John Deere Diesel Engines Powertech 4.5L 6.8L Level 11 Fuel Systems With Denso HPCR Workshop Manual – PDF DOWNLOAD
DESCRIPTION:
CTM 220 (21Jan04) 33525067201_2_1
John Deere Diesel Engines Powertech 4.5L 6.8L Level 11 Fuel Systems With Denso HPCR Workshop Manual – PDF DOWNLOAD
Forward
- This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use.
- This manual (CTM220) covers only Level 11 Electronic Fuel System with the Denso High Pressure Common Rail (HPCR). It is one of six volumes on 4.5 L and 6.8 L engines. The following five companion manuals cover the base engine, mechanical fuel system, and other electronic control systems. Each manual covers repair, operation, and diagnostics.
· CTM104—Base Engine
· CTM170—Level 4 Electronic Fuel System with
Bosch VP44 Pump
· CTM207—Mechanical Fuel Systems
· CTM284—Level 1 Electronic Fuel System with
Delphi (Lucas) DP201 Pump
· CTM331—Level 12 Electronic Fuel System with
Stanadyne DE 10 Pump
TABLE OF CONTENTS:
John Deere Diesel Engines Powertech 4.5L 6.8L Level 11 Fuel Systems With Denso HPCR Workshop Manual – PDF DOWNLOAD
CTM220 (21JAN04) PWT 45 & 68 HPCR lvl 11 (GB)pdf 0
Contents 5
General 7
Safety 9
Handle Fluids Safely—Avoid Fires 9
Handle Starting Fluid Safely 9
Service Cooling System Safely 9
Prevent Battery Explosions 10
Prepare for Emergencies 10
Handling Batteries Safely 11
Avoid High-Pressure Fluids 12
Wear Protective Clothing 12
Service Machines Safely 13
Work In Ventilated Area 13
Work in Clean Area 13
Remove Paint Before Welding or Heating 14
Avoid Heating Near Pressurized Fluid Lines 14
Illuminate Work Area Safely 14
Use Proper Lifting Equipment 15
Construct Dealer-Made Tools Safely 15
Practice Safe Maintenance 16
Use Proper Tools 16
Dispose of Waste Properly 17
Live With Safety 17
Engine Identification 19
Engine Model Designation 19
Engine Serial Number Plate Information 20
OEM Engine Option Code Label 21
Information Relative to Emissions Regulations 21
Engine Application Charts 22
Fuels, Lubricants, and Coolant 23
Lubricants and Coolant 23
Diesel Fuel 23
Bio-Diesel Fuel 24
Dieselscan Fuel Analysis 24
Lubricity of Diesel Fuel 25
Repair and Adjustments 27
Electronic Fuel System Repair and Adjustments 29
Fuel System – General Information 29
Relieve Fuel System Pressure 29
Remove and Install Pre-Filter/Water Bowl Base 30
Replace Pre-Filter Element 32
Remove and Install Final Fuel Filter/Water Bowl Base 34
Replace Final Fuel Filter Element 36
Remove Fuel Transfer Pump 37
Install Fuel Transfer Pump 38
Remove and Install High Pressure Fuel Pump 39
Remove and Install High Pressure Fuel Pump Inlet Filter 41
Remove and Install High Pressure Common Rail 42
Remove and Install Flow Dampers 44
Remove and Install Pressure Limiter 46
Remove Electronic Injectors (EIs) 48
Clean Electronic Injector (EI) Bore 49
Clean Electronic Injector (EI) Orifice 49
Clean Electronic Injector (EI) Body 49
Inspect Electronic Injector (EI) Body 49
Install Electronic Injectors (EIs) 50
Remove and Install Leak-off Lines 53
Electronic Engine Control Repair and Adjustment 55
Engine Control Unit (ECU) 55
Fuel System Sensors 56
Remove and Install Engine Coolant Temperature (ECT) Sensor 56
Remove and Install Fuel Temperature Sensor 57
Remove and Install Manifold Air Temperature (MAT) Sensor 57
Remove and Install Oil Pressure Sensor 58
Remove and Install Fuel Rail Pressure Sensor 59
Remove and Install Crank Position Sensor 60
Remove and Install Pump Position Sensor 60
Remove and Install Glow Plugs 61
Connectors 62
Use Electrical Insulating Compound 62
Using High-Pressure Washer 63
Repair WEATHERPACK™ Connector 64
