John Deere PowerTech 4.5L & 6.8L Diesel Engines Level 4 Electronic Fuel Systems workshop service repair manual CTM170 PDF - MJODCTM170.zip

A full-service repair guide featuring Electrical Wiring Diagrams for the John Deere PowerTech 4.5 L and 6.8 L Diesel Engines Level 4 Electronic Fuel Systems, packed with everything needed to service, troubleshoot, fix, and overhaul these engines the way trained technicians do.

Inside the John Deere PowerTech 4.5 L and 6.8 L Diesel Engines Level 4 Electronic Fuel Systems service repair manual, you'll find:

* 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.

ctm170 - PowerTech 4.5 L and 6.8 L OEM Diesel Engines Level 4 Electronic Fuel Systems With Bosch VP44 Pump (Worldwide Edition) Component Technical Manual.pdf

PRODUCT DETAILS:

Total Pages: 882 pages

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

Language: English

TABLE OF CONTENTS....1

Section 01: General....17

Group 000: Safety....17

Avoid Heating Near Pressurized Fluid Lines....20

Avoid High-Pressure Fluids....21

Avoid Static Electricity Risk When Refueling....22

Construct Dealer-Made Tools Safely....24

Decommissioning — Proper Recycling and Disposal of Fluids and Components....25

Follow Safety Instructions....26

Handle Agricultural Chemicals Safely....27

Handle Fluids Safely—Avoid Fires....29

Handle Starting Fluid Safely....30

Handling Batteries Safely....31

Illuminate Work Area Safely....33

Install All Guards....34

Live With Safety....35

Practice Safe Maintenance....36

Prepare for Emergencies....38

Prevent Acid Burns....39

Prevent Battery Explosions....41

Prevent Machine Runaway....42

Protect Against High Pressure Spray....43

Protect Against Noise....44

Recognize Safety Information....45

Remove Paint Before Welding or Heating....46

Replace Safety Signs....47

Service Cooling System Safely....48

Service Machines Safely....49

Stay Clear of Rotating Drivelines....50

Understand Signal Words....51

Use Proper Lifting Equipment....52

Use Proper Tools....53

Wear Protective Clothing....54

Work in Clean Area....55

Work In Ventilated Area....56

Group 001: Engine Identification....18

Engine Model Designation....59

Engine Serial Number Plate Information....61

OEM Engine Option Code Label....64

Engine Application Chart....65

Tier 1 vs. Tier 2....67

Group 002: Fuels....18

Lubricants and Coolant....70

Diesel Fuel....71

Diesel Fuel Additive Products....73

BioDiesel Fuel....74

Testing Diesel Fuel....76

Lubricity of Diesel Fuel....77

Section 02: Repair and Adjustments....78

Group 090: Electronic Fuel System Repair and Adjustments....78

Fuel System—General Information....81

Relieve Fuel System Pressure....82

Remove and Install Primary Fuel Filter/Water Separator Base - Tier 2....83

Remove and Install Final Fuel Filter/Water Separator Base - Tier 1....85

Remove and Install Final Fuel Filter/Water Separator Base - Tier 2....87

Final Fuel Filter Assembly - Tier 1....89

Final Fuel Filter Assembly - Tier 2....91

Replace Final Fuel Filter Element....93

Remove and Install Electronic Fuel Transfer Pump - Filter Mount....95

Remove and Install Electronic Fuel Transfer Pump - Remote Mount....97

Service Injection Pump Overflow Valve....99

Bosch VP44 Injection Pump Static Timing....100

Remove Bosch VP44 Fuel Injection Pump....102

Repair Bosch VP44 Fuel Injection Pump....105

Install Bosch VP44 Fuel Injection Pump....106

Remove Fuel Injection Nozzles....111

Clean Fuel Injection Nozzle Bore....113

Clean Fuel Injection Nozzles....114

Test Fuel Injection Nozzles....115

