John Deere POWERTECH E 4.5 L Technical Manual

POWERTECH E 4.5 &

Doosan purchased Bobcat Company from Ingersoll-Rand Company in

2007. Any reference to Ingersoll-Rand Company or use of trademarks, service marks, logos, or other proprietary identifying marks belonging to Ingersoll-Rand Company in this manual is his torical or nominative in nature, and is not meant to suggest a current affiliation between Ingersoll-Rand C

ompany and Doosan

Company or the products of

ith

er.

6.8L Diesel Engines

Level 16 Electronic

Fuel System With

Denso HPCR

TECHNICAL MANUAL

POWERTECH E 4.5 & 6.8 L Diesel

Engines—Level 16 Electronic Fuel

System with Denso HPCR

CTM502 31MAY07 (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.

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 (CTM502) covers only Level 16 Electronic Fuel System with the Denso High Pressure Common Rail (HPCR) and 2-valves per cylinder for PowerTech “E” engines. It is one of seven volumes on 4.5 L and

6.8 L engines. The following companion manual covers the base engine.

• CTM104—Base Engine

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. 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.

Read each block of material completely before performing service to check for differences in procedures or specifications.

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.

CD03523,000016D –19–30MAY07–1/1

CTM502 (31MAY07) 4.5 & 6.8 L Level 16 Electronic Fuel System

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SECTION 01—General

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

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 135—Air and Exhaust 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 Material

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.

DEERE & COMPANY

Moline, Illinois

A John Deere ILLUSTRUCTIONManual

CTM502 (31MAY07) i 4.5 & 6.8 L Level 16 Electronic Fuel System

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INDX

Contents

INDX

CTM502 (31MAY07) ii 4.5 & 6.8 L Level 16 Electronic Fuel System

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Page

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

Group 001—Engine Identification

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

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

Information Relative to Emissions

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

Emissions Control System Certification

Label ..............................01-001-4

Engine Application Charts ................01-001-5

Group 002—Fuels, Lubricants, and Coolant

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

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

Minimizing the Effect of Cold Weather on

Diesel Engines.......................01-002-3

Handling and Storing Diesel Fuel ..........01-002-4

Lubricity of Diesel Fuel ..................01-002-5

Testing Diesel Fuel .....................01-002-5

Engine Oil and Filter Service Intervals.......01-002-5

Diesel Engine Oil ......................01-002-6

Diesel Engine Break-In Oil ...............01-002-7

Oil Filters.............................01-002-7

Alternative and Synthetic Lubricants ........01-002-8

Lubricant Storage ......................01-002-8

Mixing of Lubricants ....................01-002-8

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

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

Supplemental Coolant Additives ..........01-002-11

Operating in Warm Temperature Climates . .01-002-12 Additional Information About Diesel

Engine Coolants and Supplemental Coolant

Additives ..........................01-002-13

Testing Diesel Engine Coolant ...........01-002-14

Drain Intervals for Diesel Engine Coolant . . .01-002-15

Section 01 General

Contents

CTM502 (31MAY07) 01-1 4.5 & 6.8 L Level 16 Electronic Fuel System

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Contents

CTM502 (31MAY07) 01-2 4.5 & 6.8 L Level 16 Electronic Fuel System

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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

Group 000

Safety

01 000 1

Recognize Safety Information

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

Follow recommended precautions and safe operating practices.

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,AIR –19–17FEB99–1/1

TS220 –UN–23AUG88

T81389 –UN–07DEC88

DX,ALERT –19–29SEP98–1/1

CTM502 (31MAY07) 01-000-1 4.5 & 6.8 L Level 16 Electronic Fuel System

DX,CLEAN –19–04JUN90–1/1

T6642EJ –UN–18OCT88

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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.

Avoid Harmful Asbestos Dust

Avoid breathing dust that may be generated when handling components containing asbestos fibers. Inhaled asbestos fibers may cause lung cancer.