Remove Blade Terminals from Connector Body 67
Repair (Pull Type) METRI-PACK™ Connectors 68
Repair (Push Type) METRI-PACK™ Connectors 70
Repair DEUTSCH™ Connectors 73
Repair AMP Connector 76
Repair SUMITOMO™ Connectors 78
Repair YAZAKI™ Connectors 80
Theory Of Operation 83
Electronic Fuel System Operation 85
About This Group 85
Fuel System Operation 86
Pre-filter Operation 87
Fuel Transfer Pump Operation 88
Final Fuel Filter Operation 89
High Pressure Fuel Pump Operation 90
High Pressure Common Rail (HPCR) Operation 91
Electronic Injector (EI) Operation 92
Electronic Control System Operation 95
About This Group 95
Electronic Control System Terminology 96
Electronic Control System Operation 97
Electronic Control System Overview 98
Monitoring Engine Parameters 99
Measuring Temperature 99
Measuring Pressure102
Measuring Throttle Position104
Measuring Engine Speed107
Pump Control Valve (PCV)108
Water in Fuel (WIF) Sensor108
Electronic Injector (EI) Wiring Harness Connector109
Engine Control Unit (ECU)110
Controlled Area Network (CAN)112
Glow Plug Operation112
Cruise Control Operation113
Engine Protection114
Derate Programs114
Multiple Torque Curve Selection115
Governor Droop Mode Selection115
Engine Control Unit (ECU) Self-Diagnosis116
Diagnostics119
Observable Diagnostics and Tests125
About This Group125
E1 – Engine Cranks/Won’t Start126
E1 – Engine Cranks/Won’t Start Diagnostic Procedure126
E2 – Engine Misfires/Runs Irregularly129
E2 – Engine Misfires/Runs Irregularly Diagnostic Procedure129
E3 – Engine Does Not Develop Full Power133
E3 – Engine Does Not Develop Full Power Diagnostic Procedure133
E4 – Engine Emits Excessive White Exhaust Smoke138
E4 – Engine Emits Excessive White Exhaust Smoke Diagnostic Procedure138
E5 – Engine Emits Excessive Black Or Gray Exhaust Smoke141
E5 – Engine Emits Excessive Black Or Gray Exhaust Smoke Diagnostic Procedure141
E6 – Engine Will Not Crank143
E7 – Engine Idles Poorly143
E8 – Abnormal Engine Noise144
E9 – Analog Throttle (A) Does Not Respond146
E10 – Analog Throttle (B) Does Not Respond146
F1 – Fuel Supply System Check148
F1 – Fuel Supply System Check Diagnostic Procedure148
F2 – Excessive Fuel Consumption153
F3 – Fuel in Oil153
D1 – ECU Does Not Communicate with DST or SERVICE ADVISOR™154
155
D1 – ECU Does Not Communicate With DST or SERVICE ADVISOR™ Diagnostic Procedure155
D2 – Diagnostic Gauge Does Not Communicate With ECU160
161
D2 – Diagnostic Gauge Does Not Communicate With ECU Diagnostic Procedure161
A2 – Glow Plug Check166
A2 – Glow Plug Check167
A2 – Glow Plug Check168
A2 – Glow Plug Check Diagnostic Procedure168
Check Fuel Supply Quality171
Test for Air in Fuel173
Check Fuel Supply Pressure174
Check for Restricted Fuel Leak-off Line175
Bleed the Fuel System177
Check and Adjust High Pressure Fuel Pump Static Timing180
Trouble Code Diagnostics and Tests181
About This Group181
Electrical Concepts182
Using a Digital Multimeter182
Electrical Circuit Malfunctions183
Troubleshooting Circuit Malfunctions186
Connecting to Diagnostic Scan Tool (DST) or SERVICE ADVISOR™190
Blinking DTCs192
Engine Configuration Data Parameters on Diagnostic Gauge193
Viewing Active DTCs on Diagnostic Gauge195
Viewing Stored DTCs on Diagnostic Gauge195
Clearing Stored DTCs on Diagnostic Gauge196
Data Parameter Description198
Engine Test Instructions—Cylinder Misfire Test202
Engine Test Instructions—Compression Test203
Engine Test Instructions— Cylinder Cutout Test204
Engine Test Instructions— Tractor Torque Curve Change Test205
Reprogramming Engine Control Unit (ECU)206
Downloading Payload File For DST207
