
CTM331 (03OCT05) 01-000-4 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=12
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.
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.
01
000
5
–UN–23AUG88 TS223 DX,LIGHT –19–04JUN90–1/1
–UN–01JUL97 LX1016749 DX,SAFE,TOOLS –19–10OCT97–1/1
CTM331 (03OCT05) 01-000-5 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=13
Safety
01
000 Practice Safe Maintenance
6
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.
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.
Use only service parts meeting John Deere specifications.
CTM331 (03OCT05) |
01-000-6 |
TS218 –UN–23AUG88
DX,SERV –19–17FEB99–1/1
TS779 –UN–08NOV89
DX,REPAIR –19–17FEB99–1/1
4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=14
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.
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.
01
000
7
TS1133 –UN–26NOV90
DX,DRAIN –19–03MAR93–1/1
Live With Safety
Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields.
–19–07OCT88 TS231 DX,LIVE –19–25SEP92–1/1
CTM331 (03OCT05) 01-000-7 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=15
Safety
01
000
8
CTM331 (03OCT05) 01-000-8 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=16
|
Group 001 |
|
|
Engine Identification |
|
|
|
|
|
|
|
Engine Model Designation |
|
01 |
|
001 |
|
|
|
1 |
|
|
|
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 ............................................................ |
POWERTECH application code |
|
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 |
|
POWERTECH is a registered trademark of Deere & Company |
|
OUO1080,00001FA –19–15NOV01–1/1 |
CTM331 (03OCT05) |
01-001-1 |
4.5 L & 6.8 L Level 12 Electronic Fuel System |
012506
PN=17
Engine Identification
01
001 Engine Serial Number Plate Information
2
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 |
|
MODEL DESIGNATION earlier in this group. |
Sequential Number |
|
000000 ................... |
6-digit sequential serial number |
Engine Application Data (C)
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)
CTM331 (03OCT05) |
01-001-2 |
RG11816 –UN–15NOV01
Engine Serial Number Plate
RG9060 –UN–16MAR98
Dubuque Engine Serial Number Plate
RG11949 –UN–07NOV01
Saran Engine Serial Number Plate
RG11948 –UN–06NOV01
Torreon Engine Serial Number Plate
OUO1080,00001FB –19–15NOV01–1/1
4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=18
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.
01
001
3
RG12027 –UN–03DEC01
OUO1080,000020E –19–26NOV01–1/1
Information Relative to Emissions Regulations
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
CTM331 (03OCT05) 01-001-3 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=19
Engine Identification
01
001 Engine Application Charts
4
|
|
JOHN DEERE AGRICULTURAL EQUIPMENT |
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 |
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 |
OUO1089,0000205 –19–23SEP05–1/2 |
CTM331 (03OCT05) 01-001-4 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=20
Engine Identification
|
|
|
01 |
|
|
JOHN DEERE CONSTRUCTION & FORESTRY EQUIPMENT |
001 |
Application |
Engine Model |
5 |
|
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 |
|
|
JOHN DEERE OEM (OUTSIDE EQUIPMENT MANUFACTURERS)
CD4045TF275
CD4045TFM75 Marine Engine
PE4045HF275
CD4045TF275
PE4045TF275
CD6068HF275
PE6068HF275
CD6068TF275
PE6068TF275
|
|
OUO1089,0000205 –19–23SEP05–2/2 |
CTM331 (03OCT05) |
01-001-5 |
4.5 L & 6.8 L Level 12 Electronic Fuel System |
012506
PN=21
Engine Identification
01
001
6
CTM331 (03OCT05) 01-001-6 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=22
|
Group 002 |
|
|
Fuels |
|
|
|
|
|
|
|
Lubricants and Coolant |
|
01 |
|
002 |
|
|
|
1 |
|
|
|
NOTE: Refer to Section 01, Group 002 of CTM104 Base Engine Manual for information on lubricants and coolants.
DPSG,OUO1004,2761 –19–16MAY00–1/1
Diesel Fuel
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.
OUOD002,0000171 –19–23SEP05–1/1
CTM331 (03OCT05) 01-002-1 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=23
01
002
2
Fuels
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.
