John Deere PowerTech 4.5 L and 6.8 L Diesel Engines Level 4 Electronic Fuel Systems Service Manual (CTM170)
Complete service repair manual with Electrical Wiring Diagrams for John Deere PowerTech 4.5 L and 6.8 L Diesel Engines Level 4 Electronic Fuel Systems, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
John Deere PowerTech 4.5 L and 6.8 L Diesel Engines Level 4 Electronic Fuel Systems 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.
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
000174.15 — Fuel Temperature High Least Severe....592
000174.15 - Fuel Temperature High Least Severe....223
000174.16 — Fuel Temperature High Moderately Severe....596
000174.16 - Fuel Temperature High Moderately Severe....223
000174.31 — Fuel Temperature Sensor Faulty....601
000174.31 - Fuel Temperature Sensor Faulty....224
000189.00 - Engine Speed Derate....224
000189.31 - Engine Speed Derate....224
000190.00 - Engine Overspeed Extreme....224
000190.01 - Engine Extremely Overloaded....224
000190.16 - Engine Overspeed Moderate....224
000190.18 - Engine Moderately Overloaded....224
000620.03 — Sensor Supply Voltage High....611
000620.03 - Sensor Supply Voltage High....224
000620.04 — Sensor Supply Voltage Low....614
000620.04 - Sensor Supply Voltage Low....224
000627.04 — ECU Unswitched Power Missing....618
000627.04 - ECU Unswitched Power Missing....224
000629.13 — ECU Error....621
000629.13 - ECU Error....224
000629.19 — ECU to Pump Communication Error....624
000629.19 - ECU to Pump Communication Error....224
000632.02 Fuel Shutoff Error....629
000632.02 - Fuel Shutoff Error....224
000632.05 — Fuel Shutoff Non-Functional....633
000632.05 - Fuel Shutoff Non-Functional....224
000636.02 — Pump Position Input Noise....637
000636.02 - Pump Position Input Noise....224
000636.08 — Pump Position Input Missing....640
000636.08 - Pump Position Input Missing....224
000636.10 — Pump Position Input Pattern Error....645
000636.10 - Pump Position Input Pattern Error....224
000637.02 — Crankshaft Position Input Noise....651
000637.02 - Crankshaft Position Input Noise....224
000637.08 — Crankshaft Position Input Missing....655
000637.08 - Crankshaft Position Input Missing....224
000637.10 — Crankshaft Position Input Pattern Error....662
000637.10 - Crankshaft Position Input Pattern Error....224
000729.03 — Inlet Air Heater Signal High....669
000729.03 - Inlet Air Heater Signal High....225
000729.05 — Inlet Air Heater Signal Low....673
000729.05 - Inlet Air Heater Signal Low....225
000810.02 — Calculated Vehicle Speed Input Signal Noise....677
000810.02 - Calculated Vehicle Speed Input Signal Noise....225
000898.09 — Vehicle Speed Invalid/Missing....680
000898.09 - Vehicle Speed Invalid/Missing....225
000970.02 — Auxiliary Engine Shutdown Switch Signal Invalid....684
000970.02 - Auxiliary Engine Shutdown Switch Signal Invalid....225
000970.31 - Auxiliary Engine Shutdown Switch Active....225
000971.31 - External Engine Derate Switch Active....225
001069.02 — Tire Size Error....691
001069.02 - Tire Size Error....225
001076.02 — Pump Detected Defect....694
001076.02 - Pump Detected Defect....225
001077.07 — Attempting to Fuel Without Command....698
001077.07 - Attempting to Fuel Without Command....225
001077.11 — Pump Supply Voltage Out Of Range....701
001077.11 - Pump Supply Voltage Out Of Range....225
001077.12 — Pump Self-Test Error....706
001077.12 - Pump Self-Test Error....225
001077.19 — Pump Detected Communication Error....710
001077.19 - Pump Detected Communication Error....225
001077.31 - Pump Initiated Engine Protection....213
001078.07 — ECU/Pump Timing Moderately Out of Sync....715
001078.07 - ECU/Pump Timing Moderately Out of Sync....225
001078.11 — ECU/Pump Engine Speed Out of Sync....721
001078.11 - ECU/Pump Engine Speed Out of Sync....225
001078.31 — ECU/Pump Timing Extremely Out of Sync....726
001078.31 - ECU/Pump Timing Extremely Out of Sync....225
