P OWERT ECH 4.5L & 6.8L Diesel Engines Level 12 Electronic Fuel System With Stanadyne DE10 Pump TECHNICAL MANUAL POWERT ECH 4.5 L & 6.8 L Diesel Engines—Level 12 Electronic Fuel System with DE10 Pump 03OCT05 (ENGLISH) For complete service information also see: POWERTECH 4.5 L and 6.8 L Diesel Engines—Base Engine ................. CTM104 Alternators and Starter Motors ........... CTM77 OEM Engine Accessories ...... CTM67 (English Only) John Deere Power Systems LITHO IN U.S.A.
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POWERTECH 4.5L & 6.8LDiesel Engines
Level 12 ElectronicFuel System With
Stanadyne DE10 Pump
TECHNICAL MANUALPOWERTECH 4.5 L & 6.8 L Diesel
Engines—Level 12 Electronic FuelSystem with DE10 Pump
This manual is written for an experienced technician.Essential tools required in performing certain servicework are identified in this manual and arerecommended for use.
This manual (CTM331) covers only Level 12 ElectronicFuel System with the Stanadyne DE10 injection pump.It is one of five volumes on 4.5 L and 6.8 L engines.The following four companion manuals cover the baseengine, mechanical fuel system, level 4 electronic fuelsystem and level 1 electronic fuel system repair,operation and diagnostics:
• CTM104—Base Engine• CTM170—Level 4 Electronic Fuel System with
Bosch VP44 Pump• CTM207—Mechanical Fuel Systems• CTM284—Level 1 Electronic Fuel Systems with
Delphi (Lucas) DP201 Pump
Other manuals will be added in the future to provideadditional information on electronic fuel systems asneeded.
Live with safety: Read the safety messages in theintroduction of this manual and the cautions presentedthroughout the text of the manual.
This is the safety-alert symbol. When you see thissymbol on the machine or in this manual, be alert tothe potential for personal injury.
Use this component technical manual in conjunctionwith the machine technical manual. An applicationlisting in Section 01, Group 001 identifiesproduct-model/component type-model relationship. Seethe machine technical manual for information on
component removal and installation, and gainingaccess to the components.
Information is organized in sections and groups for thevarious components requiring service instruction.Section 05 summarizes all applicable essential tools,service equipment and tools, other materials needed todo the job, and service parts kits. Section 06summarizes all specifications, wear tolerances, andtorque values.
Before beginning diagnosis or repair on an engine,clean the engine.
This manual contains SI Metric units of measurefollowed immediately by the U.S. customary units ofmeasure. Most hardware on these engines is metricsized.
Some components of this engine may be servicedwithout removing the engine from the machine. Referto the specific machine technical manual forinformation on components that can be servicedwithout removing the engine from the machine and forengine removal and installation procedures.
Read each block of material completely beforeperforming service to check for differences inprocedures or specifications. Follow only theprocedures that apply to the engine model number youare working on. If only one procedure is given, thatprocedure applies to all the engines in the manual.
CALIFORNIA PROPOSITION 65 WARNINGDiesel engine exhaust and some of its constituentsare known to the State of California to causecancer, birth defects and other reproductive harm.
CTM331 (03OCT05) 4.5 L & 6.8 L Level 12 Electronic Fuel System012506
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Introduction
DPSG,OUO1004,129 –19–15MAY98–1/1
POWERTECH 4.5 L Engine with Level 12 Electronic Fuel System and Stanadyne DE10Pump
RG
1193
1–U
N–0
6NO
V01
Right Side of Engine
RG
1193
2–U
N–0
6NO
V01
Left Side of Engine
POWERTECH is a registered trademark of Deere & Company
CTM331 (03OCT05) 4.5 L & 6.8 L Level 12 Electronic Fuel System012506
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Introduction
CTM331 (03OCT05) 4.5 L & 6.8 L Level 12 Electronic Fuel System012506
All information, illustrations and specifications in this manual are based onthe latest information available at the time of publication. The right isreserved to make changes at any time without notice.
06
COPYRIGHT 2002DEERE & COMPANY
Moline, IllinoisAll rights reserved
A John Deere ILLUSTRUCTION Manual
INDX
CTM331 (03OCT05) i 4.5 L & 6.8 L Level 12 Electronic Fuel System012506
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CTM331 (03OCT05) 01-1 4.5 L & 6.8 L Level 12 Electronic Fuel System012506
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Contents
01
CTM331 (03OCT05) 01-2 4.5 L & 6.8 L Level 12 Electronic Fuel System012506
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Group 000Safety
010001
DX,FLAME –19–29SEP98–1/1
Handle Fluids Safely—Avoid Fires
TS
227
–UN
–23A
UG
88
When you work around fuel, do not smoke or work nearheaters or other fire hazards.
