POWERTECH 4.5L & 6.8L Diesel Engines Mechanical Fuel …

1 POWERTECH & EnginesMechanical FuelSystemsTECHNICAL MANUALPOWERTECH L & L DieselEngines Mechanical FuelSystemsCTM207 06 OCT04 (ENGLISH)For complete service information also see: POWERTECH L and L DieselEngines Base and Starter Engine (English Only) POWERTECH L and L DieselEngines Level 4 Electronic Fuel Systemswith Bosch VP44 L and L DieselEngines Level 12 Electronic Fuel Systemswith Stanadyne DE10 L and L DieselEngines Level 1 Electronic Fuel Systemswith Delphi/Lucas DP201 L and L DieselEngines Level 11 Electronic Fuel Systemswith Denso High Pressure Common Rail..CTM220 john deere Power SystemsLITHO IN ,00014BA 19 19 AUG04 1/1 ForewordThis manual is written for an experienced tools required in performing certain servicework are identified in this manual and arerecommended for manual (CTM207) covers only Mechanical fuelsystems.

2 It is one of six volumes on L and Lengines. The following five companion manuals coverthe base engine plus electronic fuel system repair,operation and diagnostics: CTM104 Base Engine CTM170 Level 4 Electronic Fuel Systems withBosch VP44 Pump CTM331 Level 12 Electronic Fuel Systems withStanadyne DE10 Pump CTM284 Level 1 Electronic Fuel Systems withDelphi/Lucas DP201 Pump CTM220 Level 11 Electronic Fuel Systems withDenso High Pressure Common RailOther manuals will be added in the future to provideadditional information on electronic fuel systems with safety: Read the safety messages in theintroduction of this manual and the cautions presentedthroughout the text of the is the safety-alert symbol. When you see thissymbol on the machine or in this manual, be alert tothe potential for personal this component technical manual in conjunctionwith the machine technical manual.

3 An applicationlisting in Section 01, Group 001 identifiesproduct-model/component type-model relationship. Seethe machine technical manual for information oncomponent removal and installation, and gainingaccess to the is organized in sections and groups for thevarious components requiring service 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 beginning repair on an engine, clean the engineand mount on a repair manual contains SI Metric units of measurefollowed immediately by the customary units ofmeasure. Most hardware on these Engines is components of this engine may be servicedwithout removing the engine from the machine.

4 Referto the specific machine technical manual forinformation on components that can be servicedwithout removing the engine from the machine and forengine removal and installation 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 PROPOSITION 65 WARNINGD iesel engine exhaust and some of its constituentsare known to the State of California to causecancer, birth defects and other reproductive (06 OCT04) L & L Mechanical Fuel Systems100604PN=2 IntroductionOUO1032,00014C2 19 23 AUG04 1/1 john deere DealersDiscard CTM207 dated 17 SEP02 or 14 MAY03 andreplace with this new , copy this pagelisting changesto this newCTM207 and route through your Service 01 GROUP 001 (Engine Identification) Updated engine model designation chart.

5 Updated engine application 01 GROUP 002 (Fuels) Revised Diesel fuel specifications. Revised lubricity of Diesel fuel specifications. Added bio- Diesel fuel specifications. Added Dieselscan fuel analysis 02 GROUP 090 ( Mechanical FuelSystem Repair and Adjustments) Added note regarding substitution of longer fuel filterelements and addition of sediment bowls whenappropriate. Added remove and install procedure forDelphi/Lucas fuel shut-off solenoid. Added remove and install procedure forDelphi/Lucas cold start advance switch and harness. Revised inspection procedure for Stanadyneinjection pump drive gear ID and shaft OD. Revised Stanadyne DB2 fuel injection pump drivegear-to-shaft retaining nut torque specification. Revised repair instruction for Motorpal fuel injectionpumps.

6 Revised bleeding 03 GROUP 130 ( Mechanical FuelSystems Operation) Revised operational description of rotary fuel 04 GROUP 150 ( Mechanical FuelSystems Observable Diagnostics and Tests) Added warning statements regarding air, water, andcontaminants in fuel pump housings leading topremature pump failure. Revised specifications for supply pump pressuretests. Revised rotary pump cold start advance check torefer to new solenoid removal and installation storyin Section 02. Added warning statement to fuel injection nozzle testregarding fluids under pressure. Revised bleeding 05 (Tools and Other Materials) All essential tools, service tools, dealer fabricatedtools and other materials listed throughout thismanual are consolidated in this section for ease 06 (Specifications) All repair, test and diagnostic specifications listedthroughout this manual are consolidated in thissection for ease of (06 OCT04) L & L Mechanical Fuel Systems100604PN=3 IntroductionDPSG,OUO1004,129 19 09 SEP02 1/1 POWERTECH Engine with Mechanical Fuel SystemRG7636 UN 23 NOV973/4 Right Rear ViewRG7638 UN 23 NOV973/4 Left Rear ViewRG7639 UN 23 NOV973/4 Right Front ViewRG7637 UN 23 NOV973/4 Left Front ViewPOWERTECHis a registered trademark of deere & CompanyCTM207 (06 OCT04)

