Complete Mechanical Fuel Systems Component Technical Manual for John Deere PowerTech 4.5L & 6.8L Diesel Engines. It's the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

This John Deere PowerTech 4.5L & 6.8L Diesel Engines Mechanical Fuel Systems Component Technical Manual (CTM207)
is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

CTM207 (21JUL10) (ENGLISH) - John Deere PowerTech 4.5L & 6.8L Diesel Engines - John Deere Mechanical Fuel Systems Component Technical Manual.pdf
(250 pages (bookmarked, Searchable, Printable, high quality PDF))

EXCERPT:
TABLE OF CONTENTS
Section 01—General Information
Group 000—Safety
Group 001—Engine Identification and Applications
Group 002—Fuels, Lubricants, and Coolants
Section 02—Repair and Adjustments
Group 090—Mechanical Fuel System Repair and Adjustments
Section 03—Theory of Operation
Group 130—Mechanical Fuel Systems Operation
Section 04—Diagnostics
Group 150—Observable Diagnostics and Tests
Section 05—Tools and Other Materials
Group 170—Repair Tools and Other Materials
Group 180—Diagnostic Service Tools and Other Materials
Group 190—Dealer Fabricated Service Tools
Section 06—Specifications
Group 200—Repair and General OEM Specifications
Group 210—Diagnostic Specifications

TABLE OF CONTENTS................1
Section 01: General Information................18
  Group 000: Safety................18
    Work In Ventilated Area................21
    Recognize Safety Information................22
    Work in Clean Area................23
    Decommissioning — Proper Recycling and Disposal of Fluids and Components................24
    Handle Fuel Safely—Avoid Fires................25
    Avoid Static Electricity Risk When Refueling................26
    Prepare for Emergencies................28
    Handle Starting Fluid Safely................29
    Handle Fluids Safely—Avoid Fires................30
    Avoid High-Pressure Fluids................31
    Use Proper Lifting Equipment................32
    Illuminate Work Area Safely................33
    Live With Safety................34
    Service Machines Safely................35
    Handle Chemical Products Safely................36
    Protect Against Noise................37
    Remove Paint Before Welding or Heating................38
    Stay Clear of Rotating Drivelines................39
    Service Cooling System Safely................41
    Follow Safety Instructions................42
    Use Proper Tools................43
    Construct Dealer-Made Tools Safely................44
    Practice Safe Maintenance................45
    Understand Signal Words................47
    Replace Safety Signs................48
    Prevent Battery Explosions................49
    Protect Against High Pressure Spray................50
    Avoid Heating Near Pressurized Fluid Lines................51
    Wear Protective Clothing................52
    Handle Agricultural Chemicals Safely................53
    Handling Batteries Safely................55
    Install Fan Guards................58
    Avoid Hot Parts................59
  Group 001: Engine Identification and Applications................19
    Engine Serial Number Plate Information................64
    OEM Engine Option Code Label................68
    Information Relative to Emissions Regulations................69
  Group 002: Fuels, Lubricants, and Coolants................19
    Diesel Fuel................72
    Diesel Fuel Additive Products................74
    BioDiesel Fuel................75
    Minimizing the Effect of Cold Weather on Diesel Engines................77
    Handling and Storing Diesel Fuel................79
    Lubricity of Diesel Fuel................80
    Testing Diesel Fuel................81
    Fuel Filters................82
Section 02: Repair and Adjustments................83
  Group 090: Mechanical Fuel System Repair and Adjustments................83
    Fuel System—General Information................87
    Remove and Install Fuel Line with Snap-On System................88
    Relieve Fuel System Pressure................89
    Remove and Install Final Fuel Filter and/or Primary Fuel Filter/Water Separator Base................90
    Primary Fuel Filter/Water Separator Assembly (Optional)................93
    Final Fuel Filter Assembly................95
    Replace Final Fuel Filter and Primary Fuel Filter/Water Separator................97
    Remove Lucas and Stanadyne Fuel Supply Pump................99
    Bench Test Lucas and Stanadyne Fuel Supply Pump................101
    Install Lucas and Stanadyne Fuel Supply Pump................104
    Remove Denso In-Line Fuel Supply Pump................105
    Test Denso In-Line Fuel Supply Pump for Leaks................106
    Disassemble Denso In-Line Fuel Supply Pump................107
    Inspect and Repair Denso In-Line Fuel Supply Pump Components................111
    Assemble Denso In-Line Fuel Supply Pump................114
    Install Denso In-Line Fuel Supply Pump................115
    Remove Motorpal Fuel Supply Pump................116
    Inspect Motorpal Fuel Supply Pump................117
    Install Motorpal Fuel Supply Pump................118
