John Deere PowerTechTM 10.5 L and 12.5 L Diesel Engines Level 6 Electronic Fuel Systems With Lucas EUIs Component Technical Manual (CTM188)

ctm188 - John Deere PowerTech 10.5 L and 12.5 L Diesel Engines Level 6 Electronic Fuel Systems With Lucas EUIs - (Worldwide Edition) Component Technical Manual.pdf

Complete Technical Manual with electrical wiring diagrams for John Deere PowerTech 10.5 L and 12.5 L Diesel Engines Level 6 Electronic Fuel Systems With Lucas EUIs, with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.

John Deere PowerTech 10.5 L and 12.5 L Diesel Engines Level 6 Electronic Fuel Systems With Lucas EUIs - (Worldwide Edition) workshop Component Technical 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.

PRODUCT DETAILS:
Total Pages: 864 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

ctm188 - PowerTech™ 10.5 L and 12.5 L Diesel Engines Level 6 Electronic Fuel Systems With Lucas EUIs -: (Worldwide Edition)
Component Technical Manual

Table of Contents

Foreword

Trademarks

Section 01: General Information

Group 000: Safety

Avoid Heating Near Pressurized Fluid Lines

Avoid High-Pressure Fluids

Avoid Hot Exhaust

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 Model Designation

Engine Serial Number Plate Information

Engine Option Code Label

Engine Application Chart

Distinguishing ECUs

Group 002: Fuels

Lubricants and Coolant

Diesel Fuel - Tier 1

Diesel Fuel - Tier 2

Diesel Fuel Additive Products

Bio-Diesel Fuel

Lubricity of Diesel Fuel

Testing Diesel Fuel

Section 02: Repair and Adjustments

Group 090: Dual Rail Fuel System Repair and Adjustment

Dual Rail Fuel System Components (Earlier Engines)

Replace Final (Secondary) Fuel Filter Element

Replacing Primary Fuel Filter/Water Separator

Remove and Install Air Purge Valve

Remove and Install Primary Fuel Filter Check Valve

Remove and Install Fuel System Surge Tank (6125ADW01/70 Engines)

Remove and Install Dual Rail Fuel Supply Pump

Remove and Install Dual Rail Fuel Manifold

Inspect Fuel Pressure Regulating Valve and Return Check Valve

Remove and Install Electronic Unit Injectors

Adjust Electronic Unit Injector Preload

Replace Electronic Unit Injector O-Rings

Replace Electronic Unit Injector Thrust Sleeve, Pad and O-Ring

Flush Fuel Rails

Bleed Fuel System

Group 091: Single Rail Fuel System Repair and Adjustment

General Information

Single Rail Fuel System Components (Later Engines)

Fuel Filter/Water Separator Assembly

Replacing Fuel Filter/Water Separator

Remove and Install Low Pressure Regulating Valve

Remove and Install High Pressure Regulating Valve

Remove and Install 100 Micron Internal Filter Housing Screen Insert

Remove and Install Fuel Filter Check Valve

Remove and Install Primer Pump

Remove and Install Single Rail Fuel Supply Pump

Remove and Install Electronic Unit Injectors (Single Rail Fuel System)

Adjust Electronic Unit Injector Preload

Replace Electronic Unit Injector O-Rings

Replace Electronic Unit Injector Thrust Sleeve, Pad and O-Ring

Bleed Fuel System

Group 110: Electrical Engine Control Repair and Adjustment

John Deere Electronic Control System

Remove and Install Coolant Temperature Sensor

Remove and Install Fuel Temperature Sensor (Dual Rail System)

Remove and Install Fuel Temperature Sensor

Remove and Install Fuel Pressure Sensor

Remove and Install Water-in-Fuel Sensor

Remove and Install Oil Pressure Sensor

Remove and Install Manifold Air Temperature (MAT) Sensor

Remove and Install Manifold Absolute Pressure (MAP) Sensor

Remove and Install Camshaft Position Sensor

Remove and Install Crankshaft Position Sensor

Connectors

Use Electrical Insulating Compound

Using High-Pressure Washer

Connector Repair

Remove Blade Terminals from Connector Body

Repair (Pull Type) METRI-PACK Connectors

Repair (Push Type) METRI-PACK Connectors

Repair DEUTSCH Connectors

Repair CINCH Connectors

Section 03: Theory of Operation

Group 130: Electronic Fuel System Operation

About This Group

Low Pressure Dual Rail Fuel Supply System Operation

Electronic Unit Injector (EUI) Operation on the Dual Rail Fuel System

Low Pressure Single Rail Fuel Supply System Operation

Electronic Unit Injector (EUI) Operation on the Single Rail Fuel System

Group 140: Electrical Control System Operation

Electronic Control System Terminology

Electronic Control System Overview

Electronic Control System Operation

Pilot Injection Operation

Monitoring Engine Parameters

Measuring Temperature

Measuring Pressure

Water In Fuel Sensor

Measuring Throttle Position

Determining Engine Speed and Piston Position

Engine Control Unit (ECU)

