John Deere 4045 - Manual

John Deere 4045

John Deere 4045 – Manual, read for free online in PDF format. We hope this helps you resolve any issues you may have. If you have further questions, please contact us through the contact form.

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Table of Contents:

  • Page 2 – Introduction; Foreword
  • Page 3 – NOTE: This manual covers engines provided to OEM
  • Page 5 – Engine Owner
  • Page 9 – Contents; Record Keeping
  • Page 10 – Service as Required; ii
  • Page 11 – Emission System Warranty; iii
  • Page 12 – iv
  • Page 13 – Medallion; NOTE: Four-valve head engines also have “16V” or “24V”; Engine Serial Number Plate
  • Page 14 – Record Engine Serial Number
  • Page 15 – Engine Option Codes; NOTE: These option codes are based on the latest
  • Page 17 – Record Fuel Injection Pump Model Number
  • Page 18 – Safety; Recognize Safety Information
  • Page 19 – Replace Safety Signs; Avoid possible injury or death from engine runaway.; Handle Fuel Safely—Avoid Fires
  • Page 20 – Prepare for Emergencies; Be prepared if a fire starts.; Handle Starting Fluid Safely; Starting fluid is highly flammable.; Handle Fluids Safely—Avoid Fires
  • Page 21 – Service Engines Safely; Wear Protective Clothing
  • Page 22 – Handle Chemical Products Safely
  • Page 23 – Practice Safe Maintenance
  • Page 24 – Avoid High-Pressure Fluids
  • Page 25 – Remove Paint Before Welding or Heating; Avoid potentially toxic fumes and dust.; Service Cooling System Safely
  • Page 26 – Install Fan Guards; Rotating cooling system fans can cause serious injury.; Avoid Hot Parts
  • Page 27 – Avoid Harmful Asbestos Dust; Keep bystanders away from the area.; Prevent Battery Explosions
  • Page 28 – Use Proper Tools; Use only service parts meeting John Deere specifications.
  • Page 29 – Handling Batteries Safely; If you spill acid on yourself:
  • Page 30 – Protect Against High Pressure Spray
  • Page 31 – Diesel Fuel; Required fuel properties; F) or elevations above; IMPORTANT: Do not mix used diesel engine oil or; Lubricity of Diesel Fuel; IMPORTANT: Make sure the diesel fuel used in
  • Page 32 – Handling and Storing Diesel Fuel; Monitor water content of the fuel regularly.; IMPORTANT: The fuel tank is vented through the; Testing Diesel Fuel; DIESELSCAN
  • Page 33 – IMPORTANT: Raw pressed vegetable oils are NOT
  • Page 34 – Minimizing the Effect of Cold Weather on Diesel Engines; When temperatures fall below 5; NOTE: On an average, winter grade fuel has a lower
  • Page 35 – Radiator Shutters; Diesel Engine Break-In Oil; IMPORTANT: Do not use PLUS-50 oil or engine
  • Page 36 – Diesel Engine Oil; Multi-viscosity diesel engine oils are preferred.
  • Page 37 – Diesel Engine Oil and Filter Service Intervals; NOTE: The 500 hour extended oil and filter change
  • Page 39 – Mixing of Lubricants
  • Page 40 – Oil Filters; Always change filters regularly as specified in this manual.; OILSCAN
  • Page 41 – Use clean containers to handle all lubricants.
  • Page 42 – Grease; John Deere SD POLYUREA GREASE is preferred.
  • Page 43 – Diesel Engine Coolant; consult your John Deere dealer for recommendations.
  • Page 44 – Drain Intervals for Diesel Engine Coolant; When John Deere COOL-GARD
  • Page 45 – Supplemental Coolant Additives; IMPORTANT: Do not add a supplemental coolant; Testing Diesel Engine Coolant
  • Page 46 – Operating in Warm Temperature Climates; IMPORTANT: Water may be used as coolant; in; Disposing of Coolant
  • Page 47 – Instrument Panel Identification; Instrument Panels - Identification
  • Page 49 – Instrument Panel; This instrument panel for earlier; OEM Engines. These electronic
  • Page 50 – IMPORTANT: Any time an electric gauge or meter
  • Page 51 – Touch Switches
  • Page 52 – Key Start Switch
  • Page 53 – Bump Speed Enable Rocker Switch
  • Page 54 – Tachometer
  • Page 58 – Using Touch Switches to Display Information
  • Page 59 – Accessing the Menus; To scroll through the parameter list, press; either; the UP or DOWN touch switch.; simultaneously; press the UP and DOWN switches.; Selecting Engine Data Parameters
  • Page 60 – Changing Units of Measure (English or Metric); To select the
  • Page 63 – . The diagnostic gauge will
  • Page 64 – Service Code Sub-Menu; by pressing the UP or DOWN; NOTE: For a list of Service Codes or Diagnostic
  • Page 65 – by pressing the UP; DM2 Codes; The gauge will display the stored service
  • Page 66 – Instrument Panels; Later Tier 2 John Deere; OEM Engines
  • Page 69 – NOTE: Engine parameters which can be accessed will
  • Page 70 – Main Menu Navigation; NOTE: The engine does not need to be running to; Turn the key switch to the ON position. Starting at the
