John Deere PowerTech 4.5L 6.8L Engine Components Technical Manual CTM331 15FEB11

[Martin Welker]

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John Deere PowerTech 4.5L 6.8L Engine Components Technical Manual CTM331 15FEB11
Size: 11.85 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 Level 12 Electronic Fuel System With Stanadyne DE10 Pump
Part Number: CTM331
Publication Date: 2011
Number of Pages: 510 Pages

Contents:
General Information
Safety
Handle Fluids Safely—Avoid Fires
Handle Starting Fluid Safely
Prepare for Emergencies
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
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
Information Relative to Emissions Regulations
Fuels
Lubricants and Coolant
Diesel Fuel
Bio-Diesel Fuel
Testing Diesel Fuel
Lubricity of Diesel Fuel
Repair and Adjustments
Electronic Fuel System Repair and Adjustments
Fuel System—General Information
Relieve Fuel System Pressure
Remove and Install Final Fuel Filter/Water Bowl and/or Pre-Filte
Fuel Pre-Filter/Water Bowl Assembly (Optional)
Final Fuel Filter Assembly
Replace Final Fuel Filter/Water Bowl and Pre-Filter/Water Bowl
Remove Fuel Supply Pump
Install Fuel Supply Pump
Injection Pump Static Timing
Remove Injection Pump
Inspect Injection Pump Drive Gear ID and Shaft OD
Install Injection Pump
Remove Fuel Injection Nozzles
Clean Fuel Injection Nozzle Bore
Clean Fuel Injection Nozzles
Fuel Injection Nozzle Test
Disassemble Fuel Injection Nozzles
Adjust Fuel Injection Nozzle
Install Seals on Fuel Injection Nozzle
Install Fuel Injection Nozzles
Bleed the Fuel System
Electrical Engine Control Repair and Adjustment
Engine Control Unit (ECU)
Remove and Install Engine Coolant Temperature Sensor
Remove and Install Loss of Coolant Temperature Sensor
Replace Crankshaft Position Sensor
Remove and Install Oil Pressure Sensor
Remove and Install Manifold Air Temperature Sensor
Remove and Install Fuel Temperature Sensor
Remove and Install Fuel Heater
Connectors
Use Electrical Insulating Compound
Using High-Pressure Washer
Repair WEATHERPACK WEATHERPACK is a trademark of Packard Electri
Remove Blade Terminals from Connector Body
Repair (Pull Type) METRI-PACKMETRI-PACK is a trademark of Delph
Repair (Push Type) METRI-PACKMETRI-PACK is a trademark of Delph
Repair DEUTSCH DEUTSCH is a trademark of Deutsch Company™ Connec
Repair AMP Connector
Theory of Operation
Electronic Fuel System Operation
About this Group
Fuel System Operation
Fuel Supply Pump Operation
Final Fuel Filter Operation
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
Measuring Temperature
Measuring Pressure
Measuring Throttle Position
Measuring Engine Speed
Marine Throttle Control Options
Engine Synchronization Throttle Control
Throttle Control Location Transfer
Pump Solenoid
Water in Fuel (WIF) Sensor
Engine Control Unit (ECU)
Controller Area Network (CAN)
Cruise Control Operation
Intake Air Heater 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
E2 - Engine Misfires/Runs Irregularly
E3 - Engine Does Not Develop Full Power
E4 - Engine Emits Excessive White Exhaust Smoke
E5 - Engine Emits Excessive Black Or Gray Smoke
E6 - Engine Will Not Crank
E7 - Engine Idles Poorly
E8 - Abnormal Engine Noise
E9 - Analog Throttle (B) Does Not Respond
F1 - Fuel Supply System Check
F2 - Excessive Fuel Consumption
F3 - Fuel in Oil
F5 - Fuel Injection Nozzle Check
D1 - ECU Does Not Communicate with the DST or SERVICE ADVISOR
D1 - ECU Does Not Communicate With the DST orSERVICE ADVISORSERV
D2 - Diagnostic Gauge (Earlier Model) Does Not Communicate With
D2 - Diagnostic Gauge (Earlier Model) Does Not Communicate With
D3 - Diagnostic Gauge (Later Model) Does Not Communicate With EC
D3 - Diagnostic Gauge (Later Model) Does Not Communicate With EC
A1 - Intake Air Heater Check
A1 - Intake Air Heater Check - Continued
