John Deere PowerTech 4.5L 6.8L Engine Components Technical Manual CTM170

[Martin Welker]

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John Deere PowerTech 4.5L 6.8L Engine Components Technical Manual CTM170
Size: 8.17 MB
Format: PDF
Language: English
Brand: John Deere
Type of Machine: Engine
Type of Manual: Components Technical Manual
Model: John Deere PowerTech 4.5L 6.8L Engine
Part Number: CTM170
Publication Date: 2003
Number of Pages: 661 Pages

Contents:
Introduction
Forward
General
Safety
Handle Fluids Safely—Avoid Fires
Handle Starting Fluid Safely
Service Cooling System Safely
Prevent Battery Explosions
Prepare for Emergencies
Handling Batteries Safely
Avoid High-Pressure Fluids
Wear Protective Clothing
Service Machines Safely
Work In Ventilated Area
Work in Clean Area
Remove Paint Before Welding or Heating
Avoid Heating Near Pressurized Fluid Lines
Illuminate Work Area Safely
Use Proper Lifting Equipment
Construct Dealer-Made Tools Safely
Practice Safe Maintenance
Use Proper Tools
Dispose of Waste Properly
Live With Safety
Engine Identification
Engine Model Designation
Engine Serial Number Plate Information
OEM Engine Option Code Label
Engine Application Chart
Tier 1 vs. Tier 2
Fuels
Lubricants and Coolant
Diesel Fuel - Tier 1
Diesel Fuel - Tier 2
Bio-Diesel Fuel
Dieselscan Fuel Analysis
Lubricity of Diesel Fuel
Repair and Adjustments
Electronic Fuel System Repair and Adjustments
Fuel System—General Information
Relieve Fuel System Pressure
Remove and Install Primary Fuel Filter/Water Separator Base - Tier 2
Remove and Install Final Fuel Filter/Water Separator Base - Tier 1
Remove and Install Final Fuel Filter/Water Separator Base - Tier 2
Final Fuel Filter Assembly - Tier 1
Final Fuel Filter Assembly - Tier 2
Replace Final Fuel Filter Element
Remove and Install Electronic Fuel Transfer Pump - Filter Mount
Remove and Install Electronic Fuel Transfer Pump - Remote Mount
Service Injection Pump Overflow Valve
Bosch VP44 Injection Pump Static Timing
Remove Bosch VP44 Fuel Injection Pump
Repair Bosch VP44 Fuel Injection Pump
Install Bosch VP44 Fuel Injection Pump
Remove Fuel Injection Nozzles
Clean Fuel Injection Nozzle Bore
Clean Fuel Injection Nozzles
Test Fuel Injection Nozzles
Disassemble Fuel Injection Nozzles
Inspect and Clean Fuel Injection Nozzle Body
Inspect and Clean Valve and Valve Seat
Inspect Valve Adjusting Mechanism
Assemble Fuel Injection Nozzles
Adjust Fuel Injection Nozzles
Install Seals on Fuel Injection Nozzle
Install Fuel Injection Nozzles
Electrical Engine Control Repair and Adjustment
Engine Control Unit (ECU)
Remove and Install Engine Coolant Temperature Sensor
Replace Fuel Pressure Sensor
Replace Pump Position Sensor
Replace Crankshaft Position Sensor
Remove and Install Oil Pressure Sensor
Connectors
Use Electrical Insulating Compound
Using High-Pressure Washer
Repair WEATHERPACK™ Connector
Remove Blade Terminals from Connector Body
Repair (Pull Type) METRI-PACK™ Connectors
Repair (Push Type) METRI-PACK™ Connectors
Repair DEUTSCH™ Connectors
Repair AMP Connector
Theory of Operation
Electronic Fuel System Operation
About this Group
Fuel System Operation - Tier 1
Fuel System Operation - Tier 2
Primary Fuel Filter Operation - Tier 1
Primary Fuel Filter Operation - Tier 2
Final Fuel Filter Operation - Tier 1
Final Fuel Filter Operation - Tier 2
Fuel Injection Pump Operation
Fuel Injection Nozzle Operation
Electronic Control System Operation
About This Group
Electronic Control System Terminology
Electronic Control System Operation
Monitoring Engine Parameters
