John Deere PowerTech 4.5L 6.8L Diesel Engines Level 11 Denso HPCR Fuel System Component Technical Manual CTM220 PDF - MJODCTM220.zip
Full Component Service Guide covering John Deere PowerTech 4.5L and 6.8L Diesel Engines, Level 11 Electronic Fuel System equipped with Denso HPCR.
This workshop-level technical service document for the John Deere PowerTech 4.5L and 6.8L diesel engines with the Level 11 Electronic Fuel System and Denso HPCR covers:
* 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.
ctm220 - PowerTechTM 4.5 L and 6.8 L Diesel Engines Level 11 Electronic Fuel System With Denso HPCR (Worldwide Edition) Component Technical Manual.epub
ctm220 - PowerTechTM 4.5 L and 6.8 L Diesel Engines Level 11 Electronic Fuel System With Denso HPCR (Worldwide Edition) Component Technical Manual.pdf
CTM220 (21JAN04) - John Deere PowerTech 4.5L & 6.8L Diesel Engines - John Deere Level 11 Electronic Fuel System with Denso HPCR Technical Manual.pdf
PRODUCT DETAILS:
Total Pages: 675 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English
TABLE OF CONTENTS....1
Section 01: General....16
Group 000: Safety....16
Handle Fluids Safely—Avoid Fires....19
Handle Starting Fluid Safely....20
Service Cooling System Safely....21
Prevent Battery Explosions....22
Prepare for Emergencies....23
Handling Batteries Safely....24
Avoid High-Pressure Fluids....27
Avoid Static Electricity Risk When Refueling....28
Wear Protective Clothing....30
Service Machines Safely....31
Work In Ventilated Area....32
Work in Clean Area....33
Remove Paint Before Welding or Heating....34
Avoid Heating Near Pressurized Fluid Lines....35
Illuminate Work Area Safely....36
Use Proper Lifting Equipment....37
Construct Dealer-Made Tools Safely....38
Practice Safe Maintenance....39
Use Proper Tools....41
Decommissioning — Proper Recycling and Disposal of Fluids and Components....42
Live With Safety....43
Group 001: Engine Identification....16
Engine Model Designation....46
Engine Serial Number Plate Information....48
OEM Engine Option Code Label....51
Information Relative to Emissions Regulations....52
Group 002: Fuels, Lubricants, and Coolant....16
Lubricants and Coolant....54
Diesel Fuel....55
Diesel Fuel Additive Products....56
Bio-Diesel Fuel....57
Testing Diesel Fuel....58
Lubricity of Diesel Fuel....59
Section 02: Repair and Adjustments....60
Group 090: Electronic Fuel System Repair and Adjustments....60
Fuel System - General Information....63
Relieve Fuel System Pressure....64
Remove and Install Pre-Filter/Water Bowl Base....65
Replace Pre-Filter Element....67
Remove and Install Final Fuel Filter/Water Bowl Base....69
Replace Final Fuel Filter Element....71
Remove Fuel Transfer Pump....73
Install Fuel Transfer Pump....75
Remove and Install Suction Control Valve....76
Remove and Install High-Pressure Fuel Pump....81
Remove and Install High Pressure Fuel Pump Inlet Filter....85
Remove and Install High Pressure Common Rail....86
Remove and Install Flow Dampers....88
Remove and Install Pressure Limiter....91
Remove Electronic Injectors (EIs)....93
Clean Electronic Injector (EI) Bore....95
Clean Electronic Injector (EI) Orifice....96
Clean Electronic Injector (EI) Body....97
Inspect Electronic Injector (EI) Body....98
Install Electronic Injectors (EIs)....99
Remove and Install Leak-off Lines....102
Clean Electronic injectors (In Engine)....105
Group 110: Electronic Engine Control Repair and Adjustment....60
Engine Control Unit (ECU)....187
