john deere POWERTECH 4.5L Technical Manual

PowerTech 4.5L &

6.8L

PowerTech Plus 4.5L

& 6.8L

Diesel Engines

Base Engine

TECHNICAL MANUAL

PowerTech Plus 4.5L & 6.8L

Diesel Engines— Base Engine

CTM104 27JAN06 (ENGLISH)

For complete service information also see:

OWERTECH

Fuel Systems......................... CTM207

OWERTECH

Electronic Fuel Systems with Bosch VP44

Pump ............................... CTM170

OWERTECH

Electronic Fuel Systems with Stanadyne

DE10 Pump .......................... CTM331

OWERTECH

Electronic Fuel Systems with Delphi/Lucas

DP201 Pump ......................... CTM284

OWERTECH

Electronic Fuel Systems with Denso

HPCR ............................... CTM220

OWERTECH

PowerTech Plus—Level 14 Electronic Fuel

Systems with Denso HPCR.............. CTM320

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

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

 Diesel Engines—Mechanical  Diesel Engines—Level 4

 Diesel Engines—Level 12

Diesel Engines—Level 1

 Diesel Engines—Level 11

 Diesel Engines and

John Deere Power Systems

LITHO IN U.S.A.

Foreword

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 (CTM104) covers only the base engine. It is one of seven volumes on 4.5L and 6.8L engines. The following six companion manuals cover fuel system and electronics repair, operation and diagnostics:

• CTM207—Mechanical Fuel Systems

• CTM170—Level 4 Electronic Fuel Systems with

Bosch VP44 Pump

• CTM331—Level 12 Electronic Fuel Systems with Stanadyne DE10 Pump

• CTM284—Level 1 Electronic Fuel Systems with Delphi/Lucas DP201 Pump

• CTM220—Level 11 Electronic Fuel Systems with Denso High Pressure Common Rail

• CTM320—Level 14 Electronic Fuel Systems with Denso High Pressure Common Rail

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.

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 repair on an engine, clean the engine and mount on a repair stand. (See Section 02, Group

010.) 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

CTM104 (27JAN06) PowerTech Plus 4.5L & 6.8L Diesel Engines

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.

DPSG,OUO1004,2767 –19–27SEP05–1/1

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About This Manual

Introduction

The changes listed below make your CTM obsolete. Repair, operation and diagnostics on 4.5L and 6.8L diesel engines is now covered in seven manuals.

Discard CTM104 dated 30Jun05 and replace with this new manual. Also refer to the following manuals:

• CTM104—4.5L and 6.8L Diesel Engines—Base Engine

• CTM207—4.5L and 6.8L Diesel Engines— Mechanical Fuel Systems

• CTM170—4.5L and 6.8L Diesel Engines—Level 4 Electronic Fuel Systems with Bosch VP44 Pump

• CTM331—4.5L and 6.8L Diesel Engines—Level 12 Electronic Fuel Systems with Stanadyne DE10 Pump

• CTM284—4.5L and 6.8L Diesel Engines—Level 1 Electronic Fuel Systems with Delphi/Lucas DP201 Pump

• CTM220—4.5L and 6.8L Diesel Engines—Level 11 Electronic Fuel Systems with Denso High Pressure Common Rail

• CTM320—4.5L and 6.8L Diesel Engines—Level 14 Electronic Fuel Systems with Denso High Pressure Common Rail

Also, copy this page listing changes and route through your Service Department.

SECTION 01—GROUP 001 (Engine Identification)

SECTION 02—GROUP 010 (Engine Rebuild)

• Revised engine disassembly/assembly procedure.

SECTION 02—GROUP 080 (Air Intake and Exhaust System)

• Added EGR retest information.

SECTION 02—GROUP 090 (Fuel System)

NOTE: Repair procedures for fuel systems have been

moved to Section 02, Group 090 in six other technical manuals: CTM207—Mechanical Fuel Systems, CTM170—Level 4 Electronic Fuel Systems with Bosch VP44 Pump, CTM331— Level 12 Electronic Fuel Systems with Stanadyne DE10 Pump, CTM284—Level 1 Electronic Fuel Systems with Delphi/Lucas DP201 Pump, CTM220—Level 11 Electronic Fuel Systems with Denso High Pressure Common Rail and CTM320—Level 14 Electronic Fuel Systems with Denso High Pressure Common Rail.

SECTION 02—GROUP 100 (Starting and Charging Systems)

• Starting and charging systems are covered in this section/group.

