Component Technical Manual with Electrical Wiring Diagrams for John Deere PowerTech plus 4.5L & 6.8L Diesel Engines - John Deere Level 14 Electronic Fuel System with Denso HPCR, with workshop information to maintain, diagnose, repair, and rebuild like professional mechanics.

John Deere 4045-6068 Diesel Engines — Level 14 ECU - (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.

CTM320 (29AUG11) (ENGLISH) - John Deere PowerTech plus 4.5L & 6.8L Diesel Engines - John Deere Level 14 Electronic Fuel System with Denso HPCR Component Technical Manual.pdf
ctm320 - 4045-6068 Diesel Engines — Level 14 ECU -:(Worldwide Edition) Component Technical Manual.pdf
ctm320 - 4045-6068 Diesel Engines — Level 14 ECU -:(Worldwide Edition) Component Technical Manual.epub

Total Pages: 2,183 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English

ctm320 - 4045-6068 Diesel Engine — Level 14 ECU -: (Worldwide Edition)
Component Technical Manual

Table of Contents

Foreword

Trademarks

Section 01: General

Group 000: Safety

Understand Signal Words

Recognize Safety Information

Replace Safety Signs

Follow Safety Instructions

California Proposition 65 Warning

Avoid Hot Exhaust

Work In Ventilated Area

Decommissioning — Proper Recycling and Disposal of Fluids and Components

Prevent Machine Runaway

Practice Safe Maintenance

Work in Clean Area

Wear Protective Clothing

Service Machines Safely

Use Proper Tools

Construct Dealer-Made Tools Safely

Support Machine Properly

Use Proper Lifting Equipment

Protect Against Noise

Illuminate Work Area Safely

Install All Guards

Stay Clear of Rotating Drivelines

Protect Against High Pressure Spray

Service Cooling System Safely

Remove Paint Before Welding or Heating

Precautions for Welding

Wait Before Opening High-Pressure Fuel System

Avoid High-Pressure Fluids

Avoid Heating Near Pressurized Fluid Lines

Avoid Static Electricity Risk When Refueling

Handle Fluids Safely—Avoid Fires

Prepare for Emergencies

Handling Batteries Safely

Prevent Acid Burns

Prevent Battery Explosions

Live With Safety

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

Supplemental Diesel Fuel Additives

Lubricity of Diesel Fuel

Handling and Storing Diesel Fuel

BioDiesel Fuel

Testing Diesel Fuel

Fuel Filters

Minimizing the Effect of Cold Weather on Diesel Engines

Diesel Engine Break-In Oil — Non-Emissions Certified and Certified Tier 1, Tier 2, Tier 3, Stage I, Stage II, and Stage III

Diesel Engine Oil — Tier 3 and Stage III

Engine Oil and Filter Service Intervals

Mixing of Lubricants

Alternative and Synthetic Lubricants

Lubricant Storage

Oil Filters

Grease

Diesel Engine Coolant (engine with wet sleeve cylinder liners)

Water Quality for Mixing with Coolant Concentrate

Operating in Warm Temperature Climates

Testing Coolant Freeze Point

Disposing of Coolant

Group 003: Fuel System Identification

Low Pressure Fuel System Type 1

Low Pressure Fuel System Type 2

Low Pressure Fuel System Type 3

High Pressure Fuel System Type 1

High Pressure Fuel System Type 2

Fuel Lubricating Dosing System—Type 1

Section 02: Repair and Adjustments

Group 090: Electronic Fuel System Repair and Adjustments

Fuel System - General Information

Fuel System Components

Relieve Fuel System Pressure

Remove and Install Fuel Filter Plugs and Fittings

Remove and Install Fuel Lubricant Doser Header

Replace Fuel Filter Elements

Replacing Fuel Filter and Fuel Lubricating Dosing Element (4045)

Replacing Fuel Filter and Fuel Lubricating Dosing Element (6068)

Replace Fuel Filter Elements - Racor Fuel Filter System

Remove Fuel Transfer Pump

Install Fuel Transfer Pump

Remove and Install Electronic Fuel Transfer Pump - Filter Mounted

Remove and Install Electronic Fuel Transfer Pump - Racor System

Type 1 Remove and Install High Pressure Fuel Pump

Type 2 Remove and Install High Pressure Fuel Pump

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

Remove Electronic Injectors (EIs)

Clean Electronic Injector (EI) Bore

Clean Electronic Injector (EI) Orifice

Clean Electronic Injector (EI) Body

Inspect Electronic Injector (EI) Body

Install Electronic Injectors (EIs)