Remove and Install Engine Coolant Temperature (ECT) Sensor....109
Remove and Install Fuel Temperature Sensor....110
Remove and Install Manifold Air Temperature (MAT) Sensor....111
Remove and Install Oil Pressure Sensor....112
Remove and Install Fuel Rail Pressure Sensor....113
Remove and Install Crank Position Sensor....115
Remove and Install Pump Position Sensor....116
Remove and Install Glow Plugs....117
Connectors....119
Use Electrical Insulating Compound....120
Using High-Pressure Washer....121
Repair WEATHERPACK Connector....122
Remove Blade Terminals from Connector Body....125
Repair (Pull Type) METRI-PACK Connectors....126
Repair (Push Type) METRI-PACK Connectors....129
Repair DEUTSCH Connectors....132
Repair AMP Connector....135
Repair SUMITOMO™ Connectors....138
Repair YAZAKI™ Connectors....140
Section 03: Theory Of Operation....142
Group 130: Electronic Fuel System Operation....146
About This Group....326
Fuel System Operation....146
Prefilter Operation....148
Fuel Transfer Pump Operation....150
Final Fuel Filter Operation....153
High Pressure Fuel Pump Operation....154
High Pressure Common Rail (HPCR) Operation....155
Electronic Injector (EI) Operation....156
Group 140: Electronic Control System Operation....163
About This Group....326
Electronic Control System Terminology....161
Electronic Control System Operation....163
Electronic Control System Overview....164
Monitoring Engine Parameters....166
Measuring Temperature....168
Measuring Pressure....172
Measuring Throttle Position....177
Measuring Speed....182
Measuring Speed....182
Pump Control Valve (PCV)....184
Water in Fuel (WIF) Sensor....185
Electronic Injector (EI) Wiring Harness Connector....186
Engine Control Unit (ECU)....187
Controlled Area Network (CAN)....189
Pilot Injection Operation....190
Glow Plug Operation....191
Cruise Control Operation....192
Engine Protection....193
Derate Programs....194
Multiple Torque Curve Selection....195
Governor Droop Mode Selection....196
Engine Control Unit (ECU) Self-Diagnosis....197
Section 04: Diagnostics....199
Group 150: Observable Diagnostics and Tests....199
About This Group....326
E1 - Engine Cranks/Won't Start....199
E2 - Engine Misfires/Runs Irregularly....199
E3 - Engine Does Not Develop Full Power....199
E4 - Engine Emits Excessive White Exhaust Smoke....199
E5 - Engine Emits Excessive Black Or Gray Exhaust Smoke....199
E6 - Engine Will Not Crank....199
E7 - Engine Idles Poorly....199
E8 - Abnormal Engine Noise....199
E9 - Analog Throttle (A) Does Not Respond....199
E10 - Analog Throttle (B) Does Not Respond....199
F1 - Fuel Supply System Check....199
F2 - Excessive Fuel Consumption....199
F3 - Fuel in Oil....199
F4 - Excessive Fuel Filter Replacement....251
ECU Does Not Communicate with Service ADVISOR....199
D1 - ECU Does Not Communicate with DST or SERVICE ADVISOR....260
D1 - ECU Does Not Communicate with DST or SERVICE ADVISOR SERVICE ADVISOR is a trademark of Deere & Company....199
D2 - Diagnostic Gauge (Earlier Model) Does Not Communicate With ECU....267
D2 - Diagnostic Gauge (Earlier Model) Does Not Communicate With ECU....267
D3 - Diagnostic Gauge (Later Model) Does Not Communicate With ECU....274
D3 - Diagnostic Gauge (Later Model) Does Not Communicate With ECU....274
A2 - Glow Plug Check....282
A2 - Glow Plug Check....282
A2 - Glow Plug Check....282
Check Fuel Supply Quality....290
Test for Air in Fuel....292
Check Fuel Supply Pressure....294
Check for Restricted Fuel Leak-off Line....296