• Updated engine serial plate engine application

SECTION 03—GROUP 120 (Base Engine Operation)

charts.

• Added EGR system operation.

SECTION 01—GROUP 002 (Fuels, Lubricants and Coolants)

SECTION 04—GROUP 150 (Observable Diagnostics and Tests)

• Revised diesel engine fuel guidelines.

OUO1080,000023A –19–12JUN02–1/2

CTM104 (27JAN06) PowerTech Plus 4.5L & 6.8L Diesel Engines

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Introduction

NOTE: Fuel system testing and diagnostics has been

moved to Section 04, Group 150 in five other technical manuals: CTM207—Mechanical Fuel Systems, CTM170—Level 4 Electronic Fuel Systems with Bosch VP44 Pump, CTM331— Level 12 Electronic Fuel Systems with Stanadyne DE10 Pump, CTM284—Level 1 Electronic Fuel Systems with Delphi/Lucas DP201 Pump, CTM220—Level 11 Electronic Fuel Systems with Denso High Pressure Common Rail and CTM320—Level 14 Electronic Fuel Systems with Denso High Pressure Common Rail.

SECTION 5 (Tools and Other Materials)

• All essential tools, service tools, dealer fabricated tools and other materials listed throughout this manual are consolidated in this section for ease of reference.

SECTION 6 (Specifications)

• All repair, test and diagnostic specifications listed throughout this manual are consolidated in this section for ease of reference.

OUO1080,000023A –19–12JUN02–2/2

CTM104 (27JAN06) PowerTech Plus 4.5L & 6.8L Diesel Engines

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POWERTECH4.5L Engine—Tier 1/Stage I

Introduction

3/4 Right Rear View

3/4 Right Front View

RG7636 –UN–23NOV97

RG7639 –UN–23NOV97

3/4 Left Rear View

RG7638 –UN–23NOV97

RG7637 –UN–23NOV97

3/4 Left Front View

OWERTECH

CTM104 (27JAN06) PowerTech Plus 4.5L & 6.8L Diesel Engines

is a registered trademark of Deere & Company

DPSG,OUO1004,129 –19–15MAY02–1/1

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POWERTECH4.5L Engine—Tier 2/Stage II

Introduction

3/4 Right Front View—Two-Valve Head Engine

3/4 Right Front View—Four-Valve Head Engine

RG11932 –UN–06NOV01

RG13617A –UN–18MAY04

3/4 Left Rear View—Two-Valve Head Engine

RG11931 –UN–06NOV01

RG13618A –UN–18MAY04

3/4 Left Rear View—Four-Valve Head Engine

OWERTECH

CTM104 (27JAN06) PowerTech Plus 4.5L & 6.8L Diesel Engines

is a registered trademark of Deere & Company

OUO1080,0000238 –19–03JUN04–1/1

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POWERTECH6.8L Engine—Tier 1/Stage I

Introduction

3/4 Right Front View

3/4 Right Rear View

RG7641 –UN–23NOV97

RG7643 –UN–23NOV97

3/4 Left Front View

RG7640 –UN–23NOV97

RG7642 –UN–23NOV97

3/4 Left Rear View

OWERTECH

CTM104 (27JAN06) PowerTech Plus 4.5L & 6.8L Diesel Engines

is a registered trademark of Deere & Company

DPSG,OUO1004,130 –19–15MAY02–1/1

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POWERTECH6.8L Engine—Tier 2/Stage II

Introduction

3/4 Right Front View—Two-Valve Head Engine

OWERTECH

is a registered trademark of Deere & Company

RG11934 –UN–24OCT01

3/4 Left Rear View—Two-Valve Head Engine

RG11933 –UN–24OCT01

OUO1080,0000239 –19–06JUN02–1/1

CTM104 (27JAN06) PowerTech Plus 4.5L & 6.8L Diesel Engines

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Introduction

POWERTECH6.8L Engine With Electronic Fuel System—Tier 2/Stage II

6068HF475 Four-Valve Engine (Level 11 Electronic Fuel System

with Denso High Pressure Common Rail)

OWERTECH

is a registered trademark of Deere & Company

RG12199 –UN–24MAY02

6068HF475 Four-Valve Engine

RG12200 –UN–24MAY02

OUO1083,00005FC –19–21OCT05–1/1

CTM104 (27JAN06) PowerTech Plus 4.5L & 6.8L Diesel Engines

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Introduction

POWERTECH6.8L Engine With Electronic Fuel System—Tier 3/Stage IIIA

6068HF485 Engine Shown (Electronic Fuel System With Denso

High Pressure Common Rail)