    Service Denso Injection Pump Overflow Valve................119
    Remove and Install Denso Fuel Shut-Off Solenoid................121
    Remove and Install Delphi/Lucas Fuel Shut-Off Solenoid................122
    Remove and Install Motorpal Fuel Shut-Off Solenoid—If Equipped................124
    Remove and Install Stanadyne Cold Start Advance Solenoid and Valve................125
    Remove and Install Delphi/Lucas Cold Start Advance Switch and Harness................128
    Delphi/Lucas and Stanadyne Rotary Fuel Injection Pump Timing................130
    Denso and Motorpal In-Line Injection Pump Static Timing................132
    Stanadyne Rotary Fuel Injection Pump Identification................134
    Stanadyne Injection Pump and Fuel Lines (Without Lock Shaft Timing) — Removal................136
    Remove Stanadyne Model DB4 Injection Pump (with Lock Shaft Timing)................141
    Inspect Stanadyne Injection Pump Drive Gear ID and Shaft OD................145
    Repair Stanadyne Fuel Injection Pump................146
    Stanadyne Fuel Injection Pump and Fuel Lines (Without Lock Shaft Timing) — Installation................147
    Install Stanadyne Model DB4 Injection Pump (with Lock Shaft Timing)................152
    Delphi/Lucas Fuel Injection Pump — Identification................158
    Delphi/Lucas Fuel Injection Pump and Fuel Lines — Removal (DP201 / DP203)................160
    Delphi Fuel Injection Pump and Fuel Lines — Removal (DP210 / DP310)................164
    Repair Delphi/Lucas Fuel Injection Pump................170
    Delphi/Lucas Fuel Injection Pump and Fuel Lines — Installation (DP201 / DP203)................171
    Delphi Fuel Injection Pump and Fuel Lines — Installation (DP210 / DP310)................175
    Remove Denso Fuel Injection Pump................183
    Repair Denso Fuel Injection Pump................186
    Install Denso Fuel Injection Pump................192
    Install Denso Fuel Injection Pump................192
    Replace Motorpal Fuel Injection Pump Delivery Valve O-Rings................197
    Remove Motorpal Fuel Injection Pump................198
    Repair Motorpal Fuel Injection Pump................201
    Install Motorpal Fuel Injection Pump................202
    Repair Aneroid................207
    Transfer Fuel Injection Pump Timing Mark onto Replacement Front Plate................209
    Fuel Injection Nozzle Identification................210
    Diagnose Fuel Injection Nozzle Malfunctions................211
    Remove Fuel Injection Nozzles (9.5 mm)................213
    Clean Fuel Injection Nozzle Bore (9.5 mm)................215
    Clean Fuel Injection Nozzles (9.5 mm)................216
    Test Fuel Injection Nozzles (9.5 mm)................217
    Disassemble Fuel Injection Nozzles (9.5 mm)................222
    Inspect and Clean Fuel Injection Nozzle Body (9.5 mm)................226
    Inspect and Clean Valve and Valve Seat (9.5 mm)................228
    Inspect Valve Adjusting Mechanism (9.5 mm)................230
    Assemble Fuel Injection Nozzles (9.5 mm)................231
    Adjust Fuel Injection Nozzles (9.5 mm)................232
    Install Seals on Fuel Injection Nozzle(9.5 mm)................84
    Install Fuel Injection Nozzles (9.5 mm)................241
    Remove Fuel Injection Nozzles (VCO 17 mm)................243
    Clean Fuel Injection Nozzle Bore(VCO 17 mm)................85
    Clean Fuel Injection Nozzles (VCO 17 mm)................247
    Test Fuel Injection Nozzles (VCO 17 mm)................248
    Install Seals on Fuel Injection Nozzle(VCO 17 mm)................85
    Install Fuel Injection Nozzles (VCO 17 mm)................252
    Bleed the Fuel System................254
Section 03: Theory of Operation................260
  Group 130: Mechanical Fuel Systems Operation................260
    Fuel Injection Pump—General Information................262
    Fuel System Operation—Rotary Fuel Injection Pump................263
    Fuel System Operation—In-Line Fuel Injection Pump................265
    Fuel Supply Pump Operation—Rotary Injection Pump................267
    Fuel Supply Pump Operation—In-Line Injection Pump................269
    Cold Start Advance System Operation (Rotary Pumps)................272
    Light Load Advance Operation (Rotary Pumps)................274
    Final Fuel Filter/Water Separator Operation................275
    Stanadyne Rotary Fuel Injection Pump Operation................277
    Delphi/Lucas Rotary Fuel Injection Pump Operation................279
    Denso and Motorpal In-Line Fuel Injection Pump Operation................281
    Aneroid Operation (If Equipped)................282
    Fuel Injection Nozzles Operation (9.5 mm)................284
    Fuel Injection Nozzles Operation (VCO 17 mm)................286
Section 04: Diagnostics................288
  Group 150: Observable Diagnostics and Tests................288
    About This Section of the Manual................292
    E1—Engine Cranks/Won't Start................294
    E2—Engine Misfires/Runs Irregularly................298