Bleed the Fuel System....297
Check and Adjust High Pressure Fuel Pump Static Timing....300
Load Profile Information Test — Instructions....301
Primary CAN Diagnostic Procedure....404
Terminal Test....200
Diagnostic Test Box — Using....316
Group 160: Trouble Code Diagnostics and Tests....200
About This Group....326
Electrical Concepts....327
Using a Digital Multimeter....328
Electrical Circuit Malfunctions....329
Troubleshooting Circuit Malfunctions....332
Connecting to Diagnostic Scan Tool (DST)....336
Connecting to Service ADVISOR....340
Blinking DTCs....342
Viewing Active DTCs on Diagnostic Gauge (Earlier Model)....343
Viewing Stored DTCs on Diagnostic Gauge (Earlier Model)....344
Clearing Stored DTCs on Diagnostic Gauge (Earlier Model)....345
Engine Configuration Parameters on Diagnostic Gauge (Earlier Model)....347
Viewing Active DTCs on Diagnostic Gauge (Later Model)....350
Viewing Stored DTCs on Diagnostic Gauge (Later Model)....353
Clearing Stored DTCs on Diagnostic Gauge (Later Model)....355
Data Parameter Description....356
Engine Test Instructions—Cylinder Misfire Test....361
Engine Test Instructions—Compression Test....363
Engine Test Instructions— Cylinder Cutout Test....368
Fuel Rail Cap and Plug Kit....369
Engine Test Instructions— Tractor Torque Curve Change Test....371
Engine Control Unit (ECU) — Level Identification....372
Engine Control Unit (ECU) — Donating this Engine’s ECU to be Used Elsewhere....373
Engine Control Unit (ECU) — Replacing Current ECU with Another ECU....377
Engine Control Unit (ECU) — Replacing Current ECU with Another ECU — Cannot Communicate with Current ECU....379
Engine Control Unit (ECU) — Reprogramming Current ECU....381
Engine Control Unit (ECU) — Reprogramming Instructions....382
Software and Hardware Verification....384
Downloading Payload File For DST....387
Reprogramming Engine Control Unit (ECU) With DST....392
Diagnostic Trouble Codes (DTCs)....396
Listing of Diagnostic Trouble Codes (DTCs) on ECU....397
Diagnostic Procedure....404
Intermittent Fault Diagnostics....405
T1 - Multi-state Throttle Input High....407
T1 - Multi-state Throttle Input High....407
T2 - Multi-state Throttle Input Low....411
T2 - Multi-state Throttle Input Low....411
T3 - Analog Throttle (A) Input High....415
T3 - Analog Throttle (A) Input High....415
T4 - Analog Throttle (A) Input Low....421
T4 - Analog Throttle (A) Input Low....421
T5 - Analog Throttle (B) Input High....427
T5 - Analog Throttle (B) Input High....427
T6 - Analog Throttle (B) Input Low....433
T6 - Analog Throttle (B) Input Low....433
T7 - CAN Throttle Invalid....438
T7 - CAN Throttle Invalid....438
T17 - Analog Throttle (C) Input High....442
T17 - Analog Throttle (C) Input High....442
T18 - Analog Throttle (C) Input Low....446
T18 - Analog Throttle (C) Input Low....446
T22 - Analog Throttle (A) Input Voltage Out of Range....201
000028.03 - Throttle Voltage High....201
000028.04 - Throttle Voltage Low....201
000029.03 - Throttle Voltage High....201
000029.04 - Throttle Voltage Low....201
000084.31 — Vehicle Speed Mismatch....455
000084.31 - Vehicle Speed Mismatch....201
000091.03 - Throttle Voltage High....202
000091.04 - Throttle Voltage Low....202
000091.09 - Throttle Invalid....202
000091.14 - Throttle Voltage Out of Range....202
000094.03 — Fuel Rail Pressure Input Voltage High....464
000094.03 - Fuel Rail Pressure Input Voltage High....202
000094.04 Fuel Rail Pressure Input Voltage Low....469
000094.04 - Fuel Rail Pressure Input Voltage Low....202