7 L & L Mechanical Fuel Systems100604PN=4 IntroductionDPSG,OUO1004,130 19 09 SEP02 1/1 POWERTECH Engine with Mechanical Fuel SystemRG7641 UN 23 NOV973/4 Right Front ViewRG7640 UN 23 NOV973/4 Left Front ViewRG7643 UN 23 NOV973/4 Right Rear ViewRG7642 UN 23 NOV973/4 Left Rear ViewPOWERTECHis a registered trademark of deere & CompanyCTM207 (06 OCT04) L & L Mechanical Fuel Systems100604PN=5 IntroductionCTM207 (06 OCT04) L & L Mechanical Fuel Systems100604PN=6 Contents01 SECTION 01 General InformationGroup 000 SafetyGroup 001 Engine Identification and ApplicationsGroup 002 Fuels02 SECTION 02 Repair and AdjustmentsGroup 090 Mechanical Fuel System Repair andAdjustmentsSECTION 03 Theory of OperationGroup 130 Mechanical Fuel Systems OperationSECTION 04 DiagnosticsGroup 150 Observable Diagnostics and TestsSECTION 05 Tools and Other Materials03 Group 170 Repair Tools and Other MaterialsGroup 180 Diagnostic Service Tools and OtherMaterialsGroup 190 Dealer Fabricated Service ToolsSECTION 06 SpecificationsGroup 200 Repair and General OEMS pecificationsGroup 210 Diagnostic Specifications0405 All information.

8 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 2004 deere & COMPANYM oline, IllinoisAll rights reservedA john deere ILLUSTRUCTION ManualPrevious EditionsCopyright 2000, 2002, 2003 INDXCTM207 (06 OCT04) L & L Mechanical Fuel Systems100604PN=1 Contents010203040506 INDXCTM207 (06 OCT04) L & L Mechanical Fuel Systems100604PN=201 Section 01 General InformationContentsPageGroup 000 001 Engine Identification and ApplicationsEngine Model Serial Number Plate Engine Option Code Application 002 FuelsLubricants and of Diesel Fuel (06 OCT04) L & L Mechanical Fuel Systems100604PN=1 Contents01 CTM207 (06 OCT04) L & L Mechanical Fuel Systems100604PN=2 Group 000 Safety010001DX,FLAME 19 29 SEP98 1/1 Handle Fluids Safely Avoid FiresTS227 UN 23 AUG88 When you work around fuel, do not smoke or work nearheaters or other fire flammable fluids away from fire hazards.

9 Do notincinerate or puncture pressurized sure machine is clean of trash, grease, and not store oily rags; they can ignite and ,FIRE3 19 16 APR92 1/1 Handle Starting Fluid SafelyTS1356 UN 18 MAR92 Starting fluid is highly all sparks and flame away when using it. Keepstarting fluid away from batteries and prevent accidental discharge when storing thepressurized can, keep the cap on the container, and storein a cool, protected not incinerate or puncture a starting fluid ,FIRE2 19 03 MAR93 1/1 Prepare for EmergenciesTS291 UN 23 AUG88Be prepared if a fire a first aid kit and fire extinguisher emergency numbers for doctors, ambulance service,hospital, and fire department near your (06 OCT04) L & L Mechanical Fuel Systems100604PN=11 Safety010002DX,FLUID 19 03 MAR93 1/1 Avoid High-Pressure FluidsX9811 UN 23 AUG88 Escaping fluid under pressure can penetrate the skincausing serious the hazard by relieving pressure beforedisconnecting hydraulic or other lines.

10 Tighten allconnections before applying for leaks with a piece of cardboard. Protect handsand body from high pressure 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, ,WEAR 19 10 SEP90 1/1 Wear Protective ClothingTS206 UN 23 AUG88 Wear close fitting clothing and safety equipmentappropriate to the exposure to loud noise can cause impairmentor loss of a suitable hearing protective device such asearmuffs or earplugs to protect against objectionable oruncomfortable loud equipment safely requires the full attention ofthe operator.