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
RG41183,0000046 –19–18DEC01–1/1
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 |
|
DX,FUEL6 –19–14NOV05–1/1 |
CTM331 (03OCT05) |
01-002-2 |
4.5 L & 6.8 L Level 12 Electronic Fuel System |
012506
PN=24
|
Fuels |
|
|
|
|
|
|
|
Lubricity of Diesel Fuel |
|
01 |
|
002 |
|
|
|
3 |
Diesel fuel must have adequate lubricity to ensure |
Use of low lubricity diesel fuels may also cause |
|
|
||
proper operation and durability of fuel injection system |
accelerated wear, injection nozzle erosion or corrosion, |
|
components. |
engine speed instability, hard starting, low power, and |
|
|
engine smoke. |
|
Diesel fuels for highway use in the United States and |
|
|
Canada require sulfur content less than 0.05% (500 |
Fuel lubricity should pass a minimum load level of |
|
ppm). |
3100 gram as measured by the ASTM D6078 or |
|
|
maximum scar diameter of 0.45 mm as measured by |
|
Diesel fuel in the European Union requires sulfur |
ASTM D6079. |
|
content less than 0.05% (500 ppm). |
|
|
|
ASTM D975 and EN 590 specifications do not require |
|
Experience shows that some low sulfur diesel fuels |
fuels to pass a fuel lubricity test. |
|
may have inadequate lubricity and their use may |
|
|
reduce performance in fuel injection systems due to |
If fuel of low or unknown lubricity is used, add John |
|
inadequate lubrication of injection pump components. |
Deere PREMIUM DIESEL FUEL CONDITIONER (or |
|
The lower concentration of aromatic compounds in |
equivalent) at the specified concentration. |
|
these fuels also adversely affects injection pump seals |
|
|
and may result in leaks. |
|
|
|
OUOD002,0000179 –19–18DEC01–1/1 |
|
CTM331 (03OCT05) 01-002-3 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=25
Fuels
01
002
4
CTM331 (03OCT05) 01-002-4 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=26
|
|
Section 02 |
||
|
Repair and Adjustments |
|||
|
Contents |
|
|
|
|
|
02 |
||
|
|
|
|
|
|
Page |
|
Page |
|
|
|
|
||
Group 090—Electronic Fuel System Repair and |
Remove Blade Terminals from Connector |
|
|
|
Adjustments |
|
Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
02-110-11 |
|
Fuel System—General Information . . . . . . . . |
.02-090-1 |
Repair (Pull Type) METRI-PACK |
|
|
Relieve Fuel System Pressure . . . . . . . . . . . |
.02-090-1 |
Connectors . . . . . . . . . . . . . . . . . . . . . . . . |
02-110-12 |
|
Remove and Install Final Fuel Filter/Water |
|
Repair (Push Type) METRI-PACK |
|
|
Bowl and/or Pre-Filter/Water Bowl Base . . |
.02-090-2 |
Connectors . . . . . . . . . . . . . . . . . . . . . . . . |
02-110-14 |
|
Fuel Pre-Filter/Water Bowl Assembly |
|
Repair DEUTSCH Connectors . . . . . . . . . . |
02-110-17 |
|
(Optional). . . . . . . . . . . . . . . . . . . . . . . . . . |
.02-090-5 |
Repair AMP Connector . . . . . . . . . . . . . . . . . |
02-110-20 |
|
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 |
|
|
|
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
CTM331 (03OCT05) 02-1 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=1
Contents
02
CTM331 (03OCT05) 02-2 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=2
Group 090
Electronic Fuel System Repair and Adjustments
Fuel System—General Information |
|
|
|
Stanadyne DE10 pumps are static lock-pin timed |
All engines are equipped with a round final fuel filter |
|
|
during installation of the injection pump. |
with water bowl. Hand primer on top of filter element is |
|
|
|
optional. |
|
|
The fuel supply pump is a separate component |
02 |
||
|
|||
|
090 |
||
mounted on upper right-hand side of engine block and |
All engines use Stanadyne Rate Shaping Nozzles |
||
1 |
|||
is actuated by a pin in block that rides on engine |
(RSN). |
|
|
|
|||
camshaft lobe. |
|
|
|
|
Field-installed options include fuel heater, water bowl |
|
|
Engines may be equipped with an optional fuel |
and hand fuel primer. |
|
|
pre-filter/water bowl. |
|
|
|
|
OUO1089,00001F7 –19–06NOV01–1/1 |
|
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 High Pressure Fluids suspected leaks.
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.
X9811 –UN–23AUG88
|
|
RG,35,JW7625 –19–20NOV97–1/1 |
CTM331 (03OCT05) |
02-090-1 |
4.5 L & 6.8 L Level 12 Electronic Fuel System |
012506
PN=29
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. |
|
02 |
|
|
090 |
Engines are equipped with a final fuel filter/water bowl (A) |
|
2 |
|
|
|
and may have an optional pre-filter/water bowl. |
–UN–15NOV01 |
|
||
|
hand primer on machines equipped with only one filter. |
|
|
Final fuel filters/water bowls can be equipped with a |
|
|
transparent (see-through) water collection bowl and/or |
|
|
A—Final Fuel Filter/Water Bowl |
RG11989 |
|
|
|
|
|
Final Fuel Filter |
|
Continued on next page |
OUO1089,00001F6 –19–06NOV01–1/3 |
CTM331 (03OCT05) 02-090-2 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=30
Loading...