Electronic Control System Overview - Tier 1
Electronic Control System Overview - Tier 2
Measuring Temperature
Measuring Pressure
Measuring Throttle Position
Measuring Engine Speed
Electronic Fuel Transfer Pump
Water in Fuel (WIF) Sensor
Pump Control Unit
Controlled Area Network (CAN)
Intake Air Heater Operation
Cruise Control Operation
Engine Protection
Derate Programs
Multiple Torque Curve Selection
Governor Droop Mode Selection
Engine Control Unit (ECU) Self-Diagnosis
Diagnostics
Observable Diagnostics and Tests
About This Group of the Manual
E1 - Engine Cranks/Won't Start
E1 - Engine Cranks/Won't Start Diagnostic Procedure

E2 - Engine Misfires/Runs Irregularly
E2 - Engine Misfires/Runs Irregularly Diagnostic Procedure
E3 - Engine Does Not Develop Full Power
E3 - Engine Does Not Develop Full Power Diagnostic Procedure
E4 - Engine Emits Excessive White Exhaust Smoke
E4 - Engine Emits Excessive White Exhaust Smoke Diagnostic Procedure
E5 - Engine Emits Excessive Black Or Gray Smoke
E5 - Engine Emits Excessive Black Or Gray Smoke Diagnostic Procedure
E6 - Engine Will Not Crank
E7 - Engine Idles Poorly
E8 - Abnormal Engine Noise
E10 - Analog Throttle (B) Does Not Respond
F1 - Fuel Supply System Check - Tier 1
F1 - Fuel Supply System Check - Tier 1 Diagnostic Procedure
F2 - Excessive Fuel Consumption
F3 - Fuel in Oil
F4 - Fuel Supply System Check - Tier 2
F4 - Fuel Supply System Check - Tier 2 Diagnostic Procedure
F5 - Fuel Injection Nozzle Check
D1 - ECU Does Not Communicate With DST or SERVICE ADVISOR™
D1 - ECU Does Not Communicate with DST or SERVICE ADVISOR™ Diagnostic Procedure
D2 - Diagnostic Gauge Does Not Communicate With ECU
D2 - Diagnostic Gauge Does Not Communicate With ECU Diagnostic Procedure
A1 - Intake Air Heater Check
A1 - Intake Air Heater Check Diagnostic Procedure
Check Fuel Supply Quality - Tier 1
Check Fuel Supply Quality - Tier 2
Test for Fuel Drain Back
Test for Air in Fuel - Tier 1
Test for Air in Fuel - Tier 2
Check Fuel Supply Pressure
Bleed the Fuel System
Test for Cylinder Misfire (Engine Running)
Trouble Code Diagnostics and Tests
About this Group of the Manual
Electrical Concepts
Using a Digital Multimeter
Electrical Circuit Malfunctions
Troubleshooting Circuit Malfunctions
Connecting to Diagnostic Scan Tool (DST) or SERVICE ADVISOR™
Engine Configuration Data Parameters on Diagnostic Gauge
Viewing Active DTCs on Diagnostic Gauge
Viewing Stored DTCs on Diagnostic Gauge
Clearing Stored DTCs on Diagnostic Gauge
Blinking DTCs Using Diagnostic Blink Code Connector
Data Parameter Description
Engine Test Instructions—Cylinder Misfire Test
Engine Test Instructions—Compression Test
Engine Test Instructions— Cylinder Cutout Test
Engine Test Instructions - Excavator Torque Curve Change Test
Engine Test Instructions - Tractor Torque Curve Change Test
Reprogramming Engine Control Unit (ECU)
Downloading Payload File For DST
Reprogramming Engine Control Unit (ECU) With DST
Downloading Payload File For SERVICE ADVISOR™
Reprogramming Engine Control Unit (ECU) With SERVICE ADVISOR™
Diagnostic Trouble Codes (DTCs)
Listing of Diagnostic Trouble Codes (DTCs) on ECU
Diagnostic Procedure
Intermittent Fault Diagnostics
T1 - Multi-state Throttle Input High
T1 - Multi-State Throttle Input High Diagnostic Procedure
T2 - Multi-state Throttle Input Low
T2 - Multi-State Throttle Input Low Diagnostic Procedure
T3 - Analog Throttle (A) Input High
T3 - Analog Throttle (A) Input High Diagnostic Procedure
T4 - Analog Throttle (A) Input Low
T4 - Analog Throttle (A) Input Low Diagnostic Procedure
T5 - Analog Throttle (B) Input High
