Complete Component Technical Manual (CTM) with Electrical Wiring Diagrams for John Deere Electronic Fuel Injection Systems (Bosch & Denso Controls), with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

ctm68 - John Deere Electronic Fuel Injection Systems Component Technical Manual.pdf

Total Pages: 356 pages
File Format: PDF (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English etc

ctm68 - Electronic Fuel Injection Systems
Component Technical Manual

Table of Contents

Foreword

Section : Electronic Fuel Injection Systems

Group 00: Safety

Handle Fluids Safely—Avoid Fires

Prevent Battery Explosions

Prepare for Emergencies

Handle Chemical Products Safely

Avoid High-Pressure Fluids

Prevent Machine Runaway

Park Machine Safely

Support Machine Properly

Wear Protective Clothing

Work in Clean Area

Service Machines Safely

Work In Ventilated Area

Illuminate Work Area Safely

Replace Safety Signs

Use Proper Lifting Equipment

Remove Paint Before Welding or Heating

Avoid Heating Near Pressurized Fluid Lines

Avoid Harmful Asbestos Dust

Practice Safe Maintenance

Use Proper Tools

Dispose of Waste Properly

Live With Safety

Group 02: General Information

About This Manual

Engine Controller Serial Number Plate

Injection Pump Serial Number Plate

Glossary of Terms

System Power Requirements

Engine Controller Environmental Restrictions

Electrical Concepts

Using a Digital Multimeter

Use of a Diagnostic Reader

Group 05: Fuel Injection System Components

Major System Components

Engine Controller

Robert Bosch Injection Pump/Actuator Assembly

Nippondenso Injection Pump/Actuator Assembly

Auxiliary Speed Sensor

Transient Voltage Protection Module (TVP)

Group 10: Basic System and Diagnostic Features

How the Electronically-Controlled Fuel Injection System Works

Self-Diagnosis and Back Up Features

Fault Lamp Operation

Governor Modes

Starting Control

Maximum Fuel Quantity Control

Smoke Control

Fuel Temperature Compensation

Fuel Flow/Throttle Output Signal

Auxiliary Speed Output Signal

Understanding the Throttle Options

Diagnostic Codes Operation

Using the Electronic Governor Tester—JT05829

Listing of Diagnostic Codes

Group 15: Robert Bosch Fuel System Connectors

Engine Controller Connector (X1)

Auxiliary Speed/Sensor Connector (X2)

Fuel Shut-Off Solenoid Connector (X11)

Actuator Connector (X12)

Fuel Temperature Sensor Connector (X13)

In-Line Connectors (X7, X8, X9, X10)

Service Connectors (X3, X4, X5, X6)

Using the Diagnostic Voltages Connector (X3)

Using the Diagnostic Reader Connector (X4)

Group 20: Nippondenso Fuel System Connectors

Engine Controller Connector (X1)

Auxiliary Speed Sensor Connector (X2)

Fuel Shut-Off Solenoid Connector (X10)

Actuator Connectors (X7, X9)

Fuel Temperature Sensor Connector (X8)

Service Connectors (X3, X4, X5)

Using the Diagnostic Voltages Connector (X3)

Using the Diagnostic Reader Connector (X4)

Group 25: Robert Bosch Fuel Injection System Diagnostic Procedures

How to Start Troubleshooting a Problem

Troubleshooting Tools Needed

Troubleshooting Suggestions

Initial Operational Checks

Symptom-Only Procedures

Diagnostic-Codes-Present Procedures

Code 11—Primary Analog Throttle Input Too High

Code 12—Primary Analog Throttle Input Too Low

Code 13—Secondary Analog Throttle Input Too High

Code 14—Secondary Analog Throttle Input Too Low

Code 32—Actuator Solenoid Circuit Fault

Code 34—Rack Position Error

Code 35—Rack Position Voltage Too High

Code 36—Rack Position Voltage Too Low

Code 37—Fuel Temperature Input Too High

Code 38—Fuel Temperature Input Too Low

Code 39—Primary Speed Input Error

Code 41—Start Signal Missing

Code 42—Engine Overspeed

Code 43—PWM (Throttle Input Erratic, Too Short or Too Long)

