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John Deere PowerTech 8.1L Level 9 Denso HPCR Fuel System Technical Manual CTM255
John Deere PowerTech 8.1L Level 9 Denso HPCR Fuel System Technical Manual CTM255 - Image 2
John Deere PowerTech 8.1L Level 9 Denso HPCR Fuel System Technical Manual CTM255 - Image 3

John Deere PowerTech 8.1L Level 9 Denso HPCR Fuel System Technical Manual CTM255

Original price was: $29.95.Current price is: $17.95.

Official John Deere CTM255 technical manual covering the PowerTech 8.1L Level 9 electronic fuel system with Denso high-pressure common rail (HPCR) — full repair, diagnostics, and specifications in instant PDF download.

SKU: HD-CTM255-JD-PT81-HD Category: Tags: , , , Vendor: Electrics Manuals
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Description

John Deere PowerTech 8.1L Level 9 Denso HPCR Fuel System Technical Manual CTM255

This is the complete CTM255 Technical Manual for the John Deere PowerTech 8.1L diesel engine family equipped with the Level 9 Electronic Fuel System using the Denso High Pressure Common Rail (HPCR) injection system. Dated 14MAY03, this John Deere PowerTech 8.1L Level 9 Denso HPCR manual is dedicated specifically to the Denso ECD-U2 high-pressure in-line fuel pump, high pressure common rail, and electronic injectors used on the 6081H series engine, and is written for the experienced technician who needs correct, factory-based procedures rather than generic troubleshooting guesses.

  • Manual type: Technical/Component Technical Manual (CTM)
  • Brand/Engine family: John Deere PowerTech 6081H 8.1L diesel
  • Document number: CTM255
  • Publication date: 14MAY03
  • Language: English
  • Page count: 760 pages
  • File format: PDF

Chapters Covered

  • Section 01 – General: Safety, Engine Identification (model designation, serial number plate, option code label, full engine application chart), Fuels/Lubricants/Coolant (Tier 1 & Tier 2 diesel fuel, bio-diesel, fuel lubricity)
  • Section 02 – Repair and Adjustments: Electronic Fuel System Repair (fuel filters, water separator, high pressure fuel pump removal/installation, high pressure common rail, flow limiters, pressure limiter, electronic injectors); Electronic Engine Control Repair and Adjustment (ECU, sensors, connector repair for METRI-PACK, DEUTSCH, AMP, SUMITOMO, and YAZAKI connectors)
  • Section 03 – Theory Of Operation: Electronic Fuel System Operation, Electronic Control System Operation
  • Section 04 – Diagnostics: Observable Diagnostics and Tests (hard starting, low power, misfiring, exhaust smoke, engine won’t crank, abnormal noise), Trouble Code Diagnostics and Tests (extensive DTC listing with SPN/FMI-based diagnostic procedures for throttle, fuel rail pressure, water-in-fuel, manifold air pressure/temperature, and more)
  • Section 05 – Tools: Electronic Fuel/Control System Repair Tools, Diagnostic Service Tools
  • Section 06 – Specifications: Repair Specifications (torque values, general OEM engine specifications), Diagnostic Specifications (application-specific sensor specifications and ECU terminal identification by machine type)

Complete PDF Bookmark Tree

Complete Bookmarks

The complete bookmarks in the “John Deere PowerTech 8.1L Level 9 Denso HPCR Fuel System Technical Manual CTM255” are as follows:

Contentsp. 3
Generalp. 5
Safety[scSafety[ecp. 7
Handle Fluids Safely—Avoid Firesp. 7
Handle Starting Fluid Safelyp. 7
Service Cooling System Safelyp. 7
Prevent Battery Explosionsp. 8
Prepare for Emergenciesp. 8
Handling Batteries Safelyp. 9
Avoid High-Pressure Fluidsp. 10
Wear Protective Clothingp. 10
Service Machines Safelyp. 11
Work In Ventilated Areap. 11
Work in Clean Areap. 11
Remove Paint Before Welding or Heatingp. 12
Avoid Heating Near Pressurized Fluid Linesp. 12
Illuminate Work Area Safelyp. 12
Use Proper Lifting Equipmentp. 13
Construct Dealer-Made Tools Safelyp. 13
Practice Safe Maintenancep. 14
Use Proper Toolsp. 14
Dispose of Waste Properlyp. 15
Live With Safetyp. 15
Engine Identificationp. 17
Engine Model Designationp. 17
Engine Serial Number Plate Informationp. 18
Engine Option Code Labelp. 19
Engine Application Chartp. 20
Fuels, Lubricants, and Coolantp. 23
Lubricants and Coolantp. 23
Diesel Fuel – Tier 1p. 23
Diesel Fuel – Tier 2p. 24
Bio-Diesel Fuelp. 25
Dieselscan Fuel Analysisp. 25
Lubricity of Diesel Fuelp. 26
Repair and Adjustmentsp. 27
Electronic Fuel System Repair and Adjustmentsp. 29
Fuel System – General Informationp. 29
Relieve Fuel System Pressurep. 29
Clean Primary Fuel Filterp. 30
Remove and Install Final Fuel Filter/Water Separator Basep. 31
Fuel Filter Assembliesp. 34
Replace Final Fuel Filter Elementp. 36
Remove and Install High Pressure Fuel Pump Overflow Valvep. 38
Remove and Install Hand Primerp. 39
Remove High Pressure Fuel Pumpp. 40
Remove and Install High Pressure Common Railp. 42
Remove and Install Flow Limitersp. 44
Remove and Install Pressure Limiterp. 47
Install High Pressure Fuel Pumpp. 49
Remove Electronic Injectorsp. 52
Clean Electronic Injector Borep. 54
Clean Electronic Injector Orificep. 54
Clean Electronic Injector Bodyp. 54
Inspect Electronic Injector Bodyp. 54
Install Electronic Injectorsp. 55
Electronic Engine Control Repair and Adjustmentp. 59
Engine Control Unit (ECU)p. 59
Electronic Engine Control System and Sensorsp. 60
Fuel System Sensorsp. 61
Remove and Install Engine Coolant Temperature Sensorp. 61
Replace Fuel Temperature Sensorp. 61
Replace Crank Position Sensorp. 62
Replace Manifold Air Temperature (MAT) Sensorp. 62
Replace Water in Fuel Sensorp. 63
Remove and Install Oil Pressure Sensorp. 63
Remove and Install Fuel Rail Pressure Sensorp. 64
Connectorsp. 65
Use Electrical Insulating Compoundp. 65
Using High-Pressure Washerp. 66
Repair WEATHERPACK™ Connectorp. 67
Remove Blade Terminals from Connector Bodyp. 70
Repair (Pull Type) METRI-PACK™ Connectorsp. 71
Repair (Push Type) METRI-PACK™ Connectorsp. 73
Repair DEUTSCH™ Connectorsp. 76
Repair AMP Connectorp. 79
Repair SUMITOMO™ Connectorsp. 81
Repair YAZAKI™ Connectorsp. 83
Theory Of Operationp. 85
Electronic Fuel System Operationp. 87
About This Groupp. 87
Fuel System Operationp. 88
Primary Fuel Filter Operationp. 90
Fuel Transfer Pump Operationp. 91
Final Fuel Filter Operationp. 92
High Pressure Fuel Pump Operationp. 93
High Pressure Common Rail (HPCR) Operationp. 95
Electronic Injector (EI) Operationp. 96
Electronic Control System Operationp. 99
About This Groupp. 99
Electronic Control System Terminologyp. 100
Electronic Control System Operationp. 101
Electronic Control System Overviewp. 102
Monitoring Engine Parametersp. 103
Measuring Temperaturep. 103
Measuring Pressurep. 106
Measuring Throttle Positionp. 108
Measuring Engine Speedp. 112
Water In Fuel (WIF) Sensorp. 113
Pump Control Valves (PCVs)p. 114
Electronic Injector (EI) Wiring Harness Connectorp. 114
Engine Control Unit (ECU)p. 116
Controlled Area Network (CAN)p. 118
Intake Air Heater Operationp. 118
Cruise Control Operationp. 119
Engine Protectionp. 120
Derate Programsp. 120
Multiple Torque Curve Selectionp. 121
Governor Droop Mode Selectionp. 121
Engine Control Unit (ECU) Self-Diagnosisp. 122
Diagnosticsp. 125
Observable Diagnostics and Testsp. 133
About This Groupp. 133
E1 – Engine Cranks/Won't Startp. 134
E1 – Engine Cranks/Won't Start Diagnostic Procedurep. 134
E2 – Engine Misfires/Runs Irregularlyp. 139
E2 – Engine Misfires/Runs Irregularly Diagnostic Procedurep. 139