Store flammable fluids away from fire hazards. Do notincinerate or puncture pressurized containers.
Make sure machine is clean of trash, grease, and debris.
Do not store oily rags; they can ignite and burnspontaneously.
DX,FIRE3 –19–16APR92–1/1
Handle Starting Fluid Safely
TS
1356
–UN
–18M
AR
92
Starting fluid is highly flammable.
Keep all sparks and flame away when using it. Keepstarting fluid away from batteries and cables.
To prevent accidental discharge when storing thepressurized can, keep the cap on the container, and storein a cool, protected location.
Do not incinerate or puncture a starting fluid container.
DX,FIRE2 –19–03MAR93–1/1
Prepare for Emergencies
TS
291
–UN
–23A
UG
88
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service,hospital, and fire department near your telephone.
CTM331 (03OCT05) 01-000-1 4.5 L & 6.8 L Level 12 Electronic Fuel System012506
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Safety
01000
2
DX,FLUID –19–03MAR93–1/1
Avoid High-Pressure Fluids
X98
11–U
N–2
3AU
G88
Escaping fluid under pressure can penetrate the skincausing serious injury.
Avoid the hazard by relieving pressure beforedisconnecting hydraulic or other lines. Tighten allconnections before applying pressure.
Search for leaks with a piece of cardboard. Protect handsand body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluidinjected into the skin must be surgically removed within afew hours or gangrene may result. Doctors unfamiliar withthis type of injury should reference a knowledgeablemedical source. Such information is available from Deere& Company Medical Department in Moline, Illinois, U.S.A.
DX,WEAR –19–10SEP90–1/1
Wear Protective Clothing
TS
206
–UN
–23A
UG
88
Wear close fitting clothing and safety equipmentappropriate to the job.
Prolonged exposure to loud noise can cause impairmentor loss of hearing.
Wear a suitable hearing protective device such asearmuffs or earplugs to protect against objectionable oruncomfortable loud noises.
Operating equipment safely requires the full attention ofthe operator. Do not wear radio or music headphoneswhile operating machine.
CTM331 (03OCT05) 01-000-2 4.5 L & 6.8 L Level 12 Electronic Fuel System012506
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Safety
010003
DX,LOOSE –19–04JUN90–1/1
Service Machines Safely
TS
228
–UN
–23A
UG
88
Tie long hair behind your head. Do not wear a necktie,scarf, loose clothing, or necklace when you work nearmachine tools or moving parts. If these items were to getcaught, severe injury could result.
Remove rings and other jewelry to prevent electricalshorts and entanglement in moving parts.
DX,AIR –19–17FEB99–1/1
Work In Ventilated Area
TS
220
–UN
–23A
UG
88
Engine exhaust fumes can cause sickness or death. If it isnecessary to run an engine in an enclosed area, removethe exhaust fumes from the area with an exhaust pipeextension.
If you do not have an exhaust pipe extension, open thedoors and get outside air into the area
DX,CLEAN –19–04JUN90–1/1
Work in Clean Area
T66
42E
J–U
N–1
8OC
T88
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.
CTM331 (03OCT05) 01-000-3 4.5 L & 6.8 L Level 12 Electronic Fuel System012506
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Safety
01000
4
DX,PAINT –19–24JUL02–1/1
Remove Paint Before Welding or Heating
TS
220
–UN
–23A
UG
88
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heatedby welding, soldering, or using a torch.
Remove paint before heating:
• Remove paint a minimum of 100 mm (4 in.) from areato 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 withsoap and water before welding. Remove solvent orpaint stripper containers and other flammable materialfrom area. Allow fumes to disperse at least 15 minutesbefore welding or heating.
Do not use a chlorinated solvent in areas where weldingwill take place.
Do all work in an area that is well ventilated to carry toxicfumes and dust away.
Dispose of paint and solvent properly.
DX,TORCH –19–10DEC04–1/1
Avoid Heating Near Pressurized Fluid Lines
TS
953
–UN
–15M
AY
90Flammable spray can be generated by heating nearpressurized fluid lines, resulting in severe burns toyourself and bystanders. Do not heat by welding,soldering, or using a torch near pressurized fluid lines orother flammable materials. Pressurized lines canaccidentally burst when heat goes beyond the immediateflame area.
CTM331 (03OCT05) 01-000-4 4.5 L & 6.8 L Level 12 Electronic Fuel System012506
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Safety
010005
DX,LIGHT –19–04JUN90–1/1
Illuminate Work Area Safely
TS
223
–UN
–23A
UG
88
Illuminate your work area adequately but safely. Use aportable safety light for working inside or under themachine. Make sure the bulb is enclosed by a wire cage.The hot filament of an accidentally broken bulb can ignitespilled fuel or oil.