Remove and Install Leak-off and Pump Overflow Lines

Remove and Install Suction Control Valve

Clean Electronic injectors (In Engine)

Group 100: Electronic Air System Repair and Adjustment

Remove and Install Exhaust Gas Recirculation (EGR) Valve

Remove and Install EGR Exhaust Tube

Remove and Install EGR Coolant Inlet Tube

Remove and Install Exhaust Gas Recirculation (EGR) Cooler

Remove and Install Exhaust Gas Recirculation (EGR) Tubing

Remove and Install Variable Geometry Turbocharger Actuator (4-Cylinder Engine - If Equipped)

Remove and Install Variable Geometry Turbocharger Actuator (6-Cylinder Engine - If Equipped)

Remove and Install Turbocharger Actuator Linkage (6-Cylinder Engine)

Remove and Install Turbocharger Actuator Linkage — Ball Type

Group 110: Electronic Engine Control Repair and Adjustment

Engine Control Unit (ECU) Maintenance

Remove and Install Engine Control Unit (ECU) for 4.5L Engine

Remove and Install Engine Control Unit (ECU) for 6.8L Engine

Remove and Install Engine Coolant Temperature (ECT) Sensor

Remove and Install Fuel Temperature Sensor

Remove and Install Exhaust Gas Recirculation (EGR) Exhaust Temperature Sensor

Charge Air Cooler Outlet 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 Manifold Air Pressure (MAP) Sensor

Remove and Install Crank Position Sensor

Remove and Install Pump Position Sensor

Remove and Install Turbo Speed Sensor

Remove and Install Turbo Compressor Inlet Temperature Sensor

Remove and Install Water in Fuel (WIF) Sensor

Remove and Install Glow Plugs

Connectors

Connector Repair

Welding

High Pressure Washing

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 (Stanadyne)

Electric Fuel Transfer Pump Operation (Racor)

Final Fuel Filter Operation

Fuel Lubricant Doser Operation

Type 1 High Pressure Fuel Pump Operation

Type 2 High Pressure Fuel Pump Operation

High Pressure Common Rail (HPCR) Operation

Electronic Injector (EI) Operation

Group 135: Electronic Air System Operation

About This Group

Electronic Air System Control Operation

Exhaust Gas Recirculation Flow and Calculations

Exhaust Gas Recirculation Cooler

Exhaust Gas Recirculation Valve

Turbocharger

Turbocharger Actuator

Air Intake Manifold, non-EGR engines

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

Component Location Diagram 17

Component Location Diagram 18

Component Location Diagram 19

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

Exhaust Gas Recirculation (EGR) Exhaust Temperature Sensor

Charge Air Cooler Outlet Air Temperature Sensor

Intake Manifold Air Temperature (MAT) Sensor

Turbo Compressor Inlet Temperature Sensor

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

Turbo Speed 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

Glow Plug Operation

Torque Curve Selection

Governor Droop Mode Selection

Suction Control Valve

Water in Fuel (WIF) Sensor

Engine Coolant Level Switch

Cruise Control Operation

Power Supply #1

Power Supply #2

Power Supply #3

Power Supply #4

Power Supply #5

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 Smoke

E5 - Engine Emits Excessive Black Or Gray Exhaust Smoke

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

A2 - Glow Plug Check

Bleed the Fuel System

Charge Air Cooler Test

Charge Air System

Check and Adjust High Pressure Fuel Pump Static Timing

Check for Restricted Fuel Leak-off Line

Check Fuel Supply Quality

Cylinder Leak-Down Test

EGR-VGT System Temperature and Flow Test

Excessive Engine Crankcase Pressure (Blow-By)