Components in products that may contain asbestos fibers are brake pads, brake band and lining assemblies, clutch plates, and some gaskets. The asbestos used in these components is usually found in a resin or sealed in some way. Normal handling is not hazardous as long as airborne dust containing asbestos is not generated.

TS1133 –UN–26NOV90

DX,DRAIN –19–03MAR93–1/1

TS220 –UN–23AUG88

Avoid creating dust. Never use compressed air for cleaning. Avoid brushing or grinding material containing asbestos. When servicing, wear an approved respirator. A special vacuum cleaner is recommended to clean asbestos. If not available, apply a mist of oil or water on the material containing asbestos.

Keep bystanders away from the area.

DX,DUST –19–15MAR91–1/1

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Safety

Handle Fuel Safely—Avoid Fires

Handle fuel with care: it is highly flammable. Do not refuel the machine while smoking or when near open flame or sparks.

Always stop engine before refueling machine. Fill fuel tank outdoors.

Prevent fires by keeping machine clean of accumulated trash, grease, and debris. Always clean up spilled fuel.

Prepare for Emergencies

01 000 3

TS202 –UN–23AUG88

DX,FIRE1 –19–03MAR93–1/1

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.

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.

DX,FIRE2 –19–03MAR93–1/1

TS291 –UN–23AUG88

TS1356 –UN–18MAR92

CTM502 (31MAY07) 01-000-3 4.5 & 6.8 L Level 16 Electronic Fuel System

DX,FIRE3 –19–16APR92–1/1

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000

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.

Avoid High-Pressure Fluids

Safety

TS227 –UN–23AUG88

DX,FLAME –19–29SEP98–1/1

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

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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 5

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.

Live With Safety

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

DX,LIFT –19–04JUN90–1/1

TS226 –UN–23AUG88

TS223 –UN–23AUG88

DX,LIGHT –19–04JUN90–1/1

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.

CTM502 (31MAY07) 01-000-5 4.5 & 6.8 L Level 16 Electronic Fuel System

DX,LIVE –19–25SEP92–1/1

TS231 –19–07OCT88

TS228 –UN–23AUG88

DX,LOOSE –19–04JUN90–1/1

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000

Handle Chemical Products Safely

Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere equipment include such items as lubricants, coolants, paints, and adhesives.

A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques.

Safety

Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and recommended equipment.

(See your John Deere dealer for MSDS’s on chemical products used with John Deere equipment.)

Protect Against Noise

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.

TS1132 –UN–26NOV90

DX,MSDS,NA –19–03MAR93–1/1

DX,NOISE –19–03MAR93–1/1

CTM502 (31MAY07) 01-000-6 4.5 & 6.8 L Level 16 Electronic Fuel System

TS207 –UN–23AUG88

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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.

Stay Clear of Rotating Drivelines

Entanglement in rotating driveline can cause serious injury or death.

Keep tractor master shield and driveline shields in place at all times. Make sure rotating shields turn freely.

Wear close fitting clothing. Stop the engine and be sure PTO driveline is stopped before making adjustments, connections, or cleaning out PTO driven equipment.

DX,PAINT –19–24JUL02–1/1

TS1644 –UN–22AUG95

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DX,PTO –19–12SEP95–1/1

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000

Service Cooling System Safely

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

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.

Safety

Follow Safety Instructions

Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in good condition. Replace missing or damaged safety signs. Be sure new equipment components and repair parts include the current safety signs. Replacement safety signs are available from your John Deere dealer.

Learn how to operate the machine and how to use controls properly. Do not let anyone operate without instruction.

Keep your machine in proper working condition. Unauthorized modifications to the machine may impair the function and/or safety and affect machine life.

If you do not understand any part of this manual and need assistance, contact your John Deere dealer.

DX,RCAP –19–04JUN90–1/1

TS281 –UN–23AUG88

TS201 –UN–23AUG88

DX,READ –19–03MAR93–1/1

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Safety

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.

Construct Dealer-Made Tools Safely

01 000 9

TS779 –UN–08NOV89

DX,REPAIR –19–17FEB99–1/1

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.