  • Page 71 – Pressing the right arrow key will scroll down to reveal; Use the arrow keys to scroll to the desired menu item; Engine Configuration Data; NOTE: The engine configuration data is a read only
  • Page 73 – to the engine parameter display.; Accessing Stored Trouble Codes
  • Page 75 – Accessing Active Trouble Codes; During normal operation the single or four parameter; When the diagnostic gauge receives a trouble code; IMPORTANT: Ignoring active trouble codes can result
  • Page 76 – To acknowledge and hide the code and return to the; The display will return to the single or four parameter
  • Page 77 – The single or four parameter screen will display the; Engine Shutdown Codes; When the diagnostic gauge receives a severe trouble; To acknowledge and hide the trouble code and return; IMPORTANT: Ignoring the shutdown message can
  • Page 78 – The display will return to the single or four parameter; The single or four parameter screen will display the; Adjusting Backlighting
  • Page 80 – Adjusting Contrast
  • Page 82 – Selecting Units Of Measurement
  • Page 83 – There are three choices for units of measurement,
  • Page 86 – Three options are available for modification of the 1-Up; a. Use Defaults – This option contains the following
  • Page 87 – The display parameters are reset to the factory; Custom Setup - To perform a custom setup of the
  • Page 89 – inclusion in the Single Engine Parameter Display.; Automatic Scan - Selecting the scan function will
  • Page 91 – return to the engine parameter display.; Turn the key switch to the ON position. From the single
  • Page 93 – To reset the display parameters to the factory defaults,; Custom Setup - To perform a custom setup of the
  • Page 94 – The quadrant with the highlighted parameter value is; The parameter that is highlighted is the selected
  • Page 95 – parameter in the quadrant to the new parameter.; The selected quadrant has now changed to the new
  • Page 96 – Repeat the parameter selection process until all
  • Page 101 – Engine Operation - Except 4.5L “270” Engines; Engine Break-In Service; This engine is factory-filled with John Deere ENGINE
  • Page 102 – IMPORTANT: DO NOT add makeup oil until the oil; Check engine oil level more frequently during engine; IMPORTANT: Do not use PLUS-50 oil or engine oils
  • Page 103 – During the first 20 hours, avoid prolonged periods of; NOTE: Some increase in oil consumption may be; coolant temperature rises above 112; NOTE: When the coolant temperature gauge reads; Check poly-vee belt for proper alignment and seating
  • Page 104 – Starting the Engine; NOTE: If temperature is below 0; Perform all prestarting checks outlined in Lubrication &
  • Page 105 – IMPORTANT: Do not operate the starter for more than
  • Page 106 – IMPORTANT: If the key switch is released before the; After engine starts, idle engine at not more than 1200; NOTE: Hand throttle may have an analog potentiometer
  • Page 107 – Normal Engine Operation; IMPORTANT: Should the engine die while
  • Page 108 – Warming Engine; IMPORTANT: To assure proper lubrication, operate; 5 psi) at rated full load speed; NOTE: On certain engines, the oil pressure and coolant
  • Page 109 – Cold Weather Operation; Starting aids are required below 0
  • Page 110 – Follow remaining steps 5—6 as listed under earlier in
  • Page 111 – Using a Booster Battery or Charger; IMPORTANT: Be sure polarity is correct before
  • Page 112 – Start the engine. Disconnect jumper cables; Avoid Excessive Engine Idling; NOTE: Generator set applications where the governor
  • Page 113 – Changing Engine Speed
  • Page 115 – The settings will not be stored.
  • Page 116 – Stopping The Engine; IMPORTANT: Before stopping an engine that has
  • Page 117 – Auxiliary Gear Drive Limitations; IMPORTANT: When attaching an air compressor,
  • Page 119 – During the first 20 hours, avoid prolonged periods of; Check poly-vee belt for proper alignment and seating
  • Page 120 – Change engine oil and oil filter after the first 100 hours; IMPORTANT: DO NOT operate engine when oil level
  • Page 121 – Starting The Engine
  • Page 122 – Warm-up engine for at least 5 minutes before applying
  • Page 123 – Cold Weather Starting
  • Page 126 – NOTE: Generator set applications where the governor is
  • Page 127 – Stopping the Engine; IMPORTANT: Stopping the engine immediately when; Reduce engine speed to slow idle (variable speed; IMPORTANT: Make sure that exhaust stack cap (rain; Fill fuel tank to minimize possible water condensation
  • Page 130 – Lubrication and Maintenance; Observe Service Intervals; IMPORTANT: Recommended service intervals are for; Use Correct Fuels, Lubricants, and Coolant
  • Page 135 – Daily Prestarting Checks