001079.03 — Sensor Supply 1 Voltage High....732
001079.03 - Sensor Supply 1 Voltage High....225
001079.04 — Sensor Supply 1 Voltage Low....736
001079.04 - Sensor Supply 1 Voltage Low....226
001080.03 — Sensor Supply 2 Voltage High....741
001080.03 - Sensor Supply 2 Voltage High....226
001080.04 — Sensor Supply 2 Voltage Low....745
001080.04 - Sensor Supply 2 Voltage Low....226
001109.31 - Engine Protection Shutdown Warning....226
001110.31 - Engine Protection Shutdown....226
001485.02 — Pump Power Relay Fault....752
001485.02 - Pump Power Relay Fault....226
001569.31 - Fuel Derate....226
002000.13 - Security Violation....226
Section 05: Tools and Other Materials....763
Group 170: Special Tools....763
D01109AA....766
D01110AA....767
FKM10457....768
JD258....769
JDE38B....770
JDE39....771
JDE81-4....772
JDF13B....773
JDG144....774
JDG145....775
JDG155....776
JDG359....777
JDG360....778
JDG361....779
JDG362....780
JDG363....781
JDG364....782
JDG707....783
JDG708....784
JDG776....785
JDG777....786
JDG783....787
JDG820....788
JDG865....789
JDG949....790
JDG998....791
JDG1369....792
JDG10466....793
JDG11263....794
JT05412....796
JT07195B....797
JT07306....798
JT07328....799
JT25510....800
KJD10109....801
KJD10233....802
Group 180: Lubricants, Sealants, and Other Materials....764
AR54749....804
JDT405....805
TY9375....806
Section 06: Specifications....807
Group 200: Repair Specifications....807
Unified Inch Bolt and Screw Torque Values....811
Metric Bolt and Screw Torque Values....813
General OEM Engine Specifications - Tier 1....815
General OEM Engine Specifications - Tier 2....816
Electronic Fuel System Repair and Adjustment Specifications....818
Electrical Engine Control Repair and Adjustment Specifications....820
Group 210: Diagnostic Specifications....807
Fuel System Diagnostic Specifications....822
Application Specifications....823
Combines - Sensor Specifications....825
Combines - Torque Curve Selection....827
Combines -....828
Combines - ECU Terminal Identification....829
Excavators - Sensor Specifications....831
Excavators - Torque Curve Selection....833
Excavators -....834
Excavators - ECU Terminal Identification....835
Marine - Sensor Specifications....837
Marine - Torque Curve Selection....840
Marine -....841
Marine - ECU Terminal Identification....842
6.8 L Marine Application Electronic Control System Wiring Diagram....844
6.8 L Marine Application Wheel House Panel Electrical Wiring Diagram....846
6.8 L Marine Application Fly Bridge Panel Electrical Wiring Diagram....847
OEM Engines - Sensor Specifications....848
OEM Engines - Torque Curve Selection....850
OEM Engines - With OC03041 Software or Later....851
OEM Engines - With OC03034 Software or Earlier....852
OEM Engines - ECU Terminal Identification....853
ECU Terminal Identification - Continued....855
6.8 L OEM Application Electronic Control System Wiring Diagram....856
6.8 L OEM Application Instrument Panel/Engine Start Components Electrical Wiring Diagram....857
6.8 L OEM Application Instrument Panel/Engine Start Components Electrical Wiring Diagram - Continued....859
Telehandlers - Sensor Specifications....861
Telehandlers - Torque Curve Selection....863
Telehandlers -....864
Telehandlers - ECU Terminal Identification....865
Tractors - 6010 Series - Sensor Specifications....867
Tractors - 6010 Series - Torque Curve Selection....869
Tractors - 6010 Series -....870
Tractors - 6010 Series - ECU Terminal Identification....871
Tractors - 6020 Series - Sensor Specifications....873
Tractors - 6020 Series - Torque Curve Selection....875
Tractors - 6020 Series -....876
Tractors - 6020 Series - ECU Terminal Identification....877
Tractors - 7020 Series - Sensor Specifications....879
Tractors - 7020 Series - Torque Curve Selection....881
Tractors - 7020 Series -....882
Tractors - 7020 Series - ECU Terminal Identification....883
John Deere PowerTech 4.5 L and 6.8 L Diesel Engines Level 4 Electronic Fuel Systems Service Manual (CTM170)