Reprogramming Engine Control Unit (ECU) With DST212
Downloading Payload File For SERVICE ADVISOR™217
Reprogramming Engine Control Unit (ECU) With SERVICE ADVISOR™225
Diagnostic Trouble Codes (DTCs)229
Listing of Diagnostic Trouble Codes (DTCs) on ECU230
Diagnostic Procedure234
Intermittent Fault Diagnostics235
T1 – Multi-state Throttle Input High236
T3 – Analog Throttle (A) Input High Diagnostic Procedure245
00017404 — Fuel Temperature Input Voltage Low380
00018900 — Engine Speed Derate387
00019000 — Engine Overspeed Extreme388
00019016 — Engine Overspeed Moderate389
00023702 — Vehicle Identification Number Invalid390
00023713 — Vehicle Identification Option Code Invalid391
00023731 — Vehicle Model Number Invalid392
00061103 — Electronic Injector Wiring Shorted To Power Source394
00061103 Electronic Injector Wiring Shorted To Power Source Diagnostic Procedure396
00061104 Electronic Injector Wiring Shorted To Ground Diagnostic Procedure400
00089809 — Vehicle Speed or Torque Message Invalid545
00097031 — Engine Shutdown – Auxiliary Request546
00097131 — External Fuel Derate Switch Active547
00106909 — Tire Size Invalid548
00106909 — Tire Size Invalid549
00106909 Tire Size Invalid Diagnostic Procedure549
00110931 — Engine Protection Shutdown Warning570
00111031 — Engine Protection Shutdown571
00134703 — Pump Control Valve Current High572
00134703 Pump Control Valve Current High Diagnostic Procedure573
00200013 — Security Violation602
00200509 — ACU Signal Missing603
00204909 — CAB Signal Missing604
00207109 — CCU Signal Missing605
Tools607
Electronic Fuel/Control System Repair Tools and Other Materials609
Electronic Fuel System Repair and Adjustment Essential Tools609
Fuel System Repair and Adjustment Other Materials610
Electronic Engine Control Repair Tools611
Control Repair and Adjustment Other Materials616
Diagnostic Service Tools617
Electronic Fuel/Control System Diagnostic Tools617
Specifications621
Repair Specifications623
Unified Inch Bolt and Cap Screw Torque Values623
Metric Bolt and Cap Screw Torque Values624
Electronic Fuel System Repair and Adjustment Specifications625
Electronic Engine Control Repair and Adjustment Specifications627
Diagnostic Specifications629
Fuel System Diagnostic Specifications629
Application Specifications631
Combines – Sensor Specifications634
Combines – Torque Curve Selection636
Combines – Governor Mode Selection636
Combines – ECU Terminal Identification637
Loaders – Sensor Specifications638
Loaders – Torque Curve Selection640
Loaders – Governor Mode Selection641
Loaders – ECU Terminal Identification642
Motor Graders – Sensor Specifications643
Motor Graders – Torque Curve Selection645
Motor Graders – Governor Mode Selection645
Motor Graders – ECU Terminal Identification646
OEM Engines – Sensor Specifications648
OEM Engines – Torque Curve Selection650
OEM Engines – Governor Mode Selection651
OEM Engines – ECU Terminal Identification652
OEM Engines – Electronic Control System Wiring Diagram654
OEM Engines – 45L & 68L Instrument Panel/Engine Start Components Electrical Wiring Diagram656
6020 Tractors – Sensor Specifications658
6020 Tractors – Torque Curve Selection660
6020 Tractors – Governor Mode Selection661
6020 Tractors – ECU Terminal Identification662
Tractors – 7720 – 7820 Series – Sensor Specifications664
Tractors – 7720 – 7820 Series – Torque Curve Selection666
Tractors – 7720 – 7820 Series – Governor Mode Selection667
Tractors – 7720 – 7820 Series – ECU Terminal Identification668
IMAGES PREVIEW OF THE MANUAL:
VIDEO PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
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