John Deere Engine Gas Engine Powertech 6.8L 8.1L Operation And Diagnostic Manual CTM113 PDF

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John Deere Engine Gas Engine Powertech 6.8L 8.1L Operation And Diagnostic Manual CTM113 – PDF DOWNLOAD

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John Deere Engine Gas Engine Powertech 6.8L 8.1L Operation And Diagnostic Manual CTM113 – PDF DOWNLOAD

Language : English
Pages :400
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

John Deere Engine Gas Engine Powertech 6.8L 8.1L Operation And Diagnostic Manual CTM113 – PDF DOWNLOAD

Foreword

• 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. Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.
• CAUTION: This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury. Use this component technical manual in conjunction with the engine repair manual (for 6068 CNG engines use CTM146 and for 6081 CNG engines use CTM87) and the respective machine technical manual.
• See the repair manual for information on component removal and installation. See the machine technical manual for information on gaining access to the components. This manual is divided into two parts: theory of operation and diagnostics. The theory of operation section contains information that explains how the engine subsystems operate. The diagnostics section helps identify the cause of engine problems.
• Applicable special tools needed to do the job, specifications, and helpful reference materials are covered in separate groups toward the end of this manual. Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.

TABLE OF CONTENTS:

John Deere Engine Gas Engine Powertech 6.8L 8.1L Operation And Diagnostic Manual CTM113 – PDF DOWNLOAD