T5 - Analog Throttle (B) Input High Diagnostic Procedure
T6 - Analog Throttle (B) Input Low
T6 - Analog Throttle (B) Input Low Diagnostic Procedure
T7 - CAN Throttle Invalid
T7 - CAN Throttle Invalid Diagnostic Procedure
T11 - Excavator Throttle Reference Voltage High
T11 - Excavator Throttle Reference Voltage High Diagnostic Procedure
T12 - Excavator Throttle Reference Voltage Low
T12 - Excavator Throttle Reference Voltage Low Diagnostic Procedure
T13 - Excavator Throttle Ground Voltage High
T13 - Excavator Throttle Ground Voltage High Diagnostic Procedure
T14 - Excavator Throttle Ground Voltage Low
T14 - Excavator Throttle Ground Voltage Low Diagnostic Procedure
T15 - Excavator Throttle Input Voltage High
T15 - Excavator Throttle Input Voltage High Diagnostic Procedure
T16 - Excavator Throttle Input Voltage Low
T16 - Excavator Throttle Input Voltage Low Diagnostic Procedure
T17 - Analog Throttle (C) Input High
T17 - Analog Throttle (C) Input High Diagnostic Procedure
T18 - Analog Throttle (C) Input Low
T18 - Analog Throttle (C) Input Low Diagnostic Procedure
000028.03 — Throttle Voltage High
000028.04 — Throttle Voltage Low
000029.03 — Throttle Voltage High
000029.04 — Throttle Voltage Low
000084.02 — Vehicle Speed Mismatch
000084.02 Vehicle Speed Mismatch Diagnostic Procedure
000091.03 — Throttle Voltage High
000091.04 — Throttle Voltage Low
000091.09 — Throttle Invalid
000094.01 — Fuel Supply Pressure Extremely Low
000094.01 Fuel Supply Pressure Extremely Low Diagnostic Procedure
000094.03 — Fuel Supply Pressure Input Voltage High
000094.03 Fuel Supply Pressure Input Voltage High Diagnostic Procedure
000094.04 — Fuel Supply Pressure Input Voltage Low
000094.04 Fuel Supply Pressure Input Voltage Low Diagnostic Procedure
000094.18 — Fuel Supply Pressure Moderately Low
000094.18 Fuel Supply Pressure Moderately Low Diagnostic Procedure
000097.00 — Water in Fuel Continuously Detected
000097.00 Water in Fuel Continuously Detected Diagnostic Procedure
000097.16 — Water in Fuel Detected
000097.16 Water in Fuel Detected Diagnostic Procedure
000100.01 — Engine Oil Pressure Extremely Low
000100.01 Engine Oil Pressure Extremely Low Diagnostic Procedure
000100.03 — Engine Oil Pressure Input Voltage High
000100.03 Engine Oil Pressure Input Voltage High Diagnostic Procedure
000100.04 Engine Oil Pressure Input Voltage Low
000100.04 Engine Oil Pressure Input Voltage Low Diagnostic Procedure
000100.18 — Engine Oil Pressure Moderately Low
000100.18 Engine Oil Pressure Moderately Low Diagnostic Procedure
000105.00 — Manifold Air Temperature Extremely High
000105.00 Manifold Air Temperature Extremely High Diagnostic Procedure
000105.03 — Manifold Air Temperature Input Voltage High
000105.03 Manifold Air Temperature Input Voltage High Diagnostic Procedure
000105.04 Manifold Air Temperature Input Voltage Low
000105.04 Manifold Air Temperature Input Voltage Low Diagnostic Procedure
000105.16 — Manifold Air Temperature Moderately High
000105.16 Manifold Air Temperature Moderately High Diagnostic Procedure
000107.00 — Air Filter Differential Pressure
000107.00 Air Filter Differential Pressure Diagnostic Procedure
000110.00 — Engine Coolant Temperature Extremely High
000110.00 Engine Coolant Temperature Extremely High Diagnostic Procedure
000110.03 — Engine Coolant Temperature Input Voltage High
000110.03 Engine Coolant Temperature Input Voltage High Diagnostic Procedure
000110.04 — Engine Coolant Temperature Input Voltage Low
000110.04 Engine Coolant Temperature Input Voltage Low Diagnostic Procedure