OWERTECH

is a registered trademark of Deere & Company

RG13547 –UN–11NOV04

6068HF485 Shown

RG13546 –UN–11NOV04

OUO1083,00005FC –19–17DEC03–1/1

CTM104 (27JAN06) PowerTech Plus 4.5L & 6.8L Diesel Engines

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Contents

SECTION 01—General Information

Group 000—Safety Group 001—Engine Identification and Application

Charts

Group 002—Fuels, Lubricants and Coolants

SECTION 02—Repair and Adjustments

Group 010—Engine Rebuild Group 020—Cylinder Head and Valves (Two-Valve

Head Engines)

Group 021—Cylinder Head and Valves (Four-Valve

Head Engines)

Group 030—Cylinder Block, Liners, Pistons and

Rods

Group 040—Crankshaft, Main Bearings and

Flywheel

Group 050—Camshaft, Balancer Shafts and Timing

Gear Train Group 060—Lubrication System Group 070—Cooling System Group 080—Air Intake and Exhaust System Group 090—Fuel System Group 100—Starting and Charging Systems

SECTION 03—Theory of Operation

Group 120—Base Engine Operation

SECTION 04—Diagnostics

Group 150—Observable Diagnostics and Tests

SECTION 05—Tools and Other Materials

Group 170—Repair Tools and Other Materials Group 180—Diagnostic Service Tools Group 190—Dealer Fabricated Service Tools

SECTION 06—Specifications

Group 200—Repair and General OEM

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.

INDX

CTM104 (27JAN06)

DEERE & COMPANY

Moline, Illinois

A John Deere ILLUSTRUCTIONManual

PowerTech Plus 4.5L & 6.8L Diesel Engines

Previous Editions

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Contents

INDX

CTM104 (27JAN06)

PowerTech Plus 4.5L & 6.8L Diesel Engines

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Page

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

Group 001—Engine Identification and Application

Charts

Engine Serial Number Plate Information .....01-001-1

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 Coolants

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

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

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

Testing Diesel Fuel .....................01-002-3

Diesel Engine Break-In Oil ...............01-002-4

Diesel Engine Oil—Non-Certified and Tier 1

Certified Engines .....................01-002-5

Diesel Engine Oil—Tier 2/Stage II

Certified Engines .....................01-002-6

Diesel Engine Oil —Tier 3/Stage IIIA Certified

Engines ............................01-002-7

OILSCAN, OILSCAN Plus,

COOLSCAN and COOLSCAN PLUS . . .01-002-8

Oil Filters.............................01-002-8

Grease ..............................01-002-9

Diesel Engine Coolant..................01-002-10

Additional Information About Diesel

Engine Coolants and Supplemental Coolant

Additives ..........................01-002-12

Testing Diesel Engine Coolant ...........01-002-13

Supplemental Coolant Additives ..........01-002-14

Operating in Warm Temperature Climates . .01-002-14

Flush and Service Cooling System ........01-002-15

Disposing of Coolant...................01-002-16

Section 01

General Information

Contents

CTM104 (27JAN06)

01-1

PowerTech Plus 4.5L & 6.8L Diesel Engines

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Contents

CTM104 (27JAN06)

01-2

PowerTech Plus 4.5L & 6.8L Diesel Engines

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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.

Service Cooling System Safely

Explosive release of fluids from pressurized cooling system can cause serious burns.

TS1356 –UN–18MAR92

DX,FIRE3 –19–16APR92–1/1

Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

CTM104 (27JAN06)

01-000-1

DX,RCAP –19–04JUN90–1/1

PowerTech Plus 4.5L & 6.8L Diesel Engines

TS281 –UN–23AUG88

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PN=15

000

Install Fan Guards

Rotating cooling system fans can cause serious injury. Keep fan guards in place at all times during engine

operation. Wear close fitting clothes. Stop engine and be sure fan is stopped before making adjustments or connections, or cleaning near the front of the engine.

Safety

Avoid Hot Parts

Avoid skin contact with exhaust manifolds, turbochargers and mufflers. Keep flammable materials clear of the turbocharger.

External dry exhaust parts become very hot during operation. Turbochargers may reach temperatures as high as 500°C (932°F) under full load, and naturally aspired exhaust manifolds may reach 600°C (1112°F) under full load. This may ignite paper, cloth or wooden materials. Parts on engines that have been at full load and reduced to no load idle will maintain approximately 150°C (302°F).