000094.10 — Fuel Rail Pressure Loss Detected....474
000094.10 - Fuel Rail Pressure Loss Detected....202
000094.13 — Fuel Rail Pressure Higher Than Expected....478
000094.13 - Fuel Rail Pressure Higher Than Expected....202
000094.17 — Fuel Rail Pressure Not Developed....482
000094.17 - Fuel Rail Pressure Not Developed....202
000097.00 — Water in Fuel Continuously Detected....488
000097.00 - Water in Fuel Continuously Detected....202
000097.03 — Water in Fuel Signal Voltage High....492
000097.03 - Water in Fuel Signal Voltage High....202
000097.04 — Water in Fuel Signal Voltage Low....496
000097.04 - Water in Fuel Signal Voltage Low....202
000097.16 — Water in Fuel Detected....499
000097.16 - Water in Fuel Detected....202
000100.01 — Engine Oil Pressure Extremely Low....503
000100.01 - Engine Oil Pressure Extremely Low....202
000100.03 — Engine Oil Pressure Input Voltage High....507
000100.03 - Engine Oil Pressure Input Voltage High....202
000100.04 — Engine Oil Pressure Input Voltage Low....511
000100.04 - Engine Oil Pressure Input Voltage Low....202
000100.18 — Engine Oil Pressure Moderately Low....517
000100.18 - Engine Oil Pressure Moderately Low....202
000105.00 — Manifold Air Temperature Extremely High....520
000105.00 - Manifold Air Temperature Extremely High....202
000105.03 — Manifold Air Temperature Input Voltage High....523
000105.03 - Manifold Air Temperature Input Voltage High....203
000105.04 — Manifold Air Temperature Input Voltage Low....527
000105.04 - Manifold Air Temperature Input Voltage Low....203
000105.16 — Manifold Air Temperature Moderately High....531
000105.16 - Manifold Air Temperature Moderately High....203
000107.00 — Air Filter Differential Pressure....534
000107.00 - Air Filter Differential Pressure....203
000110.00 — Engine Coolant Temperature Extremely High....537
000110.00 - Engine Coolant Temperature Extremely High....203
000110.03 — Engine Coolant Temperature Input Voltage High....540
000110.03 - Engine Coolant Temperature Input Voltage High....203
000110.04 — Engine Coolant Temperature Input Voltage Low....544
000110.04 - Engine Coolant Temperature Input Voltage Low....203
000110.15 — Engine Coolant Temperature High Least Severe....548
000110.15 - Engine Coolant Temperature High Least Severe....203
000110.16 — Engine Coolant Temperature Moderately High....551
000110.16 - Engine Coolant Temperature Moderately High....203
000111.01 — Engine Coolant Level Low....554
000111.01 - Engine Coolant Level Low....203
000158.17 — ECU Power Down Error....558
000158.17 - ECU Power Down Error....203
000160.02 — Wheel Speed Input Noise....561
000160.02 - Wheel Speed Input Noise....203
000174.00 — Fuel Temperature High Most Severe....566
000174.00 - Fuel Temperature High Most Severe....203
000174.03 — Fuel Temperature Input Voltage High....569
000174.03 - Fuel Temperature Input Voltage High....203
000174.04 — Fuel Temperature Input Voltage Low....573
000174.04 - Fuel Temperature Input Voltage Low....203
000174.16 — Fuel Temperature High Moderately Severe....576
000174.16 - Fuel Temperature High Moderately Severe....203
000189.00 - Engine Speed Derate....203
000190.00 - Engine Overspeed Extreme....203
000190.16 - Engine Overspeed Moderate....204
000237.02 - Vehicle Identification Number Invalid....204
000237.13 - Vehicle Identification Option Code Invalid....204
000237.31 - Vehicle Model Number Invalid....204
000611.03 — Electronic Injector Wiring Shorted To Power Source....585