LX1016749 –UN–01JUL97

DX,SAFE,TOOLS –19–10OCT97–1/1

CTM502 (31MAY07) 01-000-9 4.5 & 6.8 L Level 16 Electronic Fuel System

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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.

Understand Signal Words

A signal word—DANGER, WARNING, or CAUTION—is used with the safety-alert symbol. DANGER identifies the most serious hazards.

DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs. CAUTION also calls attention to safety messages in this manual.

TS218 –UN–23AUG88

DX,SERV –19–17FEB99–1/1

TS187 –19–30SEP88

DX,SIGNAL –19–03MAR93–1/1

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Replace Safety Signs

Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement.

Safety

01 000 11

Protect Against High Pressure Spray

Spray from high pressure nozzles can penetrate the skin and cause serious injury. Keep spray from contacting hands or body.

If an accident occurs, see a doctor immediately. Any high pressure spray 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.

DX,SIGNS1 –19–04JUN90–1/1

TS201 –UN–23AUG88

TS1343 –UN–18MAR92

DX,SPRAY –19–16APR92–1/1

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.

CTM502 (31MAY07) 01-000-11 4.5 & 6.8 L Level 16 Electronic Fuel System

DX,TORCH –19–10DEC04–1/1

TS953 –UN–15MAY90

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000

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.

Wait Before Opening High-Pressure Fuel System

Safety

TS206 –UN–23AUG88

DX,WEAR –19–10SEP90–1/1

High-pressure fluid remaining in fuel lines can cause serious injury. Only technicians familiar with this type of system should perform repairs. Before disconnecting fuel lines, sensors, or any other components between the high-pressure fuel pump and nozzles on engines with High Pressure Common Rail (HPCR) fuel system, wait a minimum of 15 minutes after engine is stopped.

DX,WW,HPCR2 –19–07JAN03–1/1

TS1343 –UN–18MAR92

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Safety

Handle Agricultural Chemicals Safely

Chemicals used in agricultural applications such as fungicides, herbicides, insecticides, pesticides, rodenticides, and fertilizers can be harmful to your health or the environment if not used carefully.

Always follow all label directions for effective, safe, and legal use of agricultural chemicals.

Reduce risk of exposure and injury:

• Wear appropriate personal protective equipment as

recommended by the manufacturer. In the absence of

manufacturer’s instructions, follow these general

guidelines:

– Chemicals labeled ’Danger’: Most toxic. Generally

require use of goggles, respirator, gloves, and skin protection.

– Chemicals labeled ’Warning’: Less toxic. Generally

require use of goggles, gloves, and skin protections.

– Chemicals labeled ’Caution’: Least toxic. Generally

require use of gloves and skin protection.

• Avoid inhaling spray or dusts.

• Always have soap, water, and towel available when

working with chemicals. If chemical contacts skin,

hands, or face, wash immediately with soap and water.

If chemical gets into eyes, flush immediately with water.

• Wash hands and face after using chemicals and before

eating, drinking, smoking, or urination.

• Do not smoke or eat while applying chemicals.

• After handling chemicals, always bathe or shower and

change clothes. Wash clothing before wearing again.

• Seek medical attention immediately if illness occurs

during or shortly after use of chemicals.

• Keep chemicals in original containers. Do not transfer

chemicals to unmarked containers or to containers used

for food or drink.

• Store chemicals in a secure, locked area way from

human or livestock food. Keep children away.

• Always dispose of containers properly. Triple rinse

empty containers and puncture or crush containers and

dispose of properly.

01 000 13

TS220 –UN–23AUG88A34471 –UN–11OCT88

CTM502 (31MAY07) 01-000-13 4.5 & 6.8 L Level 16 Electronic Fuel System

DX,WW,CHEM01 –19–05APR04–1/1

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000

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

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. Using 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.

Explosion

TS204 –UN–23AUG88

If acid is swallowed:

1. Do not induce vomiting.

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

Acid

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.

