Part of the John Deere Repair Manuals.
Static injection pump timing on Denso, Motorpal, and Stanadyne DB2 and DB4 pumps gets settled in one place: John Deere Technical Manual CTM207, 312 pages on the PowerTech 4.5L and 6.8L diesel engines, the 4045 and 6068. Observable diagnostics and tests fill a long run of this John Deere 4045 technical manual PDF, carrying a symptom through checks to a cause before anything comes apart. Theory of operation explains how the mechanical fuel system and its injection nozzles behave, while the specifications section closes with repair, general OEM, and diagnostic figures. Set new or reconditioned RE60062 nozzles to 23 856 to 24 407 kPa (3460 to 3540 psi), then torque the Delphi/Lucas fuel shut-off solenoid to 24 N•m (18 lb-ft). A rebuild stalls over one missing number. Bookmarked and text searchable, with the service tool and dealer fabricated listings sitting where you can find them, so your parts order goes out right the first time.
What's Inside This John Deere 4045, 6068 PowerTech Manual
| System | Pages | Key Topics |
|---|---|---|
| General Information | 1-36 | Safety, Engine Identification and Applications, Fuels |
| Repair and Adjustments | 37-136 | Mechanical Fuel System Repair and Adjustments, Denso and Motorpal In-Line Injection Pump Static Timing, Remove Stanadyne Model DB2 and DB4 Injection Pump |
| Theory of Operation | 137-158 | Mechanical Fuel Systems Operation, Fuel Injection Nozzles Operation |
| Diagnostics | 159-234 | Observable Diagnostics and Tests |
| Tools and Other Materials | 235-252 | Repair Tools and Other Materials, Diagnostic Service Tools and Other Materials, Dealer Fabricated Service Tools |
| Specifications | 253-312 | Repair and General OEM Specifications, Diagnostic Specifications |
Documents This Manual Refers To
The manufacturer cites these publications by number. We carry them:
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Naturally Aspirated Engines | ||
| RE60062 Nozzles Opening Pressure for Setting (New or Reconditioned) | 23 856 to 24 407 kPa (238 to 244 bar) (3460 to 3540 psi) | p. 110 |
| RE60062 Nozzles Opening Pressure for Checking (Minimum) | 21 856 kPa (218 bar) (3170 psi) | p. 110 |
| All Models | ||
| Motorpal Fuel Supply Pump Mounting Cap Screws Torque | 8 N•m (6 lb-ft) (72 lb-in.) | p. 61 |
| Fuel Supply Pump Inlet and Outlet Lines Torque | 10 N•m (7 lb-ft) | p. 61 |
| Delphi/Lucas Fuel Shut-Off Solenoid Resistance | 9 Ohms | p. 213 |
| Denso Fuel Shut-Off Solenoid (12-Volt System) Pull Coil Resistance | 0.134-0.200 Ohms | p. 214 |
| Rotary Fuel Supply Pump Operating Pressure | 21 to 34 kPa (0.21 to 0.34 bar) (3 to 5 psi) | p. 202 |
| Denso In-Line Fuel Supply Pump Minimum Pressure at 2400 rpm | 69 kPa (0.69 bar) (10 psi) | p. 203 |
| Motorpal In-Line Fuel Supply Pump Minimum Pressure at 2000 rpm | 80 kPa (0.80 bar) (11.6 psi) | p. 203 |
| Denso Fuel Shut-Off Solenoid (12-Volt) Pull Coil Resistance | 0.134 to 0.200 Ohms | p. 214 |
| 4045 | ||
| Rotary Injection Pump Mounting Nuts Torque | 27 N•m (20 lb-ft) | p. 264 |
| 6068 | ||
| Fuel Injection Nozzle Hold-Down Clamp Cap Screws Torque | 40 N•m (30 lb-ft) | p. 264 |
John Deere 4045, 6068 PowerTech Common Problems This Manual Covers
John Deere 4045 cranks but will not start, no smoke from the exhaust
Check the fuel shut-off solenoid before you pull anything apart. Ohm the Delphi/Lucas solenoid coil on page 213: it should read 9 Ohms. Open or high resistance means the solenoid never pulls the rack. Install the replacement and torque it to 24 N•m (18 lb-ft) as listed on page 64.