  • Page 136 – Check the coolant level when engine is cold. Coolant; NOTE: Refer to your vehicle’s operator’s manual for
  • Page 137 – NOTE: Engine may be equipped with a water sensor at; Check the fuel filters for water or debris. If filter is fitted; IMPORTANT: Drain water into a suitable container; c. When fuel starts to drain out, tighten drain plugs
  • Page 138 – If the air cleaner has an automatic dust unloader valve; IMPORTANT: Maximum air intake restriction is 6.25; Make a thorough inspection of the engine; NOTE: It is normal for a small amount of leakage to occur
  • Page 140 – Servicing Fire Extinguisher; Checking Engine Mounts; IMPORTANT: Use only Grade SAE 8 or higher grade; Inspect overall condition of vibration isolators, if
  • Page 141 – Servicing Battery; cell to bottom of filler neck with distilled water.; NOTE: Coat battery terminals and connectors with a; Keep battery fully charged, especially during cold
  • Page 143 – Manual Belt Tensioner Adjustment; NOTE: Two types of manual tensioners shown.; to remove all excess slack in belt.; IMPORTANT: Do not pry against alternator rear frame.; Stretch belt by prying outward on alternator front frame; Run engine for ten minutes and immediately re-check
  • Page 144 – NOTE: The JD1520 Belt Tension Tool may not be; and over alternator mounting screw.
  • Page 145 – Continue to hold tension with torque wrench and
  • Page 146 – Changing Engine Oil and Replacing Filter; IMPORTANT: 6-Cylinder engines with oil pan option
  • Page 147 – Drain crankcase oil from engine while warm.; NOTE: Drain plug location may vary, depending on the; NOTE: Depending on engine application, oil filter may be; Install and tighten oil filter by hand until firmly against
  • Page 148 – IMPORTANT: Immediately after completing any oil; Checking Crankcase Vent System
  • Page 149 – Closed Crankcase Ventilation System (If Equipped)
  • Page 150 – Checking Air Intake System; IMPORTANT: The air intake system must not leak.; Replace indicator as necessary.; IMPORTANT: If not equipped with air restriction
  • Page 151 – Replacing Fuel Filter Elements; Thoroughly clean fuel filter assemblies and surrounding; helps to get it past raised locators.; Inspect filter mounting base for cleanliness. Clean as
  • Page 152 – NOTE: Raised locators on fuel filter canisters must be; Install new filter elements onto mounting bases. Be; is heard and a release of the retaining ring is felt.
  • Page 153 – Checking Belt Wear
  • Page 154 – Checking Tensioner Spring Tension; Release tension on belt using a breaker bar and; NOTE: While belt is removed, inspect pulleys and; Release tension on tension arm and remove breaker; NOTE: Threads on belt tensioner roller cap screw are
  • Page 155 – Checking Cooling System; IMPORTANT: Air must be expelled from cooling; Visually check entire cooling system for leaks. Tighten
  • Page 156 – IMPORTANT: Do not add supplemental coolant; is used. The cooling system; DO NOT mix one brand of SCA with a different brand.; or COOLSCAN PLUS
  • Page 157 – IMPORTANT: ALWAYS maintain coolant at correct
  • Page 158 – Coolant Test Strips
  • Page 159 – Pressure Testing Cooling System; NOTE: These tests apply only to John Deere; Test Cooling System
  • Page 160 – Checking and Adjusting Engine Speeds
  • Page 161 – Warm engine to normal operating temperature.
  • Page 162 – Grasp vibration damper with both hands and attempt to; IMPORTANT: The vibration damper assembly is not; Check vibration damper radial runout by positioning a
  • Page 163 – Flushing and Refilling Cooling System; Pressure test entire cooling system and pressure cap if
  • Page 164 – NOTE: On earlier “475” engines, the engine block drain; Open radiator drain valve. Drain all coolant from
  • Page 166 – Inspect the fan belt for wear and check belt tension.; Testing Thermostats Opening Temperature; Visually inspect area around thermostat housing for; Remove and discard all gasket material. Clean gasket
  • Page 167 – Suspend thermostat and a thermometer in a container; NOTE: Due to varying tolerances of different suppliers,; Remove thermostat and observe its closing action as it
  • Page 168 – To Install Thermostats; Clean all gasket material from thermostat cover and
  • Page 169 – IMPORTANT: Valve clearance MUST BE checked and; Remove rocker arm cover and crankcase ventilator; IMPORTANT: Visually inspect contact surfaces of; Remove plastic plugs or cover plate from engine; NOTE: Some engines are equipped with flywheel; Using JDE83 or JDG281AFlywheel Turning Tool, rotate
  • Page 170 – If valves need adjusting, use the appropriate valve; Replace rocker arm cover and crankcase ventilator
  • Page 171 – Adjust valve clearance on No. 1 and 3 exhaust valves
  • Page 172 – Using JDE83 or JDG820 Flywheel Turning Tool, rotate