DPSG,OUO1004,2758 –19–23JAN07–1/1

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TS203 –UN–23AUG88

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Safety

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.

01 000 15

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

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OUO1083,00005FF –19–22DEC05–1/1

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000

Safety

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Engine Serial Number Plate Information

Group 001

Engine Identification

01 001 1

RG7778 –UN–11NOV97

A—Engine Serial Number Plate B—Engine Serial Number (13 C—Application Data or Type D—Internal Factory

IMPORTANT: The engine serial number plate can

be easily destroyed. Remove the plate or record the information elsewhere, before “hot tank”

digits) Identification (Saran

Each engine has a 13-digit John Deere engine serial number identifying the producing factory, engine displacement, emission “Tier” level and sequential engine number. The following is an example:

Engine Serial Number/Application Data Plate

engines only)

cleaning the block.

Engine Serial Number (B)

CD6068L123456

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

6 ................................................................ Number of Cylinders

068 ............................................................ Liter displacement (6.8 liters)

L ................................................................ Emission Tier Level

123456 ...................................................... 6-digit sequential engine number

Factory Producing Engine

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

JO ............................................................. Rosario, Argentina

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

Emission Tier Level

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

CD30857 –UN–21AUG06

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. The following is an example:

CTM502 (31MAY07) 01-001-1 4.5 & 6.8 L Level 16 Electronic Fuel System

Continued on next page

CD03523,000016E –19–04MAY07–1/2

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Engine Identification

001

6068HF285

6 ................................................................ Number of Cylinders

068 ............................................................ Liter displacement (6.8 liters)

H ............................................................... Aspiration code

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

285 ............................................................ Application code

Aspiration code

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

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

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

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

User Factory Code

AP ............................................................. Industries JohnDeere Mexico S.A. de C.V. (Saltillo/Monterrey, Mexico)

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

BE ............................................................. Bell EquipmnetCo. (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

FS ............................................................. SDMO Applications

FU ............................................................. Power Unit for Generator Set

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

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

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

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

285 etc. ................................................... This is the specific engine model for a given application. In this example (285), “2” denotes

CTM502 (31MAY07) 01-001-2 4.5 & 6.8 L Level 16 Electronic Fuel System

2-valves per cylinder and “85” denotes Tier 3 engines.

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OEM Engine Option Code Label

Engine Identification

01 001 3

OEM Engine Option Code Label

A—Engine Base Code

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

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.

CD30858 –UN–21AUG06

option codes is given in parts catalogs and operator’s manuals.

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

codes are recorded elsewhere.

CD03523,000016F –19–21AUG06–1/1

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:

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

CTM502 (31MAY07) 01-001-3 4.5 & 6.8 L Level 16 Electronic Fuel System

• Fuel injection system

• Intake manifold

• Turbocharger

• Charge air cooling system

• Piston

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001

Emissions Control System Certification Label

Engine Identification

6.8L Engine Emissions Label

CAUTION: Statutes providing severe penalties for tampering with emissions controls may apply at the user’s location.

The emissions warranty described below applies only to those engines marketed by John Deere that have been certified by the United States Environmental Protection Agency (EPA) and/or California Air Resources Board (CARB); and used in the United States and Canada. The presence of an emissions label like the one shown signifies that the engine has been certified with the EPA and/or CARB. The EPA and CARB warranties only apply to new engines

RG14852 –UN–26APR06

having the certification label affixed to the engine and sold as stated above in the geographic areas. The presence of an EU number in the third line of the label signifies that the engine has been certified with the European Union countries per Directive 97/68/EC. The emissions warranty does not apply to the EU countries.

NOTE: The hp/kW rating on the engine emissions

certification label specifies the gross engine hp/kW, which is flywheel power without fan. In most applications this will not be the same rating as the advertised vehicle hp/kW rating.

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Engine Identification

Engine Application Charts

This component technical manual (CTM502) covers repair and diagnosis of Level 16 Electronic Fuel System on PowerTech “E” 4.5 & 6.8 L engines produced by John Deere SARAN “CD” (France) and John Deere TORREON “PE” (Mexico). Refer to the chart below to know which applications are covered by this manual.