Rotating Fan

TS677 –UN–21SEP89

OUO1083,00005FE –19–17DEC03–1/1

TS271 –UN–23AUG88

Hot Surface

Prevent Battery Explosions

Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode.

Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer.

Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).

CTM104 (27JAN06)

01-000-2

OUO1083,00005FF –19–22DEC05–1/1

DX,SPARKS –19–03MAR93–1/1

PowerTech Plus 4.5L & 6.8L Diesel Engines

TS204 –UN–23AUG88

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Safety

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.

01 000 3

Handling Batteries Safely

DX,FIRE2 –19–03MAR93–1/1

TS291 –UN–23AUG88

TS204 –UN–23AUG88TS203 –UN–23AUG88

CTM104 (27JAN06)

Continued on next page

01-000-3

DPSG,OUO1004,2758 –19–22DEC05–1/2

PowerTech Plus 4.5L & 6.8L Diesel Engines

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PN=17

000

Safety

CAUTION: Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check battery electrolyte level.

Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.

Always remove grounded (-) battery clamp first and replace it last.

Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).

CAUTION: Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.

Avoid the hazard by:

1. Filling batteries in a well-ventilated area.

2. Wearing eye protection and rubber gloves.

3. Avoiding breathing fumes when electrolyte is added.

4. Avoiding spilling or dripping electrolyte.

5. Use proper jump start procedure.

If you spill acid on yourself:

1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize the acid.

3. Flush your eyes with water for 15—30 minutes. Get medical attention immediately.

If acid is swallowed:

1. Do not induce vomiting.

2. Drink large amounts of water or milk, but do not exceed2L(2quarts).

3. Get medical attention immediately.

WARNING: Battery posts, terminals, and related

accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.

CTM104 (27JAN06)

01-000-4

DPSG,OUO1004,2758 –19–22DEC05–2/2

PowerTech Plus 4.5L & 6.8L Diesel Engines

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Safety

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.

01 000 5

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

CTM104 (27JAN06)

01-000-5

PowerTech Plus 4.5L & 6.8L Diesel Engines

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000

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.

Safety

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

CTM104 (27JAN06)

01-000-6

DX,CLEAN –19–04JUN90–1/1

PowerTech Plus 4.5L & 6.8L Diesel Engines

T6642EJ –UN–18OCT88

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Safety

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.

01 000 7

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

CTM104 (27JAN06)

01-000-7

PowerTech Plus 4.5L & 6.8L Diesel Engines

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000

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.

Safety

Use Proper Lifting Equipment

Lifting heavy components incorrectly can cause severe injury or machine damage.

Follow recommended procedure for removal and installation of components in the manual.

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

TS226 –UN–23AUG88

DX,LIFT –19–04JUN90–1/1

CTM104 (27JAN06)

01-000-8

Construct Dealer-Made Tools Safely

DPSG,OUO1004,899 –19–19MAY99–1/1

PowerTech Plus 4.5L & 6.8L Diesel Engines

LX1016749 –UN–01JUL97

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Safety

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.

01 000 9

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.

CTM104 (27JAN06)

01-000-9

DX,REPAIR –19–17FEB99–1/1

PowerTech Plus 4.5L & 6.8L Diesel Engines

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000

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.

Safety

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

CTM104 (27JAN06)

01-000-10

DX,LIVE –19–25SEP92–1/1

PowerTech Plus 4.5L & 6.8L Diesel Engines

TS231 –19–07OCT88

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Engine Identification and Application Charts

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.

NOTE: Four-valve head engines have “16V” or “24V”

printed on a plate located on the rocker arm cover. The 4045HF475 model has “16V” to denote 16 valves total while 6068HF475 has “24V” to denote 24 valves total.

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:

CD4045L123456

CD ...................... Engine Manufacturing Location

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

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

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

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

4 ........................ Number of Cylinders

045 .................... Displacement in Liters ( 4.5 Liters)

L ........................ Aspiration Code (Early Engines) or Emission

Tier Level (Later Engines)

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

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

A ............... Turbocharged and air-to-coolant aftercooled

H ............... Turbocharger and air-to-water aftercooled

S ............... Turbocharged and air-to sea water aftercooled

B ................ Non-certified engine

C,E or F ..... Tier 1/Stage I emission certified engine

G, J or K .... Tier 2/Stage II emission certified engine

L, M, N or P Tier 3/Stage IIIA emission certified engine

123456 ............... 6-digit unique sequence number

Engine Model Designation (C)

Group 001

01 001 1

RG7778 –UN–11NOV97

RG13806 –UN–23JAN06

Saran Serial Number Plate

RG13716 –UN–23JAN06

Torreon 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.