  • Page 173 – NOTE: While rocker arm cover is removed, test glow; Install rocker arm cover and crankcase ventilator tube.
  • Page 175 – Install new glow plugs and torque to specifications.; Reinstall rocker arm cover and crankcase ventilator tube.
  • Page 176 – Additional Service Information
  • Page 177 – Do Not Modify Fuel System; IMPORTANT: Never steam clean or pour cold water
  • Page 178 – Adding Coolant; IMPORTANT: Never pour cold liquid into a hot; Loosen temperature sending unit fitting at rear of; IMPORTANT: When adding coolant to the system, use
  • Page 179 – Tighten plugs and fittings when air has been expelled
  • Page 180 – Replacing Single Stage Air Cleaner; IMPORTANT: ALWAYS REPLACE air cleaner when air; Install new filter so that overlap (B) of air cleaner outlet; IMPORTANT: Do NOT overtighten body clamp.; If equipped, fully depress air restriction indicator reset
  • Page 181 – IMPORTANT: ALWAYS REPLACE primary air cleaner
  • Page 182 – NOTE: Some engines may have a dust unloader valve
  • Page 183 – Thoroughly clean all dirt from inside housing and from; IMPORTANT: Do NOT use latches on cover to force; Close housing with dust unloader valve aimed down
  • Page 184 – If equipped, fully depress air restriction indicator reset
  • Page 185 – Replacing Fan and Alternator Belts; Replace if necessary.; Install new belt, making sure belt is correctly seated in
  • Page 186 – Checking Fuses; NOTE: The instrument panels for later electronically
  • Page 187 – After fuel filter changes.
  • Page 188 – IMPORTANT: NEVER pressurize the fuel tank to prime; Bleed Fuel System at Fuel Injection Nozzles; connections at injection nozzles.; Repeat procedure for remaining injection nozzles (if
  • Page 190 – hand on fuel filter base.; Tighten bleed plug securely, continue operating primer
  • Page 191 – At Fuel Injection Pump; Operate fuel supply pump primer lever or primer button; At Fuel Injection Nozzles
  • Page 193 – Tighten bleed vent screw securely. Continue operating
  • Page 195 – free from air bubbles.
  • Page 196 – Operate fuel supply pump primer lever until fuel,; Move the engine speed control lever to half throttle
  • Page 197 – Troubleshooting; General Troubleshooting Information; Know the engine and all related systems.; NOTE: The engines covered in this manual have
  • Page 198 – Disconnect the connectors from the ECU.; IMPORTANT: Do not steam clean any electrical or
  • Page 202 – Engine Wiring Diagram (With Earlier Electronic Instrument Panel)
  • Page 206 – Engine Troubleshooting; Engine cranks but will not start
  • Page 207 – Engine hard to start or will not
  • Page 208 – Engine runs irregularly or stalls
  • Page 209 – Lack of power
  • Page 210 – High oil consumption
  • Page 211 – Engine overheats
  • Page 212 – Undercharged electrical system
  • Page 213 – Starter and hour meter functions
  • Page 214 – Using a short piece of wire, jump terminals A and B in
  • Page 215 – wire, and recap the diagnostic reader connector.
  • Page 216 – IMPORTANT: Care should be used during diagnostic
  • Page 217 – Displaying Of Diagnostic Trouble Codes (DTCs)
  • Page 224 – NOTE: The Diagnostic Gauge on the earlier electronic
  • Page 225 – Intermittent Fault Diagnostics (With Electronic Controls); component LEAST likely to fail.; Faulty contact between terminals in connector.; NOTE: Refer to wiring diagrams earlier in this section; NOTE: The following steps can be used to display the; Starting at the single or four engine parameter display,
  • Page 226 – the utilities function.
  • Page 227 – Storage; Engine Storage Guidelines; John Deere engines can be stored outside for up to
  • Page 228 – Preparing Engine for Long Term Storage; IMPORTANT: Any time your engine will not be
  • Page 229 – Removing Engine from Long Term Storage; IMPORTANT: DO NOT operate starter more than
  • Page 230 – Specifications; General OEM Engine Specifications
  • Page 232 – Engine Power Ratings
  • Page 235 – Engine Crankcase Oil Fill Quantities; NOTE: Crankcase oil capacity may vary slightly from
  • Page 236 – Unified Inch Bolt and Screw Torque Values
  • Page 237 – Metric Bolt and Screw Torque Values
  • Page 238 – Lubrication and Maintenance Records; Using Lubrication and Maintenance Records; IMPORTANT: The service recommendations
  • Page 240 – Flush and refill cooling system.
  • Page 241 – Add coolant
  • Page 242 – U.S. EPA Emissions Control Warranty Statement
  • Page 243 – Emissions Control System Certification Label; NOTE: The hp/kW rating on the engine emissions
  • Page 244 – John Deere Service Literature Available; Technical Information; Available information includes:
  • Page 245 – – Fundamentals of Machine Operation manuals explain
  • Page 247 – Index
Loading the manual