JOHN DEERE AGRICULTURAL EQUIPMENT

Machine Model Engine Model

6230 Advantage Tractor CD4045HL282

6230 Premium Tractor (North America) CD4045HL280

6330 Advantage Tractor CD4045HL283

6330 Premium Tractor (North America) CD4045HL281

6430 Advantage Tractor CD4045HL283

6430 Premium Tractor (North America) CD4045HL281

7130 Advantage Tractor CD6068HL280

7130 Premium Tractor (North America) PE6068HRW72

7230 Advantage Tractor CD6068HL280

7230 Premium Tractor (North America) PE6068HRW72

7330 Premium Tractor (North America) PE6068HRW74

1450 CWS Combine CD6068HCQ82

W330 Combine CD6068HCQ82

NOTE: Information on how to remove and reinstall the

Tractor

Combine

01 001 5

engine in the vehicle is contained in the relevant machine Technical Manual.

JOHN DEERE CONSTRUCTION and FORESTRY EQUIPMENT

Machine Model Engine Model

Backhoe, Loader

444J Loader PE4045HDW53

544J Loader PE4045HDW70

Crawler Dozer, Crawler Loader

700J Crawler Dozer PE6068HT066

750J Crawler Dozer PE6068HT063

Excavator

160DLC Excavator PE4045HT056

200DLC Excavator PE6068HT069

CTM502 (31MAY07) 01-001-5 4.5 & 6.8 L Level 16 Electronic Fuel System

Continued on next page

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Engine Identification

001

Engine Model Application

4045TF285

4045HF285

4045HF279 Generator set

4045HFS73 Generator set

4045HFS82 Generator set

4045HFS83 Generator set

4045HFU79 Generator set

6086HF285

6068HF279 Generator set

6068HFS73 Generator set

6068HFS82 Generator set

6068HFS83 Generator set

6068HFU79 Generator set

JOHN DEERE OEM (OUTSIDE EQUIPMENT MANUFACTURERS)

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Diesel Fuel

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

Group 002

Fuels, Lubricants, and Coolant

01 002 1

scar diameter of 0.45 mm as measured by ASTM D6079 or ISO 12156-1.

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 shall 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 level of 3100 grams as measured by ASTM D6078 or maximum

Sulfur content:

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

• Use of diesel fuel with sulfur content less than

0.10% (1000 ppm) is STRONGLY recommended.

• Use of diesel fuel with sulfur content 0.10% (1000 ppm to 0.50% (5000 ppm) may result in REDUCED oil and filter change intervals.

• BEFORE using diesel fuel with sulfur content greater than 0.50% (5000 ppm), contact your John Deere dealer.

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

IMPORTANT: Do not mix used diesel engine oil or

any other type of lubricating oil with diesel fuel.

IMPORTANT: Improper fuel additive usage may

cause damage on fuel injection equipment of diesel engines.

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002

Bio-Diesel Fuel

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

Fuels, Lubricants, and Coolant

leaving deposits on injectors and in the combustion chamber.

Bio-diesel fuels may be used ONLY if the bio-diesel fuel properties meet the latest edition of ASTM D6751, EN 14214, or equivalent specification.

It is recommended to purchase bio-diesel fuel blended with B100 from a BQ-9000 Accredited Producer or a BQ-9000 Certified Marketer as recommended by the National Bio-diesel Board.

The maximum allowable bio-diesel concentration is a 5% blend (also known as B5) in petroleum diesel fuel. It has been found that bio-diesel fuels may improve lubricity in concentrations up to this 5% blend.

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 oil becomes diluted with fuel, shorten oil change intervals accordingly.

IMPORTANT: Raw pressed vegetable oils are NOT

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

These oils do not burn completely, and will cause engine failure by

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

Consult your fuel supplier for additives to improve storage and performance of bio-diesel fuels.

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