A—Engine Serial Number Plate B—Engine Serial Number C—Engine Application Data D—Empty, Coefficient of Absorption or Saran internal

factory identification

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Dubuque Engine Serial Number Plate

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PowerTech Plus 4.5L & 6.8L Diesel Engines

RG9060 –UN–16MAR98

RG19661,0000005 –19–27JAN06–1/2

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Engine Identification and Application Charts

001

4045HF485

4 ..................................................... Number of Cylinders

045 ................................................. Displacement in Liters ( 4.5 Liters)

H .................................................... Aspiration Code )

F ..................................................... User Code

485 Application Code See Engine Application Charts later in this group

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

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

A ...................................... Turbocharged and air-to-coolant aftercooled

H ...................................... Turbocharger and air-to-water aftercooled

S ...................................... Turbocharged and air-to sea water aftercooled

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 (Original Equipment Manufacturers)

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

FM .................................... Marine Engine

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

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

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

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

LV ...................................... John Deere Commercial Product (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 (formerly Timberjack) (Sweden/Finland/Canada/USA)

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

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

Coefficient of Absorption (D) — (Early Saran-Built Engines - Later Engines, Internal Factory Identification)

The second line of information on Saran serial number plate may also contain the coefficient of absorption value for smoke emissions or, for later engines, an internal factory identification number.

RG19661,0000005 –19–27JAN06–2/2

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Engine Identification and Application Charts

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

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CD30433 –UN–10MAY95

DPSG,OUO1004,482 –19–07NOV98–1/1

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 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

• EGR cooler

• EGR valve

• Charge air cooling system

• Piston

OUO1080,0000035 –19–29AUG01–1/1

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Engine Identification and Application Charts

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Engine Application Charts

JOHN DEERE AGRICULTURAL EQUIPMENT Machine Model Engine Model Bell Equipment, South Africa

884 Cane Loader CD4045TBE50 (Tier 1) 904 Haul Tractor CD4045TBE51 (Tier 1) 1266 Haul Tractor CD6068TBE50 (Tier 1) 1866 Haul Tractor CD6068TBE51 (Tier 2) 2256 Haul Tractor CD6068HBE50 (Tier 1)

Des Moines, Iowa

4700 Sprayer (138 kW) T06068TN050, PE6068TN050, T06068TN053, PE6068TN053 4700 Sprayer (149 kW) PE6068TN052 4710 Sprayer PE6068TN052 4720 Sprayer PE6068HN051 (Tier 2) 6700 Sprayer T04045TN050, PE4045TN050 7455 Cotton Stripper T06068TN051, PE6068TN051 7460 Cotton Stripper PE6068TN054 9935 Cotton Picker T06068TN051, PE6068TN051 9970 Cotton Picker PE6068HN052 (Tier 2)

East Moline, Illinois

9400 Combine T06068HH050 9410 Combine T06068HH051 9450 Combine T06068HH052, PE6068HH052 9550 Combine (Low Power) PE6068HH054 (4-Valve) (Tier 2) 9550/9550SH Combine (High Power) PE6068HH055 (4-Valve) (Tier 2) 9560 Combine (Low Power) PE6068HH054 (4-Valve) (Tier 2) 9560 Combine (High Power) PE6068HH055 (4-Valve) (Tier 2)

9965 Peanut Combine PE6068HH057

Horizontina, Brazil

1165 Combine J06068TCQ11 1170 Combine CD6068TCQ50 1175 Combine J06068TCQ12 1450 Combine J06068TCQ04 1450 CWS/WTS Combine CD6068HCQ60, JO6068TCG04(Tier 2) 1550 CWS/WTS Combine CD6068HCQ61, JO6068ACQ04(Tier 2) 3518 Combine J06068TYC51 9650 Combine J06068HCQ01 5403/5605 Tractor J04045DCQ01 5705 Tractor J04045TCQ02 6405 Tractor J04045TCQ01

PE6068HH058 (4-Valve) Tier 3)

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Engine Identification and Application Charts

JOHN DEERE AGRICULTURAL EQUIPMENT

Machine Model Engine Model

6415 Tractor J04045TCQ03 6605 Tractor J06068TCQ02 6615 Tractor J06068TCQ15 7505 Tractor J06068TCQ03 7515 Tractor J06068TCQ14

