John Deere 6.8L 8.1L PowerTech Diesel Engine Level 3 Electronic Fuel Systems Bosch In-Line Pump Component Technical Manual CTM134 - MJODCTM134.zip
This complete component technical manual covers the John Deere 6.8L and 8.1L PowerTech Diesel Engines, Level 3 Electronic Fuel Systems with Bosch In-Line injection. Inside, you'll find every piece of technical data needed to service, troubleshoot, fix, and overhaul these engines the way a professional technician would.
The John Deere 6.8L & 8.1L PowerTech Diesel Engines Level 3 Electronic Fuel Systems workshop service and repair guide contains:
* 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.
ctm134 - John Deere 6.8L & 8.1L PowerTech Diesel Engines Level 3 Electronic Fuel Systems with Bosch In-Line Pump (Worldwide Edition) Component Technical Manual.pdf
ctm134 - John Deere 6.8L & 8.1L PowerTech Diesel Engines Level 3 Electronic Fuel Systems with Bosch In-Line Pump (Worldwide Edition) Component Technical Manual.epub
PRODUCT DETAILS:
Total Pages: 762 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality) & EPUB/MOBI/AZW for Kindle etc.
Language: English
TABLE OF CONTENTS
Forward
Section 01: General
Group 000: Safety
Handle Fluids Safely—Avoid Fires
Handle Starting Fluid Safely
Service Cooling System Safely
Prevent Battery Explosions
Prepare for Emergencies
Handling Batteries Safely
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
Use Proper Lifting Equipment
Construct Dealer-Made Tools Safely
Practice Safe Maintenance
Use Proper Tools
Decommissioning — Proper Recycling and Disposal of Fluids and Components
Live With Safety
Group 001: Engine Identification
Engine Application Chart (John Deere Agricultural Equipment)
Engine Application Chart (John Deere Construction Equipment)
Engine Application Chart (OEM) (Outside Equipment Manufacturers)
Distinguishing ECUs on 8.1 L Engines
Distinguishing ECUs on 6.8 L Engines
Group 002: Fuels
Lubricants and Coolant
Diesel Fuel
Diesel Fuel Additive Products
Bio-Diesel Fuel
Lubricity of Diesel Fuel
Handle Fluids Safely—Avoid Fires
Handle Fluids Safely—Avoid Fires
Handle Starting Fluid Safely
Service Cooling System Safely
Prevent Battery Explosions
Prepare for Emergencies
Handling Batteries Safely
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
Use Proper Lifting Equipment
Construct Dealer-Made Tools Safely
Practice Safe Maintenance
Use Proper Tools
Decommissioning — Proper Recycling and Disposal of Fluids and Components
Live With Safety
Engine Application Chart (John Deere Agricultural Equipment)
Engine Application Chart (John Deere Agricultural Equipment)
Engine Application Chart (John Deere Construction Equipment)
Engine Application Chart (OEM) (Outside Equipment Manufacturers)
Distinguishing ECUs on 8.1 L Engines
Distinguishing ECUs on 6.8 L Engines
Lubricants and Coolant
Lubricants and Coolant
Diesel Fuel
Diesel Fuel Additive Products
Bio-Diesel Fuel
Lubricity of Diesel Fuel
Section 02: Repair and Adjustments
Group 090: Electronic Fuel System Repair and Adjustments
Fuel System — General Information
Relieve Fuel System Pressure
Replace Rectangular Fuel Filter Element
Replace Fuel Filter Check Valve
Replace Primary (Round) Fuel Filter/Water Separator
Identification of Fuel Supply Pumps
Remove Fuel Supply Pump
Inspect Fuel Supply Pump
Install Fuel Supply Pump
Service Injection Pump Overflow Valve
Identification of In-Line Fuel Injection Pumps
Service of Fuel Injection Pumps
Remove Fuel Injection Pump
Install Fuel Injection Pump
Remove Fuel Injection Nozzles
Test Fuel Injection Nozzles
Perform Opening Pressure Test
Injection Nozzle Opening Pressure Specifications
Perform Nozzle Leakage Test
Perform Chatter and Spray Pattern Test
Disassemble Fuel Injection Nozzle
Clean and Inspect Fuel Injection Nozzle Assembly
Clean Spray Orifices
Inspect Nozzle Holder
Inspect Gland Nut
Assemble Fuel Injection Nozzle
Inspect and Clean Cylinder Head Nozzle Bore
Inspect and Clean Nozzle Seating Surface
Install Fuel Injection Nozzles
Group 110: Electrical Engine Control Repair and Adjustment
John Deere Level 3 Electronic Engine Control System and Sensors
Remove and Install Sensors
Engine Control Unit (ECU)
Transient Voltage Protection (TVP) Module
Connectors
Diagnostic Connector Installation
Using High-Pressure Washer
Repair WEATHERPACK WEATHERPACK is a trademark of Packard Electric Connector
Install WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Contact
Remove Blade Terminals from Connector Body
Repair (Pull Type) METRI-PACK METRI-PACK is a trademark of Delphi Packard Electric Systems Connectors
Repair (Push Type) METRI-PACK™ Connectors
Use Electrical Insulating Compound
Repair DEUTSCH Connectors
Install DEUTSCH DEUTSCH is a trademark of Deutsch Co. Contact
Fuel System — General Information
Fuel System — General Information
Relieve Fuel System Pressure
Replace Rectangular Fuel Filter Element
Replace Fuel Filter Check Valve
Replace Primary (Round) Fuel Filter/Water Separator
Identification of Fuel Supply Pumps
Remove Fuel Supply Pump