Disassemble Fuel Injection Nozzles....119

Inspect and Clean Fuel Injection Nozzle Body....123

Inspect and Clean Valve and Valve Seat....125

Inspect Valve Adjusting Mechanism....127

Assemble Fuel Injection Nozzles....128

Adjust Fuel Injection Nozzles....130

Install Seals on Fuel Injection Nozzle....135

Install Fuel Injection Nozzles....136

Group 110: Electrical Engine Control Repair and Adjustment....78

Engine Control Unit (ECU)....208

Remove and Install Engine Coolant Temperature Sensor....140

Replace Fuel Pressure Sensor....142

Replace Pump Position Sensor....144

Replace Crankshaft Position Sensor....145

Remove and Install Oil Pressure Sensor....146

Connectors....147

Use Electrical Insulating Compound....148

Using High-Pressure Washer....149

Repair WEATHERPACK WEATHERPACK is a trademark of Packard Electric Connector....79

Remove Blade Terminals from Connector Body....153

Repair (Pull Type) METRI-PACK METRI-PACK is a trademark of Delphi Packard Electric Systems Connectors....147

Repair (Push Type) METRI-PACK METRI-PACK is a trademark of Delphi Packard Electric Systems Connectors....147

Repair DEUTSCH Connectors....160

Repair AMP Connector....163

Section 03: Theory of Operation....166

Group 130: Electronic Fuel System Operation....166

About this Group....169

Fuel System Operation - Tier 1....170

Fuel System Operation - Tier 2....172

Primary Fuel Filter Operation - Tier 1....174

Primary Fuel Filter Operation - Tier 2....175

Final Fuel Filter Operation - Tier 1....176

Final Fuel Filter Operation - Tier 2....178

Fuel Injection Pump Operation....180

Fuel Injection Nozzle Operation....182

Group 140: Electronic Control System Operation....188

About This Group....185

Electronic Control System Terminology....186

Electronic Control System Operation....188

Monitoring Engine Parameters....189

Electronic Control System Overview - Tier 1....190

Electronic Control System Overview - Tier 2....192

Measuring Temperature....194

Measuring Pressure....197

Measuring Throttle Position....199

Measuring Engine Speed....203

Electronic Fuel Transfer Pump....204

Water in Fuel (WIF) Sensor....206

Pump Control Unit....207

Engine Control Unit (ECU)....208

Controlled Area Network (CAN)....210

Intake Air Heater Operation....211

Cruise Control Operation....212

Engine Protection....213

Derate Programs....214

Multiple Torque Curve Selection....215

Governor Droop Mode Selection....216

Engine Control Unit (ECU) Self-Diagnosis....217

Section 04: Diagnostics....219

Group 150: Observable Diagnostics and Tests....219

About This Group of the Manual....229

E1 - Engine Cranks/Won't Start....219

E2 - Engine Misfires/Runs Irregularly....219

E3 - Engine Does Not Develop Full Power....219

E4 - Engine Emits Excessive White Exhaust Smoke....219

E5 - Engine Emits Excessive Black Or Gray Smoke....219

E6 - Engine Will Not Crank....219

E7 - Engine Idles Poorly....219

E8 - Abnormal Engine Noise....219

E10 - Analog Throttle (B) Does Not Respond....219

F1 - Fuel Supply System Check - Tier 1....263

F1 - Fuel Supply System Check - Tier 1....263

F2 - Excessive Fuel Consumption....219

F3 - Fuel in Oil....219

F4 - Fuel Supply System Check - Tier 2....275

F4 - Fuel Supply System Check - Tier 2....275

F5 - Fuel Injection Nozzle Check....219

F6 - Excessive Fuel Filter Replacement....289

D1 - ECU Does Not Communicate With DST or SERVICE ADVISOR SERVICE ADVISOR is a trademark of Deere & Company....219

D1 - ECU Does Not Communicate With DST or SERVICE ADVISOR SERVICE ADVISOR is a trademark of Deere & Company....219