Code 44—Auxiliary Speed Input Error

Code 47—Derated Torque Curve Selected

Code 71—Diagnostic Codes Output Stuck High

Code 72—Diagnostic Codes Output Stuck Low

Code 73—Fuel Flow/Throttle Output Stuck High

Code 74—Fuel Flow/Throttle Output Stuck Low

Group 30: Robert Bosch Component Repairs and Adjustments

Analog Throttle Adjustments

Fuel Injection System Components

Essential Tools

Other Materials

Relieve System Pressure

Remove Fuel Shut-Off Solenoid Housing

Install Fuel Shut-Off Solenoid Housing

Remove and Replace Fuel Shut-Off Solenoid

Bleed the Fuel System

Engine Controller

Transient Voltage Protection (TVP) Module

Connectors

Clean Engine Controller Connector (X1)

Disassemble Engine Controller Connector (X1)

Remove Contact from Contact Housing

Install New Contacts

Reassemble Engine Controller Connector (X1)

Replace Fuel Shut-Off Solenoid Connector (X11)

Replace WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Connector

Install WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Contact

Sensors

Replace Fuel Temperature Sensor

Replace Auxiliary Speed Sensor

Group 35: Nippondenso Fuel Injection System Diagnostic Procedures

How To Start Troubleshooting a Problem

Troubleshooting Tools Needed

Troubleshooting Suggestions

Initial Operational Checks

Symptom-Only Procedures

Diagnostic-Codes-Present Procedures

Code 11—Primary Analog Throttle Input Too High

Code 12—Primary Analog Throttle Input Too Low

Code 13—Secondary Analog Throttle Input Too High

Code 14—Secondary Analog Throttle Input Too Low

Code 28—Engine Controller Failure

Code 29—Sensor Excitation Voltage Too High or Too Low

Code 33—Actuator Solenoid Output Shorted High

Code 34—Rack Position Error

Code 35—Rack Position Voltage Too High

Code 36—Rack Position Voltage Too Low

Code 37—Fuel Temperature Input Too High

Code 38—Fuel Temperature Input Too Low

Code 39—Primary Speed Input Error

Code 41—Start Signal Missing

Code 42—Engine Overspeed

Code 44—Auxiliary Speed Input Error

Code 47—Derated Torque Curve Selected

Code 51—Electrical Noise on Analog Throttle Input

Code 54—Electrical Noise on Rack Position Voltage Input

Code 55—Electrical Noise on Fuel Temperature Input

Code 56—Electrical Noise on Fuel Limit Select Input

Code 57—Electrical Noise on Speed Regulation Select Input

Code 58—Electrical Noise on 3-State Throttle Input

Code 59—Electrical Noise on Sensor +5V Supply

Code 71—Diagnostic Codes Output Stuck High

Code 72—Diagnostic Codes Output Stuck Low

Code 73—Fuel Flow/Throttle Output Stuck High

Code 74—Fuel Flow/Throttle Output Stuck Low

Group 40: Nippondenso Component Repairs and Adjustments

Analog Throttle Adjustments

Fuel Injection System Components

Essential Tools

Other Materials

Relieve System Pressure

Injection Pump/Actuator Assembly

Remove Fuel Shut-Off Solenoid Housing

Install Fuel Shut-Off Solenoid Housing

Replace Fuel Shut-Off Solenoid

Bleed Fuel System

Engine Controller

Transient Voltage Protection (TVP) Module

Connectors

Clean Engine Controller Connector (X1)

Disassemble Engine Controller Connector (X1)

Remove Contact From Housing

Install New Contacts

Reassemble Engine Controller Connector (X1)

Replace WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Connector

Install WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Contact

Sensors

Replace Fuel Temperature Sensor

Replace Auxiliary Speed Sensor

Group 45: Wiring

Robert Bosch—Wiring Harness

Robert Bosch Electronically-Controlled Fuel Injection System with Wiring Harnesses

Robert Bosch—System Wiring Schematic

Robert Bosch Connectors

Nippondenso Wiring Harness

Nippondenso Electronically-Controlled Fuel Injection System with Wiring Harness

Nippondenso System Wiring Schematic

Nippondenso Connectors