A1 - Intake Air Heater Check
Check Fuel Supply Quality
Test for Fuel Drain Back
Test for Air in Fuel
Check Fuel Supply Pressure
Bench Test Fuel Supply Pump
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
Viewing Active DTCs on Diagnostic Gauge (Earlier Model)
Viewing Stored DTCs on Diagnostic Gauge (Earlier Model)
Clearing Stored DTCs on Diagnostic Gauge (Earlier Model)
Engine Configuration Parameters on Diagnostic Gauge (Earlier Mod
Viewing Active DTCs on Diagnostic Gauge (Later Model)
Viewing Stored DTCs on Diagnostic Gauge (Later Model)
Clearing Stored DTCs on Diagnostic Gauge (Later Model)
Blinking DTCs
Data Parameter Description
Engine Test Instructions - Excavator Torque Curve Change Test
Reprogramming Engine Control Unit (ECU)
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
T2 - Multi-state Throttle Input Low
T2 - Multi-state Throttle Input Low
T3 - Analog Throttle (A) Input High
T3 - Analog Throttle (A) Input High
T4 - Analog Throttle (A) Input Low
T4 - Analog Throttle (A) Input Low
T5 - Analog Throttle (B) Input High
T5 - Analog Throttle (B) Input High
T6 - Analog Throttle (B) Input Low
T6 - Analog Throttle (B) Input Low
T7 - CAN Throttle Invalid
T7 - CAN Throttle Invalid
T11 - Excavator Throttle Reference Voltage High
T11 - Excavator Throttle Reference Voltage High
T12 - Excavator Throttle Reference Voltage Low
T12 - Excavator Throttle Reference Voltage Low
T13 - Excavator Throttle Ground Voltage High
T13 - Excavator Throttle Ground Voltage High
T14 - Excavator Throttle Ground Voltage Low
T14 - Excavator Throttle Ground Voltage Low
T15 - Excavator Throttle Input Voltage High
T15 - Excavator Throttle Input Voltage High
T16 - Excavator Throttle Input Voltage Low
T16 - Excavator Throttle Input Voltage Low
T17 - Analog Throttle (C) Input High
T17 - Analog Throttle (C) Input High
T18 - Analog Throttle (C) Input Low
T18 - Analog Throttle (C) Input Low
T19 - Throttle Not Calibrated Properly
T20 - Throttle Input Voltage Below Lower Calibration Limit
T21 - Throttle Calibration Aborted
T22 - Analog Throttle (A) Input Voltage Out of Range
T23 - Multi-state Throttle Input Voltage Out of Range
000028.03 — Throttle Voltage High
000028.04 — Throttle Voltage Low
000029.03 — Throttle Voltage High
000029.04 — Throttle Voltage Low
000029.14 — Throttle Voltage Out of Range
000084.31 — Vehicle Speed Mismatch
000084.31 — Vehicle Speed Mismatch
000091.03 — Throttle Voltage High
000091.04 — Throttle Voltage Low
000091.07 — Throttle Calibration Invalid
000091.09 — Throttle CAN message Missing
000091.10 — Throttle Voltage Low
000091.13 — Throttle Calibration Aborted
000091.14 — Throttle Voltage Out of Range
000094.01 — Fuel Pressure Extremely Low
000094.01 — Fuel Pressure Extremely Low
000094.03 — Fuel Pressure Input Voltage High
000094.03 — Fuel Pressure Input Voltage High
000094.04 — Fuel Pressure Input Voltage Low
000094.04 — Fuel Pressure Input Voltage Low
000094.18 — Fuel Pressure Moderately Low
000094.18 — Fuel Pressure Moderately Low
000097.00 — Water in Fuel Continuously Detected
000097.00 — Water in Fuel Continuously Detected Diagnostic Proce
000097.03 — Water in Fuel Signal Voltage High
000097.03 — Water in Fuel Signal Voltage High
000097.04 — Water in Fuel Signal Voltage Low
000097.04 — Water in Fuel Signal Voltage Low
000097.16 — Water in Fuel Detected
000097.16 — Water in Fuel Detected
000097.31 — Water in Fuel Detected (750J Crawler Only)
000097.31 — Water in Fuel Detected (750J Crawler Only)
000100.01 — Engine Oil Pressure Extremely Low
000100.01 — Engine Oil Pressure Extremely Low
000100.03 — Engine Oil Pressure Input Voltage High
000100.03 — Engine Oil Pressure Input Voltage High
000100.04 — Engine Oil Pressure Input Voltage Low
000100.04 — Engine Oil Pressure Input Voltage Low