Exhaust Gas Recirculation (EGR) System Diagnostic

EGR Cooler Test

Load Profile Information Test — Instructions

Temperature Sensor Validity Test

Test for Air in Fuel

Variable Geometry Turbocharger (VGT) Component Test

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 Codes List

Digital Multimeter — Using

EGR Valve — Clean Test Instructions

EGR Valve — Learn Value Reset Instructions

Electrical Circuit Concepts

Electrical Noise — Possible Causes

Electronic Injector — Calibration Information

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

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 Instructions

Intermittent DTC Diagnostics

Internal Data Monitor — Instructions

Keep Electronic Control Unit Connectors Clean

Load Profile Information Test — Instructions

Service ADVISOR Data Parameter Description

Short to Voltage Procedure

Snapshot Instructions

Software and Hardware Verification

Terminal Test

Trim Options Information

Verification Procedure

VGT — Learn Value Reset Instructions

VGT Actuator Travel Range Test

Wiggle Test

000028.03 - Digital Throttle Signal Out of Range High

000028.04 - Digital Throttle Signal Out of Range Low

000029.03 - Secondary Analog Throttle Signal Out of Range High

000029.04 - Secondary Analog Throttle Signal Out of Range Low

000084.31 - ECU Calculated Vehicle Speed and CAN bus Vehicle Speed Mismatch

000091.03 - Primary Analog Throttle Signal Out of Range High

000091.04 - Primary Analog Throttle Signal Out of Range Low

000091.09 - Throttle CAN message Missing

000094.03 - Low Pressure Fuel Signal Out of Range High

000094.04 - Low Pressure Fuel Signal Out of Range Low

000094.17 - Low Pressure Fuel Signal Slightly Low

000094.18 - Low Pressure Fuel Signal Moderately Low

000097.00 - Water in Fuel Detected Most Severe Level

000097.03 - Water In Fuel Signal Out of Range High

000097.04 - Water In Fuel Signal Out of Range Low

000097.16 - Water in Fuel Detected

000100.01 - Engine Oil Pressure Signal Extremely Low

000100.04 - Engine Oil Pressure Signal Out of Range Low

000100.18 - Engine Oil Pressure Signal Moderately Low

000100.31 - Engine Oil Pressure Detected with Engine Stopped

000102.02 - Manifold Air Pressure Signal Invalid

000102.03 - Manifold Air Pressure Signal Out of Range High

000102.04 - Manifold Air Pressure Signal Out of Range Low

000103.00 - Turbo Speed Signal Extremely High

000103.05 - Turbo Speed Signal Circuit has High Resistance

000103.08 - Turbo Speed Signal Invalid

000103.31 - Turbo Speed Signal Missing

000105.00 - Manifold Air Temperature Signal Extremely High

000105.03 - Manifold Air Temperature Signal Out of Range High

000105.04 - Manifold Air Temperature Signal Out of Range Low

000105.15 - Manifold Air Temperature Signal Slightly High

000105.16 - Manifold Air Temperature Signal Moderately High

000107.00 - Air Filter Restriction Switch Activated

000107.31 - Air Filter Restriction Switch Activated

000108.02 - Barometric Air Pressure Signal Invalid

000110.00 - Coolant Temperature Signal Extremely High

000110.03 - Coolant Temperature Signal Out of Range High

000110.04 - Coolant Temperature Signal Out of Range Low

000110.15 - Coolant Temperature Signal Slightly High

000110.16 - Coolant Temperature Signal Moderately High

000110.17 - Coolant Temperature Signal Slightly Low

000111.01 - Engine Coolant Level Extremely Low

000157.01 - Fuel Rail Pressure Signal Extremely Low

000157.03 - Fuel Rail Pressure Signal Out of Range High

000157.04 - Fuel Rail Pressure Signal Out of Range Low

000157.10 - Fuel Rail Pressure Loss Detected

000157.17 - Fuel Rail Pressure Not Developed

000157.18 - Fuel Rail Pressure Signal Moderately Low

000158.17 - ECU Power Down Error

000160.02 - Vehicle Speed Signal Invalid

000174.00 - Fuel Temperature Signal Extremely High

000174.03 - Fuel Temperature Signal Out of Range High

000174.04 - Fuel Temperature Signal Out of Range Low

000174.16 - Fuel Temperature Signal Moderately High

