John Deere PowerTech 10.5L 12.5L Diesel Engine Lucas EUI Fuel System Repair Manual CTM115 PDF - MJODCTM115.zip

John Deere PowerTech 10.5 L and 12.5 L Diesel Engines with Lucas Electronic Fuel Systems Featuring Lucas EUIs — Component Technical Manual (CTM115)

ctm115 - Service guide for John Deere PowerTech 10.5 L and 12.5 L diesel engines equipped with Lucas electronic fuel injection (EUI) systems - (Worldwide Edition) Component Technical Manual.pdf

Complete Component Technical Manual with Electrical Wiring Diagrams for John Deere PowerTech 10.5 L & 12.5 L Diesel EnginesLucas ElectronicFuel Systems With Lucas EUIs - (Worldwide Edition), with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

John Deere PowerTech 10.5 L & 12.5 L Diesel EnginesLucas ElectronicFuel Systems With Lucas EUIs - (Worldwide Edition) workshop service repair manual includes:

* Numbered table of contents easy to use so that you can find the information you need fast.

* Detailed sub-steps expand on repair procedure information

* Numbered instructions guide you through every repair procedure step by step.

* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.

* Notes, cautions and warnings throughout each chapter pinpoint critical information.

* Bold figure number help you quickly match illustrations with instructions.

* Detailed illustrations, drawings and photos guide you through every procedure.

* Enlarged inset helps you identify and examine parts in detail.

PRODUCT DETAILS:

Total Pages: 507 pages

File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)

Language: English

ctm115 - PowerTech 10.5 L &12.5 L Diesel EnginesLucas ElectronicFuel SystemsWith Lucas EUIs -: (Worldwide Edition)

Component Technical Manual

Table of Contents

Foreword

Section 01: General Information

Group 000: Safety

Avoid Heating Near Pressurized Fluid Lines

Avoid High-Pressure Fluids

Avoid Hot Exhaust

Construct Dealer-Made Tools Safely

Decommissioning — Proper Recycling and Disposal of Fluids and Components

Follow Safety Instructions

Handle Agricultural Chemicals Safely

Handle Fluids Safely—Avoid Fires

Handling Batteries Safely

Illuminate Work Area Safely

Install All Guards

Live With Safety

Park Machine Safely

Practice Safe Maintenance

Precautions for Welding

Prepare for Emergencies

Prevent Acid Burns

Prevent Battery Explosions

Prevent Machine Runaway

Protect Against High Pressure Spray

Protect Against Noise

Recognize Safety Information

Remove Paint Before Welding or Heating

Replace Safety Signs

Service Cooling System Safely

Service Machines Safely

Stay Clear of Rotating Drivelines

Support Machine Properly

Understand Signal Words

Use Proper Lifting Equipment

Use Proper Tools

Use Steps and Handholds Correctly

Wait Before Opening High-Pressure Fuel System

Wear Protective Clothing

Work in Clean Area

Work In Ventilated Area

Group 001: Engine Identification

Engine Model Designation

Engine Serial Number Plate Information

Engine Option Code Label

Engine Application Chart

Distinguishing ECUs

Group 002: Fuels

Lubricants and Coolant

Diesel Fuel

Diesel Fuel Additive Products

Bio-Diesel Fuel

Lubricity of Diesel Fuel

Testing Diesel Fuel

Section 02: Repair and Adjustments

Group 090: Electronic Fuel System Repair and Adjustment

Fuel System Components

Replace Final (Secondary) Fuel Filter Element

Replacing Primary Fuel Filter/Water Separator

Remove and Install Air Purge Valve

Remove and Install Primary Fuel Filter Check Valve

Remove and Install Fuel System Surge Tank (6125ADW01/70 Engines)

Remove and Install Fuel Supply Pump

Remove and Install Fuel Manifold

Inspect Fuel Pressure Regulating Valve and Return Check Valve

Remove and Install Electronic Unit Injectors

Adjust Electronic Unit Injector Preload

Replace Electronic Unit Injector O-Rings

Replace Electronic Unit Injector Thrust Sleeve, Pad and O-Ring

Flush Fuel Rails

Bleed Fuel System

Group 110: Electrical Engine Control Repair and Adjustment

Lucas Electronic Control System

Remove and Install Coolant Temperature Sensor

Remove and Install Fuel Temperature Sensor

Remove and Install Oil Pressure Sensor

Remove and Install Manifold Air Temperature (MAT) Sensor

Remove and Install Manifold Absolute Pressure (MAP) Sensor

Remove and Install Camshaft Position Sensor

Remove and Install Crankshaft Position Sensor

Connectors

Use Electrical Insulating Compound

Using High-Pressure Washer

Connector Repair

Remove Blade Terminals from Connector Body

Repair (Pull Type) METRI-PACK™ Connectors

Repair (Push Type) METRI-PACK™ Connectors

Repair DEUTSCH Connectors

Section 03: Theory of Operation

Group 130: Electronic Fuel System Operation

About This Group

Low Pressure Fuel System Flow Diagram

Low Pressure Fuel Supply System Operation

Electronic Unit Injector (EUI) Operation

Group 140: Electrical Control System Operation

Electronic Control System Glossary of Terms

Electronic Control System Overview

Electronic Control System Operation

Monitoring Engine Parameters

Measuring Temperature

Measuring Manifold Air Pressure

Measuring Throttle Position

Determining Engine Airflow

Determining Engine Speed and Piston Position

Engine Control Unit (ECU)