000100.16 - Engine Oil Pressure High, Moderately Severe Level
000100.16 — Engine Oil Pressure High, Moderately Severe Level In
000100.18 — Engine Oil Pressure Moderately Low
000100.18 — Engine Oil Pressure Moderately Low
000100.31 — Engine Oil Pressure Detected with Engine Stopped
000100.31 — Engine Oil Pressure Detected with Engine Stopped
000105.00 — Manifold Air Temperature Extremely High
000105.00 — Manifold Air Temperature Extremely High
000105.03 — Manifold Air Temperature Input Voltage High
000105.03 — Manifold Air Temperature Input Voltage High
000105.04 — Manifold Air Temperature Input Voltage Low
000105.04 — Manifold Air Temperature Input Voltage Low
000105.16 — Manifold Air Temperature Moderately High
000105.16 — Manifold Air Temperature Moderately High
000107.00 — Air Filter Restriction Switch Activated
000107.00 — Air Filter Restriction Switch Activated
000110.00 — Engine Coolant Temperature Extremely High
000110.00 — Engine Coolant Temperature Extremely High
000110.03 — Engine Coolant Temperature Input Voltage High
000110.03 — Engine Coolant Temperature Input Voltage High
000110.04 — Engine Coolant Temperature Input Voltage Low
000110.04 — Engine Coolant Temperature Input Voltage Low
000110.15 — Engine Coolant Temperature High Least Severe
000110.15 — Engine Coolant Temperature High Least Severe
000110.16 — Engine Coolant Temperature Moderately High
000110.16 — Engine Coolant Temperature Moderately High
000111.00 — Loss of Coolant Temperature Extremely High
000111.00 — Loss of Coolant Temperature Extremely High
000111.03 — Loss of Coolant Temperature Input Voltage High
000111.03 — Loss of Coolant Temperature Input Voltage High
000111.04 — Loss of Coolant Temperature Input Voltage Low
000111.04 — Loss of Coolant Temperature Input Voltage Low
000158.17 — ECU Power Down Error
000158.17 — ECU Power Down Error
000160.02 — Wheel Speed Input Noise
000160.02 — Wheel Speed Input Noise
000171.03 — Ambient Air Temperature Input Voltage Out Of Range H
000171.03 — Ambient Air Temperature Input Voltage Out Of Range H
000171.04 — Ambient Air Temperature Input Voltage Out Of Range L
000171.04 — Ambient Air Temperature Input Voltage Out Of Range L
000174.00 — Fuel Temperature Extremely High
000174.00 — Fuel Temperature Extremely High
000174.03 — Fuel Temperature Input Voltage High
000174.03 — Fuel Temperature Input Voltage High
000174.04 — Fuel Temperature Input Voltage Low
000174.04 — Fuel Temperature Input Voltage Low
000174.16 — Fuel Temperature High Moderately Severe
000174.16 — Fuel Temperature High Moderately Severe
000189.00 — Engine Speed Derate
000190.00 — Engine Overspeed Extreme
000190.01 — Engine Speed Below Normal Operational Range, Most Se
000190.01 — Engine Speed Below Normal Operational Range, Most Se
000190.16 — Engine Overspeed Moderate
000190.18 — Engine Speed Below Normal Operational Range, Moderat
000523.09 — Current Gear Selection Invalid or Not Received (J-se
000620.03 — Sensor Supply Voltage High
000620.03 — Sensor Supply Voltage High
000620.04 — Sensor Supply Voltage Low
000620.04 — Sensor Supply Voltage Low
000629.13 — ECU Error
000637.02 — Crank Position Input Noise
000637.02 — Crank Position Input Noise
000637.08 — Crank Position Input Missing
000637.08 — Crank Position Input Missing
000637.10 — Crank Position Input Pattern Error
000637.10 — Crank Position Input Pattern Error
000639.13 — CAN Bus Error
000639.13 — CAN Bus Error
000644.02 — External Speed Command Input (OEM, Marine Only)
000729.03 — Inlet Air Heater Signal High
000729.03 — Inlet Air Heater Signal High
000729.05 — Inlet Air Heater Signal Low
000729.05 — Inlet Air Heater Signal Low
000898.09 — Vehicle Speed or Torque Message Invalid
000970.31 — Auxiliary Engine Shutdown Switch Active
000971.31 — External Engine Derate Switch Active
001069.09 — Tire Size Invalid