000189.00 - Engine Speed Derate Condition Exists

000190.00 - Engine Speed Extremely High

000190.01 - Engine Overload Moderate

000190.16 - Engine Speed Moderately High

000190.18 - Engine Overload Severe

000237.02 - VIN Security Data Invalid

000237.13 - VIN Option Code Security Data Conflict

000237.31 - VIN Security Data Missing

000412.00 - EGR Temperature Signal Extremely High

000412.03 - EGR Temperature Signal Out of Range High

000412.04 - EGR Temperature Signal Out of Range Low

000412.15 - EGR Temperature Signal Slightly High

000412.16 - EGR Temperature Signal Moderately High

000611.03 - Injector Shorted to Voltage Source

000611.04 - Injector Shorted to Ground

000627.01 - All Injectors Circuits Have High Resistance

000627.18 - Injector Power Supply Voltage Out of Range Low

000629.12 - ECU EEPROM Error

000629.13 - ECU Boot Block Error

000636.02 - Camshaft Position Signal Invalid

000636.05 - Camshaft Position Circuit Has High Resistance

000636.06 - Camshaft Position Circuit Has Low Resistance

000636.08 - Camshaft Position Sensor Signal Missing

000636.10 - Camshaft Position Signal Rate of Change Abnormal

000637.02 - Crankshaft Position Signal Invalid

000637.05 - Crankshaft Position Sensor Circuit Has High Resistance

000637.06 - Crankshaft Position Circuit Has Low Resistance

000637.07 - Crankshaft and Camshaft Position Signals Out of Sync

000637.08 - Crankshaft Position Signal Missing

000637.10 - Crankshaft Position Signal Rate of Change Abnormal

000640.31 - External Derate Commanded

000641.04 - VGT Actuator Supply Voltage Out of Range Low

000641.12 - VGT Actuator Communication Error

000641.13 - VGT Actuator Learn Error

000641.16 - Turbo Actuator Temperature Moderately High

000644.02 - External Speed Command Input Erratic

000647.05 - Engine Fan Drive Circuit Has High Resistance

000647.31 - Engine Fan Drive Manual Purge Switch Active Too Long

000651.02 - Injector #1 Part # Data Invalid

000651.05 - Injector #1 Circuit Has High Resistance

000651.06 - Injector #1 Circuit Has Low Resistance

000651.07 - Injector #1 Not Responding

000651.13 - Injector #1 Calibration Fault

000652.02 - Injector #2 Part # Data Invalid

000652.05 - Injector #2 Circuit Has High Resistance

000652.06 - Injector #2 Circuit Has Low Resistance

000652.07 - Injector #2 Not Responding

000652.13 - Injector #2 Calibration Fault

000653.02 - Injector #3 Part # Data Invalid

000653.05 - Injector #3 Circuit Has High Resistance

000653.06 - Injector #3 Circuit Has Low Resistance

000653.07 - Injector #3 Not Responding

000653.13 - Injector #3 Calibration Fault

000654.02 - Injector #4 Part # Data Invalid

000654.05 - Injector #4 Circuit Has High Resistance

000654.06 - Injector #4 Circuit Has Low Resistance

000654.07 - Injector #4 Not Responding

000654.13 - Injector #4 Calibration Fault

000655.02 - Injector #5 Part # Data Invalid

000655.05 - Injector #5 Circuit Has High Resistance

000655.06 - Injector #5 Circuit Has Low Resistance

000655.07 - Injector #5 Not Responding

000655.13 - Injector #5 Calibration Fault

000656.02 - Injector #6 Part # Data Invalid

000656.05 - Injector #6 Circuit Has High Resistance

000656.06 - Injector #6 Circuit Has Low Resistance

000656.07 - Injector #6 Not Responding

000656.13 - Injector #6 Calibration Fault

000676.03 - Cold Start Aid Signal Received When Not Expected

000676.05 - Cold Start Aid Circuit Has High Resistance

000898.09 - Engine Speed CAN Message Invalid

000970.31 - External Shutdown Switch Activated

000971.31 - External Derate Switch Activated

001069.31 - Tire Size Error

001075.05 - Low Pressure Fuel Pump Circuit Has High Resistance

001075.06 - Low Pressure Fuel Pump Circuit Has Low Resistance

001075.12 - Low Pressure Fuel Pump Status Error

001109.31 - Approaching Engine Protection Shutdown

001110.31 - Engine Protection Shutdown Active

001136.00 - ECU Temperature Signal Extremely High

001136.16 - ECU Temperature Signal Moderately High