Inspect Fuel Supply Pump
Install Fuel Supply Pump
Service Injection Pump Overflow Valve
Identification of In-Line Fuel Injection Pumps
Service of Fuel Injection Pumps
Remove Fuel Injection Pump
Install Fuel Injection Pump
Remove Fuel Injection Nozzles
Test Fuel Injection Nozzles
Perform Opening Pressure Test
Injection Nozzle Opening Pressure Specifications
Perform Nozzle Leakage Test
Perform Chatter and Spray Pattern Test
Disassemble Fuel Injection Nozzle
Clean and Inspect Fuel Injection Nozzle Assembly
Clean Spray Orifices
Inspect Nozzle Holder
Inspect Gland Nut
Assemble Fuel Injection Nozzle
Inspect and Clean Cylinder Head Nozzle Bore
Inspect and Clean Nozzle Seating Surface
Install Fuel Injection Nozzles
John Deere Level 3 Electronic Engine Control System and Sensors
John Deere Level 3 Electronic Engine Control System and Sensors
Remove and Install Sensors
Engine Control Unit (ECU)
Transient Voltage Protection (TVP) Module
Connectors
Diagnostic Connector Installation
CAN Terminator Verification
Installation of Diagnostic Connector with Termination Present
Installation of Diagnostic Connector with no Termination Present
Using High-Pressure Washer
Repair WEATHERPACK™ Connector
Install WEATHER PACK™ Contact
Remove Blade Terminals from Connector Body
Repair (Pull Type) METRI-PACK™ Connectors
Repair (Push Type) METRI-PACK™ Connectors
Use Electrical Insulating Compound
Repair DEUTSCH Connectors
Install DEUTSCH™ Contact
Section 03: Theory of Operation
Group 130: Electronic Fuel System Operation
Fuel System Overview
Fuel Supply Pump Operation
Fuel Supply Pump Operation - Continued
Rectangular Final Fuel Filter Operation
Round Primary Fuel Filter/Water Separator Operation
Fuel Injection Pump Operation
Fuel Injection Nozzle Operation
Group 140: Electronic Control System Operation
Electronic Control System Overview
Electronic Control System Terminology
Electronic Control System Operation
Monitoring Engine Parameters
Measuring Temperature
Water In Fuel Sensor
Measuring Throttle Position
Measuring Oil Pressure
Measuring Engine Speed
Measuring Rack Position
Actuator Solenoid
Fuel Shut-off Solenoid
Engine Control Unit (ECU)
Cruise Control Operation
Intake Air Heater Operation
Engine Protection
Different Derate Programs
Multiple Torque Curve Selection
Governor Droop Mode Selection
Engine Control Unit (ECU) Self-diagnosis Operation
Fuel System Overview
Fuel System Overview
Fuel Supply Pump Operation
Fuel Supply Pump Operation - Continued
Rectangular Final Fuel Filter Operation
Round Primary Fuel Filter/Water Separator Operation
Fuel Injection Pump Operation
Fuel Injection Nozzle Operation
Electronic Control System Overview
Electronic Control System Overview
Electronic Control System Terminology
Electronic Control System Operation
Engine Starting Mode
Engine Running Mode
Monitoring Engine Parameters
Measuring Temperature
ECT (Engine Coolant Temperature) Sensor
MAT (Manifold Air Temperature) Sensor
AAT (Ambient Air Temperature) Sensor
Fuel Temperature Sensor
Loss of Coolant Temperature Switch
Charge Air Temperature Switch
Water In Fuel Sensor
Measuring Throttle Position
Measuring Oil Pressure
Measuring Engine Speed
Engine Speed Sensor
Injection Pump Speed Sensor
Measuring Rack Position
Actuator Solenoid
Fuel Shut-off Solenoid
Engine Control Unit (ECU)
Analog/Digital Converters
Central Processing Unit (CPU)
Memory
Cruise Control Operation
Intake Air Heater Operation
Engine Protection
Shutdown Override
Different Derate Programs
Low Oil Pressure Protection
High Engine Coolant Temperature Protection
Loss of Coolant Protection
High Charge Air Temperature Protection (“H” Engines Only)
High Fuel Temperature Protection
Multiple Torque Curve Selection
Governor Droop Mode Selection
Engine Control Unit (ECU) Self-diagnosis Operation
2 or 3–Digit Codes
SPN/FMI Codes
Section 04: Diagnostics
Group 150: 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 Exhaust Smoke
E5 - Engine Emits Excessive Black or Gray Exhaust Smoke
E6 - Engine Will Not Crank
E7 - Engine Idles Poorly
E8 - Abnormal Engine Noise
F1 - Fuel Supply System Check
F2 - Excessive Fuel Consumption
F3 - Fuel in Oil
F4 - Excessive Fuel Filter Replacement
ECU Does Not Communicate with Service ADVISOR
D1 - ECU Does Not Communicate with DST
D2 - ECU Does Not Communicate with Diagnostic Gauge
D2 - ECU Does Not Communicate with Diagnostic Gauge
D3 - Error Codes on Electronic Governor Tester (JT05829)
D3 - Error Codes on Electronic Governor Tester (JT05829)
Check Fuel Supply Quality
Measure Fuel Supply Pump Pressure
Check Fuel Supply Pump Operation
Bleed the Fuel System
Cylinder Misfire Test
Test for Fuel Drain Back
Test for Air in Fuel
Check for Restricted Fuel Return Line
Check and Adjust Injection Pump Static Timing
Load Profile Information Test — Instructions
Primary CAN Diagnostic Procedure
Terminal Test
Diagnostic Test Box — Using
Group 160: Trouble Code Diagnostics and Tests
About This Group the Manual
Electrical Concept
Electrical Circuit Malfunctions
Troubleshooting Circuit Malfunctions