000110.15 — Engine Coolant Temperature High Least Severe
000110.15 Engine Coolant Temperature High Least Severe Diagnostic Procedure
000110.16 — Engine Coolant Temperature Moderately High
000110.16 Engine Coolant Temperature Moderately High Diagnostic Procedure
000111.01 — Engine Coolant Level Low
000111.01 Engine Coolant Level Low Diagnostic Procedure
000158.17 — ECU Power Down Error
000158.17 ECU Power Down Error Diagnostic Procedure
000174.00 — Fuel Temperature High Most Severe
000174.00 Fuel Temperature High Most Severe Diagnostic Procedure
000174.15 — Fuel Temperature High Least Severe
000174.15 Fuel Temperature High Least Severe Diagnostic Procedure
000174.16 — Fuel Temperature High Moderately Severe
000174.16 Fuel Temperature High Moderately Severe Diagnostic Procedure
000174.31 — Fuel Temperature Sensor Faulty
000174.31 Fuel Temperature Sensor Faulty Diagnostic Procedure
000189.00 — Engine Speed Derate
000189.31 — Engine Speed Derate
000190.00 — Engine Overspeed Extreme
000190.16 — Engine Overspeed Moderate
000620.03 — Sensor Supply Voltage High
000620.03 Sensor Supply Voltage High Diagnostic Procedure
000620.04 — Sensor Supply Voltage Low
000620.04 Sensor Supply Voltage Low Diagnostic Procedure
000627.04 — ECU Unswitched Power Missing
000627.04 ECU Unswitched Power Missing Diagnostic Procedure
000629.13 — ECU Error
000629.13 ECU Error Diagnostic Procedure
000629.19 — ECU to Pump Communication Error
000629.19 ECU to Pump Communication Error Diagnostic Procedure
000632.02 Fuel Shutoff Error
000632.02 Fuel Shutoff Error Diagnostic Procedure
000632.05 — Fuel Shutoff Non-Functional
000632.05 Fuel Shutoff Non-Functional Diagnostic Procedure
000636.02 — Pump Position Input Noise
000636.02 Pump Position Input Noise Diagnostic Procedure
000636.08 — Pump Position Input Missing
000636.08 Pump Position Input Missing Diagnostic Procedure
000636.10 — Pump Position Input Pattern Error
000636.10 Pump Position Input Pattern Error Diagnostic Procedure
000637.02 — Crankshaft Position Input Noise
000637.02 Crankshaft Position Input Noise Diagnostic Procedure
000637.08 — Crankshaft Position Input Missing
000637.08 Crankshaft Position Input Missing Diagnostic Procedure
000637.10 — Crankshaft Position Input Pattern Error
000637.10 Crankshaft Position Input Pattern Error Diagnostic Procedure
000729.03 — Inlet Air Heater Signal High
000729.03 Inlet Air Heater Signal Low Diagnostic Procedure
000729.05 — Inlet Air Heater Signal Low
000729.05 Inlet Air Heater Signal Low Diagnostic Procedure
000810.02 — Calculated Vehicle Speed Input Signal Noise
000810.02 Calculated Vehicle Speed Input Signal Noise Diagnostic Procedure
000898.09 — Vehicle Speed Invalid/Missing
000898.09 Vehicle Speed Invalid/Missing Diagnostic Procedure
000970.02 — Auxiliary Engine Shutdown Switch Signal Invalid
000970.02 Auxiliary Engine Shutdown Switch Signal Invalid Diagnostic Procedure
000970.31 — Auxiliary Engine Shutdown Switch Active
000971.31 — External Engine Derate Switch Active
001069.02 — Tire Size Error
001069.02 Tire Size Error Diagnostic Procedure
001076.02 — Pump Detected Defect
001076.02 Pump Detected Defect Diagnostic Procedure
001077.07 — Attempting to Fuel Without Command
001077.07 Attempting to Fuel Without Command Diagnostic Procedure
001077.11 — Pump Supply Voltage Out Of Range
001077.11 Pump Supply Voltage Out Of Range Diagnostic Procedure
001077.12 — Pump Self-Test Error
001077.12 Pump Self-Test Error Diagnostic Procedure
001077.19 — Pump Detected Communication Error
001077.19 Pump Detected Communication Error Diagnostic Procedure
