John Deere PowerTech E 4.5L & 6.8L Diesel Engines 4045 6068 Component Workshop Repair Service Manual CTM502 PDF - MJODCTM502.zip
A Component Technical Manual featuring complete electrical wiring diagrams for the John Deere PowerTech E 4.5L and 6.8L diesel engines, containing every piece of shop-level guidance needed to service, troubleshoot, fix, and rebuild these units just like a seasoned professional technician.
This workshop service and repair manual for the John Deere PowerTech E 4.5L & 6.8L diesel engines delivers:
* 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.
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PRODUCT DETAILS:
Total Pages: 1,501 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
ctm502 - 4045-6068 Diesel Engine — Level 16 ECU -: (Worldwide Edition) Component Technical Manual - Table of Contents
Foreword
Trademarks
Section 01: General
Group 000: Safety
Avoid Heating Near Pressurized Fluid Lines
Avoid High-Pressure Fluids
Avoid Hot Exhaust
Avoid Static Electricity Risk When Refueling
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 Serial Number Plate Information
OEM Engine Option Code Label
Information Relative to Emissions Regulations
Emissions Control System Certification Label
Group 002: Fuels, Lubricants, and Coolant
Diesel Fuel
Diesel Fuel Additive Products
BioDiesel Fuel
Minimizing the Effect of Cold Weather on Diesel Engines
Handling and Storing Diesel Fuel
Lubricity of Diesel Fuel
Testing Diesel Fuel
Engine Oil and Filter Service Intervals
Diesel Engine Oil — Tier 3 and Stage III
Diesel Engine Break-In Oil — Non-Emissions Certified and Certified Tier 1, Tier 2, Tier 3, Stage I, Stage II, and Stage III
Oil Filters
Grease
Alternative and Synthetic Lubricants
Lubricant Storage
Mixing of Lubricants
Diesel Engine Coolant (engine with wet sleeve cylinder liners)
Supplemental Coolant Additives
Operating in Warm Temperature Climates
Additional Information About Diesel Engine Coolants and John Deere LIQUID COOLANT CONDITIONER
Diesel Engine Coolant
Testing Diesel Engine Coolant
Drain Intervals for Diesel Engine Coolant
Section 02: Repair and Adjustments
Group 090: Electronic Fuel System Repair and Adjustments
Fuel System - General Information
Relieve Fuel System Pressure
Fuel System Components
Replace Fuel Filter Element (Primary or Final)
Remove and Install Fuel Filter Base (Primary and Final)
Remove Fuel Transfer Pump
Install Fuel Transfer Pump
Remove and Install High-Pressure Fuel Pump
Remove and Install Suction Control Valve
Remove and Install High-Pressure Common Rail
Remove and Install Flow Dampers
Remove and Install Pressure Limiter
Remove and Install Fuel Injection Wire Harness Assembly
Injector Identification Tag Information
Remove Electronic Injector (EI)
Clean Electronic Injector (EI) Bore
Clean Electronic Injector (EI) Orifice
Clean Electronic Injector (EI) Body
Inspect Electronic Injector (EI) Body
Install Electronic Injector (EI)
Remove and Install Fuel Leak-Off Line
Clean Electronic injectors (In Engine)
Group 110: Electronic Engine Control Repair and Adjustment
Engine Control Unit (ECU) Maintenance
Welding
High Pressure Washing
Remove and Install Engine Control Unit (ECU) on Engine (Optional Equipment)
Remove and Install Adaptation Parts for Engine Control Unit (ECU) Mounted on Engine (Optional Equipment)
Remove and Install Engine Coolant Temperature (ECT) Sensor
Remove and Install Fuel Temperature Sensor
Remove and Install Manifold Air Temperature (MAT) Sensor
Remove and Install Oil Pressure Sensor
Remove and Install Fuel Rail Pressure Sensor
Remove and Install Fuel Transfer Pump Pressure Sensor
Remove and Install Crankshaft Position Sensor
Remove and Install Pump Position Sensor
Remove and Install Water-In-Fuel (WIF) Sensor
Install Wiring Harness for Engine Mount ECU
Install Wiring Harness for Remote ECU
Connectors
Connector Repair
Installation of Repair Wire Assembly (RWA)
Repair WEATHERPACK Connector
Repair Cinch FlexBox Connector
Repair Metri-Pack Connectors (Push Type)
Repair DT Series DEUTSCH Connectors
Repair HD Series DEUTSCH Connectors
Section 03: Theory Of Operation
Group 130: Electronic Fuel System Operation
About This Group
Fuel System Operation
Prefilter Operation
Mechanical Fuel Transfer Pump Operation
Electric Fuel Transfer Pump Operation
Final Fuel Filter Operation
Type 1 High Pressure Fuel Pump Operation
High Pressure Common Rail (HPCR) Operation
Electronic Injector (EI) Operation
Group 135: Air and Exhaust Operation
Air Intake and Exhaust System Operation
Air Cleaner Operation
Turbocharger Operation
How the Turbocharger Is Lubricated
Group 140: Electronic Control System Operation
