John Deere PowerTech 4.5 L and 6.8 L Non-Certified and Tier 1 Certified OEM Diesel Engines Official Operators Manual
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OMRG25204 Issue 02Nov06 (ENGLISH)
Record Keeping
Instrument (Gauge) Panel (North America). …….15-2
PowerTech Medallion . …………………………………01-1
VDO Instrument (Gauge) Panel (Except
Engine Serial Number Plate . ………………………..01-1
North America) . ………………………………………15-4
Record Engine Serial Number . …………………….01-2
Engine Break-In Service . ……………………………..15-6
Engine Option Codes . …………………………………01-3
Auxiliary Gear Drive Limitations . …………………..15-9
Record Fuel Injection Pump Model Number . …..01-5
Generator Set (Standby) Applications. ……………15-9
Starting the Engine. …………………………………..15-10
Warming Engine . ………………………………………15-12
Safety . …………………………………………………….05-1
Normal Engine Operation . ………………………….15-13
Cold Weather Operation . ……………………………15-14
Fuels, Lubricants, and Coolant
Changing Engine Speed. ……………………………15-15
Diesel Fuel . ……………………………………………….10-1
Avoid Excessive Engine Idling . …………………..15-15
Lubricity of Diesel Fuel . ……………………………….10-1
Stopping the Engine . …………………………………15-16
Handling and Storing Diesel Fuel . …………………10-2
Using a Booster Battery or Charger . ……………15-17
Testing Diesel Fuel. …………………………………….10-2
Bio-Diesel Fuel . ………………………………………….10-3
Lubrication and Maintenance
Aviation (Jet) Fuels. …………………………………….10-4
Burner Fuels. ……………………………………………..10-4
Observe Service Intervals. ……………………………20-1
Minimizing the Effect of Cold Weather on
Lubrication and Maintenance Service
Diesel Engines . ………………………………………10-5
Interval Chart—Standard Industrial Engines . . 20-2
Diesel Engine Break-In Oil . ………………………….10-6
Lubrication and Maintenance Service
Diesel Engine Oil . ………………………………………10-7
Interval Chart—Generator (Standby)
Extended Diesel Engine Oil Service Intervals . . . 10-8
Applications . ………………………………………….20-4
Mixing of Lubricants . …………………………………..10-8
Use Correct Fuels, Lubricants, and Coolant . …..20-1
OILSCANand COOLSCAN . …………………….10-9
Lubrication & Maintenance/Daily
Alternative and Synthetic Lubricants . ……………..10-9
Daily Prestarting Checks . ……………………………25-1
Lubricant Storage . …………………………………….10-10
Oil Filters . ……………………………………………….10-10
Grease . …………………………………………………..10-11
Lubrication & Maintenance/250 Hour/6 Month
Diesel Engine Coolant . ……………………………..10-12
Servicing Fire Extinguisher . ………………………….30-1
Drain Intervals for Diesel Engine Coolant . …..10-13
Changing Engine Oil and Replacing Filter . …….30-2
Additional Information About Diesel
Checking Engine Mounts . ……………………………30-4
Engine Coolants and Supplemental Coolant
Servicing Battery . ………………………………………30-5
Additives . ……………………………………………..10-14
Manual Belt Tensioner Adjustment . ……………….30-7
Supplemental Coolant Additives . …………………10-15
Manual Belt Tensioner Adjustment Using
Additional Information About Diesel
Belt Tension Tool (Alternate Method
Engine Coolants and Supplemental Coolant
For Engines Without Auxiliary Drive) . ………….30-8
Additives . ……………………………………………..10-16
Testing Diesel Engine Coolant . …………………..10-17
Lubrication & Maintenance/500 Hour/12 Month
Operating in Warm Temperature Climates . …..10-18
Cleaning Crankcase Vent Tube . …………………..35-1
Disposing of Coolant . ……………………………….10-18
Checking Air Intake System . ………………………..35-2
Replacing Fuel Filter Element (Single Filter). …..35-3
Engine Operating Guidelines
Instrument (Gauge) Panels. ………………………….15-1
Replacing Fuel Filter Elements (Dual Filters) . . . 35-5
Specifications
General OEM Engine Specifications—4.5 L
Checking Belt Tensioner Spring Tension
and Belt Wear (Automatic Tensioner) . ………..35-6
Engines. …………………………………………………60-1
Checking Engine Speeds . ……………………………35-9
Checking Engine Electrical Ground
General OEM Engine Specifications—6.8 L
Engines. …………………………………………………60-2
Connections . ………………………………………….35-9
Engine Power Ratings And Fuel Injection
Checking Cooling System. ………………………….35-10
Pump Specifications . ……………………………….60-3
Replenishing Supplemental Coolant
Additives (SCAs) Between Coolant
Engine Crankcase Oil Fill Quantities . ………….60-11
Unified Inch Bolt and Screw Torque Values . . . 60-15
Metric Bolt and Screw Torque Values. ………….60-16
Changes . ……………………………………………..35-11
Testing Diesel Engine Coolant . …………………..35-12
Pressure Testing Cooling System. ……………….35-13
Lubrication and Maintenance Records
Using Lubrication and Maintenance Records . . . 65-1
Daily (Prestarting) Service . ………………………….65-1
Lubrication & Maint./2000 Hour/24 Month
250 Hour/6 Month Service . ………………………….65-2
Adjusting Variable Speed (Droop) on
500 Hour/12 Month Service . ………………………..65-3
Generator Set Engines . ……………………………40-1
Checking Crankshaft Vibration Damper
2000 Hour/24 Month Service . ………………………65-4
(6-Cylinder Engine Only) . ………………………….40-3
Service as Required . …………………………………..65-5
Flushing and Refilling Cooling System . ………….40-4
Emission System Warranty
Testing Thermostats Opening Temperature . …..40-7
U.S. EPA Emissions Control Warranty
Check and Adjust Valve Clearance . ……………40-10
Statement . ……………………………………………..70-1
Emissions Control System Certification Label . . . 70-1
Service as Required
Additional Service Information . …………………….45-1
Do Not Modify Fuel System . ………………………..45-1
Adding Coolant. ………………………………………….45-2
Replacing Single Stage Air Cleaner . ……………..45-3
Replacing Axial Seal Air Cleaner Filter
Element . ……………………………………………….45-4
Replacing Radial Seal Air Cleaner Filter
Element . ……………………………………………….45-6
Replacing Fan and Alternator Belts . ……………..45-8
Checking Fuses In Instrument Panels . ………….45-9
Checking Air Compressors . ………………………..45-10
Bleeding the Fuel System. ………………………….45-11
Troubleshooting
General Troubleshooting Information . ……………50-1
Engine Wiring Diagram Legend
(Standard Instrument Panel For North
America) . ……………………………………………….50-3
Wiring Diagram (Standard Instrument
Panel For North America) . ………………………..50-4
Engine Wiring Diagram—VDO
Instrument Panel (Except North America) . …..50-5
Engine Wiring Diagram Legend—VDO
Instrument Panel (Except North America) . …..50-6
Engine Troubleshooting . ……………………………..50-7
Storage
Engine Storage Guidelines . ………………………….55-1
Preparing Engine for Long Term Storage . ………55-2
Removing Engine from Long Term Storage . …..55-3
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