    E3—Engine Does Not Develop Full Power................302
    E4—Engine Emits Excessive White Exhaust Smoke................307
    E5—Engine Emits Excessive Black or Gray Exhaust Smoke................311
    E6—Engine Will Not Crank................314
    E7—Engine Idles Poorly................315
    E8—Abnormal Engine Noise................316
    F1—Fuel Supply System Check................318
    F2—Excessive Fuel Consumption................322
    F3—Fuel in Oil................323
    F4—Excessive Fuel Filter Replacement................324
    Cylinder Misfire Test (Engine Running)................327
    Using TACH-N-TIME Meter as Tachometer................328
    Using TIME TRAC as a Tachometer................330
    Check and Adjust Rotary Injection Pump Dynamic Timing Using TACH-N-TIME™................331
    Check and Adjust Rotary Injection Pump Dynamic Timing Using TIME TRAC®................348
    Check and Adjust Rotary Injection Pump Dynamic Timing Using TIME TRAC®................348
    Check and Adjust In-Line Injection Pump Static Timing................357
    Check Fuel Supply Quality................359
    Test Air in Fuel................361
    Check for Restricted Fuel Return Line................362
    Measure Fuel Supply Pump Pressure—Rotary Injection Pump................363
    Measure Fuel Supply Pump Pressure—In-Line Injection Pump................364
    Test Fuel Supply Pump for Leaks—In-Line Injection Pump................365
    Check Fuel Supply Pump Operation—In-Line Injection Pump................366
    Service Denso Fuel Supply Pump................368
    Check Cold Start Switch Operation—Rotary Pumps................369
    Check Cold Start Advance System Operation—Rotary Pumps................370
    Check Light Load Advance Operation—Rotary Pumps................372
    Check Fuel Shut-Off Solenoid Operation—In-Line Injection Pumps................373
    Test Fuel Shut-Off Solenoid Resistance—Delphi/Lucas Pump................375
    Test Fuel Shut-Off Solenoid Resistance—Denso Pump................376
    Test Fuel Shut-Off Solenoid Resistance—Motorpal Pump................377
    Adjust Fuel Shut-Off Solenoid Linkage—In-Line Injection Pumps................378
    Check and Adjust Engine Speeds on Delphi/Lucas Pump................380
    Adjust Variable Speed on Generator Set Engines (Delphi/Lucas Pumps Only)................382
    Check and Adjust Engine Speeds on Stanadyne Pump................383
    Adjust Variable Speed (Droop) on Generator Set Engines (3—5% Governor Regulation)—Stanadyne DB2 and DB4 Injection Pumps................385
    Check and Adjust Fast Idle Speed—Denso and Motorpal Fuel Injection Pump................387
    Check and Adjust Slow Idle Speed—Denso Fuel Injection Pump................391
    Check and Adjust Slow Idle Speed—Denso Fuel Injection Pump................391
    Check and Adjust Slow Idle Speed—Motorpal Fuel Injection Pump................393
    Change Engine Rated Speed and Adjust Droop—Denso Fuel Injection Pump................394
    Test Fuel Injection Nozzles (Engine Running)................396
    Fuel Drain-Back Test Procedure................398
    Charge Air Cooler Test................400
Section 05: Tools and Other Materials................402
  Group 170: Special Tools................402
    D01109AA................404
    D01110AA................405
    D01209AA................406
    DFRG5................407
    DFRG11................408
    JD258................410
    JDE38B................411
    JDE39................412
    JDE83................413
    JDF13B................414
    JDF15................415
    JDF22................416
    JDG820................417
    JDG839................418
    JDG886................419
    JDG949................420
    JDG1515................421
    JDG1515-1................422
    JDG1515-2................423
    JDG1521................424
    JDG1522................425
    JDG1560................426
    JDG1571................427
    JDG10576................428
    JDG11411................429
    JT05536................430
    JT25510................431
  Group 180: Lubricants, Sealants, and Other Materials................402
    Other Material................433
Section 06: Specifications................434
  Group 200: Repair and General OEM Specifications................434
    Unified Inch Bolt and Screw Torque Values................437
    Metric Bolt and Screw Torque Values................439
    General OEM Engine Specifications................441
    Mechanical Fuel System Repair Specifications................443
  Group 210: Diagnostic Specifications................434
    Fuel Injection Pump Specifications................449
    Fuel Injection Pump Specifications (Agricultural Applications)................450
    Fuel Injection Pump Specifications (Construction and Forestry Equipment)................477
    Fuel Injection Pump Specifications (4045 Engines for OEM Applications)................490
    Fuel Injection Pump Specifications (6068 Engines for OEM Applications)................501
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