001069.09 — Tire Size Invalid
001069.31 — Tire Size Error
001069.31 — Tire Size Error
001076.00 — Pump Control Valve Closure Too Long
001076.00 — Pump Control Valve Closure Too Long
001076.01 — Pump Control Valve Closure Too Short
001076.01 — Pump Control Valve Closure Too Short
001076.03 — Pump Solenoid Current High
001076.03 — Pump Solenoid Current High
001076.05 — Pump Solenoid Circuit Open
001076.05 — Pump Solenoid Circuit Open
001076.06 — Pump Solenoid Circuit Severely Shorted
001076.06 — Pump Solenoid Circuit Severely Shorted
001076.07 — Pump Control Valve Closure Not Detected
001076.07 — Pump Control Valve Closure Not Detected
001076.10 — Pump Solenoid Circuit Moderately Shorted
001076.10 — Pump Solenoid Circuit Moderately Shorted
001076.13 — Pump Current Decay Time Invalid
001076.13 — Pump Current Decay Time Invalid
001079.03 — Sensor Supply Voltage High
001079.03 — Sensor Supply Voltage High
001079.04 — Sensor Supply Voltage Low
001079.04 — Sensor Supply Voltage Low
001109.31 — Engine Protection Shutdown Warning
001110.31 — Engine Protection Shutdown
001568.02 — Torque Curve Selection Invalid or Missing (750J Craw
001569.31 — Fuel Derate
002000.06 — Internal ECU Failure
002006.06 — Internal ECU Failure
002000.13 — Security Violation
Tools and Other Materials
Electronic Fuel/Control System Repair Tools and Other Materials
Fuel System Repair and Adjustment Essential Tools
Fuel System Repair and Adjustment Service Equipment and Tools
Fuel System Repair and Adjustment Other Materials
Control System Repair and Adjustment Essential Tools
Control System Repair and Adjustment Other Materials
Diagnostic Service Tools
ic Fuel System Diagnostic Tools
Specifications
Repair Specifications
Unified Inch Bolt and Screw Torque Values
Metric Bolt and Screw Torque Values
General OEM Engine Specifications
Electronic Fuel System Repair and Adjustment Specifications
Electronic Engine Control Repair and Adjustment Specifications
Diagnostic Specifications
Group 150/160 Electronic Fuel System Diagnostic Specifications
Application Specifications
Backhoes - Sensor Specifications
Backhoes - Torque Curve Selection
Backhoes - Governor Mode Selection
Backhoes - ECU Terminal Identification
Crawlers - Sensor Specifications
Crawlers - Torque Curve Selection
Crawlers - Governor Mode Selection
Crawlers - ECU Terminal Identification
Excavators - Sensor Specifications
Excavators - Torque Curve Selection
Excavators - Governor Mode Selection
Excavators - ECU Terminal Identification
Forwarders - Sensor Specifications
Forwarders - Torque Curve Selection
Forwarders - Governor Mode Selection
Forwarders - ECU Terminal Identification
Harvesters - Sensor Specifications
Harvesters - Torque Curve Selection
Harvesters - Governor Mode Selection
Harvesters - ECU Terminal Identification
OEM Engines - Sensor Specifications
OEM Engines - Torque Curve Selection
OEM Engines - Governor Mode Selection With OC03038 Software or L
OEM Engines - Governor Mode Selection With OC03033 Software or E
OEM Engines - ECU Terminal Identification
OEM Engines - Electronic Control System Wiring Diagram - Base EC
OEM Engines - Electronic Control System Wiring Diagram - Extende
OEM Engines - Electronic Control System Wiring Diagram - Extende
OEM Engines - 4.5L & 6.8L Instrument Panel/Engine Start Componen
Skidders - Sensor Specifications
Skidders - Torque Curve Selection
Skidders - Governor Mode Selection
Skidders - ECU Terminal Identification
Telehandlers - Sensor Specifications
Telehandlers - Torque Curve Selection
Telehandlers - Governor Mode Selection
Telehandlers - ECU Terminal Identification
Tractors - Sensor Specifications
Tractors - Torque Curve Selection
Tractors - Governor Mode Selection
Tractors - ECU Terminal Identification
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