E3 – Engine Does Not Develop Full Powerp. 143
E3 – Engine Does Not Develop Full Power Diagnostic Procedurep. 143
E4 – Engine Emits Excessive White Exhaust Smokep. 149
E4 – Engine Emits Excessive White Exhaust Smoke Diagnostic Procedurep. 149
E5 – Engine Emits Excessive Black Or Gray Exhaust Smokep. 152
E5 – Engine Emits Excessive Black Or Gray Exhaust Smoke Diagnostic Procedurep. 152
E6 – Engine Will Not Crankp. 154
E7 – Engine Idles Poorlyp. 154
E8 – Abnormal Engine Noisep. 155
E9 – Analog Throttle (A) Does Not Respondp. 157
E10 – Analog Throttle (B) Does Not Respondp. 157
F1 – Fuel Supply System Checkp. 158
F1 – Fuel Supply System Check Diagnostic Procedurep. 158
F2 – Excessive Fuel Consumptionp. 164
F3 – Fuel in Oilp. 164
D1 – ECU Does Not Communicate with DST or SERVICE ADVISORp. 166
D1 – ECU Does Not Communicate With DST or SERVICE ADVISOR™ Diagnostic Procedurep. 167
D2 – Diagnostic Gauge Does Not Communicate With ECUp. 172
D2 – Diagnostic Gauge Does Not Communicate With ECU Diagnostic Procedurep. 173
Check Fuel Supply Qualityp. 177
Test for Air in Fuelp. 179
Check Fuel Supply Pressurep. 181
Check for Restricted Fuel Return Linep. 184
Bleed the Fuel Systemp. 186
Restarting Engine That Has Run Out Of Fuelp. 189
Check and Adjust High Pressure Fuel Pump Static Timingp. 192
Trouble Code Diagnostics and Testsp. 193
About This Groupp. 193
Electrical Conceptsp. 194
Using a Digital Multimeterp. 194
Electrical Circuit Malfunctionsp. 195
Troubleshooting Circuit Malfunctionsp. 198
Connecting to Diagnostic Scan Tool (DST) or SERVICE ADVISOR™p. 202
Engine Configuration Data Parameters on Diagnostic Gaugep. 204
Viewing Active DTCs on Diagnostic Gaugep. 206
Viewing Stored DTCs on Diagnostic Gaugep. 206
Clearing Stored DTCs on Diagnostic Gaugep. 207
Data Parameter Descriptionp. 208
Engine Test Instructions—Cylinder Misfire Testp. 212
Engine Test Instructions—Compression Testp. 214
Engine Test Instructions— Cylinder Cutout Testp. 215
Engine Test Instructions— Tractor Torque Curve Change Testp. 216
Reprogramming Engine Control Unit (ECU)p. 217
Downloading Payload File For DSTp. 218
Reprogramming Engine Control Unit (ECU) With DSTp. 223
Downloading Payload File For SERVICE ADVISOR™p. 228
Reprogramming Engine Control Unit (ECU) With SERVICE ADVISOR™p. 236
Diagnostic Trouble Codes (DTCs)p. 240
Listing of Diagnostic Trouble Codes (DTCs) on ECUp. 242
Diagnostic Procedurep. 248
Intermittent Fault Diagnosticsp. 249
T1 – Multi-state Throttle Input Highp. 250
T1 – Multi-State Throttle Input High Diagnostic Procedurep. 251
T2 – Multi-state Throttle Input Lowp. 254
T2 – Multi-State Throttle Input Low Diagnostic Procedurep. 255
T3 – Analog Throttle (A) Input Highp. 258
T3 – Analog Throttle (A) Input High Diagnostic Procedurep. 259
T4 – Analog Throttle (A) Input Lowp. 262
T4 – Analog Throttle (A) Input Low Diagnostic Procedurep. 263
T5 – Analog Throttle (B) Input Highp. 266
T5 – Analog Throttle (B) Input High Diagnostic Procedurep. 267
T6 – Analog Throttle (B) Input Lowp. 270
T6 – Analog Throttle (B) Input Low Diagnostic Procedurep. 271
T7 – CAN Throttle Invalidp. 274
T7 – Can Throttle Invalid Diagnostic Procedurep. 275
T8 – PWM Throttle Input Highp. 278
T8 – PWM Throttle Input High Diagnostic Procedurep. 279
T9 – PWM Throttle Input Lowp. 282
T9 – PWM Throttle Input Low Diagnostic Procedurep. 283
T10 – PWM Throttle Abnormal Pulse Widthp. 286
T10 – PWM Throttle Abnormal Pulse Width Diagnostic Procedurep. 287
T11 – Excavator Throttle Reference Voltage Highp. 290
T11 – Excavator Throttle Reference Voltage High Diagnostic Procedurep. 291
T12 – Excavator Throttle Reference Voltage Lowp. 294
T12 – Excavator Throttle Reference Voltage Low Diagnostic Procedurep. 295
T13 – Excavator Throttle Ground Voltage Highp. 298
T13 – Excavator Throttle Ground Voltage High Diagnostic Procedurep. 299
T14 – Excavator Throttle Ground Voltage Lowp. 302
T14 – Excavator Throttle Ground Voltage Low Diagnostic Procedurep. 303
T15 – Excavator Throttle Input Voltage Highp. 306
T15 – Excavator Throttle Input Voltage Highp. 307
T15 – Excavator Throttle Input Voltage High Diagnostic Procedurep. 307