P

OWER

T

ECH

4.5 and 6.8 L

4045 and 6068

Tier 2 / Stage II

OEM Diesel Engines

OPERATOR’S MANUAL

P

OWER

T

ECH

4.5 and 6.8 L Tier 2 /

Stage II OEM Diesel Engines

OMRG33324 Issue 7Aug06 (ENGLISH)

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.

If this product contains a gasoline engine:

WARNING

The engine exhaust from this product contains chemicals

known to the State of California to cause cancer, birth

defects or other reproductive harm.

The State of California requires the above two warnings.

John Deere Power Systems

LITHO IN U.S.A.

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Summary

Page 2 - Introduction; Foreword

Introduction OURGP11,000006E –19–04AUG06–1/2 Foreword THIS MANUAL CONTAINS INFORMATION to operateand service the following Tier 2 / Stage IIemission-certified 1 engines: Saran-built (France) Tier 2 Mechanically ControlledEngines: • CD4045DF270 • CD4045TF270 Saran-built (France) Tier 2 Electronically...

Page 3 - NOTE: This manual covers engines provided to OEM

Introduction OURGP11,000006E –19–04AUG06–2/2 IMPORTANT: This manual covers only P OWER T ECH  Tier 2 / Stage II emission certified 4.5 and 6.8 L OEMengines listed. These engines meetTier 2 emission certificationstandards. 2 (This is for both the U.S. EPA and European Union Council(EU) standards.) E...

Page 5 - Engine Owner

Introduction OURGP11,0000251 –19–27JUL06–1/1 Engine Owner John Deere Engine Owner: Don’t wait until you need warranty or other service tomeet your local John Deere Engine Distributor orService Dealer. To register your engine for warrantyvia the Internet, use the following URL:http://www.johndeere.co...

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