001172.03 - Compressor Inlet Temperature Signal Out of Range High

001172.04 - Compressor Inlet Temperature Signal Out of Range Low

001180.00 - Calculated Turbine Inlet Temperature Signal Extremely High

001180.16 - Calculated Turbine Inlet Temperature Signal Moderately High

001347.03 - Suction Control Valve Signal Out of Range High

001347.05 - Suction Control Valve Circuit Has High Resistance

001347.07 - Fuel Rail Pressure Actual to Desired Mismatch

001349.02 - Fuel Rail Pressure Signals Mismatch

001349.03 - Redundant Fuel Rail Pressure Signal Out of Range High

001349.04 - Redundant Fuel Rail Pressure Signal Out of Range Low

001569.31 - Engine in Power Derate Condition

001638.00 - Hydraulic Oil Temperature Extremely High

001638.03 - Hydraulic Oil Temperature Signal Out of Range High

001638.04 - Hydraulic Oil Temperature Signal Out of Range Low

001638.16 - Hydraulic Oil Temperature Signal Moderately High

001639.01 - Fan Speed Signal Extremely Low

001639.16 - Fan Speed Signal Moderately High

001639.18 - Fan Speed Signal Moderately Low

002000.13 - Incorrect ECU for Application

002003.09 - No CAN Message From Source Address 3

002004.09 - No CAN Message From Source Address 4

002005.09 - No CAN Message From Source Address 5

002005.14 - Incorrect CAN Message Received From Source Address 5

002030.09 - No CAN Message From Source Address 23

002033.09 - No CAN Message From Source Address 33

002033.14 - Incorrect CAN Message Received From Source Address 33

002033.19 - Synchronizing Problem With Source Address 33

002057.09 - No CAN Message From Source Address 57

002071.09 - No CAN Message From Source Address 71

002580.03 - Brake Pressure Signal Out of Range High

002580.04 - Brake Pressure Signal Out of Range Low

002630.00 - Charge Air Cooler Outlet Temperature Signal Extremely High

002630.03 - Charge Air Cooler Outlet Temperature Signal Out of Range High

002630.04 - Charge Air Cooler Outlet Temperature Signal Out of Range Low

002630.15 - Charge Air Cooler Outlet Temperature Signal Slightly High

002630.16 - Charge Air Cooler Outlet Temperature Signal Moderately High

002659.02 - Calculated EGR Flow Rate Invalid

002659.15 - Calculated EGR Flow Rate Slightly High

002659.17 - Calculated EGR Flow Rate Slightly Low

002790.16 - Calculated Compressor Outlet Temperature Moderately High

002791.02 - EGR Valve Position Signal Invalid

002791.03 - EGR Valve Position Signal Out of Range High

002791.04 - EGR Valve Position Signal Out of Range Low

002791.07 - EGR Valve Not Reaching Expected Position

002791.13 - EGR Valve Calibration Change Over a Short Period of Time

002791.31 - EGR Valve Calibration Change over a Long Time

002795.07 - VGT Actuator Not Reaching Expected Position

003509.03 - Sensor Supply #1 Voltage Out of Range High

003509.04 - Sensor Supply #1 Voltage Out of Range Low

003510.03 - Sensor Supply #2 Voltage Out of Range High

003510.04 - Sensor Supply #2 Voltage Out of Range Low

003511.03 - Sensor Supply #3 Voltage Out of Range High

003511.04 - Sensor Supply #3 Voltage Out of Range Low

003512.03 - Sensor Supply #4 Voltage Out of Range High

003512.04 - Sensor Supply #4 Voltage Out of Range Low

003513.03 - Sensor Supply #5 Voltage Out of Range High

003513.04 - Sensor Supply #5 Voltage Out of Range Low

003587.05 - Ether Hold Control Circuit Has High Resistance

003587.06 - Ether Hold Control Circuit Has Low Resistance

516598.00 - Engine Overload Condition Exists – Most Severe Level

516598.16 - Engine Overload Condition Exists – Moderately Severe Level

523792.04 - EPGDS LTC Pump Signal Out of Range Low

524099.11 - EPGDS LTC Pump Blockage

Section 05: Tools and Other Materials

Group 170: Special Tools

D17030BR

DFRG11

J-35616-20

JDE83

JDG145

JDG359

JDG360

JDG361

JDG362

JDG363

JDG364

JDG776

JDG777

JDG783

JDG785

JDG820

JDG839

JDG865

JDG1560

JDG1571

JDG1652A

JDG1725

JDG1727

JDG1744

JDG1869

JDG10194

JDG10234