T16 – Excavator Throttle Input Voltage Lowp. 310
T16 – Excavator Throttle Input Voltage Low Diagnostic Procedurep. 311
T22 – Analog Throttle (A) Input Voltage Out of Rangep. 314
T23 – Multi-state Throttle Input Voltage Out of Rangep. 315
000028.03 — Throttle Voltage Highp. 316
000028.04 — Throttle Voltage Lowp. 316
000029.03 — Throttle Voltage Highp. 317
000029.04 — Throttle Voltage Lowp. 317
000029.14 — Throttle Voltage Out of Rangep. 318
000084.09 — Vehicle Speed Invalid or Missingp. 319
000091.03 — Throttle Voltage Highp. 320
000091.04 — Throttle Voltage Lowp. 321
000091.08 — PWM Throttle Abnormal Pulse Widthp. 322
000091.09 — Throttle Invalidp. 322
000091.14 — Throttle Voltage Out of Rangep. 323
000094.03 — Fuel Rail Pressure Input Voltage Highp. 324
000094.03 Fuel Rail Pressure Input Voltage High Diagnostic Procedurep. 325
000094.04 — Fuel Rail Pressure Input Voltage Lowp. 328
000094.04 Fuel Rail Pressure Input Voltage Low Diagnostic Procedurep. 329
000094.10 — Fuel Rail Pressure Loss Detectedp. 332
DTC 000094.10 Fuel Rail Pressure Loss Detected Diagnostic Procedurep. 333
000094.13 — Fuel Rail Pressure Higher Than Expectedp. 336
000094.13 Fuel Rail Pressure Higher Than Expected Diagnostic Procedurep. 337
000094.17 — Fuel Rail Pressure Not Developedp. 340
000094.17 Fuel Rail Pressure Not Developed Diagnostic Procedurep. 341
000097.00 — Water in Fuel Continuously Detectedp. 344
000097.00 Water in Fuel Continuously Detected Diagnostic Procedurep. 345
000097.03 — Water in Fuel Signal Voltage Highp. 348
000097.03 Water In Fuel Signal Voltage High Diagnostic Procedurep. 349
000097.04 — Water in Fuel Signal Voltage Lowp. 352
000097.04 Water In Fuel Signal Voltage Low Diagnostic Procedurep. 353
000097.16 — Water in Fuel Detectedp. 356
000097.16 Water In Fuel Detected Diagnostic Procedurep. 357
000097.31 — Water in Fuel Detectedp. 360
000097.31 Water In Fuel Detected Diagnostic Procedurep. 361
000100.01 — Engine Oil Pressure Extremely Lowp. 364
000100.01 Engine Oil Pressure Extremely Low Diagnostic Procedurep. 366
000100.03 — Engine Oil Pressure Input Voltage Highp. 368
000100.03 Engine Oil Pressure Input Voltage High Diagnostic Procedurep. 369
000100.04 — Engine Oil Pressure Input Voltage Lowp. 372
000100.04 Oil Pressure Input Voltage Low Diagnostic Procedurep. 374
000100.18 — Engine Oil Pressure Moderately Lowp. 378
000100.18 Engine Oil Pressure Moderately Low Diagnostic Procedurep. 379
000102.03 — Manifold Air Pressure Input Voltage Highp. 380
000102.03 Manifold Air Pressure Input Voltage High Diagnostic Procedurep. 381
000102.04 — Manifold Air Pressure Input Voltage Lowp. 384
000102.04 Manifold Air Pressure Input Voltage Low Diagnostic Procedurep. 385
000105.03 — Manifold Air Temperature Input Voltage Highp. 388
000105.03 Manifold Air Temperature Input Voltage High Diagnostic Procedurep. 389
000105.04 — Manifold Air Temperature Input Voltage Lowp. 392
000105.04 Manifold Air Temperature Input Voltage Low Diagnostic Procedurep. 393
000105.16 — Manifold Air Temperature Moderately Highp. 396
000105.16 Manifold Air Temperature Moderately High Diagnostic Procedurep. 397
000107.00 — Air Filter Differential Pressurep. 398
000107.00 Air Filter Differential Pressure Diagnostic Procedurep. 399
000110.00 — Engine Coolant Temperature Extremely Highp. 402
000110.00 Engine Coolant Temperature Extremely High Diagnostic Procedurep. 403
000110.03 — Engine Coolant Temperature Input Voltage Highp. 404
000110.03 Engine Coolant Temperature Input Voltage High Diagnostic Procedurep. 405
000110.04 — Engine Coolant Temperature Input Voltage Lowp. 408
000110.04 Engine Coolant Temperature Input Voltage Low Diagnostic Procedurep. 409
000110.15 — Engine Coolant Temperature High Least Severep. 412
000110.15 Engine Coolant Temperature High Least Severe Diagnostic Procedurep. 413
000110.16 — Engine Coolant Temperature Moderately Highp. 414
000110.16 Engine Coolant Temperature Moderately High Diagnostic Procedurep. 415
000110.31 — Engine Coolant Temperature Highp. 416
000110.31 Engine Coolant Temperature High Diagnostic Procedurep. 417
000111.01 — Engine Coolant Level Lowp. 418