D2 - Diagnostic Gauge (Earlier Model) Does Not Communicate With ECU....299

D2 - Diagnostic Gauge (Earlier Model) Does Not Communicate With ECU....299

D3 - Diagnostic Gauge (Later Model) Does Not Communicate With ECU....306

D3 - Diagnostic Gauge (Later Model) Does Not Communicate With ECU....306

A1 - Intake Air Heater Check....312

A1 - Intake Air Heater Check....312

Check Fuel Supply Quality - Tier 1....319

Check Fuel Supply Quality - Tier 2....321

Test for Fuel Drain Back....322

Test for Air in Fuel - Tier 1....323

Test for Air in Fuel - Tier 2....325

Check Fuel Supply Pressure....327

Bleed the Fuel System....328

Load Profile Information Test — Instructions....331

Load Profile Information Test — Instructions (Service ADVISOR 5)....335

Test for Cylinder Misfire (Engine Running)....337

Group 160: Trouble Code Diagnostics and Tests....220

About this Group of the Manual....339

Electrical Concepts....340

Using a Digital Multimeter....341

Electrical Circuit Malfunctions....342

Troubleshooting Circuit Malfunctions....345

Connecting to Diagnostic Scan Tool (DST)....349

Connecting to Service ADVISOR....353

Engine Configuration Data Parameters on Diagnostic Gauge (Earlier Model)....355

Viewing Active DTCs on Diagnostic Gauge (Earlier Model)....358

Viewing Stored DTCs on Diagnostic Gauge (Earlier Model)....359

Clearing Stored DTCs on Diagnostic Gauge (Earlier Model)....360

Viewing Active DTCs on Diagnostic Gauge (Later Model)....362

Viewing Stored DTCs on Diagnostic Gauge (Later Model)....365

Clearing Stored DTCs on Diagnostic Gauge (Later Model)....367

Blinking DTCs Using Diagnostic Blink Code Connector....368

Data Parameter Description....370

Cylinder Misfire Test Instructions....376

Engine Test Instructions — Compression Test....378

Engine Test Instructions— Cylinder Cutout Test....383

Engine Test Instructions - Excavator Torque Curve Change Test....387

Engine Test Instructions - Tractor Torque Curve Change Test....388

Engine Control Unit (ECU) — Level Identification....389

Engine Control Unit (ECU) — Donating this Engine’s ECU to be Used Elsewhere....390

Engine Control Unit (ECU) — Replacing Current ECU with Another ECU....394

Engine Control Unit (ECU) — Replacing Current ECU with Another ECU — Cannot Communicate with Current ECU....396