Controller Area Network (CAN)

Cruise Control Operation

Engine Protection

Different Derate Programs

Multiple Torque Curve Selection

Governor Droop Mode Selection

Engine Control Unit (ECU) Self-Diagnosis

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 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

F1 - Dual Rail Fuel Supply System Check

F1 - Dual Rail Fuel Supply System Check

F2 - Excessive Fuel Consumption on a Dual Rail Fuel System

F3 - Fuel in Oil on a Dual Rail Fuel System

F4 - Single Rail Fuel Supply System Check

F4 - Single Rail Fuel Supply System Check

F5 - Excessive Fuel Consumption on Single Rail Fuel System

F6 - Fuel in Oil on Single Rail Fuel System

F7 - 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

D2 - ECU Does Not Communicate with Diagnostic Gauge (Earlier Model)

D2 - ECU Does Not Communicate with Diagnostic Gauge (Earlier Model)

D3 - ECU Does Not Program With Service ADVISOR

D3 - ECU Does Not Communicate with Diagnostic Gauge (Later Model)

D3 - ECU Does Not Communicate with Diagnostic Gauge (Later Model)

Check Dual Rail Fuel Supply Pressure

Bleed Dual Rail Fuel System

Check Single Rail Fuel Supply Pressure

Bleed Single Rail Fuel System

Restarting Engine That Has Run Out Of Fuel (Single Rail Fuel System)

Load Profile Information Test — Instructions

Load Profile Information Test — Instructions (Service ADVISOR 5)

Group 160: Trouble Code Diagnostics and Tests

About This Group of the Manual

Electrical Concepts

Electrical Circuit Malfunctions

Troubleshooting Circuit Malfunctions

Using a Digital Multimeter

Connecting to Diagnostic Scan Tool (DST)

Connecting to Service ADVISOR

Viewing Active DTCs on Diagnostic Gauge (Earlier Model)

Viewing Stored DTCs on Diagnostic Gauge (Earlier Model)

Clearing Stored DTCs on Diagnostic Gauge (Earlier Model)

Engine Configuration Parameters on Diagnostic Gauge (Earlier Model)

Viewing Active DTCs on Diagnostic Gauge (Later Model)

Viewing Stored DTCs on Diagnostic Gauge (Later Model)

Clearing Stored DTCs on Diagnostic Gauge (Later Model)

Data Parameter Description

Engine Test Instructions—Cylinder Misfire Test

Engine Test Instructions—Compression Test

Cylinder Cutout Test Instructions

Cylinder Cutout Test Using JDG1250

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

Downloading Payload File For DST

Reprogramming Engine Control Unit (ECU) With DST

Diagnostic Trouble Codes (DTCs)