Contents 5
Operation and Diagnostics 7
Safety 11
Handle Fluids Safely — Avoid Fires 11
Handle Natural Gas Safely 11
Prevent Battery Explosions 12
Prepare for Emergencies 12
Prevent Acid Burns 13
Avoid High-Pressure Fluids 14
Wear Protective Clothing 14
Service Machines Safely 15
Work in Ventilated Area 15
Work in Clean Area 15
Remove Paint Before Welding or Heating 16
Avoid Heating Near Pressurized Fluid Lines 16
Illuminate Work Area Safely 16
Use Proper Lifting Equipment 17
Practice Safe Maintenance 17
Use Proper Tools 18
Dispose of Waste Properly 18
Handle Compressed Natural Gas (CNG) Safely 19
Service Compressed Natural Gas (CNG) Systems Safely 19
Protect Against High Pressure 20
Protect Against Extremely Cold CNG Leakage 20
Live With Safety 20
Theory of Operation 21
General Engine Operation 21
Head Gasket Joint Construction and Operation 22
Lubrication System Operation on a 6068 CNG Engine 24
25
Lubrication System Operation on a 6081 CNG Engine 26
27
Cooling System Operation on a 6068 CNG Engine 28
29
Cooling System Operation on a 6081 HFN01/HFN03 CNG Engines With Water Cooled Turbo 30
Cooling System Operation on a 6081 HFN02 CNG Engines 31
32
Intake and Exhaust Systems Operation 34
35
How the Turbocharger Works 36
How the Wastegate Works 38
How the Turbocharger is Lubricated 39
Theory of Lean-Burn Engines 40
High Pressure Fuel Supply System Storage and Routing 41
Electronic Engine Controls Theory of Operation 46
HFN01/HFN03 Electronic Engine Control System Overview 49
HFN02 Electronic Engine Control System Overview 50
Throttle Operation 51
Temperature Sensors 52
Position Sensors 53
Pressure Sensors 54
Engine Airflow Measurement 55
Air/Fuel Ratio Measurement — UEGO Sensor 56
Camshaft Position Sensor 57
Crankshaft Position Sensor 59
ECU 60
Fuel Control on a 6068 CNG Engine 61
Fuel Control on a 6081 HFN01/HFN03 CNG Engine 63
Fuel Control on a 6081 HFN02 CNG Engine 64
65
Fuel Control Modes 66
Air Control 67
Ignition Control 69
Engine Diagnostics and Testing Procedures 71
Diagnosing Head Gasket Joint Failures 71
Head Gasket Inspection and Repair Sequence 75
Diagnosing Lubrication System Malfunctions 77
Diagnosing Cooling System Malfunctions 78
Test Engine Compression Pressure 79
Check Engine Oil Pressure 81
Diagnosing Turbocharger Malfunctions 82
Starting and Charging System Diagnostics 83
Starting and Charging Systems Handling Precaution 83
Starting and Charging Systems Diagnostics 84
Electronic Engine Controls Diagnostics 87
About This Section of the Manual 87
Physical Differences Between Early HFN01, Current HFN01/HFN03, and HFN02 Wiring Harnesses 88
Electrical Concepts 90
Using a Digital Multimeter 91
Electrical System Basic Information 93
High Resistance Circuit 94
Open Circuit 95
Grounded Circuit 97
Shorted Circuit 98
Using the Diagnostic Scan Tool (DST) 100
Spark System Test 109
Injector Test 110
Throttle/Pedal Test 112
Wastegate Control Test 113
Injector Cleaning 114
UEGO Test 121
Adaptive Learn Screen 122
System Part Number Screen 123
Adjustable EEPROM Parameter & Fuelgauge Update 124
Knock/Environment Screen 125
Procedure to Program an ECU With New Calibration File 126
Diagnostic System128
Listing of DTCs 130
131
Diagnostic Procedure132
Intermittent Fault Diagnostics134
B1 – “Check Engine” Light (CEL) Does Not Illuminate 136
137
B2 – ECU Does Not Communicate With DST 138
140
141
B3 – Engine Cranks/Won’t Start 142
143
144
145
B4 – Engine Won’t Idle (Not Missing or Running Rough) 146
148
B5 – Engine Miss/Runs Rough 150
152
153
154
B6 – Low Power 156
158
159
DTC 13 UEGO Sense Cell Failure 160
162
DTC 14 NGT Voltage High 164
165
DTC 15 NGT Voltage Low 166
167
DTC 16 External 5 Volt Supply Error 168
169
DTC 17 EBP Voltage High 170
171
DTC 18 EBP Voltage Low 172
173
DTC 19 EBP Higher Than Expected 174
175
DTC 21 FPP1 Voltage High 176
179
DTC 22 FPP1 Voltage Low 180
183
184
DTC 23 MAT Voltage High 186
187
DTC 24 MAT Higher Than Expected 188
189
DTC 25 MAT Voltage Low 190
191
DTC 26 ECT Voltage High 192
193
DTC 27 ECT Voltage Low 194
195
DTC 28 ECT Higher Than Expected 196
197
DTC 29 EBP Lower than Expected 198
199
DTC 31 FPP2 Voltage High 200
203
DTC 32 FPP2 Voltage Low 204
207
DTC 33 MAP Voltage High 208
209
DTC 34 MAP Voltage Low 210
211
DTC 35 BP Higher than Expected 212
213
DTC 36 BP Lower Than Expected 214
215
DTC 37 PTP Voltage High 216
217
DTC 38 NGP Voltage High 218
219
DTC 39 NGP Voltage Low 220
221
DTC 41 NGP Higher Than Expected 222
223
DTC 42 Camshaft Position Sensor Error (6081 CNG Only) 224
225
DTC 42 Camshaft Position Sensor Error (6068 CNG Only) 226
227
DTC 43 NGP Lower Than Expected 228
229
DTC 43 NGP Lower Than Expected – Continued230
DTC 44 Closed Loop Multiplier Limit High 232
234
235
DTC 45 Closed Loop Multiplier Limit Low 236
238
239
DTC 46 Adaptive Learn Multiplier Limit High 240
242
DTC 46 Adaptive Learn Multiplier Limit High – Continued243
DTC 47 Adaptive Learn Multiplier Limit Low 244
246
DTC 47 Adaptive Learn Multiplier Limit Low – Continued247
248
249
DTC 49 PTP Not Active 250
251
DTC 51 RAM Error 252
252
DTC 52 Battery Voltage Low 254
255
DTC 53 Battery Voltage High 256
257
DTC 54 TPS Voltage High 258
259
DTC 55 ECU Error 260
261
DTC 56 TPS Voltage Low 262
264
DTC 57 TPS Higher Than Expected 266
267
DTC 58 UEGO Heater Current High 268
270
DTC 59 UEGO Heater Current Low 272
274
DTC 61 Environment Sensor Error 276
277
278
DTC 62 UEGO Pump Cell Voltage Low 280
282
DTC 63 UEGO Pump Cell Voltage High 284
286
DTC 64 NGTT Voltage High 288
289
DTC 65 NGTT Voltage Low 290
291
DTC 66 NGTP Voltage High 292
293
DTC 67 NGTP Voltage Low 294
295
DTC 68 UEGO Calibration Resistor Voltage High 296
298
DTC 69 UEGO Calibration Resistor Low 300
302
DTC 71 Boost Higher Than Expected 304
305
DTC 72 Boost Lower Than Expected 306
307
DTC 73 Overboost 308
310
DTC 74 Oil Pressure Low 312
313
DTC 75 Injector Duty Cycle High 314
316
DTC 77 NGT Lower Than Expected 318
319
DTC 78 IVS Status OFF Unexpected 320
322
DTC 79 IVS Status ON Unexpected 324
327
DTC 81 TPS Lower Than Expected 328
329
DTC 82 Crankshaft Position Sensor Error (6068 CNG Only) 330
331
DTC 83 NGTP Higher Than Expected 332
333
DTC 84 Vehicle Network Transmit Fault 334
335
DTC 85 Vehicle Network Receive Fault 336
337
DTC 86 FPP1 Signal Different Than Expected 338
341
342
343
344
DTC 87 FPP2 Signal Different Than Expected 346
349
350
351
352
DTC 94 ECU Internal Voltage Error 354
355
DTC 95 Knock Sensor Error 356
357
358
DTC 96 NGP Voltage Excessively High 360
361
D1 – Gas Pressure 362
363
D2 – Ignition System 364
366
367
D2 – Ignition System – Continued368
D2 – Ignition System – Continued369
D3 – Fuel Injectors Diagnostic Chart 370
371
Specifications373
Specifications373
Engine Diagnostics and Testing Procedures Specifications 373
Electronic Engine Control System Component Location Diagram (6068 CNG Engine Left)374
Electronic Engine Control System Component Location Diagram (6068 CNG Engine Rear)375
Electronic Engine Control System Component Location Diagram (6068 CNG Engine Right)376
Electronic Engine Control System Component Location Diagram (6081 CNG Engine with Early Wiring Harness – HFN01)378
Electronic Engine Control System Component Location Diagram (6081 CNG Engine with Current Wiring Harness – HFN01/HFN03) 380
Electronic Engine Control System Component Location Diagram (6081 CNG Engine Wiring Harness – HFN02)382
ECU Terminal Identification384
385
386
Special or Essential Tools387
Group 105 Engine Diagnostics and Testing Procedures Tools 387
Group 110 Starting and Charging System Diagnostics Tools 389
Group 115 Electronic Engine Controls Diagnostics Tools390
Other Material392
Page Numbers 5
Section 7
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