Jiamusi, China

1075 Combine CD6068TYC50, J06068TYC50 3518 Combine CD6068TYC51, CD6068HYC50, J06068TYC51

Zweibrucken, Germany

2254 Combine CD6068HZ050 3200/3400 Telehandler CD4045TZ250 3215/3415 Telehandler (European Version) CD4045HZ275, CD4045TZ270 3215/3415 Telehandler (North American Version) CD4045HZ275, CD4045TZ270 3220/3420 Telehandler (European Version) CD4045HZ275 3220/3420 Telehandler (North American Version) CD4045HZ275 3800 Telehandler, Articulated CD4045HZ050, 4045HZ060 9540/9540 Hillmaster Combine CD6068HZ060

CD6068HZ480 (4-Valve) (Tier 3)

9560/9560HM Combine CD6068HZ470 (4-Valve) (Tier 2)

CD6068HZ481 (4-Valve) (Tier 3)

Ottumwa, Iowa

4890 Windrower T04045TE050, PE4045TE050 4895 Windrower T04045TE051, PE4045TE051 4990 Windrower T06068TE050, PE6068TE050 4995 Windrower PE6068TE051

Waterloo, Iowa

7210 (SYNCROPLUS) Tractor T06068TRW53 7210 (POWRQUAD) Tractor T06068TRW50, PE6068TRW50 7220 Tractor CD6068TRW01, PE6068TRW01, PE6068HRW59 7220 IVT Tractor PE6068HRW61 7320 Tractor CD6068HRW01, PE6068HRW01, PE6068HRW59 7320 IVT Tractor PE6068HRW61 7410 (SYNCROPLUS) Tractor T06068TRW54, PE6068HRW54 7410 (POWRQUAD) Tractor T06068TRW51, PE6068TRW51 7420 Tractor CD6068HRW01, PE6068HRW01 7510 (POWRQUAD) Tractor T06068TRW70, PE6068TRW70 7520 Tractor CD6068HRW01, PE6068HRW01 7610 Tractor (105 kW) T06068TRW52, PE6068TRW52

01 001 5

SYNCROPLUS is a trademark of Deere & Company POWRQUAD is a trademark of Deere & Company

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Engine Identification and Application Charts

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Machine Model Engine Model

7610 Tractor (110 kW) T06068TRW72, PE6068TRW72 7720 Tractor (Auxilliary Drive) PE6068HRW54 (4-Valve) (Tier 2) 7810 Tractor (Export-Brazil) PE6068TRW73 7815 Tractor (Export-Brazil) PE6068HRW63 7820 Tractor (Non-Auxilliary Drive) PE6068HRW54 (4-Valve) (Tier 2)

Mannheim, Germany (European Market)

3210 Tractor CD4045DRT50 3310 Tractor CD4045DRT51 3410 Tractor CD4045TRT50 5620 Tractor CD4045DL270 5720 Tractor CD4045TL273 5820 Tractor CD4045TL274 6010 Tractor CD4045DL050 6020 Tractor CD4045DL070 6020SE Tractor CD4045TL270 (Tier 2) 6110 Tractor (Direct Fan Drive) CD4045TL058 6110 Tractor (Viscous Fan Drive) CD4045TL050 6120 Tractor CD4045TL070 6120 Tractor (Premium) CD4045TL271 6120SE Tractor CD4045TL271 6205 Tractor CD4045TL064 6210 Tractor (Direct Fan Drive) CD4045TL059 6210 Tractor (Viscous Fan Drive) CD4045TL051 6215 Tractor (Classic) CD4045TL072 6215 Tractor (Classic) CD4045TL071 6215 Tractor (Classic) CD4045TL272 (Tier 2) 6220 Tractor CD4045TL071 6220 Tractor (Premium) CD4045TL272 (Tier 2) 6220SE Tractor CD4045TL272 6310 Tractor (Direct Fan Drive) CD4045TL060 6310 Tractor (Viscous Fan Drive) CD4045TL052 6310 Tractor (ECU Level 4) CD4045TLA50 6320 Tractor CD4045HL072 6320 IVT Tractor CD4045HLA70 6320 Tractor (Premium) CD4045HL472 6320SE Tractor CD4045TL073, CD4045HL270 (Tier 2) 6410 Tractor (Direct Fan Drive) CD4045TL061 6410 Tractor (Viscous Fan Drive) CD4045TL053 6410 Tractor (ECU Level 4) CD4045TLA51

JOHN DEERE AGRICULTURAL EQUIPMENT

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