Listing of Diagnostic Trouble Codes (DTCs) on ECU

Diagnostic Procedure

Intermittent Fault Diagnostics

Terminal Test

T1 - Multi-state Throttle Input High

T1 - Multi-state Throttle Input High

T2 - Multi-state Throttle Input Low

T2 - Multi-state Throttle Input Low

T3 - Analog Throttle (A) Input High

T3 - Analog Throttle (A) Input High

T4 - Analog Throttle (A) Input Low

T4 - Analog Throttle (A) Input Low

T5 - Analog Throttle (B) Input High

T5 - Analog Throttle (B) Input High

T6 - Analog Throttle (B) Input Low

T6 - Analog Throttle (B) Input Low

T7 - CAN Throttle Invalid

T7 - CAN Throttle Invalid

T8 - PWM Throttle Input High

T8 - PWM Throttle Input High

T9 - PWM Throttle Input Low

T9 - PWM Throttle Input Low

T10 - PWM Throttle Abnormal Pulse Width

T10 - PWM Throttle Abnormal Pulse Width

T11 - Excavator Throttle Reference Voltage High

T11 - Excavator Throttle Reference Voltage High

T12 - Excavator Throttle Reference Voltage Low

T12 - Excavator Throttle Reference Voltage Low

T13 - Excavator Throttle Ground Voltage High

T13 - Excavator Throttle Ground Voltage High

T14 - Excavator Throttle Ground Voltage Low

T14 - Excavator Throttle Ground Voltage Low

T15 - Excavator Throttle Input Voltage High

T15 - Excavator Throttle Input Voltage High

T16 - Excavator Throttle Input Voltage Low

T16 - Excavator Throttle Input Voltage Low

T22 - Analog Throttle (A) Input Voltage Out of Range

000028.03 - Throttle Voltage High

000028.04 - Throttle Voltage Low

000029.03 - Throttle Voltage High

000029.04 - Throttle Voltage Low

000091.03 - Throttle Voltage High

000091.04 - Throttle Voltage Low

000091.08 - PWM Throttle Abnormal Pulse Width

000091.09 - Throttle Invalid

000091.14 - Throttle Voltage Out of Range

000094.01 — Fuel Supply Pressure Extremely Low

000094.01 - Fuel Supply Pressure Extremely Low

000094.03 — Fuel Supply Pressure Input Voltage High

000094.03 - Fuel Supply Pressure Input Voltage High

000094.04 — Fuel Supply Pressure Input Voltage Low

000094.04 - Fuel Supply Pressure Input Voltage Low

000094.16 — Fuel Supply Pressure Moderately High

000094.16 - Fuel Supply Pressure Moderately High

000094.18 — Fuel Supply Pressure Moderately Low

000094.18 - Fuel Supply Pressure Moderately Low

000097.00 — Water in Fuel Continuously Detected

000097.00 - Water in Fuel Continuously Detected

000097.03 — Water in Fuel Signal Voltage High

000097.03 - Water in Fuel Signal Voltage High

000097.04 — Water in Fuel Signal Voltage Low

000097.04 - Water in Fuel Signal Voltage Low

000097.16 — Water in Fuel Detected

000097.16 - Water in Fuel Detected

000097.31 — Water in Fuel Detected

000097.31 - Water in Fuel Detected

000100.01 — Engine Oil Pressure Extremely Low

000100.01 - Engine Oil Pressure Extremely Low

000100.03 — Engine Oil Pressure Input Voltage High

000100.03 - Engine Oil Pressure Input Voltage High

000100.04 — Engine Oil Pressure Input Voltage Low

000100.04 - Engine Oil Pressure Input Voltage Low

000100.18 — Engine Oil Pressure Moderately Low

000100.18 - Engine Oil Pressure Moderately Low

000102.03 — Manifold Air Pressure Input Voltage High

000102.03 - Manifold Air Pressure Input Voltage High

000102.04 — Manifold Air Pressure Input Voltage Low

000102.04 - Manifold Air Pressure Input Voltage Low

000105.03 — Manifold Air Temperature Input Voltage High

000105.03 - Manifold Air Temperature Input Voltage High

000105.04 — Manifold Air Temperature Input Voltage Low

000105.04 - Manifold Air Temperature Input Voltage Low

000105.16 — Manifold Air Temperature Moderately High

000105.16 - Manifold Air Temperature Moderately High

000107.00 — Air Filter Restriction High

000107.00 - Air Filter Restriction High

000107.31 — Air Filter Restriction High

000107.31 - Air Filter Restriction High

000110.00 — Engine Coolant Temperature High Most Severe

000110.00 - Engine Coolant Temperature High Most Severe

000110.03 — Engine Coolant Temperature Input Voltage High

000110.03 - Engine Coolant Temperature Input Voltage High

000110.04 — Engine Coolant Temperature Input Voltage Low

000110.04 - Engine Coolant Temperature Input Voltage Low

000110.15 — Engine Coolant Temperature High Least Severe

000110.15 - Engine Coolant Temperature High Least Severe

000110.16 Engine Coolant Temperature High Moderately Severe

000110.16 - Engine Coolant Temperature High Moderately Severe

000111.01 — Engine Coolant Level Low

000111.01 - Engine Coolant Level Low

000158.17 — ECU Power Down Error

000158.17 - ECU Power Down Error

000174.03 — Fuel Temperature Input Voltage High

000174.03 - Fuel Temperature Input Voltage High

000174.04 — Fuel Temperature Input Voltage Low

000174.04 - Fuel Temperature Input Voltage Low

000177.09 - Transmission Oil Temperature Invalid

000190.00 - Engine Speed Extremely High

000190.01 - Engine Extremely Overloaded