DX,SAFE,TOOLS –19–10OCT97–1/1
Construct Dealer-Made Tools Safely
LX10
1674
9–U
N–0
1JU
L97
Faulty or broken tools can result in serious injury. Whenconstructing tools, use proper, quality materials, and goodworkmanship.
Do not weld tools unless you have the proper equipmentand experience to perform the job.
CTM331 (03OCT05) 01-000-5 4.5 L & 6.8 L Level 12 Electronic Fuel System012506
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Safety
01000
6
DX,SERV –19–17FEB99–1/1
Practice Safe Maintenance
TS
218
–UN
–23A
UG
88
Understand service procedure before doing work. Keeparea clean and dry.
Never lubricate, service, or adjust machine while it ismoving. Keep hands, feet , and clothing frompower-driven parts. Disengage all power and operatecontrols to relieve pressure. Lower equipment to theground. Stop the engine. Remove the key. Allow machineto cool.
Securely support any machine elements that must beraised for service work.
Keep all parts in good condition and properly installed. Fixdamage immediately. Replace worn or broken parts.Remove any buildup of grease, oil, or debris.
On self-propelled equipment, disconnect battery groundcable (-) before making adjustments on electrical systemsor welding on machine.
On towed implements, disconnect wiring harnesses fromtractor before servicing electrical system components orwelding on machine.
DX,REPAIR –19–17FEB99–1/1
Use Proper Tools
TS
779
–UN
–08N
OV
89Use tools appropriate to the work. Makeshift tools andprocedures can create safety hazards.
Use power tools only to loosen threaded parts andfasteners.
For loosening and tightening hardware, use the correctsize tools. DO NOT use U.S. measurement tools onmetric fasteners. Avoid bodily injury caused by slippingwrenches.
Use only service parts meeting John Deere specifications.
CTM331 (03OCT05) 01-000-6 4.5 L & 6.8 L Level 12 Electronic Fuel System012506
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Safety
010007
DX,DRAIN –19–03MAR93–1/1
Dispose of Waste Properly
TS
1133
–UN
–26N
OV
90
Improperly disposing of waste can threaten theenvironment and ecology. Potentially harmful waste usedwith John Deere equipment include such items as oil, fuel,coolant, brake fluid, filters, and batteries.
Use leakproof containers when draining fluids. Do not usefood or beverage containers that may mislead someoneinto drinking from them.
Do not pour waste onto the ground, down a drain, or intoany water source.
Air conditioning refrigerants escaping into the air candamage the Earth’s atmosphere. Government regulationsmay require a certified air conditioning service center torecover and recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of wastefrom your local environmental or recycling center, or fromyour John Deere dealer.
DX,LIVE –19–25SEP92–1/1
Live With Safety
TS
231
–19–
07O
CT
88
Before returning machine to customer, make suremachine is functioning properly, especially the safetysystems. Install all guards and shields.
CTM331 (03OCT05) 01-000-7 4.5 L & 6.8 L Level 12 Electronic Fuel System012506
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Safety
01000
8
CTM331 (03OCT05) 01-000-8 4.5 L & 6.8 L Level 12 Electronic Fuel System012506
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Group 001Engine Identification
010011
OUO1080,00001FA –19–15NOV01–1/1
Engine Model Designation
John Deere Engine Model—4045 and 6068 Engines
John Deere engine model designation includes number ofcylinders, displacement in liters, aspiration, user code, andapplication code. For example:
4045TF275 Engine4 ................................................................ Number of cylinders4.5 ............................................................. Liter displacementT ............................................................... Aspiration codeF ............................................................... User code275 ............................................................ POWERTECH application codeAspiration CodeD ............................................................... Naturally aspiratedT ............................................................... Turbocharged, no aftercoolingA ............................................................... Turbocharged and Air-to-Coolant AftercooledH ............................................................... Turbocharged and Air-to-Air AftercooledUser Factory CodeAP Industries John Deere Mexica S. A de C. V. (Saltillo/Monterrey, MexicoAT ............................................................. Agritalia srl (Vittoria, Sicily, Italy)BE Bell Equipment Co. (Richards Bay, South Africa)CQ ............................................................ John Deere Brazil (Horizontina, Brazil)DW ............................................................ John Deere Davenport Works (Davenport, Iowa)E ............................................................... John Deere Ottumwa Works (Ottumwa, Iowa)F ............................................................... OEM (Outside Equipment Manufacturers)FF ............................................................. Deere-Hitachi (Kernersville, North Carolina)FG ............................................................. Goldoni S.P.A. (Modena, Italy)FM ............................................................ Marine EnginesH ............................................................... John Deere Harvester Works (East Moline, Illinois)KV ............................................................. John Deere Commercial Worksite Products (Knoxville, Tennessee)L ................................................................ John Deere Werke Mannheim (Germany)LA ............................................................. John Deere Werke Mannheim (Germany) (Engines with Bosch VP44 Injection Pump)LV ............................................................. John Deere Commercial Products (Augusta, Georgia)N ............................................................... John Deere Des Moines Works (Des Moines, Iowa)P ............................................................... Industrias John Deere Mexico S.A. de C.V. (Saltillo/Monterrey, Mexico)PY ............................................................. Larson & Toubro Ltd. (Pune, India)RW ............................................................ John Deere Waterloo Tractor Works (Waterloo, Iowa)T ............................................................... John Deere Dubuque Works (Dubuque, Iowa)T8 ............................................................. Cameco Industries (Thibodaux, Louisiana)TJ .............................................................. John Deere Forestry (Timberjack) (Sweden/Finland/Canada)YC ............................................................. John Deere Jialian Harvester Co. Limited (China)Z ............................................................... John Deere WERKE Zweibrucken (Germany)Application Code001, etc. .................................................... See ENGINE APPLICATION CHARTS, later in this Group
POWERTECH is a registered trademark of Deere & Company
CTM331 (03OCT05) 01-001-1 4.5 L & 6.8 L Level 12 Electronic Fuel System012506
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Engine Identification
01001
2
OUO1080,00001FB –19–15NOV01–1/1
Engine Serial Number Plate Information
RG
1181
6–U
N–1
5NO
V01
Engine Serial Number Plate
RG
9060
–UN
–16M
AR
98
Dubuque Engine Serial Number Plate
RG
1194
9–U
N–0
7NO
V01
Saran Engine Serial Number Plate
RG
1194
8–U
N–0
6NO
V01
Torreon Engine Serial Number Plate
A—Engine Serial Number PlateB—Engine Serial NumberC—Engine Application DataD—Coefficient of Absorption (Saran Engines Only)
IMPORTANT: The engine serial number plate (A) canbe easily destroyed. Before “hot tank”cleaning the block, remove the plate.
Engine Serial Number (B)
Each engine has a 13-digit John Deere engine serialnumber identifying the producing factory, engine modeldesignation, and a 6-digit sequential number. Thefollowing is an example:
CD4045T000000CD .......................... Factory producing engine4045T ..................... Engine model designation000000 ................... Sequential serial numberFactory Code (Engine Manufacturer)T0 ........................... Dubuque, IowaCD .......................... Saran, FrancePE .......................... Torreon, MexicoJ0 ........................... Rosario, ArgentinaEngine Model Designation4045T ..................... Definition explained previously. See ENGINE
MODEL DESIGNATION earlier in this group.Sequential Number000000 ................... 6-digit sequential serial number
Engine Application Data (C)
The second line of information on the serial number plateidentifies the engine/machine or OEM relationship. SeeENGINE APPLICATION CHARTS later in this group.
Coefficient of Absorption (D) — (Saran-Built EnginesOnly)
The second line of information on the Saran serial numberplate also contains the coefficient of absorption value forsmoke emissions.
CTM331 (03OCT05) 01-001-2 4.5 L & 6.8 L Level 12 Electronic Fuel System012506
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Engine Identification
010013
OUO1080,000020E –19–26NOV01–1/1
OEM Engine Option Code Label
RG
1202
7–U
N–0
3DE
C01
An option code label is secured to the top of the valvecover and identifies the factory installed options on eachOEM engine to ensure correct parts acquisition.
Always provide option code information and engine basecode when ordering repair parts. A listing of option codesis given in parts catalogs and operator’s manuals.
NOTE: Before “hot tank” cleaning, ensure that optioncodes are recorded elsewhere.
OUO1080,0000035 –19–29AUG01–1/1
Information Relative to Emissions Regulations
Depending on the final destination, engines can meetthe emissions regulations according to the USEnvironmental Protection Agency (EPA), California AirResources Board (CARB) and for Europe, theDirective 97/68/EC relating the measures against theemissions of particles and gaseous pollutant frominternal combustion engines. Such engines are called“CERTIFIED” and receive an emission label stuck onthe engine.
The regulations prohibit tampering with theemission-related components listed below which wouldrender that component inoperative or to make anyadjustment on the engine beyond publishedspecifications. It is also illegal to install a part or
component where the principle effect of thatcomponent is to bypass, defeat, or render inoperativeany engine component or device which would affectthe engine’s conformance to the emission regulations.To summarize, it is illegal to do anything exceptreturn the engine to its original publishedspecifications.