000111.01 Engine Coolant Level Low Diagnostic Procedurep. 419
000158.17 — ECU Power Down Errorp. 422
000158.17 ECU Power Down Error Diagnostic Procedurep. 423
000160.02 — Wheel Speed Input Noisep. 426
000160.02 Wheel Speed Input Noise Diagnostic Procedurep. 427
000174.00 — Fuel Temperature High Most Severep. 430
000174.00 Fuel Temperature High Most Severe Diagnostic Procedurep. 431
000174.03 — Fuel Temperature Input Voltage Highp. 434
000174.03 Fuel Temperature Input Voltage High Diagnostic Procedurep. 435
000174.04 — Fuel Temperature Input Voltage Lowp. 438
000174.04 Fuel Temperature Input Voltage Low Diagnostic Procedurep. 439
000174.16 — Fuel Temperature High Moderately Severep. 442
000174.16 Fuel Temperature High Moderately Severe Diagnostic Procedurep. 443
000189.00 — Engine Speed Deratep. 445
000190.00 — Engine Overspeed Extremep. 446
000190.16 — Engine Overspeed Moderatep. 447
000237.02 — Vehicle Identification Number Invalidp. 448
000237.13 — Vehicle Identification Option Code Invalidp. 449
000237.31 — Vehicle Model Number Invalidp. 450
000523.09 — Gear Selection Invalidp. 452
000611.03 — Electronic Injector Wiring Shorted To Power Sourcep. 454
000611.03 Electronic Injector Wiring Shorted To Power Source Diagnostic Procedurep. 455
000611.04 — Electronic Injector Wiring Shorted To Groundp. 458
000611.04 Electronic Injector Wiring Shorted To Ground Diagnostic Procedurep. 459
000620.03 — Sensor Supply 1 Voltage Highp. 462
000620.03 Sensor Supply 1 Voltage High Diagnostic Procedurep. 463
000620.04 — Sensor Supply 1 Voltage Lowp. 466
000620.04 Sensor Supply 1 Voltage Low Diagnostic Procedurep. 467
000627.01 — Electronic Injector Supply Voltage Problemp. 470
000627.01 Electronic Injector Supply Voltage Problem Diagnostic Procedurep. 471
000629.13 — ECU Errorp. 474
000629.13 ECU Error Diagnostic Procedurep. 475
000636.02 — Pump Position Sensor Input Noisep. 476
000636.02 Pump Position Sensor Input Noise Diagnostic Procedurep. 477
000636.08 — Pump Position Sensor Input Missingp. 480
000636.08 Pump Position Sensor Input Missing Diagnostic Procedurep. 481
000636.10 — Pump Position Sensor Input Pattern Errorp. 484
000636.10 Pump Position Sensor Input Pattern Error Diagnostic Procedurep. 485
000637.02 — Crank Position Input Noisep. 488
000637.02 Crank Position Input Noise Diagnostic Procedurep. 489
000637.07 — Crank Position/Pump Position Timing Moderately Out of Syncp. 492
000637.07 Crank Position/Pump Position Timing Moderately Out of Sync Diagnostic Procedurep. 493
000637.08 — Crank Position Input Missingp. 498
000637.08 Crank Position Input Missing Diagnostic Procedurep. 499
000637.10 — Crank Position Input Pattern Errorp. 502
000637.10 Crank Position Input Pattern Error Diagnostic Procedurep. 503
000639.13 — CAN Bus Errorp. 506
000639.13 CAN Bus Error Diagnostic Procedurep. 507
000640.11 — Engine Shutdown – Vehicle Request Invalidp. 510
000640.11 Engine Shutdown – Vehicle Request Invalid Diagnostic Procedurep. 511
000640.31 — Engine Shutdown – Vehicle Requestp. 514
000651.05 — Cylinder #1 EI Circuit Openp. 516
000651.05 Cylinder #1 EI Circuit Open Diagnostic Procedurep. 517
000651.06 — Cylinder #1 EI Circuit Shortedp. 520
000651.06 Cylinder #1 EI Circuit Shorted Diagnostic Procedurep. 521
000651.07 — Cylinder #1 EI Fuel Delivery Failurep. 524
000651.07 Cylinder #1 EI Fuel Delivery Failure Diagnostic Procedurep. 525
000652.05 — Cylinder #2 EI Circuit Openp. 528
000652.05 Cylinder #2 EI Circuit Open Diagnostic Procedurep. 529
000652.06 — Cylinder #2 EI Circuit Shortedp. 532
000652.06 Cylinder #2 EI Circuit Shorted Diagnostic Procedurep. 533
000652.07 — Cylinder #2 EI Fuel Delivery Failurep. 536
000652.07 Cylinder #2 EI Fuel Delivery Failure Diagnostic Procedurep. 537
000653.05 — Cylinder #3 EI Circuit Openp. 540
000653.05 Cylinder #3 EI Circuit Open Diagnostic Procedurep. 541
000653.06 — Cylinder #3 EI Circuit Shortedp. 544
000653.06 Cylinder #3 EI Circuit Shorted Diagnostic Procedurep. 545
000653.07 — Cylinder #3 EI Fuel Delivery Failurep. 548
000653.07 Cylinder #3 EI Fuel Delivery Failure Diagnostic Procedurep. 549