000190.16 - Engine Speed Moderately High

000190.18 - Engine Moderately Overloaded

000523.09 - Gear Selection Invalid

000611.03 — Injector Wiring Shorted To Power Source

000611.03 - Injector Wiring Shorted To Power Source

000611.04 — Injector Wiring Shorted To Ground

000611.04 - Injector Wiring Shorted To Ground

000620.03 — Sensor Supply Voltage High

000620.03 - Sensor Supply Voltage High

000620.04 — Sensor Supply Voltage Low

000620.04 - Sensor Supply Voltage Low

000627.01 — Injector Supply Voltage Problem

000627.01 - Injector Supply Voltage Problem

000629.12 - ECU Error

000629.13 - ECU Error

000636.02 — Cam Position Input Noise

000636.02 - Cam Position Input Noise

000636.08 — Cam Position Input Missing

000636.08 - Cam Position Input Missing

000636.10 — Cam Position Input Pattern Error

000636.10 - Cam Position Input Pattern Error

000637.02 — Crank Position Input Noise

000637.02 - Crank Position Input Noise

000637.07 — Crank Position/Cam Position Out of Sync

000637.07 - Crank Position/Cam Position Out of Sync

000637.08 — Crank Position Input Missing

000637.08 - Crank Position Input Missing

000637.10 — Crank Position Input Pattern Error

000637.10 - Crank Position Input Pattern Error

000639.13 — CAN Error

000639.13 - CAN Error

000651.05 — Cylinder #1 EUI Circuit Open

000651.05 - Cylinder #1 EUI Circuit Open

000651.06 — Cylinder #1 EUI Circuit Shorted

000651.06 - Cylinder #1 EUI Circuit Shorted

000652.05 — Cylinder #2 EUI Circuit Open

000652.05 - Cylinder #2 EUI Circuit Open

000652.06 — Cylinder #2 EUI Circuit Shorted

000652.06 - Cylinder #2 EUI Circuit Shorted

000653.05 — Cylinder #3 EUI Circuit Open

000653.05 - Cylinder #3 EUI Circuit Open

000653.06 — Cylinder #3 EUI Circuit Shorted

000653.06 - Cylinder #3 EUI Circuit Shorted

000654.05 — Cylinder #4 EUI Circuit Open

000654.05 - Cylinder #4 EUI Circuit Open

000654.06 — Cylinder #4 EUI Circuit Shorted

000654.06 - Cylinder #4 EUI Circuit Shorted

000655.05 — Cylinder #5 EUI Circuit Open

000655.05 - Cylinder #5 EUI Circuit Open

000655.06 — Cylinder #5 EUI Circuit Shorted

000655.06 - Cylinder #5 EUI Circuit Shorted

000656.05 — Cylinder #6 EUI Circuit Open

000656.05 - Cylinder #6 EUI Circuit Open

000656.06 — Cylinder #6 EUI Circuit Shorted

000656.06 - Cylinder #6 EUI Circuit Shorted

000970.02 — Auxiliary Engine Shutdown Switch Signal Invalid

000970.02 - Auxiliary Engine Shutdown Switch Signal Invalid

000970.31 - Auxiliary Engine Shutdown Switch Active

000971.31 - External Fuel Derate Switch Active

001109.31 - Engine Shutdown Warning

001110.31 - Engine Shutdown

001569.31 - Fuel Derate

002000.13 - Security Violation

Section 05: Tools

Group 170: Repair Tools

JDG145

JDG155

JDG359

JDG364

JDG707

JDG776

JDG777

JDG783

JDG820

JDG865

JDG971

JDG998

JDG1334

JDG10466

JDG11263

JT03513C

JT05412

JT07306

JT07328

JT07195B

Other Material

Electronic Control System Other Material

Group 180: Diagnostic Service Tools

Electronic Control System Diagnostic Tools

Section 06: Specifications

Group 200: Repair Specifications

Unified Inch Bolt and Screw Torque Values

Metric Bolt and Screw Torque Values

General OEM Engine Specifications

Dual Rail Fuel System Specifications

Single Rail Fuel System Specifications

Electronic Engine Control System Specifications

Group 210: Diagnostic Specifications

Fuel System Diagnostic Specifications

Application Specifications

Combines - Sensor Specifications

Combines - Torque Curve Selection

Combines - Governor Mode Selection

Combines - ECU Terminal Identification

Excavators - Sensor Specifications

Excavators - Torque Curve Selection

Excavators - Governor Mode Selection

Excavators - ECU Terminal Identification

Forage Harvesters - Sensor Specifications

Forage Harvesters - Torque Curve Selection

Forage Harvesters - Governor Mode Selection

Forage Harvesters - ECU Terminal Identification

Loaders - Sensor Specifications

Loaders - Torque Curve Selection

Loaders - Governor Mode Selection

Loaders - ECU Terminal Identification

Marine Engines - Sensor Specifications

Marine Engines - Torque Curve Selection

Marine Engines - Governor Mode Selection

Marine Engines - ECU Terminal Identification

Marine Engines - Electronic Control System Wiring Diagram

12.5 L Marine Application Wheel House Panel Electrical Wiring Diagram

12.5 L Marine Application Fly Bridge Panel Electrical Wiring Diagram

OEM Engines - Sensor Specifications

OEM Engines - Torque Curve Selection

OEM Engines - Governor Mode Selection

OEM Engines - ECU Terminal Identification

OEM Engines - Electronic Control System Wiring Diagram

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

Tractors - Sensor Specifications

Tractors - Torque Curve Selection

Tractors - Governor Mode Selection

Tractors - ECU Terminal Identification