John Deere Powertech 4.5L, Powertech 6.8L Service Manual

Workshop manual

John Deere

Diesel engines

Powertech 4.5L and 6.8L

Level 11 Fuel systems

with Denso HPCR

CTM 220 (21Jan04)

33525067201_2_1

OWERTECH

Level 11 Electronic

Fuel System With



4.5L & 6.8L

Diesel Engines

Denso HPCR

TECHNICAL MANUAL

OWERTECH

Engines—Level 11 Electronic Fuel

System with Denso HPCR



4.5 L & 6.8 L Diesel

CTM220 21JAN04 (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 (CTM220) covers only Level 11 Electronic Fuel System with the Denso High Pressure Common Rail (HPCR). It is one of six volumes on 4.5 L and 6.8 L engines. The following five companion manuals cover the base engine, mechanical fuel system, and other electronic control systems. Each manual covers 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 System with

Delphi (Lucas) DP201 Pump

• CTM331—Level 12 Electronic Fuel System with Stanadyne DE 10 Pump

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

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. At the beginning of each group are summaries of the up coming group.

Before beginning 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 are 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.

A complete set of all these manuals covering 4.5 L and 6.8 L engines is available in a binder by ordering CTM 350 Binder Set.

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

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.

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CTM220 (21JAN04) 4.5 L & 6.8 L Level 11 Electronic Fuel System

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SECTION 01—General

Group 000—Safety Group 001—Engine Identification Group 002—Fuels, Lubricants, and Coolant

Contents

SECTION 02—Repair and Adjustments

Group 090—Electronic Fuel System Repair and

Adjustments

Group 110—Electronic 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

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

CTM220 (21JAN04)

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 11 Electronic Fuel System

INDX

012104

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Contents

INDX

CTM220 (21JAN04)

4.5 L & 6.8 L Level 11 Electronic Fuel System

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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

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

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

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

Dieselscan Fuel Analysis.................01-002-2

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

Section 01

General

Contents

CTM220 (21JAN04)

01-1

4.5 L & 6.8 L Level 11 Electronic Fuel System

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Contents

CTM220 (21JAN04)

01-2

4.5 L & 6.8 L Level 11 Electronic Fuel System

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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.

CTM220 (21JAN04)

01-000-1

DX,RCAP –19–04JUN90–1/1

4.5 L & 6.8 L Level 11 Electronic Fuel System

TS281 –UN–23AUG88

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000

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).

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.

DX,SPARKS –19–03MAR93–1/1

TS204 –UN–23AUG88

TS291 –UN–23AUG88

DX,FIRE2 –19–03MAR93–1/1

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4.5 L & 6.8 L Level 11 Electronic Fuel System

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Handling Batteries Safely

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.

Safety

01 000 3

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

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.

TS204 –UN–23AUG88TS203 –UN–23AUG88

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.

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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 5

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

CTM220 (21JAN04)

01-000-5

DX,CLEAN –19–04JUN90–1/1

4.5 L & 6.8 L Level 11 Electronic Fuel System

T6642EJ –UN–18OCT88

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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 76 mm (3 in.) from area to be affected by heating.

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

Safety

TS220 –UN–23AUG88

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 be accidentally cut when heat goes beyond the immediate flame area.

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.

DX,PAINT –19–22OCT99–1/1

TS953 –UN–15MAY90

DX,TORCH –19–03MAR93–1/1

CTM220 (21JAN04)

01-000-6

DX,LIGHT –19–04JUN90–1/1

4.5 L & 6.8 L Level 11 Electronic Fuel System

TS223 –UN–23AUG88

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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.

Safety

01 000 7

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,LIFT –19–04JUN90–1/1

TS226 –UN–23AUG88

LX1016749 –UN–01JUL97

Construct Dealer-Made Tools Safely

DPSG,OUO1004,899 –19–19MAY99–1/1

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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.

CTM220 (21JAN04)

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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 9

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

CTM220 (21JAN04)

01-000-9

DX,LIVE –19–25SEP92–1/1

4.5 L & 6.8 L Level 11 Electronic Fuel System

TS231 –19–07OCT88

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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

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

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 .............................................................. Timberjack (Deere) (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

CTM220 (21JAN04)

01-001-1

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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

CTM220 (21JAN04)

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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

RG40854,0000006 –19–10APR02–1/1

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

RG40854,0000007 –19–10APR02–1/1

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Engine Identification

001

Engine Application Charts

Machine Model Engine Model Waterloo - Tractors

7220 Tractor PE6068HRW61 7320 Tractor PE6068HRW61 7420 Tractor PE6068HRW62 7520 Tractor PE6068HRW62 7720 Tractor 7820 Tractor PE6068HRW54

Mannheim - Tractors

6120 6220 6420 Tractor Premium (NA/RII) CD4045HL473 64XX Tractor Premium (RII) IVT, 40K/50K CD4045HL474 6520 Tractor Premium (NA/RII) CD6068HL470 6520L Tractor Premium (NA) CD4045HL475 6620 Tractor Premium (NA/RII) CD6068HL471 6820 Tractor Premium (RII) CD6068HL472 6920 Tractor Premium (RII) CD6068HL473 69XX Tractor Premium (RII) IVT, 40K/50K CD6068HL474

Moline - Combines

9550LP Combine T06068HH054 9550HP Combine T06068HH055 9965 Amadas Peanut Combine PE6068HH057

JOHN DEERE AGRICULTURAL EQUIPMENT

PE6068HRW56

Zweibrucken - Combines

9560/9560HM Combine CD6068HZ070

JOHN DEERE CONSTRUCTION AND FORESTRY EQUIPMENT Machine Model Engine Model Davenport

624 Loader PE6068HDW57 670 Motor Grader PE6068HDW61 672 Motor Grader PE6068HDW61

JOHN DEERE OEM (OUTSIDE EQUIPMENT MANUFACTURERS)

PE4045HF475 CD4045HF475 PE6068HF475 CD6068HF475

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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, Lubricants, and Coolant

01 002 1

RG40854,000000A –19–10APR02–1/1

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, crankcse 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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Fuels, Lubricants, and Coolant

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.