000654.05 — Cylinder #4 EI Circuit Openp. 552
000654.05 Cylinder #4 EI Circuit Open Diagnostic Procedurep. 553
000654.06 — Cylinder #4 EI Circuit Shortedp. 556
000654.06 Cylinder #4 EI Circuit Shorted Diagnostic Procedurep. 557
000654.07 — Cylinder #4 EI Fuel Delivery Failurep. 560
000654.07 Cylinder #4 EI Fuel Delivery Failure Diagnostic Procedurep. 561
000655.05 — Cylinder #5 EI Circuit Openp. 564
000655.05 Cylinder #5 EI Circuit Open Diagnostic Procedurep. 565
000655.06 — Cylinder #5 EI Circuit Shortedp. 568
000655.06 Cylinder #5 EI Circuit Shorted Diagnostic Procedurep. 569
000655.07 — Cylinder #5 EI Fuel Delivery Failurep. 572
000655.07 Cylinder #5 EI Fuel Delivery Failure Diagnostic Procedurep. 573
000656.05 — Cylinder #6 EI Circuit Openp. 576
000656.05 Cylinder #6 EI Circuit Open Diagnostic Procedurep. 577
000656.06 — Cylinder #6 EI Circuit Shortedp. 580
000656.06 Cylinder #6 EI Circuit Shorted Diagnostic Procedurep. 581
000656.07 — Cylinder #6 EI Fuel Delivery Failurep. 584
000656.07 Cylinder #6 EI Fuel Delivery Failure Diagnostic Procedurep. 585
000898.09 — Vehicle Speed or Torque Message Invalidp. 588
000970.31 — Engine Shutdown – Auxiliary Requestp. 590
000971.31 — External Fuel Derate Switch Activep. 591
001069.09 — Tire Size Invalidp. 592
001069.31 — Tire Size Errorp. 593
001079.03 — Sensor Supply 2 Voltage Highp. 594
001079.03 Sensor Supply 2 Voltage High Diagnostic Procedurep. 595
001079.04 — Sensor Supply 2 Voltage Lowp. 598
001079.04 Sensor Supply 2 Voltage Low Diagnostic Procedurep. 599
001080.03 — Fuel Rail Pressure Sensor Supply Voltage Highp. 602
001080.03 Fuel Rail Pressure Sensor Supply Voltage High Diagnostic Procedurep. 603
001080.04 — Fuel Rail Pressure Sensor Supply Voltage Lowp. 606
001080.04 Fuel Rail Pressure Sensor Supply Voltage Low Diagnostic Procedurep. 607
001109.31 — Engine Protection Shutdown Warningp. 610
001110.31 — Engine Protection Shutdownp. 611
001347.05 — Pump Control Valve #1 Errorp. 612
001347.05 Pump Control Valve #1 Error Diagnostic Procedurep. 613
001347.07 — Fuel Rail Pressure Control Errorp. 616
001347.07 Fuel Rail Pressure Control Error Diagnostic Procedurep. 617
001347.10 — Pump Control Valve #1 Fuel Flow Not Detectedp. 622
001347.10 — Pump Control Valve #1 Fuel Flow Not Detectedp. 623
001347.10 Pump Control Valve #1 Fuel Flow Not Detected Diagnostic Procedurep. 623
001348.05 — Pump Control Valve #2 Errorp. 626
001348.05 Pump Control Valve #2 Error Diagnostic Procedurep. 627
001348.10 — Pump Control Valve #2 Fuel Flow Not Detectedp. 630
001348.10 — Pump Control Valve #2 Fuel Flow Not Detectedp. 631
001348.10 Pump Control Valve #2 Fuel Flow Not Detected Diagnostic Procedurep. 631
001568.02 — Torque Curve Selection Invalidp. 634
001568.09 — Torque Curve Selection Missingp. 635
001569.31 — Fuel Deratep. 636
001639.01 — Fan Speed Input Missingp. 638
001639.01 Fan Speed Input Missing Diagnostic Procedurep. 639
001639.02 — Fan Speed Input Erraticp. 642
001639.02 Fan Speed Input Erratic Diagnostic Procedurep. 643
001639.16 — Fan Speed Higher Than Expectedp. 646
001639.16 Fan Speed Higher Than Expected Diagnostic Procedurep. 647
001639.18 — Fan Speed Lower Than Expectedp. 650
001639.18 Fan Speed Lower Than Expected Diagnostic Procedurep. 651
002000.09 — Vehicle ID Missingp. 654
002000.13 — Security Violationp. 655
002005.09 — ACU Signal Missingp. 656
002049.09 — CAB Signal Missingp. 657
002071.09 — CCU Signal Missingp. 658
Toolsp. 659
Electronic Fuel/Control System Repair Tools and Other Materialsp. 661
Group 090 – Electronic Fuel System Repair and Adjustment Essential Toolsp. 661
Fuel System Repair and Adjustment Other Materialsp. 663
Group 110 – Electronic Engine Control Repair Toolsp. 664
Control Repair and Adjustment Other Materialsp. 670
Diagnostic Service Toolsp. 671
Group 150/160 – Electronic Fuel System Diagnostic Toolsp. 671
Specificationsp. 675
Repair Specificationsp. 677
Unified Inch Bolt and Cap Screw Torque Valuesp. 677
Metric Bolt and Cap Screw Torque Valuesp. 678
General OEM Engine Specificationsp. 679
Electronic Fuel System Repair and Adjustment Specificationsp. 681