Manual Section: Fuel Shut-Off Solenoid Diagnostics p. 213Engine misfires and runs rough at idle, one cylinder contributing nothing
Pop test the nozzles on a tester before condemning the pump. On naturally aspirated engines, RE60062 nozzles must open at 23 856 to 24 407 kPa (3460 to 3540 psi) per page 110, and no two cylinders may differ by more than 700 kPa (100 psi). Reset the pressure adjusting screw lock nut to 10 N•m (7 lb-ft).
Manual Section: Fuel Injection Nozzle Testing p. 110Loses power under load and smokes gray, fuel supply pressure suspected
Tee a gauge into the supply line ahead of the injection pump and run it. Rotary supply pump pressure should hold 21 to 34 kPa (3 to 5 psi) per page 202. Below that, change the filter and check for air entry at every fitting, then torque the supply pump inlet and outlet lines to 10 N•m (7 lb-ft).
Manual Section: Fuel Supply Pump Pressure Tests p. 202Runs normally, then dies without warning and restarts a few minutes later
Measure the shut-off solenoid coils hot, right when the fault drops it out. A Denso 12-volt unit reads 0.134 to 0.200 Ohms on the pull coil and 6.63 to 8.11 Ohms on the hold coil, per page 214. Drifting resistance points at the solenoid, not the ECU. Torque the actuator rod hardware to 15 to 20 N•m (11 to 15 lb-ft).
Manual Section: Fuel Shut-Off Solenoid Diagnostics p. 214Excessive black smoke and hard starting after injection pump reinstall on a 4045
Verify static or dynamic timing before you chase fuel. Reindex the pump to the marks, then torque the rotary injection pump mounting nuts to 27 N•m (20 lb-ft) as specified on page 264 for the 4045. Bring the delivery lines to 27 N•m (20 lb-ft) and the leak-off hex nuts to 5 N•m (44 lb-in.) dry.
Manual Section: Fuel Injection Pump Timing p. 264Nozzles dribble on the tester and tips wet down after shutdown
Inspect the tip seat first. Bring the nozzle to 10 300 kPa and count return leakage: 3 to 10 drops per 30 seconds is acceptable per page 113. The tip must stay dry after 5 seconds on the valve seat tightness check, and spray angle runs 144°. Set the lift adjusting screw lock nut at 5 N•m (42 lb-in.).
Manual Section: Fuel Injection Nozzle Testing p. 113Frequently Asked Questions
What are the fuel filter replacement specs for a John Deere 4045, 6068 PowerTech diesel engine?
Replacement intervals for fuel filters are determined by the operator's manual. When replacing, ensure the new filter element is properly indexed on the mounting base, then install the retaining ring and tighten about 1/3 turn until it snaps into the detent. p. 47
What is the torque spec for the fuel filter base mounting bracket to cylinder head on a John Deere 4045, 6068 PowerTech?
The torque specification for the fuel filter base mounting bracket-to-cylinder head is 35 N•m (26 lb-ft). p. 42
What is the Stanadyne DB2 drive gear retaining nut torque on a John Deere 4045, 6068 PowerTech?
The torque specification for the Stanadyne DB2 fuel injection pump drive gear-to-shaft retaining nut is 125 N•m (92 lb-ft). p. 76
How do I bleed the fuel system at the final filter?
To bleed the final filter, loosen the air bleed vent screw (A) two full turns by hand. Operate the supply pump primer lever (B) until fuel flow is free from air bubbles, then tighten the bleed plug securely. p. 132
What is the resistance spec for the Delphi/Lucas fuel shut-off solenoid on a John Deere 4045, 6068 PowerTech?
The resistance specification for the Delphi/Lucas fuel shut-off solenoid is 9 Ohms. p. 213
Is this John Deere 4045 Technical Manual a digital download?
Instant PDF download. You get the full 312-page searchable Technical Manual immediately after payment. Open it on your laptop, tablet, or phone right in the shop.
Are there any print restrictions on this John Deere 4045 manual?
Yes. No DRM, nothing blocks printing, so run off the pages you need on whatever printer you have.
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