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

Dieselscan Fuel Analysis

DIESELSCAN is a John Deere fuel sampling program to help you monitor the quality of your fuel source. It verifies fuel type, cleanliness, water content, suitability for cold weather operation, and if fuel is within ASTM specifications. Check with your John Deere dealer for availability of DIESELSCAN kits.

DIESELSCAN is a trademark of Deere & Company

CTM220 (21JAN04)

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Fuels, Lubricants, and Coolant

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.

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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002

Fuels, Lubricants, and Coolant

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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 Pre-Filter/Water Bowl

Base ..............................02-090-2

Replace Pre-Filter Element ...............02-090-4

Remove and Install Final Fuel Filter/Water

Bowl Base ..........................02-090-6

Replace Final Fuel Filter Element ..........02-090-8

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

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

Remove and Install High Pressure Fuel

Pump.............................02-090-11

Remove and Install High Pressure Fuel

Pump Inlet Filter ....................02-090-13

Remove and Install High Pressure

Common Rail.......................02-090-14

Remove and Install Flow Dampers ........02-090-16

Remove and Install Pressure Limiter.......02-090-18

Remove Electronic Injectors (EIs) .........02-090-20

Clean Electronic Injector (EI) Bore ........02-090-21

Clean Electronic Injector (EI) Orifice .......02-090-21

Clean Electronic Injector (EI) Body ........02-090-21

Inspect Electronic Injector (EI) Body .......02-090-21

Install Electronic Injectors (EIs) ...........02-090-22

Remove and Install Leak-off Lines ........02-090-25

Contents

Using High-Pressure Washer .............02-110-9

Repair WEATHERPACK Connector ......02-110-10

Remove Blade Terminals from Connector

Body .............................02-110-13

Repair (Pull Type) METRI-PACK

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

Repair (Push Type) METRI-PACK

Connectors ........................02-110-16

Repair DEUTSCH Connectors ..........02-110-19

Repair AMP Connector .................02-110-22

Repair SUMITOMO Connectors .........02-110-24

Repair YAZAKI Connectors ............02-110-26

Group 110—Electronic Engine Control Repair and

Adjustment

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

Fuel System Sensors ...................02-110-2

Remove and Install Engine Coolant

Temperature (ECT) Sensor .............02-110-2

Remove and Install Fuel Temperature

Sensor.............................02-110-3

Remove and Install Manifold Air Temperature

(MAT) Sensor .......................02-110-3

Remove and Install Oil Pressure Sensor.....02-110-4

Remove and Install Fuel Rail Pressure

Sensor.............................02-110-5

Remove and Install Crank Position Sensor . . .02-110-6 Remove and Install Pump Position Sensor . . .02-110-6

Remove and Install Glow Plugs............02-110-7

Connectors ...........................02-110-8

Use Electrical Insulating Compound ........02-110-8

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Contents

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Electronic Fuel System Repair and Adjustments

Fuel System - General Information

Group 090

The Level 11 Engine Control Unit (ECU) is used control the the High Pressure Common Rail (HPCR) fuel system. The HPCR fuel system includes the high pressure fuel pump, high pressure common rail, and electronic injectors.

The electronic injectors can not be serviced. If any part of the component fails, the entire injector must be replaced.

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.

Electronic injectors cannot be tested for opening pressure, as they are controlled electronically.

02 090 1

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X9811 –UN–23AUG88

High Pressure Fluids

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 Section 04, Group 150 in this manual.

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Electronic Fuel System Repair and Adjustments

Remove and Install Pre-Filter/Water Bowl Base

NOTE: For Combine and 6020 Tractors, refer to Vehicle

090

NOTE: Water bowl attachments are an optional

1. Thoroughly clean pre-filter/water bowl assembly and

2. Connect a fuel line to filter drain (if equipped) on

3. Remove pre-filter element (A) and water bowl (B).

NOTE: Fuel lines may be connected to different inlet and

4. Disconnect fuel lines from fuel inlet (C) and fuel outlet

manual for pre-filter information.

component for pre-filters.

surrounding area to keep from getting dirt and debris into fuel system.

bottom of filter and drain all fuel from the system.

outlet ports depending on engine application.

(D).

Pre-filter (OEM engines)

RG12451A –UN–14JUN02

A—Pre-filter Element B—Water Bowl C—Fuel Inlet D—Fuel Outlet E—Pre-filter Base Capscrews (one on opposite

side)

F—Pre-filter Base

5. If applicable, disconnect fuel transfer pump connector and water in fuel sensor connector.

6. Remove filter base cap screws (E) and pre-filter base (F).

NOTE: Mounting bracket does not need to be removed.

7. Replace parts as necessary.

NOTE: The specifications below refer to OEM engines

ONLY. For other applications, see Vehicle Manual for pre-filter specifications.

8. If mounting bracket is removed, install on engine. Install filter base on mounting bracket. Tighten cap screws to specification.

Pre-filter Mounting Bracket-to-Cylinder Head Cap

Screws—Torque 73 N•m (53.8 lb-ft)...........................................................

Pre-filter Fuel Filter Base-to-Bracket Cap Screws—

Torque 50 N•m (36.9 lb-ft)..........................................................................

Specification

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Continued on next page

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