Electronic Engine Control Repair and Adjustment Specificationsp. 684
Diagnostic Specificationsp. 685
Fuel System Diagnostic Specificationsp. 685
Application Specificationsp. 687
Articulated Dump Trucks – Sensor Specificationsp. 690
Articulated Dump Trucks – Torque Curve Selectionp. 691
Articulated Dump Trucks – Governor Mode Selectionp. 691
Articulated Dump Trucks – ECU Terminal Identificationp. 692
Combines – Sensor Specificationsp. 693
Combines – Torque Curve Selectionp. 694
Combines – Governor Mode Selectionp. 694
Combines – ECU Terminal Identificationp. 695
Excavators – Sensor Specificationsp. 697
Excavators – Torque Curve Selectionp. 698
Excavators – Governor Mode Selectionp. 698
Excavators – ECU Terminal Identificationp. 699
Feller Bunchers – Sensor Specificationsp. 701
Feller Bunchers – Torque Curve Selectionp. 703
Feller Bunchers – Governor Mode Selectionp. 703
Feller Bunchers – ECU Terminal Identificationp. 704
Forwarders – Sensor Specificationsp. 706
Forwarders – Torque Curve Selectionp. 707
Forwarders – Governor Mode Selectionp. 707
Forwarders – ECU Terminal Identificationp. 708
Harvesters – Forestry – Sensor Specificationsp. 709
Harvesters – Forestry – Torque Curve Selectionp. 710
Harvesters – Forestry – Governor Mode Selectionp. 710
Harvesters – Forestry – ECU Terminal Identificationp. 711
Loaders – Sensor Specificationsp. 712
Loaders – Torque Curve Selectionp. 713
Loaders – Governor Mode Selectionp. 713
Loaders – ECU Terminal Identificationp. 714
OEM Engines – Sensor Specificationsp. 715
OEM Engines – Torque Curve Selectionp. 718
OEM Engines – Governor Mode Selection With OC03040 Software or Laterp. 719
OEM Engines – Governor Mode Selection With OC03036 Software or Earlierp. 719
OEM Engines – ECU Terminal Identificationp. 720
OEM Engines – ECU Terminal Identification – Continuedp. 721
Electronic Control System Wiring Diagramp. 722
6081 OEM Application Instrument Panel/Engine Start Components Electrical Wiring Diagramp. 724
6081 OEM Application Instrument Panel/Engine Start Components Electrical Wiring Diagram – Continuedp. 725
Self Propelled Forage Harvester – Sensor Specificationsp. 726
Self Propelled Forage Harvester – Torque Curve Selectionp. 727
Self Propelled Forage Harvester – Governor Mode Selectionp. 727
Self Propelled Forage Harvester – ECU Terminal Identificationp. 728
Skidders – Forestry – Sensor Specificationsp. 729
Skidders – Forestry – Torque Curve Selectionp. 730
Skidders – Forestry – Governor Mode Selectionp. 730
Skidders – Forestry – ECU Terminal Identificationp. 731
Tractors – 7010 Series – Sensor Specificationsp. 732
Tractors – 7010 Series – Torque Curve Selectionp. 733
Tractors – 7010 Series – Governor Mode Selectionp. 734
Tractors – 7010 Series – ECU Terminal Identificationp. 735
Tractors – 7020 Series – Sensor Specificationsp. 736
Tractors – 7020 Series – Torque Curve Selectionp. 738
Tractors – 7020 Series – Governor Mode Selectionp. 739
Tractors – 7020 Series – ECU Terminal Identificationp. 740
Tractors – 8020 Series – Sensor Specificationsp. 742
Tractors – 8020 Series – Torque Curve Selectionp. 743
Tractors – 8020 Series – Governor Mode Selectionp. 743
Tractors – 8020 Series – ECU Terminal Identificationp. 744
Tractors – 9120 Series – Sensor Specificationsp. 745
Tractors – 9120 Series – Torque Curve Selectionp. 746
Tractors – 9120 Series – Governor Mode Selectionp. 746
Tractors – 9120 Series – ECU Terminal Identificationp. 747
Page Numbersp. 3
Section 01p. 5
Group 000p. 7
1p. 7
2p. 8
3p. 9
4p. 10
5p. 11
6p. 12
7p. 13
8p. 14
9p. 15
10p. 16
Group 001p. 17
1p. 17
2p. 18
3p. 19
4p. 20
5p. 21
6p. 22
Group 002p. 23
1p. 23
2p. 24
3p. 25
4p. 26
5p. 27
6p. 28
Section 02p. 27
Group 090p. 29
1p. 29
2p. 30
3p. 31
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Group 110p. 59
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Section 03p. 85
Group 130p. 87
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Group 140p. 99
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Group 160p. 193
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Section 06p. 675
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64p. 748