About This Group
Electronic Control System Terminology
Electronic Control Unit (ECU) System Operation
Component Location Diagram 1
Component Location Diagram 2
Component Location Diagram 3
Component Location Diagram 4
Component Location Diagram 5
Component Location Diagram 6
Component Location Diagram 7
Component Location Diagram 8
Component Location Diagram 9
Component Location Diagram 10
Component Location Diagram 11
Component Location Diagram 12
Component Location Diagram 13
Component Location Diagram 14
Component Location Diagram 15
Component Location Diagram 16
Engine Control Unit (ECU)
Controller Area Network (CAN)
Pilot Injection Operation
Monitoring Engine Parameters
Measuring Temperature
Engine Control Unit (ECU) Temperature Sensor
Engine Coolant Temperature (ECT) Sensor
Fuel Temperature Sensor
Intake Manifold Air Temperature (MAT)
Turbo Turbine Inlet Temperature
Measuring Pressure
Barometric Air Pressure (BAP) Sensor
Fuel Rail Pressure Sensor
Fuel Transfer Pump Pressure Sensor
Manifold Air Pressure (MAP) Sensor
Oil Pressure Sensor
Dual Fuel Rail Pressure Sensor (Redundant ECU Applications)
Measuring Speed
Crank Position Sensor
Pump Position Sensor
Throttle Descriptions
CAN Throttle
Pulse-Width-Modulated (PWM) Throttle
Analog Throttle
Digital Multi-State Throttle
Dual-State Throttle
Tri-State Throttle
Ramp Throttle
Throttle Adjustments
Throttle Offsets
Self-Calibration
Combination Throttle
Marine Throttle
Engine Derate and Shutdown Protection
Electronic Injector (EI) Wiring Harness Connector
Intake Air Heater Operation
Torque Curve Selection
Governor Droop Mode Selection
Suction Control Valve
Water in Fuel (WIF) Sensor
Cruise Control Operation
Power Supply #1
Power Supply #2
Power Supply #3
Section 04: Diagnostics
Group 150: Observable Diagnostics and Tests
About This Group
E1 - Engine Cranks/Won't Start
E2 - Engine Misfires/Runs Irregularly
E3 - Engine Does Not Develop Full Power
E4 - Engine Emits Excessive White Exhaust
E5 - Engine Emits Excessive Black or Gray Exhaust
E6 - Engine Will Not Crank
E7 - Engine Idles Poorly
E8 - Abnormal Engine Noise
E9 - Primary Analog Throttle Does Not Respond
E10 - Secondary Analog Throttle Does Not Respond
F1 - Low-Pressure Fuel Supply System Test
F2 - High-Pressure Fuel Supply System Test
F3 - Excessive Fuel Consumption
F4 - Fuel in Oil
F5 - Excessive Fuel Filter Replacement
D1 - ECU Does Not Communicate with Service ADVISOR
D2 - ECU Does Not Communicate with Diagnostic Gauge or Gauge Displays CAN Bus Error
D5 - ECU Does Not Program With Service ADVISOR
A1 - Intake Air Heater Check
Bleed the Fuel System
Charge Air Cooler Test
Charge Air System
Check and Adjust High-Pressure Fuel Pump Static Timing
Check Engine Oil Pressure
Check for Restricted Fuel Leak-off Line
Check Fuel Supply Quality
Cylinder Leak-Down Test
Cooling System Test
EGR Cooler Test
Engine Coolant Temperature Below Normal
Excessive Engine Crankcase Pressure (Blow-By) Test
Test for Air in Fuel
Thermostat — Testing
Group 160: Trouble Code Diagnostics and Tests
About This Group
Change Fan Speed Table
Communication Error Test Instructions
Connecting to Service ADVISOR
Control Unit Information and Overview Test
Cylinder Cutout Test Instructions
Cylinder Electronic Compression Test Instructions
Cylinder Misfire Test Instructions
Diagnostic Gauge Active DTC Viewing Instructions
Diagnostic Gauge Data Parameters Viewing Instructions
Diagnostic Gauge Stored DTC Clearing Instructions
Diagnostic Gauge Stored DTC Viewing Instructions
Diagnostic Test Box — Using
Diagnostic Trouble Code Designations
Diagnostic Trouble Code List
Digital Multimeter — Using
Electrical Circuit Concepts
Electrical Noise — Possible Causes
Electronic Injector — Calibration Information
Engine Hours — Updating Instructions
Failure Mode Indicator Designations
Fuel Rail Cap and Plug Kit
Harness Diagnostic Mode Test
Interactive Tests and Calibration Results — Printing, Exporting, or Saving Instruction
Intermittent DTC Diagnostics
Internal Data Monitor — Instructions
Keep Electronic Control Unit Connectors Clean
Load Profile Information Test — Instructions
Engine Control Unit (ECU) — Level Identification
Engine Control Unit (ECU) — Donating this Engine’s ECU to be Used Elsewhere
Engine Control Unit (ECU) — Replacing Current ECU with Another ECU
Engine Control Unit (ECU) — Replacing Current ECU with Another ECU — Cannot Communicate with Current ECU
Engine Control Unit (ECU) — Reprogramming Current ECU
Engine Control Unit (ECU) — Reprogramming Instructions
Problem Not Found Procedure
Service Advisor Data Parameter Description
Short to Voltage Procedure
Snapshot Instructions
Software and Hardware Verification