Engine Control Unit (ECU) — Reprogramming Current ECU....398

Engine Control Unit (ECU) — Reprogramming Instructions....399

Software and Hardware Verification....401

Downloading Payload File For DST....404

Reprogramming Engine Control Unit (ECU) With DST....409

Diagnostic Trouble Codes (DTCs)....413

Listing of Diagnostic Trouble Codes (DTCs) on ECU....414

Diagnostic Procedure....418

Intermittent Fault Diagnostics....419

T1 - Multi-state Throttle Input High....422

T1 - Multi-state Throttle Input High....422

T2 - Multi-state Throttle Input Low....427

T2 - Multi-state Throttle Input Low....427

T3 - Analog Throttle (A) Input High....431

T3 - Analog Throttle (A) Input High....431

T4 - Analog Throttle (A) Input Low....437

T4 - Analog Throttle (A) Input Low....437

T5 - Analog Throttle (B) Input High....443

T5 - Analog Throttle (B) Input High....443

T6 - Analog Throttle (B) Input Low....449

T6 - Analog Throttle (B) Input Low....449

T7 - CAN Throttle Invalid....454

T7 - CAN Throttle Invalid....454

T11 - Excavator Throttle Reference Voltage High....458

T11 - Excavator Throttle Reference Voltage High....458

T12 - Excavator Throttle Reference Voltage Low....462

T12 - Excavator Throttle Reference Voltage Low....462

T13 - Excavator Throttle Ground Voltage High....466

T13 - Excavator Throttle Ground Voltage High....466

T14 - Excavator Throttle Ground Voltage Low....470

T14 - Excavator Throttle Ground Voltage Low....470

T15 - Excavator Throttle Input Voltage High....474

T15 - Excavator Throttle Input Voltage High....474

T16 - Excavator Throttle Input Voltage Low....478

T16 - Excavator Throttle Input Voltage Low....478

T17 - Analog Throttle (C) Input High....482

T17 - Analog Throttle (C) Input High....482

T18 - Analog Throttle (C) Input Low....487

T18 - Analog Throttle (C) Input Low....487

000028.03 - Throttle Voltage High....222

000028.04 - Throttle Voltage Low....222

000029.03 - Throttle Voltage High....222

000029.04 - Throttle Voltage Low....222

000084.02 — Vehicle Speed Mismatch....495

000084.02 - Vehicle Speed Mismatch....222

000091.03 - Throttle Voltage High....222

000091.04 - Throttle Voltage Low....222

000091.09 - Throttle Invalid....222

000094.01 — Fuel Supply Pressure Extremely Low....503

000094.01 - Fuel Supply Pressure Extremely Low....222

000094.03 — Fuel Supply Pressure Input Voltage High....506

000094.03 - Fuel Supply Pressure Input Voltage High....222

000094.04 — Fuel Supply Pressure Input Voltage Low....510

000094.04 - Fuel Supply Pressure Input Voltage Low....222

000094.18 — Fuel Supply Pressure Moderately Low....516

000094.18 - Fuel Supply Pressure Moderately Low....222

000097.00 — Water in Fuel Continuously Detected....519

000097.00 - Water in Fuel Continuously Detected....222

000097.16 — Water in Fuel Detected....522

000097.16 - Water in Fuel Detected....222

000100.01 — Engine Oil Pressure Extremely Low....525

000100.01 - Engine Oil Pressure Extremely Low....222

000100.03 — Engine Oil Pressure Input Voltage High....529

000100.03 - Engine Oil Pressure Input Voltage High....222

000100.04 Engine Oil Pressure Input Voltage Low....533

000100.04 - Engine Oil Pressure Input Voltage Low....222

000100.18 — Engine Oil Pressure Moderately Low....539

000100.18 - Engine Oil Pressure Moderately Low....223

000105.00 — Manifold Air Temperature Extremely High....542

000105.00 - Manifold Air Temperature Extremely High....223

000105.03 — Manifold Air Temperature Input Voltage High....546

000105.03 - Manifold Air Temperature Input Voltage High....223

000105.04 Manifold Air Temperature Input Voltage Low....550

000105.04 - Manifold Air Temperature Input Voltage Low....223

000105.16 — Manifold Air Temperature Moderately High....554

000105.16 - Manifold Air Temperature Moderately High....223

000107.00 — Air Filter Differential Pressure....557

000107.00 - Air Filter Differential Pressure....223

000110.00 — Engine Coolant Temperature Extremely High....560

000110.00 - Engine Coolant Temperature Extremely High....223

000110.03 — Engine Coolant Temperature Input Voltage High....564

000110.03 - Engine Coolant Temperature Input Voltage High....223

000110.04 — Engine Coolant Temperature Input Voltage Low....569

000110.04 - Engine Coolant Temperature Input Voltage Low....223

000110.15 — Engine Coolant Temperature High Least Severe....574

000110.15 - Engine Coolant Temperature High Least Severe....223

000110.16 — Engine Coolant Temperature Moderately High....577

000110.16 - Engine Coolant Temperature Moderately High....223

000111.01 — Engine Coolant Level Low....580

000111.01 - Engine Coolant Level Low....223

000158.17 — ECU Power Down Error....584

000158.17 - ECU Power Down Error....223

000174.00 — Fuel Temperature High Most Severe....587

000174.00 - Fuel Temperature High Most Severe....223