001077.31 — Pump Initiated Engine Protection
001078.07 — ECU/Pump Timing Moderately Out of Sync
001078.07 ECU/Pump Timing Moderately Out of Sync Diagnostic Procedure
001078.11 — ECU/Pump Engine Speed Out of Sync
001078.11 ECU/Pump Engine Speed Out of Sync Diagnostic Procedure
001078.31 — ECU/Pump Timing Extremely Out of Sync
001078.31 ECU/Pump Timing Extremely Out of Sync Diagnostic Procedure
001079.03 — Sensor Supply 1 Voltage High
001079.03 Sensor Supply 1 Voltage High Diagnostic Procedure
001079.04 — Sensor Supply 1 Voltage Low
001079.04 Sensor Supply 1 Voltage Low Diagnostic Procedure
001080.03 — Sensor Supply 2 Voltage High
001080.03 Sensor Supply 2 Voltage High Diagnostic Procedure
001080.04 — Sensor Supply 2 Voltage Low
001080.04 Sensor Supply 2 Voltage Low Diagnostic Procedure
001109.31 — Engine Protection Shutdown Warning
001110.31 — Engine Protection Shutdown
001485.02 — Pump Power Relay Fault
001485.02 Pump Power Relay Fault Diagnostic Procedure
001569.31 — Fuel Derate
002000.13 — Security Violation
Tools and Other Materials
Electronic Fuel/Control System Repair Tools and Other Materials
Group 090 - Electronic Fuel System Repair and Adjustment Essential Tools
Fuel System Repair and Adjustment Service Equipment and Tools
Fuel System Repair and Adjustment Other Materials
Group 110 - Electronic Engine Control System Repair Tools
Control Repair and Adjustment Other Materials
Diagnostic Service Tools
Group 150/160 - Electronic Fuel System Diagnostic Tools
Specifications
Repair Specifications
Unified Inch Bolt and Cap Screw Torque Values
Metric Bolt and Cap Screw Torque Values
General OEM Engine Specifications - Tier 1
General OEM Engine Specifications - Tier 2
Electronic Fuel System Repair and Adjustment Specifications
Electrical Engine Control Repair and Adjustment Specifications
Diagnostic Specifications
Fuel System Diagnostic Specifications
Application Specifications
Combines - Sensor Specifications
Combines - Torque Curve Selection
Combines -
Combines - ECU Terminal Identification
Excavators - Sensor Specifications
Excavators - Torque Curve Selection
Excavators -
Excavators - ECU Terminal Identification
Marine - Sensor Specifications
Marine - Torque Curve Selection
Marine -
Marine - ECU Terminal Identification
6.8 L Marine Application Electronic Control System Wiring Diagram
6.8 L Marine Application Wheel House Panel Electrical Wiring Diagram
6.8 L Marine Application Fly Bridge Panel Electrical Wiring Diagram
OEM Engines - Sensor Specifications
OEM Engines - Torque Curve Selection
OEM Engines - With OC03041 Software or Later
OEM Engines - With OC03034 Software or Earlier
OEM Engines - ECU Terminal Identification
6.8 L OEM Application Electronic Control System Wiring Diagram
6.8 L OEM Application Instrument Panel/Engine Start Components Electrical Wiring Diagram
6.8 L OEM Application Instrument Panel/Engine Start Components Electrical Wiring Diagram - Continued
Telehandlers - Sensor Specifications
Telehandlers - Torque Curve Selection
Telehandlers -
Telehandlers - ECU Terminal Identification
Tractors - 6010 Series - Sensor Specifications
Tractors - 6010 Series - Torque Curve Selection
Tractors - 6010 Series -
Tractors - 6010 Series - ECU Terminal Identification
Tractors - 6020 Series - Sensor Specifications
Tractors - 6020 Series - Torque Curve Selection
Tractors - 6020 Series -
Tractors - 6020 Series - ECU Terminal Identification
Tractors - 7020 Series - Sensor Specifications
Tractors - 7020 Series - Torque Curve Selection
Tractors - 7020 Series -
Tractors - 7020 Series - ECU Terminal Identification
Page Numbers