Taken together, this John Deere CTM255 manual gives a technician everything needed to service the Level 9 HPCR fuel system correctly from end to end — identification, teardown and reassembly procedures, circuit theory, DTC-driven diagnostics, and the exact torque and performance specifications to check the work against.

Engine Coverage

This PowerTech 8.1L Denso HPCR manual documents the 6081H engine family across two application groups shown in the general specifications: 6081HF001 (Engine S.N. —199,999) and 6081HF070 (Engine S.N. 200,000— ), both in-line 6-cylinder, 4-cycle, turbocharged and air-to-air aftercooled diesels with 8.1 L (496 cu in.) displacement, 116 mm bore, 129 mm stroke, and a 15.7:1 compression ratio. The engine application chart lists the specific machines these engines were installed in, including John Deere 7710/7810, 7820, 7920, 8120/8220, 8320, 8420, 8520, and 9120 tractors; 9550/9650/9650 CTS/9750 STS and Zweibrucken 9560–9780 combines; 7200 self-propelled forage harvester; 644H/724H loaders; Hitachi 330CLC/370C excavators; Timberjack/John Deere feller bunchers, forwarders, harvesters, and skidders; the Bell 250D/300D articulated dump truck; and OEM industrial and genset engines rated from 200 to 413 HP.

IMAGES PREVIEW

John Deere PowerTech 8.1L Level 9 Denso HPCR Fuel System Technical Manual CTM255 — PDF page 1 preview
John Deere PowerTech 8.1L Level 9 Denso HPCR Fuel System Technical Manual CTM255 — PDF page 34 preview
John Deere PowerTech 8.1L Level 9 Denso HPCR Fuel System Technical Manual CTM255 — PDF page 39 preview

What This Manual Enables

With the John Deere PowerTech 8.1L Level 9 Denso HPCR Fuel System Technical Manual CTM255, a technician can correctly relieve fuel system pressure, service the primary and final fuel filters and water separator, remove and install the high pressure fuel pump and common rail, replace flow limiters and the pressure limiter, and remove and install the electronic injectors — all using the exact torque values and timing procedures John Deere specifies. The diagnostics sections walk through both observable symptom diagnosis (hard starting, low power, smoke, no-crank, abnormal noise) and full DTC-based diagnostic procedures, so faults can be traced to a specific sensor or circuit instead of guessed at. Because HPCR fuel systems run at extremely high pressure and the electronic injectors cannot be field-serviced, following the correct procedure in this CTM255 manual isn’t optional — it’s what keeps the repair safe and the engine running to factory specification. This is an instant PDF download: there’s no shipping and no waiting, you can access it immediately on a phone, tablet, laptop, or in the shop, and you’re free to print any page you need at the bench.

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