JDG10244

JDG10259

JDG10261

JDG10273

JDG10395

JDG10415

JDG10416

JDG10452

JDG10453

JDG10466

JDG10576

JDG10760

JDG10854

JDG11072

JDG11100A

JDG11263

JDG11264

JDG11269

JDG11409

JT03513C

JT05470

JT05536

JT07253

JT07306

Group 180: Lubricants, Sealants, and Other Materials

Other Materials

Section 06: Wiring Harness and Schematics

Group 190: Wiring Harness Information

ECU Wiring Harness Routing for 4.5L Engine

ECU Wiring Harness Routing for 6.8L Engine

Remove and Install Engine Wire Harness for 4.5L Engine

Remove and Install Engine Wire Harness for 6.8L Engine

4.5L Wire Splice Location Diagrams

6.8L Wire Splice Location Diagrams

Redundant ECU Option 6.8L Wire Splice Location Diagram

Group 191: Wiring Harness Information — Marine

Marine Harness Type Identification

4.5 L Electrical System Layout — Marine Type A

6.8 L Electrical System Layout — Marine Type A

Transition Harness — Marine Type A

Engine Wiring Harness Routing — Marine Type B

ECU Wiring Harness Routing — Marine Type B

Main and Remote Station Wiring Harness Routing — Marine Type B

Remove and Install Engine Wiring Harness — Marine Type B

Group 195: Electrical Schematics

4.5L 12V ECU Wiring Diagram 1

4.5L 12V ECU Wiring Diagram 2

4.5L 12V ECU Wiring Diagram 3

4.5L 12V ECU Wiring Diagram 4

4.5L 12V ECU Wiring Diagram 5

4.5L 12V ECU Wiring Diagram 6

4.5L 12V ECU Wiring Diagram 7

4.5L 12V ECU Wiring Diagram 8

4.5L 24V ECU Wiring Diagram 1

4.5L 24V ECU Wiring Diagram 2

4.5L 24V ECU Wiring Diagram 3

4.5L 24V ECU Wiring Diagram 4

4.5L 24V ECU Wiring Diagram 5

4.5L 24V ECU Wiring Diagram 6

4.5L 24V ECU Wiring Diagram 7

4.5L 24V ECU Wiring Diagram 8

6.8L 12V ECU Wiring Diagram 1

6.8L 12V ECU Wiring Diagram 2

6.8L 12V ECU Wiring Diagram 3

6.8L 12V ECU Wiring Diagram 4

6.8L 12V ECU Wiring Diagram 5

6.8L 12V ECU Wiring Diagram 6

6.8L 12V ECU Wiring Diagram 7

6.8L 12V ECU Wiring Diagram 8

6.8L 24V ECU Wiring Diagram 1

6.8L 24V ECU Wiring Diagram 2

6.8L 24V ECU Wiring Diagram 3

6.8L 24V ECU Wiring Diagram 4

6.8L 24V ECU Wiring Diagram 5

6.8L 24V ECU Wiring Diagram 6

6.8L 24V ECU Wiring Diagram 7

6.8L 24V ECU Wiring Diagram 8

OEM Instrument Panel / Engine Start Components Electrical Wiring Diagram

OEM Instrument Panel / Engine Start Components Electrical Wiring Diagram - Continued

Oil Temperature Switch Option

Redundant ECU Option 6.8L Wiring Diagrams

Group 196: Electrical Schematics — Marine

Marine Schematic Type Identification

4045TFM85 Wiring Diagram 1 — Marine Type A

4045TFM85 Wiring Diagram 2 — Marine Type A

4045TFM85 Wiring Diagram 3 — Marine Type A

4045TFM85 Wiring Diagram 4 — Marine Type A

4045AFM85 Wiring Diagram 1 — Marine Type A

4045AFM85 Wiring Diagram 2 — Marine Type A

4045AFM85 Wiring Diagram 3 — Marine Type A

4045AFM85 Wiring Diagram 4 — Marine Type A

6.8 L Wiring Diagram 1 — Marine Type A

6.8 L Wiring Diagram 2 — Marine Type A

6.8 L Wiring Diagram 3 — Marine Type A

Wheel House Instrument Panel Wiring Diagram 1 — Marine Type A

Wheel House Instrument Panel Wiring Diagram 2 — Marine Type A

Fly Bridge Instrument Panel Wiring Diagram — Marine Type A

Engine Schematic — Marine Type B

ECU Schematic — Marine Type B

Main and Remote Station Schematic — Marine Type B

Section 07: Specifications

Group 200: Repair Specifications

Unified Inch Bolt and Cap Screw Torque Values

Metric Bolt and Cap Screw Torque Values

Electronic Air system Repair and Adjustment Specifications

Electronic Fuel System Repair and Adjustment Specifications

Electronic Engine Control Repair and Adjustment Specifications

Group 210: Diagnostic Specifications

Fuel System Diagnostic Specifications

Application Specifications

OEM Engines - Derate Specifications

OEM Engines - Glow Plug Specifications

EGR Temperature Sensor Characteristics

Compressor Inlet Air Temperature Sensor Characteristics

Manifold Air Temperature Sensor and Charged Air Cooler Outlet Temperature Sensor Characteristics