Pilot Injection Operation

Governor Modes

Maximum Fuel Quantity Control

Engine Control Unit (ECU) Self-Diagnosis

Section 04: Diagnostics

Group 150: Observable Diagnostics and Tests

Time study test block

About this Group of the Manual

Lucas ECU - Diagnosing Engine Malfunctions

Lucas ECU - Diagnosing Low Pressure Fuel System Malfunctions

B1 - ECU Does Not Communicate With DST

B2 - Engine Cranks/No Start or Starts Hard (DST Available)

B3 - Engine Cranks/No Start or Starts Hard (DST Not Available)

B4 - Engine Misfires/Runs Irregularly

B5 - Low Power/Excessive Black Smoke (DST Available)

B6 - Low Power/Excessive Black Smoke (DST Not Available)

B7 - Fuel Supply System Check

B8 - Excessive Fuel Filter Replacement

Check Fuel Supply Pressure

Bleed the Fuel System

Group 160: Trouble Code Diagnostics and Tests

About This Group of the Manual

Electrical Concepts

Electrical Circuit Malfunctions

Troubleshooting Circuit Malfunctions

Using a Digital Multimeter

Using the Break-Out-Box (BOB)

Cylinder Cutout Test Using JDG1250

Data Parameter Description

Diagnostic Scan Tool (DST) Engine Test Instructions—Cylinder Misfire Test

Diagnostic Scan Tool (DST) Engine Test Instructions—Relative Compression Test

Listing of Diagnostic Trouble Codes (DTCs)

John Deere Instrument (Gauge) Panel (Continued)

Diagnostic Procedure

Intermittent Fault Diagnostics

Engine 011 - Analog Throttle Input Voltage Too High

Engine 012 - Analog Throttle Input Voltage Too Low

Engine 013 - PWM Throttle Input Too High

Engine 014 - PWM Throttle Input Too Low

Engine 021 - MAP Input Voltage Too High

Engine 022 - MAP Input Voltage Too Low

Engine 023 - MAT Input Voltage Too High

Engine 024 - MAT Input Voltage Too Low

Engine 025 - ECT Input Voltage Too High

Engine 026 - ECT Input Voltage Too Low

Engine 027 - Fuel Rail Pressure Periodically Low

Engine 028 - Fuel Rail Pressure Continuously Low

Engine 031 - Cylinder 1 EUI Fault

Engine 032 - Cylinder 2 EUI Fault

Engine 033 - Cylinder 3 EUI Fault

Engine 034 - Cylinder 4 EUI Fault

Engine 035 - Cylinder 5 EUI Fault

Engine 036 - Cylinder 6 EUI Fault

Engine 037 - Fuel Temperature Input Voltage Too High

Engine 038 - Fuel Temperature Input Voltage Too Low

Engine 041 - Crank Position Input Missing

Engine 042 - Crank Position Input Out of Sync

Engine 043 - Cam Position Input Missing

Engine 044 - Cam Position Input Out of Sync

Engine 045 - Cam/Crank Inputs Out of Sync

Engine 050 - Fuel Rail Pressure Switch Fault

Engine 052 - MAP Input Voltage Erratic

Engine 053 - MAT Input Voltage Erratic

Engine 054 - ECT Input Voltage Erratic

Engine 055 - Fuel Temp Input Voltage Erratic

Engine 081 - Engine Control Unit (ECU) Error

Engine 084 - Power Down Error

Section 05: Tools

Group 170: Special Tools

JDG107

JDG139

JDG140

JDG141

JDG142

JDG143

JDG144

JDG145

JDG360

JDG361

JDG362

JDG363

JDG364

JDG707

JDG776

JDG777

JDG783

JDG785

JDG820

JDG865

JDG971

JDG998

JDG1334

JDG10466

JDG11100A

JDIS121

JDIS122

JT02171

JT03513C

JT05412

JT07306

JT07328

Section 06: Specifications

Group 200: Repair Specifications

Unified Inch Bolt and Screw Torque Values

Metric Bolt and Screw Torque Values

General OEM Engine Specifications

Fuel System Repair Specifications

Electronic Engine Control System Specifications

Group 210: Diagnostic Specifications

Fuel System Diagnostic Specifications

Torque Curve Selection

ECU Terminal Identification

6105H/6125H Engines Electronic Control System Component Location

10.5 L & 12.5 L Electronic Control System Wiring Diagram

10.5 L & 12.5 L OEM Application (With John Deere Instrument Panel) Electronic Control System Wiring Diagram